EMHART-Trouble Shooting Guide

Fault notifications
Control- and
Energysource TE
© Stanley Engineered Fastening
TUCKER GmbH
Max-Eyth-Straße 1
D-35394 Gießen
Tel.: +49 (0) 641 405 0
Fax.: +49 (0) 641 405-300
sef.europe@sbdinc.com
www.tucker.de
2 26.11.2014
Fault notifications Control- and Energysource TE
Faults
Table of Contents
Table of Contents .......................................................................................................................................................3

1 Faults ...............................................................................................................................................................13
Fault 8000: Unknown Message .............................................................................................................................13
Fault 10005: Weld procedure sequence fault ........................................................................................................13
Fault 10013: SMPS: Lift fault .................................................................................................................................13
Fault 10014: Short-circuit weld ..............................................................................................................................14
Fault 10015: weld time timeout ..............................................................................................................................15
Fault 10016: Open circuit, no arc ..........................................................................................................................16
Fault 10017: Measurement line broken .................................................................................................................17
Fault 10030: SMPS: Weld out of tolerance ...........................................................................................................18
Fault 10031: Weld aborted due to pilot arc voltage ...............................................................................................18
Fault 10033: Common measurement line broken .................................................................................................18
Fault 10034: Safety circuit fault .............................................................................................................................19
Fault 10041: SMPS: Weld program parameters invalid ........................................................................................19
Fault 10202: SMPS: Temperature too high ...........................................................................................................19
Fault 10204: SMPS: Hardware fault ......................................................................................................................20
Fault 11000: SMPS: Pilot arc disrupted.................................................................................................................20
Fault 13001: LMC: Error channel A of lift measurement signal .............................................................................20
Fault 13002: LMC: Error channel B of lift measurement signal .............................................................................21
Fault 13003: LMC: Lift height out of tolerance ......................................................................................................21
Fault 13004: LMC: Temperature error of LM amplifier ..........................................................................................22
Fault 13005: LMC: Voltage ling voltage to high (> 180V)......................................................................................22
Fault 13006: LMC: Linear motor voltage is to low (< 90V) ....................................................................................23
Fault 13007: LMC: Linear motor lift timeout ..........................................................................................................23
Fault 13008: LMC: Penetration out of tolerance ....................................................................................................23
Fault 13009: LMC: Stickout not enough for programmed penetration ..................................................................23
Fault 13010: LMC: The linear motor reach the mechanical end stop ...................................................................26
Fault 13011: LMC: No room for lift ........................................................................................................................26
Fault 13012: LMC: No +5V amplifiere driver voltage ............................................................................................27
Fault 13013: LMC: Error during stickout measurement.........................................................................................27
Fault 13014: LMC: LM Motor Overload .................................................................................................................28
Fault 13015: LMC: LWL transmit buffer overflow ..................................................................................................28
Fault 13016: LMC: Error of position at the end of lift .............................................................................................28
Fault 13017: LM position overshot ........................................................................................................................29
Fault 13018: LMC: Wrong software for board E606A ...........................................................................................30
Fault 13019: LMC: Fault of linear motor amplifiere ...............................................................................................30
Fault 13038: LMC: error CAN interface feeder ......................................................................................................31
Fault 13039: LMC: error CAN interface weld tool ..................................................................................................31
Fault 13041: LMC: CAN Bus - Bit Error .................................................................................................................31
Fault 13050: LMC: supply voltage for linear motor not detect ...............................................................................31
Fault 13052: LMC: CAN Bus - Wrong Receiver Routing Information ...................................................................32
Fault 13053: LMC: CAN Bus - Wrong CAN Address ............................................................................................32
Fault 13054: LMC: CAN Bus - Timeout Error ......................................................................................................32
Fault 13056: LMC: CAN Bus - Wrong Data Length ...............................................................................................32
26.11.2014 3
Faults
Fault 13060: LMC: Error while reading EEProm data ...........................................................................................32

Fault 14018: Feeder: Maintenance user counter required ....................................................................................32
Fault 14022: Feeder: Maintenance feeding tube required ....................................................................................33
Fault 14052: Feeder: unknown feeder type ...........................................................................................................33
Fault 14142: Feeder: Stud divider position not reached........................................................................................33
Fault 14349: Extern Pickup station: loading pin not in back position (Timeout) ...................................................34
Fault 14350: Extern Pickup station: loading pin not in front position (Timeout) ....................................................35
Fault 14351: Extern Pickup station: rotation segment not in feeding position ......................................................36
Fault 14352: Extern Pickup station: rotation segment not in loading position .......................................................37
Fault 14358: Feeder: Separation fault - stud has not left feeder ...........................................................................38
Fault 14746: Feeder: Maintenance feeder required ..............................................................................................39
Fault 15000: Feeder: No hardware configuration exist .........................................................................................40
Fault 15001: Feeder: Fault during stud separation ...............................................................................................40
Fault 15002: Feeder: Voltage supply for drum motor is missing ...........................................................................41
Fault 15003: Feeder: 24V external control voltage not available ..........................................................................41
Fault 15004: Feeder: Air pressure not sufficient ...................................................................................................42
Fault 15005: Feeder: 24V internal control voltage not available ...........................................................................42
Fault 15006: Feeder: 5V CAN bus voltage not available ......................................................................................43
Fault 15007: Feeder: Maintenance feed rail required ...........................................................................................43
Fault 15008: Feeder: Maintenance divider feeding tube required .........................................................................43
Fault 15009: Feeder: Voltage supply for vibrating bowl is missing .......................................................................44
Fault 15010: Feeder: drum motor overcurrent protection (drum blocked) ...........................................................44
Fault 15011: Extern Pickup station: loading pin don't leave back position ...........................................................44
Fault 15012: Extern Pickup station: loading pin don't leave front position ............................................................45
Fault 15013: Extern Pickup station: rotation segment don't leave feeding position ..............................................45
Fault 15014: Extern Pickup station: rotation segment don't leave pick up position ..............................................46
Fault 15015: Feeder: No fastener (stud) leave the feeder ....................................................................................47
Fault 15016: Extern Pickup station: Stud-arrival sensor permanently active ........................................................48
Fault 15017: Extern Pickup station: Maintenance Extern Pickup station required ................................................49
Fault 15018: Feeder: Fastener (stud) fill level is to low, Please refill studs. .........................................................49
Fault 16018: Weld Tool: Maintenance user counter (feedings) required ..............................................................50
Fault 16019: Weld Tool: Maintenance collet/gripper required ...............................................................................51
Fault 16020: Weld Tool: Maintenance weld tool (feeds) required .........................................................................51
Fault 16022: Weld Tool: Maintenance feeding tube required ...............................................................................51
Fault 16023: Weld Tool: Welding gun sequence not followed ..............................................................................52
Fault 16048: TR: no rotation movement allowed ...................................................................................................54
Fault 16052: Weld tool: unknownweld tool type ....................................................................................................54
Fault 16106: Weld tool: Feeding tube locking .......................................................................................................54
Fault 16110: Weld tool: Gripper not closed ...........................................................................................................54
Fault 16112: Weld tool: protective gas pressure not sufficient ..............................................................................55
Fault 16179: Weld tool: Gripper teaching fault ......................................................................................................55
Fault 16188: Weld tool: Gripper not opened .........................................................................................................55
Fault 16300: TR: Overload rotation motor .............................................................................................................56
Fault 16301: TR: Overvoltage rotation motor ........................................................................................................56
Fault 16302: TR: Controller rotation motor over temperature ...............................................................................57
Fault 16303: TR: Maximum output power controller rotation motor achieved.......................................................57
4 26.11.2014
Faults
Fault 16304: TR: Undervoltage rotation motor ......................................................................................................58

Fault 16310: TR: Error with the encoder signals of the rotation motor..................................................................58
Fault 16311: TR: Position fault during rotation ......................................................................................................58
Fault 16317: TR: Angle not allowed ......................................................................................................................59
Fault 16346: Weld tool: Wrong stud length (variable stud block) ..........................................................................59
Fault 16347: Weld tool: Wrong stud diameter .......................................................................................................60
Fault 16349: TR: Pickup station 1: loading pin not in back position ......................................................................60
Fault 16350: TR: Pickup station 1: loading pin not in front position ......................................................................61
Fault 16351: TR: Pickup station 1: rotation segment not in feeding position ........................................................62
Fault 16352: TR: Pickup station 1: rotation segment not in loading position ........................................................63
Fault 16360: TR: Pickup station 2: loading pin not in back position ......................................................................65
Fault 16361: TR: Pickup station 2: loading pin not in front position ......................................................................65
Fault 16362: TR: Pickup station 2: rotation segment not in feeding position ........................................................66
Fault 16363: TR: Pickup station 2: rotation segment not in loading position ........................................................67
Fault 16376: Weld tool: Stud-arrival sensor detected no stud ..............................................................................69
Fault 17000: Weld tool: No hardware configuration exist ......................................................................................69
Fault 17001: Weld tool: start feeding for an unknown feeder ................................................................................69
Fault 17002: Weld tool: feeder is not ready for a feeding process ........................................................................69
Fault 17003: Weld tool:24V external control voltage not available .......................................................................69
Fault 17004: Weld tool: Air pressure not sufficient ................................................................................................70
Fault 17005: Weld tool: 24V internal control voltage not available .......................................................................70
Fault 17006: Weld tool: 5V voltage CAN bus is missing .......................................................................................70
Fault 17007: Weld tool: Hardware configuration is not correct .............................................................................71
Fault 17008: Weld Tool: Weld tool remains in R position......................................................................................71
Fault 17009: Weld Tool: Weld tool not in R position .............................................................................................73
Fault 17010: Weld Tool: Weld tool ID change between weld gun and weld head ................................................75
Fault 17011: TR: Feeding-cmd includes no pickup-station ...................................................................................75
Fault 17012: TR: Stud Block Poti not In Zero-Position ..........................................................................................75
Fault 17013: TR: Error in the Controller of the rotation motor ...............................................................................76
Fault 17014: TR: Communication Error to the controller of the rotation Motor .....................................................76
Fault 17015: TR: Error during the reference run of the rotation motor ..................................................................76
Fault 17016: TR: Rotation error - the angle was not reached ...............................................................................77
Fault 17017: Weld Tool: Maintenance weld tool (welds) required ........................................................................77
Fault 17018: Weld Tool: Maintenance slide rail required ......................................................................................77
Fault 17019: Weld Tool: Maintenance loading pin required ..................................................................................78
Fault 17020: TR: Maintenance pick up station 1 required .....................................................................................78
Fault 17021: TR: Maintenance pick up station 2 required .....................................................................................78
Fault 17022: TR: The actual angle is not admitted for a slidemovement or a welding .........................................79
Fault 17023: TR: Studblock was pushed back during slide movement.................................................................79
Fault 17024: TR: Maintenance feeding tube pick up station 2 required ................................................................80
Fault 17025: TR: Move slide forward is not allowed, because the rotation is not referenced. ..............................80
Fault 17026: TR: Slowmotion controller detected a too fast rotation ....................................................................81
Fault 17027: TR: Slowmotion controller has a system failure ...............................................................................81
Fault 17028: TR: Rotation not possible, because slide is not in back-position .....................................................81
Fault 17029: Weld tool: Gripper don't leave Closed Position ................................................................................82
Fault 17030: Weld tool: Gripper don't leave Open Position ..................................................................................82
26.11.2014 5
Faults
Fault 17031: Weld tool: Weldtool Don't Reach Front Position ..............................................................................83
Fault 17032: Weld tool: extern üick up station is not ready for pick up process ...................................................85
Fault 17033: Weld tool: No fastener (stud) loaded ................................................................................................85
Fault 17034: Weld tool: No fastener (stud) leave the feeder .................................................................................85
Fault 17035: Weld tool: Stud-arrival sensor permanently active ...........................................................................86
Fault 17036: Weld tool: Loading pin don't leave back position .............................................................................87
Fault 17037: Weld tool: Loading pin don't leave front position ..............................................................................87
Fault 17038: Weld tool: The "Stud in gripper" senor is permanently active ..........................................................87
Fault 17039: TR: Pickup station 1: loading pin don't leave front position ..............................................................88
Fault 17040: TR: Pickup station 1: loading pin don't leave back position .............................................................88
Fault 17041: TR: Pickup station 1: rotation segment don't leave pick up position ................................................89
Fault 17042: TR: Pickup station 1: rotation segment don't leave feed position ....................................................89
Fault 17043: TR: Pickup station 1: Stud-arrival sensor permanently active..........................................................90
Fault 17044: TR: Pickup station 2: loading pin don't leave front position ..............................................................91
Fault 17045: TR: Pickup station 2: loading pin don't leave back position .............................................................91
Fault 17046: TR: Pickup station 2: rotation segment don't leave pick up position ................................................92
Fault 17047: TR: Pickup station 2: rotation segment don't leave feed position ....................................................93
Fault 17048: TR: Pickup station 2: Stud-arrival sensor permanently active..........................................................93
Fault 17049: Weld tool: No fastener (stud) in cage of the pick up station loaded and no stud arrival sensor
was detected ..........................................................................................................................................................94
Fault 17050: Weld tool: No fastener (stud) in cage of the pick up station loaded .................................................94
Fault 17051: Weld tool: Absolute back pos. don't reached during move loading pin backward ...........................95
Fault 17052: Weldtool: Wrong stud length before the welding ..............................................................................95
Fault 17053: Weldtool: Wrong stud diameter before the Welding .........................................................................96
Fault 17054: TR: rotation motor reached iit-limit during weldprocess ...................................................................96
Fault 17055: TR: Studblock was pushed back during weld process .....................................................................96
Fault 17056: TR: Pickup station 1: loading pin both sensors are aktive ...............................................................97
Fault 17058: TR: Pickup station 1: rotation segment both sensors are aktive ......................................................98
Fault 17064: TR: Angle is not valid for pick up a stud out of an external pickup-station .....................................100
Fault 17065: Weld tool: no feeding allowed ........................................................................................................100
Fault 17066: TR: Enable of the rotation motor controllor failled ..........................................................................100
Fault 17067: Weld tool: No fastener (stud) at the external pickup ......................................................................101
Fault 17068: Weld tool: Absolute front pos. don't reached during move loading pin forward .............................101
Fault 17069: Weld tool: Restriction front pos. don't reached during move loading pin forward ..........................102
Fault 17070: Weld tool: Stud-arrival and stud-departure sensor detected no stud .............................................103
Fault 17071: Weld tool: protection gas flow rate not sufficient ............................................................................104
Fault 20002: No SOW..........................................................................................................................................104
Fault 20003: Weld tool not in R position ..............................................................................................................106
Fault 20004: SOW not reset ................................................................................................................................108
Fault 20006: DCPU-PM: Program not selected ..................................................................................................108
6 26.11.2014
Faults
Fault 20025: Wrong fastener (stud) loaded .........................................................................................................110

Fault 20028: No SOW - fastener (stud) has been not detected by stud-departure sensor .................................111
Fault 20029: No SOW - fastener (stud) has been not detected by stud-arrival sensor ......................................113
Fault 20030: DCPU-PM: Weld out of tolerance ...................................................................................................113
Fault 20038: Data connection feeder ..................................................................................................................113
Fault 20039: Internal connection customer interface ..........................................................................................113
Fault 20040: Fiber optic connection SMPS .........................................................................................................114
Fault 20041: SMPS: Weld program parameters invalid ......................................................................................114
Fault 20046: DCPU-PM: Feed cycle failed ..........................................................................................................114
Fault 20058: DCPU-PM: Weld start signal invalid during current operation state...............................................114
Fault 20103: CPM: Air pressure not sufficient .....................................................................................................115
Fault 20109: Feeder: Timeout feeding tube ........................................................................................................116
Fault 20112: CPM: Pressure monitor protective gas ...........................................................................................116
Fault 20160: DCPU-PM: Color marking not possible ..........................................................................................117
Fault 20168: DCPU-PM: TR Angle position not achieved ...................................................................................117
Fault 20325: DCPU-PM: Timeout robot retreating to weld position ....................................................................117
Fault 20345: DCPU-PM: Continuing weld cycle after e-stop/protection circuit not possible ...............................118
Fault 21000: CPM: Phase monitor ......................................................................................................................118
Fault 21001: DCPU-PM: Changing of operation state not allowed .....................................................................118
Fault 21002: CPM: USB-Module not available ....................................................................................................118
Fault 21003: CPM: Faulty firmware configuration ...............................................................................................118
Fault 21004: CPM: Faulty hardware configuration ..............................................................................................118
Fault 21008: DCPU-PM: Weldtool number not assigned ....................................................................................119
Fault 21009: UNUSED: DCPU-PM: Component type changed ..........................................................................119
Fault 21010: DCPU-PM: Initialization failed - Unacknowledged exchange of component..................................119
Fault 21011: DCPU-PM: Initialization failed - the datamanagement component didn't react within the
expected span of time..........................................................................................................................................119
Fault 21012: DCPU-PM: Initialization failed - component didn't sent the configuration parameter set...............119
Fault 21013: DCPU-PM: Initialization failed - Touchpad wasn't initialized ..........................................................120
Fault 21014: DCPU-PM: Initialization failed - programmable parameter set couldn't be saved .........................120
Fault 21016: DCPU-PM: Initialization failed - schema set for configuration parameter set couldn't be saved ...120
Fault 21017: DCPU-PM: Initialization failed - schema set for programmable parameter set couldn't be saved 120
Fault 21018: DCPU-PM: Initialization failed - configuration parameter set couldn't be saved ............................120
Fault 21019: DCPU-PM: Initialization failed - component did not complete initialization ....................................120
Fault 21030: DCPU-PM: Missing Component .....................................................................................................121
Fault 21031: Data connection weld tool ..............................................................................................................121
Fault 21032: DCPU-PM: Whole weld cycle canceled due to missing LMC ........................................................121
Fault 21033: DCPU-PM: Whole weld cycle canceled due to missing feeder ......................................................121
Fault 21034: DCPU-PM: Whole weld cycle canceled due to missing weld tool ..................................................121
Fault 21035: DCPU-PM: Timeout weld head rotation cycle ................................................................................121
Fault 21036: DCPU-PM: Weld head rotation canceled .......................................................................................121
Fault 21037: DCPU-PM: Weld head rotation cycle canceled due to a start signal during a operation state that
does not allow a rotation start ..............................................................................................................................122
Fault 21038: DCPU-PM: Timeout weld tool gripper move cycle .........................................................................122
Fault 21039: DCPU-PM: Weld tool gripper move cycle canceled due to a start signal during a operation state
that does not allow a gripper movement..............................................................................................................122
26.11.2014 7
Faults
Fault 21040: DCPU-PM: Weldhead couldn't be moved due to a timeout ...........................................................123

Fault 21041: DCPU-PM: weld head couldn't be moved due to a cancel request ...............................................123
Fault 21042: DCPU-PM: Timeout move cycle wait for rotation ...........................................................................123
Fault 21043: DCPU-PM: Request for weldstart canceled while weld cycle is running .......................................123
Fault 21044: DCPU-PM: Main weld cycle canceled due to a timeout .................................................................124
Fault 21045: DCPU-PM: Whole weld cycle canceled due to a timeout ..............................................................124
Fault 21046: LMC: Lift program parameters invalid ............................................................................................124
Fault 21047: DCPU-PM: Unkown weld mode .....................................................................................................124
Fault 21048: Fiber optic connection LMC ............................................................................................................124
Fault 21049: DCPU-DM: Measurement data could not be saved .......................................................................125
Fault 21050: DCPU-PM: Weld head move start signal invalid during current operation state............................125
Fault 21051: DCPU-PM: Wrong stud length (stickout) ........................................................................................125
Fault 21053: DCPU-PM: Feeder not selected .....................................................................................................125
Fault 21054: DCPU-PM: Start weld not permitted ...............................................................................................125
Fault 21055: DCPU-PM: Component not ready for welding ...............................................................................125
Fault 21056: DCPU-PM: Timeout stud length check ...........................................................................................126
Fault 21057: DCPU-PM: Timeout for acknowledge of process parameters .......................................................126
Fault 21058: No fastener (stud) loaded ...............................................................................................................126
Fault 21059: DCPU-PM: Rotation angle not valid for welding ............................................................................127
Fault 21060: SysUpdate: Corrupt update of SMPS.............................................................................................127
Fault 21061: SysUpdate: Corrupt software update of feeder ..............................................................................127
Fault 21062: SysUpdate: Corrupt software update of LMC ................................................................................128
Fault 21063: SysUpdate: Corrupt software update of weldtool ...........................................................................128
Fault 21064: DCPU-PM: Whole weld cycle canceled due to a missing component ...........................................128
Fault 21065: DCPU-PM: Feed start signal invalid during current operation state ..............................................128
Fault 21066: DCPU-PM: Self-resetting fault during weld process ......................................................................129
Fault 21067: SysUpdate: No valid software in control board of LMC..................................................................129
Fault 21068: SysUpdate: No valid software in control board of SMPS ...............................................................129
Fault 21069: SysUpdate: No valid software in control board of weldtool ............................................................130
Fault 21070: SysUpdate: No valid software in control board of feeder ...............................................................130
Fault 21071: SysUpdate: No valid software in control board of ICPU.................................................................130
Fault 21082: DCPU-PM: Feed cycle canceled due to missing LMC ...................................................................130
Fault 21083: DCPU-PM: Feed cycle canceled due to missing feeder ................................................................130
Fault 21084: DCPU-PM: Feed cycle canceled due to missing weld tool ............................................................130
Fault 21085: DCPU-PM: Timeout feed cycle wait for rotation .............................................................................130
Fault 21086: DCPU-DM: Database of statistical data damaged .........................................................................131
Fault 21087: DCPU-DM: Database of programmable data damaged .................................................................131
Fault 21088: DCPU-DM: Database of statistical data has been automatically restored .....................................131
Fault 21089: DCPU-DM: Database of programmable data has been automatically restored ............................131
Fault 21090: DCPU-DM: Fault storage cleared ...................................................................................................132
Fault 21091: DCPU-DM: Version of database ist newer than version of the installed CPM-software ................132
Fault 21092: DCPU-DM: database of programmable data has been recreated .................................................132
Fault 21093: DCPU-DM: database of quality data has been recreated ..............................................................133
Fault 21094: DCPU-DM: databases have been recreated ..................................................................................133
Fault 21095: DCPU-DM: Damaged Database ....................................................................................................133
Fault 21096: DCPU-PM: Stud-ID difference weld and feed cycle .......................................................................133
8 26.11.2014
Faults
Fault 21097: DCPU-PM: Stud-ID difference weld and rotation cycle ..................................................................134
Fault 21098: DCPU-PM: Wrong fastener (stud) loaded ......................................................................................134
Fault 21100: DCPU-PM: Timeout rotation cycle wait for feeding ........................................................................134
Fault 21101: DCPU-PM: Timeout rotation cycle wait for weld head move .........................................................134
Fault 21102: DCPU-PM: Weld head not ready for rotation .................................................................................135
Fault 21103: DCPU-PM: Reset of active faults failed..........................................................................................135
Fault 21104: DCPU-PM: Timeout Automatic Teaching .......................................................................................135
Fault 21105: DCPU-PM: Stick out measurement failed during automatic teaching ............................................135
Fault 21110: DCPU-PM: Following Stud-ID not selected ....................................................................................135
Fault 21111: DCPU-PM: Following Stud-ID on different outlet ...........................................................................135
Fault 21140: DCPU: UPS not charged ................................................................................................................136
Fault 21141: DCPU: UPS power supply error .....................................................................................................136
Fault 21150: DCPU-PM: Timeout tool check ......................................................................................................137
Fault 21151: DCPU-PM: Wrong weld tool docked ..............................................................................................137
Fault 21152: DCPU-PM: No weld tool docked ....................................................................................................138
Fault 21153: DCPU-PM: Tool check start signal invalid during current operation state .....................................139
Fault 21200: DCPU-PM: Timeout short circuit test SMPS ..................................................................................139
Fault 21201: DCPU-PM: Timeout feeding test cycle ...........................................................................................139
Fault 21202: DCPU-PM: Start short circuit test invalid during current operation state .......................................139
Fault 21203: DCPU-PM: Start feeding test cycle invalid during current operation state .....................................139
Fault 21210: DCPU-PM: Mean value of slider movement time (forward) excceeds tolerated limits...................139
Fault 21211: DCPU-PM: Mean value of slider movement time (backward) excceeds tolerated limits ...............140
Fault 21212: DCPU-PM: Mean value of feeding time excceeds tolerated limits .................................................140
Fault 21213: DCPU-PM: Wrong software version DCPU....................................................................................140
Fault 21214: DCPU-PM: Wrong software version feeder....................................................................................140
Fault 21215: DCPU-PM: Wrong software version LMC ......................................................................................140
Fault 21216: DCPU-PM: Wrong software version weld tool................................................................................140
Fault 21217: DCPU-PM: Wrong software version DCPU-OS .............................................................................141
Fault 21218: DCPU-PM: Wrong software version ICPU .....................................................................................141
Fault 21219: DCPU-PM: Wrong software version SMPS....................................................................................141
Fault 23000: DCPU-CI: Start weld signal from robot invalid during current operation mode .............................141
Fault 23001: DCPU-CI: Start feed signal from robot invalid during current operation mode .............................142
Fault 23002: DCPU-CI: Restart signal from robot invalid during current operation mode .................................142
Fault 23003: DCPU-CI: Forced WC signal from robot invalid during current operation mode............................142
Fault 23004: DCPU-CI: Activate protective gas signal from robot invalid during current operation mode ........142
Fault 23005: DCPU-CI: Set color mark signal from robot invalid during current operation mode.......................142
Fault 23006: DCPU-CI: Move weld tool signal from robot invalid during current operation mode ......................143
Fault 23007: DCPU-CI: Communication failure with customer interface ............................................................143
Fault 23008: DCPU-CI: Customer Interface Protocol Type not selected ............................................................143
Fault 23009: DCPU-CI: Customer Interface parameter are incorrect .................................................................143
Fault 23010: DCPU-CI: Customer Interface Protocol Type is incompatible........................................................143
Fault 23011: DCPU-CI: Customer interface configuration failure .......................................................................143
Fault 23012: DCPU-CI: Weldstart handshake error ............................................................................................144
Fault 23045: DCPU-CI: Start weld cycle not reset ..............................................................................................144
Fault 23046: DCPU-CI: Weld without current ......................................................................................................144
Fault 23047: DCPU-CI: Parity Error in Stud-ID ...................................................................................................144
26.11.2014 9
Faults
Fault 23048: DCPU-CI: Parity Error in Action Code ............................................................................................144

Fault 23050: DCPU-CI: Weld start initiated while the signal StudID valid was not active ...................................145
2 Warnings .......................................................................................................................................................147
Feeder: Maintenance user counter required .......................................................................................................147
Feeder: Maintenance feeding tube required .......................................................................................................147
Feeder: Separation fault - stud has not left feeder ..............................................................................................147
Extern pickup station: Stud-arrival sensor detected no stud ...............................................................................148
Feeder: Maintenance feeder required .................................................................................................................149
Feeder: Fault during stud separation...................................................................................................................149
Feeder: Maintenance feed rail required...............................................................................................................150
Feeder: Maintenance divider feeding tube required ............................................................................................150
Extern Pickup station: Maintenance Extern Pickup station required ...................................................................150
Feeder: Stud fill level is low .................................................................................................................................150
Feeder: Stud door is not locked...........................................................................................................................150
Feeder: Stud-departure sensor permanently active ............................................................................................150
Weld Tool: Maintenance user counter required ..................................................................................................151
Weld Tool: Maintenance collet/gripper required ..................................................................................................151
Weld Tool: Maintenance weld tool (feeds) required ............................................................................................151
Weld Tool: Maintenance feeding tube required ...................................................................................................151
Weld tool: Stud-arrival sensor detected no stud ..................................................................................................151
Weld Tool: Maintenance weld tool (welds) required ............................................................................................152
Weld Tool: Maintenance slide rail required .........................................................................................................152
Weld Tool: Maintenance loading pin required .....................................................................................................152
TR: Maintenance pick up station 1 required ........................................................................................................152
TR: Maintenance pick up station 2 required ........................................................................................................152
TR: Maintenance feeding tube pick up station 2 required ...................................................................................153
Weld tool: Loading pin don't leave front position .................................................................................................153
Weld tool: Absolute front pos. reached during move weldtool forward ...............................................................153
Weld tool: Absolute front pos. don't reached during move loading pin forward ..................................................153
Weld tool: Absolute back pos. don't reached during move loading pin backward ..............................................154
TR: Pickup station 1: Feed stud-arrival sensor timeout.......................................................................................155
TR: Pickup station 2: Feed stud-arrival sensor timeout.......................................................................................155
TR: Pickup station 1: The Rotation did not reach load position during a feeding cycle ......................................155
TR: Pickup station 2: The Rotation did not reach load position during a feeding cycle ......................................156
Weld Tool: Premaintenance warning collet/gripper required...............................................................................156
Weld tool: Weld tool don't leave the front position...............................................................................................156
TR: Gripper value not valid at the first measurement ..........................................................................................156
TR: Studblock value not valid at the first measurement ......................................................................................156
TR: rotation motor reached iit-limit ......................................................................................................................156
TR: The Clamping of the variable studblock does not work correctly .................................................................157
CPM: The battery of the clock is low ...................................................................................................................157
CPM: Faulty configuration USB-Module ..............................................................................................................157
CPM: Faulty configuration SD-Card ....................................................................................................................157
CPM: Mean value of slider movement time (forward) excceeds tolerated limits.................................................157
CPM: Mean value of slider movement time (backwards) excceeds tolerated limits ...........................................157
CPM: Mean value of feeding time excceeds tolerated limits ...............................................................................157
10 26.11.2014
Faults
DCPU-PM: Wrong software version DCPU .........................................................................................................158

DCPU-PM: Wrong software version feeder .........................................................................................................158
DCPU-PM: Wrong software version LMC ...........................................................................................................158
DCPU-PM: Wrong software version weld tool .....................................................................................................158
DCPU-PM: Wrong software version DCPU-OS ..................................................................................................158
DCPU-PM: Wrong software version ICPU ..........................................................................................................158
DCPU-PM: Wrong software version SMPS .........................................................................................................159
CPM: Authorization failed ....................................................................................................................................159
CPM: Authorization failed - user unknown ..........................................................................................................159
CPM: Authorization failed - wrong password ......................................................................................................159
CPM: Authorization failed - unknown key ............................................................................................................159
CPM: Authorization failed - timeout .....................................................................................................................159
CPM: Authorization failed - internal error ............................................................................................................159
CPM: Authorization failed - list of registered users not available ........................................................................160
CPM: Authorization failed - error in EKS reader ..................................................................................................160
CPM: Authorization failed - unknown privilege level ...........................................................................................160
CPM: Authorization failed - Customer not selected .............................................................................................160
CPM: Authorization failed - key has expired .......................................................................................................160
CPM: Authorization failed - EKS reader not available .........................................................................................160
CPM: Authorization failed - key is not valid for this production area ...................................................................160
DCPU-PM: Feed start signal invalid during current operation state ....................................................................161
DCPU: TR Slow Motion active .............................................................................................................................161
DCPU: UPS not charged .....................................................................................................................................161
DCPU: UPS power supply error ..........................................................................................................................161
DCPU-CI: Weldstart removed while weld process has not been completed ......................................................161
DCPU-NI: The ProFeP System kann not be activated ........................................................................................161
DCPU-NI: ProFeP invalid DNS server information ..............................................................................................162
DCPU-NI: ProFeP DNS request failed ................................................................................................................162
DCPU-NI: ProFeP DNS request failed ................................................................................................................162
26.11.2014 11
Faults
12 26.11.2014
Faults
1 Faults
Fault 8000: Unknown Message

Description The receiver of a sent message doesn't know the command code of the message.
Version Conflict
The versions of the participating communication components conflict with each other.
Update the receiver components

The recipient of the message is reported in the fault, which is unknown to the recipient. Please update
the components of the recipient.
Fault 10005: Weld procedure sequence fault

Description Due to a malfunction the weld process cannot be completed properly.
The fault number 5 is a collective fault that is only used for customer interfaces which use
only 1 byte for fault code. The fault number 5 does not appear in the fault menu and the fault
The internal monitoring of the weld process detected a problem.
Check whether the weld tool or the tension tongs are defective.
This can occur if the SOW was interrupted directly before for the weld current was switched on.
Check welding program
Check the software version in weld unit

The problem may be caused by incompatible software
Fault 10013: SMPS: Lift fault

Description The welder control cannot detect a lift movement of the welding part.
26.11.2014 13
Faults
The collet is worn or defective
Replace the collet
Weld tool is heavily contaminated
Clean weld tool
Replace weld tool
Component contaminated
Inspect component for contamination and clean as needed

Typical types of contamination may be: Grease, oil, adhesives
Lift movement is not smooth
Replace weld tool
Defective cable package between weld unit and weld tool
Check the cable package for correct function

It is recommended to use the cable package test box.
Replace cable package
Weld tool defective
Replace weld tool
SMPS is defective
Replace weld unit or SMPS
Fault 10014: Short-circuit weld

Description The welder control has detected a short-circuit during the weld current phase.
14 26.11.2014
Faults
Weld parameter not correct
Check lift height in welding program and adjust as needed
Check weld current in welding program and adjust as needed
Collet defective
Check collet for wear and replace as needed
Springy workpiece
Fix the workpiece using the counter bearing
Incorrectly positioned weld tool

Distance between weld tool and workpiece too large.
Check distance and adjust as needed

The procedure is described in the operating instructions of the respective weld tool.
Air supply of the loading pin not correct
Check the air supply of the weld tool

It is recommended you use the cable package test box.
Pressure loss due to defective pneumatic connector
Replace defective components
Pressure loss due to kinked or defective pneumatic lines
Replace defective components
Fault 10015: weld time timeout

Description The welder control has detected a too long drop down time during the welding process.
26.11.2014 15
Faults
Incorrectly connected ground measurement cable on the workpiece
Inspect connection or laying of the ground measurement cable
Insufficient ground connection to workpiece
Check ground connection to workpiece
Clean ground contact and set as needed
SMPS is defective
Burn-up on fastener too large
Inspect programmed drop time and adjust as needed

Only possible in "manual" drop time mode.
Parameters may only be changed in consultation with the responsible technical department.
Inspect programmed lift height and adjust as needed

Inspect weld parameter in welding program and adjust as needed

Fault 10016: Open circuit, no arc

Description Arc is extinguished during weld process (either during Pilot Arc or Main Arc phases).
16 26.11.2014
Faults
Insufficient ground connection to workpiece
Check ground connection to workpiece
Clean ground contact and set as needed
Springy workpiece
Check the parameter "Start delay" in the welding program and increase the value if needed
Weld gun was moved during the welding
Do not pull the weld gun away before the welding has finished
Weld head was moved during the welding
Check the mounting of the weld head
Path-measuring system in the weld tool is defective
Replace path-measuring system
Error in the cable package between the weld tool and the weld unit
Weld tool is defective
Error in the cable harness between the path-measuring system and the PCB of the
weld tool
Replace cable harness
Replace weld tool
SMPS is defective
Fault 10017: Measurement line broken

Description Measurement line circuit disturbed.
26.11.2014 17
Faults
Cable package is defective

Inspect electrical contacts

Check all multi-coupling connectors from weld unit up to weld head.
Weld spatter creates an electrical connection between the sustainer/mouthpiece and the
collet
Remove any weld spatter from the sustainer/mouthpiece and collet
Contamination in the transition between the receiver and the feed tube on the weld tool
Remove the contamination
Power supply for the ground cable monitoring/SOW is defective.

The PCB to produce the SOW - voltage is located directly beside the SMPS main contactor.
Inspect the function of PCB A9 in the SMPS and replace if needed

A flashing LED on the PCB indicates if the power supply is functioning correctly.
Fault 10030: SMPS: Weld out of tolerance

Description One or more of the observed weld parameters are out of the programmed tolerance range.
Inspect the quality of the weld and repeat the weld if required
Component contaminated
Inspect component for contamination and clean as needed

Typical types of contamination may be: Grease, oil, adhesives
Fault 10031: Weld aborted due to pilot arc voltage

Description In the pilot current phase of the weld process a pilot arc voltage out of the programmed range
of tolerance has been detected.
Fault 10033: Common measurement line broken
18 26.11.2014
Faults
Description Common measurement line circuit disturbed.
Faulty system wiring
Inspect system wiring and correct if required

Make sure that all lines are laid out to the correct feeders and weld tools.
Power supply for the ground cable monitoring/SOW is defective.

The PCB to produce the SOW - voltage is located directly beside the SMPS main contactor.
Inspect the function of PCB A9 in the SMPS and replace if needed

A flashing LED on the PCB indicates if the power supply is functioning correctly.
Fault 10034: Safety circuit fault

Description Output voltage of SMPS has exceeded the limit voltage of 48V. In this case the power supply
stops operating.
Cabling in the SMPS is defective
Check the cabling on the SMPS PCB control for the components.
Check the primary cabling on the transformer for the PCB auxiliary board
A PCB in the SMPS is defective
Replace the PCB control in the SMPS
Replace the primary PCB auxiliary board
Fault 10041: SMPS: Weld program parameters invalid

Description The weld program received by the SMPS contains invalid parameters.
An error occurred during the inspection of the welding program
Check welding program

In exceptional cases there may be gaps during the inspection of the welding program in the control
panel. In the welding program, cancel the most recent changes step by step.
Check the software version in weld unit

The problem may be caused by incompatible software
Fault 10202: SMPS: Temperature too high

Description The temperature in the SMPS has exceeded the maximum allowed limit of 70°C (158°F).
26.11.2014 19
Faults
Ambient temperature is too high
Ventilate environment
Weld power is too high
Reduce required weld power

Insert longer welding pauses. If possible, reduce the weld current or the weld time.
Fault 10204: SMPS: Hardware fault

Description A component within the SMPS is defective.
Cabling in the SMPS is defective
Check the cabling on the SMPS PCB control for the components.
Check the primary cabling on the transformer for the PCB auxiliary board
A PCB in the SMPS is defective
Replace the PCB control in the SMPS
Replace the primary PCB auxiliary board
Fault 11000: SMPS: Pilot arc disrupted

Description The pilot arc has been disrupted at the beginnig of the weld.
SMPS is defective
Repeat the weld

Try to repeat the weld. If the fault occurs frequently, the SMPS must be checked.
Check pilot arc circuit in the SMPS

Check the wiring of th bypass SCR, replace the control board in the SMPS, replace the bypass SCR.
Fault 13001: LMC: Error channel A of lift measurement signal

Description The LMC detected an incorrect signal sequence on path-measuring channel A.
20 26.11.2014
Faults

Replace weld tool
Replace position measurement system
Replace cable package of position measurement system
Fault 13002: LMC: Error channel B of lift measurement signal

Description The LMC detected an incorrect signal sequence on path-measuring channel B.

Replace weld tool
Replace position measurement system
Replace cable package of position measurement system
Fault 13003: LMC: Lift height out of tolerance

Description The observed lift height is out of the programmed tolerance range.
26.11.2014 21
Faults
Linear motor lift is not smooth
Maintenance of the weld tool required
Fastening screws have become loose

The fastening screws of the path-measuring system, path-measuring rule or yoke became loose or were not
tightened with the prescribed tightening torque.
Tighten all screws with the prescribed tightening torque
Error in the cable harness between the path-measuring system and the PCB of the weld
tool
Fault 13004: LMC: Temperature error of LM amplifier

Description The temperature of linear motor amplifier is more than 80 °C
Linear motor output stage is defective
Replace linear motor output stage
Replace weld unit
Fault 13005: LMC: Voltage ling voltage to high (> 180V)

Description The voltage for the linear motor exceeded the limit of 180 V for at least 500 ms.
LMC is defective
Replace LMC controller and output stage
Replace weld unit
The transformer for the supply of the LMC output stage is defective
Replace transformer
Replace weld unit
22 26.11.2014
Faults
Fault 13006: LMC: Linear motor voltage is to low (< 90V)

Description The voltage for the linear motor undershot the limit of 90 V for at least 500 ms.
The F1 fuse on the LMC backplane is defective
Replace fuse
Replace weld tool
LMC is defective
Fault 13007: LMC: Linear motor lift timeout

Description Time between 'lift start' and 'lift end' is to large.
LTF is defective
The communication connection (LTF) between the two affected components is defective.
Replace the LTF
Fault 13008: LMC: Penetration out of tolerance

Description The observed penetration is out of the programmed tolerance range.
Collet is defective
Inspect the collet and replace if required
The stud is not positioned correctly in the collet
Parameters in the welding program are not correct
Adjust the parameters in the welding program

The parameters in the welding program must be adjusted to the respective application.
Contamination on the surface of the workpiece
Ensure the workpiece is not contaminated
Fault 13009: LMC: Stickout not enough for programmed penetration
26.11.2014 23
Faults
Description The measured stickout is not enough to arrive the required penetration. Please be sure that
the stickout is greater than the requested penetration.
24 26.11.2014
Faults
The programmed values of the penetration are not correct in the welding program
Inspect the programmed values of the penetration in the welding program
The sustainer of the weld tool is not set correctly
Correct the setting of the sustainer on the weld tool
The slide of the weld tool is at the end stop

The slide of the weld tool moved to the end stop but the sustainer did not touch the workpiece.
Check whether the working range of the slide is correct
Weld spatter creates an electrical connection between the sustainer/mouthpiece and the
collet
Contamination in the transition between the receiver and the feed tube on the weld tool
The force of the loading pin is not sufficient to press the stud completely forward
The load pin does not reach the front position
Ensure sufficient compressed-air supply

(input air pressure should be between 5 and 8 bar)
Ensure the correct function of the compressed-air line in the cable package
Inspect the cable package between the control unit and the weld tool for leaks or kinks in the
compressed-air line and repair or replace if required
Check if the loading pin moves smoothly
Stud is too short (incorrect stud loaded)
Incorrect stud must be removed

You can do this, e.g., via manual feed.
Check if the hopper or drum has been filled incorrectly
Springy workpiece
Stabilizer and welding position not on the same height level

26.11.2014 25
Faults
Fault 13010: LMC: The linear motor reach the mechanical end stop
Description The linear motor reach the mechanical end stop. So it is not possible to plunge the stud with
the requested force.
Insufficient or no air pressure on the weld tool

You can find the correct setting value for the input air pressure in the assembly instructions (typical
values are 5 to 8 bar).
Check the compressed-air supply of the weld tool
Ensure the correct function of the compressed-air line in the cable package
Inspect the cable package between the control unit and the weld tool for leaks or kinks in the
compressed-air line and repair or replace if required
Fault 13011: LMC: No room for lift

Description The linear motor can not execute the current lift because the is no room for the lift. Please
check the stickout and lift higth values.
The remaining LM travel is insufficient for the programmed lift. The sum of the stickout and
the programmed lift must
26 26.11.2014
Faults
Welding is attempted on an existing stud
Check whether a stud has already been correctly welded in this position
If a stud has already been welded in this position, it must be inspected for a correct weld result or
marked for rework, if required.
Then the fault must be acknowledged with "Forced WC".
Stickout is too large
Set the stickout correctly

Use proper gauge for setting (see parts list).
The sustainer of the weld tool is not set correctly
Collet is defective
Stud with incorrect length in the weld tool
Repeat the stud feeding process and restart the welding (RESTART)
Check whether the right studs are in the feeder and exchange if needed
Fault 13012: LMC: No +5V amplifiere driver voltage

Description This Problem can be the result of a faulty E607 board.
Replace linear motor output stage
Replace weld unit
Fault 13013: LMC: Error during stickout measurement

Description During the stickout measurement the SOW signal lost for more than 200ms.
26.11.2014 27
Faults
Springy workpiece
Check the parameter "Start delay" in the welding program and increase the value if needed
Fault 13014: LMC: LM Motor Overload

Description The monitoring of the LM motor temperature has detected a overload and switched it off to
prevent a damage of the motor.

Replace weld tool
Replace weld tool
LMC is defective
Fault 13015: LMC: LWL transmit buffer overflow

Description The internal communication of the LMC is overloaded.
Fault 13016: LMC: Error of position at the end of lift

Description The programmed penetration (or target position) could not be reached.
28 26.11.2014
Faults
Parameters in the welding program are not correct
Adjust the parameters in the welding program

The parameters in the welding program must be adjusted to the respective application.

tool
Fault 13017: LM position overshot

Description The error of LM position is more than 100µm . This will be checked at Lift Off command.
26.11.2014 29
Faults

tool
Fault 13018: LMC: Wrong software for board E606A

Description The software, running on LMC Board E606A, only works with an E606 Board of index B or
higher.
Fault 13019: LMC: Fault of linear motor amplifiere

Description The linear motor amplifiere can not switch the required current.

The electronics on the PCB of the linear motor output stage has an error.
Replace the PCB of the linear motor output stage
The electrical connection to the linear motor is damaged

The error may be in the cable package to the weld tool or there is a cable break in the weld tool or in the
weld current source.
Inspect the electrical connection to the linear motor and replace if required
Check the electrical connection of the linear motor and replace it if necessary
30 26.11.2014
Faults
Fault 13038: LMC: error CAN interface feeder

Description The CAN bus for the connection between the LMC and the feeder signalled an error.
The control cable between the weld unit and the feeder is defective
Inspect the connector on the weld unit and the feeder
Replace the control cable
Feeder is defective
Replace feeder
The weld unit is defective
Replace weld unit
Fault 13039: LMC: error CAN interface weld tool

Description The CAN bus for the connection between the LMC and the weld tool signalled an error.
The control cable between the weld unit and the weld tool is defective
Replace the control cable
Inspect the connector on the weld unit and the weld tool
Replace weld tool
Replace weld unit
Fault 13041: LMC: CAN Bus - Bit Error

Description CAN Bus node LMC - Weldtool bit error.
Fault 13050: LMC: supply voltage for linear motor not detect
Description The LMC system do not measure the supply voltage of the linear motor. It is possible that the
fuse F1 an the board E605 is broken.
26.11.2014 31
Faults
Fault 13052: LMC: CAN Bus - Wrong Receiver Routing Information

Description CAN Bus node LMC - Weldtool wrong receiver routing information. The current CAN
message is not for Feeder.
Fault 13053: LMC: CAN Bus - Wrong CAN Address

Description CAN Bus node LMC - Weldtool, wrong CAN adress for this node.
Fault 13054: LMC: CAN Bus - Timeout Error

Description CAN Bus node LMC - Weldtool timeout error.
Fault 13056: LMC: CAN Bus - Wrong Data Length

Description CAN Bus node LMC - Weldtool, wrong data length.
Fault 13060: LMC: Error while reading EEProm data

Description During the read data cycle at the EEProm a fault was detected. The data are invalid.
Fault 14018: Feeder: Maintenance user counter required

Description The limit of the "user counter" has been reached. The limit can be programmed in the
feederparameters. This counter is increased with each feeding cycle.
32 26.11.2014
Faults
The limit value of the user-defined counter was reached
Delete the counter reading after the maintenance work

Carry out the maintenance work and checks specified for this counter.
Then delete the current counter reading in the menu "Maintenance information/Statistics counter".
If required, adjust the counter in the programming of the weld output.
Fault 14022: Feeder: Maintenance feeding tube required

Description The limit of the "feeding tube maintenance counter" has been reached. The limit can be
programmed in the feederparameters. This counter is increased with each feeding cycle.
The limit value of the preventative maintenance counter for the feed tube was reached

Fault 14052: Feeder: unknown feeder type

Description Unknown feeder type, check the feeder hardware configuration and the feeder software.
The software does not to recognize the configured feeder type
Adjust the hardware configuration of the feeder
Import new software into the feeder
Fault 14142: Feeder: Stud divider position not reached

Description The requested stud divider position has not been reached within the maximum allowed
monitoring time.
26.11.2014 33
Faults
Insufficient or no air pressure

Hindrance in the dividing mechanism
Check for correct feed tube connection
Check stud divider for hindrance in divider mechanism

Disconnect pneumatic connections and check that the slider moves smoothly by manually moving it left
and right to the end stops.
Position sensor fault
Check the position of the sensor and replace if necessary
Check the wiring to the sensor
The control cable to the divider is defective
Replace control cable
Defective solenoid valve
Replace solenoid valve
Defective feeder PCB control
Replace feeder PCB control
Cable harness between X3 and feeder PCB control defective
Check cable harness
Fault 14349: Extern Pickup station: loading pin not in back position (Timeout)
Description The loading pin of the extern pickup station has not reached the back position. The requested
position has not been reached within the maximum allowed monitoring time.
34 26.11.2014
Faults
Supply air on the feeder not connected or pressure insufficient
Supply air of the loading pin not connected or pressure insufficient
Check the supply air of the loading pin
The sensor for detecting the back position of the loading pin is set incorrectly
Set the sensor for detecting the back position of the loading pin
The sensor for detecting the back position of the loading pin is defective
Replace sensor
The line on the valve connector of the solenoid valve for actuating the loading pin cylinder
is defective
Check the line contacts and seat; replace if needed
The solenoid valve for actuating the loading pin cylinder is defective
The air cylinder of the loading pin is defective
Replace the loading pin air cylinder
Fault 14350: Extern Pickup station: loading pin not in front position (Timeout)
Description The loading pin of the extern pickup station has not reached the front position. The requested
position has not been reached within the maximum allowed monitoring time.
26.11.2014 35
Faults
Supply air on the feeder not connected or pressure insufficient
The sensor for detecting the front position of the loading pin is set incorrectly
Set the sensor for detecting the front position of the loading pin
The sensor for detecting the front position of the loading pin is defective
Replace sensor
is defective
Fault 14351: Extern Pickup station: rotation segment not in feeding position
Description The rotation segment of the extern pickup station has not reached the feeding position. The
requested position has not been reached within the maximum allowed monitoring time.
36 26.11.2014
Faults
The rotation segment of the pickup station is mechanically jammed
Remedy the jam in the rotation segment
The sensor for detecting the feed position of the rotation segment is set incorrectly
Set sensor
The sensor for detecting the feed position of the rotation segment is defective
Replace sensor
The line on the valve connector of the solenoid valve for actuating the rotation segment is
defective
The solenoid valve for actuating the rotation segment is defective
The air cylinder of the rotation segment is defective
Replace the rotation segment air cylinder
Supply air not connected or pressure insufficient
Connect or reset supply air

Supply air of the rotation segment not connected or pressure insufficient
Check the supply air of the rotation segment
Fault 14352: Extern Pickup station: rotation segment not in loading position
Description The rotation segment of the extern pickup station has not reached the loading position. The
requested position has not been reached within the maximum allowed monitoring time.
26.11.2014 37
Faults
The sensor for detecting the loading position of the rotation segment is set incorrectly
Set sensor
The sensor for detecting the loading position of the rotation segment is defective
Replace sensor
defective

Fault 14358: Feeder: Separation fault - stud has not left feeder
Description The stud-departure sensor on the feeding tube has not detected a stud during the feeding
cycle.
38 26.11.2014
Faults
The air pressure on the feeder is too low
Check the air connection and the air pressure

The input air pressure should be between 6 and 8 bar.
Check the setting of the pressure reducer in the feeder

For the procedure, see the assembly instructions of the feeder.
The air throttle for the stud feeder is set incorrectly
Set the air throttle
Contaminated separation guide
Clean separation guide
Jammed stud between slider and separation guide
Remove jammed stud and check the distance between the slider and the separation guide; set as
needed
Separation block jammed due to a stud in the separation chamber
Open the separation chamber and remove the stud
The programmed parameter "Time rear isolating blade" too short
Increase the "Time rear isolating blade"
The beginning of the feed tube is not correctly attached or not cut straight
Check the beginning of the tube and, if needed, re-cut it and place it correctly
Stud fill level too low
Refill studs
The initiator on the beginning of the tube is defective
Check that the initiator on the beginning of the hose is functioning and replace it necessary
Fault 14746: Feeder: Maintenance feeder required

Description The limit of the "feeder maintenance counter" has been reached. The limit can be
26.11.2014 39
Faults
The limit value of the maintenance counter for the feeder was reached

Fault 15000: Feeder: No hardware configuration exist

Description There is no hardware configuration stored in the feeder. The feeder needs to be configured!
The feeder cannot be used without a hardware configuration
Import hardware configuration
Fault 15001: Feeder: Fault during stud separation

Description The feed rail of the feeder was not filled.
40 26.11.2014
Faults
Refill studs
Stud in the feeder jammed while the separation guide was being filled
Remove jammed stud
Defective fuse on the drum motor driver PCB
Replace fuse F1 (drum motor driver PCB)
Replace fuse (feeder PCB control)
Defective motor driver PCB
Replace the defective PCB
Defective proximity switch in the separation guide
Replace the defective switch
Only TF12, TE46, TF47:
Vibrating conveyor set incorrectly (hopper and/or vibrating bowl)
Adjust programming on the touchpad
Fault 15002: Feeder: Voltage supply for drum motor is missing

Description Please check the fuse for the drum motor.
Drum motor driver PCB has no power supply
Check the wiring of the drum motor driver PCB
Fault 15003: Feeder: 24V external control voltage not available

Description The external 24V control voltage has not been detected.
26.11.2014 41
Faults
Fuse F4 on the feeder PCB control is defective
Check the F4 fuse on the feeder PCB control and replace it if necessary
The transformer in the TE system or its fuse is defective
Check the fuse and the transformer and replace them if necessary
The feeder supply line is defective
Replace the feeder supply line
Fault 15004: Feeder: Air pressure not sufficient

Description Input air pressure to the feeder has fallen under the permitted value.


For the procedure, see the assembly instructions of the feeder.
The compressed-air throttle for the feeder is not set correctly
Set the compressed-air throttle
Compressed-air connection defective
Check the compressed-air supply of the feeder
Pressure control device defective
Replace the feeder or the pressure control device

If the pressure displayed on the manometer is correct, the pressure control device may be defective or
set incorrectly.
Feeder PCB control is defective
Replace the feeder or the PCB control
The electrical connection of the pressure control device is defective
Replace feeder
Fault 15005: Feeder: 24V internal control voltage not available
42 26.11.2014
Faults
Description The internal 24V control voltage has not been detected.
Replace fuse F3 on the feeder PCB control
The feeder supply line is defective
Replace the feeder supply line
Fault 15006: Feeder: 5V CAN bus voltage not available

Description The 5V CAN bus voltage has not been detected.
Replace fuse F2 on the feeder PCB control
Fault 15007: Feeder: Maintenance feed rail required

Description The limit of the "feed rail maintenance counter" has been reached. The limit can be
The limit value of the preventative maintenance counter for the feed guide was reached

Fault 15008: Feeder: Maintenance divider feeding tube required

Description The limit of the "feeding tube after divider maintenance counter" (feeding tube after the
divider, which is direct connected to the feeder) has been reached. The limit can be
programmed in the feederparameters. This counter is increased with each feeding
26.11.2014 43
Faults
The limit value of the preventative maintenance counter for the divider feed tube was
reached

Fault 15009: Feeder: Voltage supply for vibrating bowl is missing

Description Please check the fuse for the vibrating bowl .
Defective fuse on the vibrating conveyor driver PCB
Replace fuse F1 (vibrating conveyor driver PCB)
Vibrating conveyor driver PCB has no power supply
Check the wiring of the vibrating conveyor driver PCB
Fault 15010: Feeder: drum motor overcurrent protection (drum blocked)

Description The drum motor will be is switched off, if the over-current protection is activ. Reason may be
that the drum is blocked (e.g. by a weld stud)
The drum is blocked (e.g.: by a weld stud)
Switch off the feeder and remove the jam
Fault 15011: Extern Pickup station: loading pin don't leave back position
Description The loading pin of the extern pickup station don't leave the back position. Both end position
sensors are active, please check sensors.
44 26.11.2014
Faults
Correctly set the sensor for detecting the front position of the loading pin
Replace the sensor for detecting the front position of the loading pin
Correctly set the sensor for detecting the back position of the loading pin
Replace the sensor for detecting the back position of the loading pin
Fault 15012: Extern Pickup station: loading pin don't leave front position
Description The loading pin of the extern pickup station don't leave the front position. Both end position
sensors are active, please check sensors.
Correctly set the sensor for detecting the back position of the loading pin
Fault 15013: Extern Pickup station: rotation segment don't leave feeding position
Description The rotation segment of the extern pickup station don't leave the feeding position. Both end
position sensors are active, please check sensors.
26.11.2014 45
Faults
The cylinder switch for detecting the feed position of the rotation segment is set
incorrectly
Set the cylinder switch
The cylinder switch for detecting the feed position of the rotation segment is defective
Replace the cylinder switch
defective

Fault 15014: Extern Pickup station: rotation segment don't leave pick up position
Description The rotation segment of the extern pickup station don't leave the pick up position. Both end
position sensors are active, please check sensors.
46 26.11.2014
Faults
The cylinder switch for detecting the feed position of the rotation segment is set
incorrectly
Set the cylinder switch
The cylinder switch for detecting the feed position of the rotation segment is defective
Replace the cylinder switch
defective

Fault 15015: Feeder: No fastener (stud) leave the feeder

Description The feeding cycle could not be completed correctly. The fastener (stud) has been not
detected by the Stud-Departure-Sensor and the Stud-Arrival-Sensor. Probably the fastener
(stud) didn't left the feeder.
26.11.2014 47
Faults
The stud fill level is too low
Refill studs
Jammed fastener (stud) between slider and separation guide
Remove jammed fastener (stud)

A fastener (stud) in the separation chamber is blocking the separation block
Open the separation chamber and remove the fastener (stud)
The feed tube is not attached correctly to the feeder or is not cut straight
Check the feed tube on the feeder; if needed, re-cut it and attach it correctly
The stud fill level is too high
Remove fasteners (studs)

Mind maximum filling height
The stud departure sensor is not set correctly or is defective
Set the stud departure sensor correctly or replace it
Programmed parameter "Time separating slider" too short
Increase "Time separating slider"

Fault 15016: Extern Pickup station: Stud-arrival sensor permanently active

Description No feeding cycle is possible, because the stud-arrival sensor of the extern pickup station is
permanently active.
48 26.11.2014
Faults
The stud arrival sensor is not set correctly or is defective
Set the stud arrival sensor correctly or replace it
There are studs in the feed tube
Remove studs
Fault 15017: Extern Pickup station: Maintenance Extern Pickup station required
Description The limit of the "extern pickup station maintenance counter" has been reached. The limit can
be programmed in the feederparameters. This counter is increased with each feeding cycle.
The limit value of the preventative maintenance counter for the divider feed tube was
reached

Fault 15018: Feeder: Fastener (stud) fill level is to low, Please refill studs.
Description The fastener (stud) has been not detected by the Stud-Departure-Sensor, the feed rail of the
feeder was not filled and the Stud fill level is low. Please refill studs.
26.11.2014 49
Faults
Refill studs


Fault 16018: Weld Tool: Maintenance user counter (feedings) required

Description The limit of the "user counter" has been reached. The limit can be programmed in the weld
tool parameters. This counter is increased with each feeding cycle.
50 26.11.2014
Faults
The limit value of the user-defined counter was reached

Fault 16019: Weld Tool: Maintenance collet/gripper required

Description The limit of the "collet/gripper maintenance counter" has been reached. The limit can be
programmed in the weld tool parameters. This counter is increased with each feeding cycle.
The limit value of the preventative maintenance counter for the collet was reached

Fault 16020: Weld Tool: Maintenance weld tool (feeds) required

Description The limit of the "weld tool maintenance counter" has been reached. The limit can be
The limit value of the preventative maintenance counter for the weld tool was reached

Fault 16022: Weld Tool: Maintenance feeding tube required

26.11.2014 51
Faults
The limit value of the preventative maintenance counter for the feed tube was reached

Fault 16023: Weld Tool: Welding gun sequence not followed

Description The correct sequence of operation while welding with a welding gun (PK/PLM) was not
observed.
The weld sequence with a welding gun should follow this order:
a. Welding with regard to angularity switch:

1) SOW = Stud On Work
52 26.11.2014
Faults
The worker did not maintain the correct sequence
New start attempt with the correct sequence

To do so it is necessary to first remove the weld gun from the workpiece and release the start button.
Then you can restart in the correct sequence.
No electrical contact to the workpiece

In the menu "Status welding process" of the control panel, you can check if the SOW signal is generated
when the weld gun is set on the workpiece.
Check the electrical connection to the workpiece
No stud in the collet
The feeder cannot convey any more studs
Check the fill level of the feeder and refill if necessary

The feed tube is kinked
Check the lay of the feed tube
Replace the feed tube
The feeding process is programmed incorrectly
Check the feed parameters

This includes, among other things, the feed time and the load time
Worn, contaminated or interrupted weld and ground cables
Inspect the weld cables, ground cables, ground hold-down device and the cable package for
defects and contamination and replace them if needed
Defective or incorrectly set weld tool
Replace the collet
The stud is jammed in the weld tool
Remove the stud from the weld tool
The mouthpiece is set incorrectly or is defective
Clean the mouthpiece
Check the mouthpiece setting
26.11.2014 Ensure that the required stickout is present. 53
The weld tool is defective

Faults
Fault 16048: TR: no rotation movement allowed

Description The input signal "TR movement release" required for the rotation was not set via the
customer interface.
The input signal "TR movement release" is not set

The robot/higher-order PLC did not set the input signal "TR movement release".
Set the input signal "TR movement release" on the customer interface
The input signals of the customer interface can be checked via the control panel of the TE control.
Fault 16052: Weld tool: unknownweld tool type

Description Unknown weld tool type, check the weld tool hardware configuration and the weld tool
software.
The software does not recognize the configured weld tool

The configuration of the connected weld tool is missing. It does not know what type it is or which sensors
and actuators are available
Adjust the hardware configuration of the weld tool

Set the configuration of the weld tool on a test bench
Replace the weld head

Replace the weld head with a configured weld head.
Import new software into the weld tool
Fault 16106: Weld tool: Feeding tube locking

Description The feeding tube is not properly connected to the weld tool.
The feed tube is not connected correctly to the weld tool
Attached the feed to so that the interlock switch is pressed
Defective cable package
Replace the defective cable package
Fault 16110: Weld tool: Gripper not closed

Description It is trying to start a weld process but the gripper is not closed.
54 26.11.2014
Faults
The gripper is jammed
Clean the gripper
Check that the gripper moves smoothly

To do so you must dismount the gripper (see operating instructions)
The compressed-air supply of the weld tool is defective
Check the cable package to the weld tool
Fault 16112: Weld tool: protective gas pressure not sufficient

Description Input protective gas pressure to the weld tool has fallen under the permitted value.
Insufficient or no pressure
Ensure sufficient pressure supply

Pressure connection defective
Check the pressure supply of the weld tool
Defective weld tool PCB
Fault 16179: Weld tool: Gripper teaching fault

Description The weld head has not recognized any gripper movement during teaching.
Fault 16188: Weld tool: Gripper not opened

Description The weld head has not recognized the gripper position "open".
26.11.2014 55
Faults
The gripper is mechanically blocked

Due to contamination or mechanical blocking, the gripper cannot completely open or close
Open and close the gripper several times

Move the gripper several times either by using the manual functions or by switching the supply air off
and moving it by hand.
The solenoid valve is broken

If the gripper is completely closed although the LED of the solenoid valve is illuminated, then the valve
might be broken.
Replace the solenoid valve

Replace the solenoid valve on the gripper.
The control signal does not reach the solenoid valve

If the LED on the solenoid valve does not illuminate, the control signal of the PCB does not reach the
gripper valve.
Check the cabling

You must check the cabling from the PCB control to the solenoid valve. Then replaced defective
components.
Fault 16300: TR: Overload rotation motor

Description The TRweld head has recognized an overload of the rotation motor e.g. through blocking or
stiffness.
The rotary tool is blocked by an interfering contour in the work area
Check the work area of the rotary tool for interfering contours and consult a specialist if necessary
Rotary tool does not move smoothly
Check if the rotary tool moves smoothly and replace the TR if required
With the unit switched off, turn the rotary tool by hand to check if it moves smoothly.
Rotation motor is defective
Check rotation using the manual functions of the weld tool
Replace the rotation motor
Fault 16301: TR: Overvoltage rotation motor

Description The supply voltage for the rotation motor has exceeded the maximum allowed value.
56 26.11.2014
Faults

Power supply in the weld unit is defective
Replace the power supply or weld unit
Fault 16302: TR: Controller rotation motor over temperature

Description The temperature of the controller amplifier of the rotation motor has exceeded the maximum
allowed value.
Fault 16303: TR: Maximum output power controller rotation motor achieved
Description The rotation motor of the TR has been overloaded. The allowed duty ratio (power on-time)
has been exceeded.
26.11.2014 57
Faults
Fault 16304: TR: Undervoltage rotation motor

Description The supply voltage for the rotation motor has fallen below the minimum allowed value.

Power supply in the weld unit is defective
Replace the power supply or weld unit
The total length of the cable package is too large
Use a shorter cable package
Fault 16310: TR: Error with the encoder signals of the rotation motor
Description The controller of the rotation motor detects no valid encoder signals. The cable or the
encoder might be damaged.
The control cable of the rotary motor is not wired correctly or is defective
Check the connector pin assignment and the control cable

You can find detailed information in the service manual
The 5 V power supply in the motor controller is defective
Check the controller of the rotation motor and replace if needed
Fault 16311: TR: Position fault during rotation

Description The TR control board has recognized a deviation from the given path during rotation
movement.
58 26.11.2014
Faults
Fault 16317: TR: Angle not allowed

Description The rotation command includs an unvalid angle. The angle is out of the valid range from -
17,0° - 273,0°.
Angle specification outside of permissible range

the Angle for the rotation of the rotary tool is out of the valid angle range
Only specify permissible angles for the rotation

Correct the angle specification via the customer interface or in the welding program.
Fault 16346: Weld tool: Wrong stud length (variable stud block)
Description During pick up of a stud out of the pickup station a stud length deviating from the reference
value has been recognized.
The stud is outside of tolerance or incorrect
Remove the stud and feed a new one
The sustainer was shifted

The sustainer was shifted after the stud had been calibrated
Recalibrate the stud
Tolerances for the stud length are parametrised incorrectly
Define new tolerance values
The clamping of the variable end stop is defective

The clamping is blocking the movement of the variable end stop so that no valid measurement of the stud
values is possible
Check the clamping of the variable end stop

It should be possible to lightly press the variable end stop backwards when the gripper is open (the TR
must be supplied with air for this)
26.11.2014 59
Faults
Fault 16347: Weld tool: Wrong stud diameter

Description A stud diameter deviating from the reference value has been detected in the gripper of the
weld head.
The sustainer was shifted

The sustainer was shifted after the stud had been calibrated
Recalibrate the stud
Gripper finger interchanged but the burn-up correction value not deleted
Reset the gripper burn-up correction value

values is possible

Fault 16349: TR: Pickup station 1: loading pin not in back position
Description The loading pin of the pickup station 1 has not reached the back position.
60 26.11.2014
Faults
Replace sensor
is defective or connected incorrectly
Check the cable for correct contact and seat; replace if needed
Compressed air of the pickup station is not connected
Check the compressed air of the pickup station

Check the setting of the pressure reducer

For the procedure, see the operating instructions.
Fault 16350: TR: Pickup station 1: loading pin not in front position
Description The loading pin of the pickup station 1 has not reached the front position.
26.11.2014 61
Faults
Replace sensor


Fault 16351: TR: Pickup station 1: rotation segment not in feeding position
Description The rotation segment of the pickup station 1 has not reached the feeding position.
62 26.11.2014
Faults
To remedy the jam, open the rotation segment and clean it
If necessary, use the manual functions to move the rotation segment in order to release the jams
Set sensor correctly
Replace sensor
defective
Replace the air cylinder of the rotation segment


Fault 16352: TR: Pickup station 1: rotation segment not in loading position
Description The rotation segment of the pickup station 1 has not reached the loading position.
26.11.2014 63
Faults
Fastener (stud) is blocking the rotation segment

One or more fasteners (studs) are blocking the rotation segment
Remove the fasteners (studs) from the rotation segment

If multiple fasteners (studs) are in the rotation segment, they must be removed
Increase the time of the loading pin delay

An insufficient loading pin delay or a fastener that springs back can cause the rotation segment to jam.
Clean the exhaust air channel of the feed air

A clogged exhaust air channel can cause the fastener (stud) to spring back.
Replace sensor
defective


64 26.11.2014
Faults
Fault 16360: TR: Pickup station 2: loading pin not in back position
Description The loading pin of the pickup station 2 has not reached the back position.
Replace sensor


Fault 16361: TR: Pickup station 2: loading pin not in front position
Description The loading pin of the pickup station 2 has not reached the front position.
26.11.2014 65
Faults
Replace sensor


Fault 16362: TR: Pickup station 2: rotation segment not in feeding position
Description The rotation segment of the pickup station 2 has not reached the feeding position.
66 26.11.2014
Faults
Replace sensor
defective


Fault 16363: TR: Pickup station 2: rotation segment not in loading position
Description The rotation segment of the pickup station 2 has not reached the loading position.
26.11.2014 67
Faults




Replace sensor
defective


68 26.11.2014
Faults
Fault 16376: Weld tool: Stud-arrival sensor detected no stud

Description The stud-arrival sensor detected no stud during a stud feeding process
Stud arrival sensor defective

The stud arrival sensor no longer works
Replace the stud arrival sensor

Stud arrival sensor is not set correctly.
The sensitivity ("Sens.") must be set correctly.
Stud stuck in the feeding tube.
Check if a stud stuck in the feeding tube.
Fault 17000: Weld tool: No hardware configuration exist

Description There is no hardware configuration stored in the weld tool. The weld tool needs to be
configured!
The weld tool cannot be used without a hardware configuration
Import hardware configuration
Fault 17001: Weld tool: start feeding for an unknown feeder

Description The weld tool received a "start feeding" for a not existing feeder
Fault 17002: Weld tool: feeder is not ready for a feeding process
Description The weld tool received a feed start from the TE system although the feeder reports that it is
not ready to feed studs.
Fault 17003: Weld tool:24V external control voltage not available

Description The external 24V control voltage has not been detected.
26.11.2014 69
Faults
The weld tool supply line is defective
Replace the weld tool supply line
Fault 17004: Weld tool: Air pressure not sufficient

Description Input air pressure to the weld tool has fallen under the permitted value.

Replace the weld tool or the pressure control device
Weld tool PCB control is defective
Replace the weld tool or the PCB control
Replace weld tool
Fault 17005: Weld tool: 24V internal control voltage not available
Description The internal 24V control voltage has not been detected.
The weld tool supply line is defective
Replace the weld tool supply line
Fault 17006: Weld tool: 5V voltage CAN bus is missing
70 26.11.2014
Faults
Description The 5V CAN bus voltage has not been detected.
PCB is defective
replace PCB
Fault 17007: Weld tool: Hardware configuration is not correct

Description The saved hardware configuration in the weld tool does not correspond to the function start
requirements
The weld tool cannot be used without a correct hardware configuration
Adjust hardware configuration
Fault 17008: Weld Tool: Weld tool remains in R position

Description After the weld start has been carried out the weld head remains in R position (rear position)
or moves into F position (front position) too slowly.
26.11.2014 71
Faults
The sensor for detecting the back position of the weld tool is defective
Replace the sensor for detecting the back position of the weld tool


The setting of the front and back air throttles on the weld tool is not correct
Check the setting of the front and back air throttles on the weld tool

Check the compressed air connection

Check all air pressure connections to weld head.
The weld tool does not slide smoothly

Switch off the air pressure supply from TE system and push the weld head forward and backward manually
in order to recognize blockings. The movement has to be smooth and should not get stuck.
Check if the weld tool moves smoothly

Interrupt the compressed air supply on the TE system and move the weld tool forwards and backwards
by hand to determine if it moves smoothly. It must move freely and smoothly.
Check the laying of the cable package and correct if needed

The cable package must display no kinks or damage.
Replace weld tool
The solenoid valve for the slide movement is defective
Check the function of the solenoid valve and replace if needed
Clean weld tool
Replace weld tool
72 26.11.2014
Faults
Fault 17009: Weld Tool: Weld tool not in R position

Description The welder control detects that the weld tool is not in R position (rear position).
26.11.2014 73
Faults
Collet welded with the workpiece or fastener
Loosen the collet and replace
The sensor for detecting the back position of the weld tool is set incorrectly
Correctly set the sensor for detecting the back position of the weld tool







Replace weld tool
74 26.11.2014
Replace weld tool

Faults
Fault 17010: Weld Tool: Weld tool ID change between weld gun and weld head
Description Weld tool ID change between weld gun and weld head, check cable package and connectors.
Cable package defective

It is recommended you use the cable package test box.
Inspect electrical contacts

Check all multi-coupling connectors on the feeder up to weld head.
Check whether a weld head was detected by the weld unit

Check the connected weld tool in the control panel
Fault 17011: TR: Feeding-cmd includes no pickup-station

Description TR: A feeding-command was sent to the TR-weldhead, which included an invalid
pickupstation.
The assignment of the feeder to the pickup stations is not programmed correctly
Correctly assign the feeder to the pickup stations

You can check and adjust the reassignments under "Programming > Components > Configuration >
Weld tool".
Fault 17012: TR: Stud Block Poti not In Zero-Position

Description When the gripper is open, the variable end stop is pressed (forwards) into the home position
by a spring. Before a stud was collected, the measuring system determined that the end stop
was not in the home position.
26.11.2014 75
Faults
The clamping of the variable stud end stop is contaminated
Clean the clamping and the potentiometer rod of the stud end stop
The fastener (stud) is jammed between the gripper finger and the stud end stop
Remove fastener (stud)
The spring of the variable stud end stop is contaminated or defective
Clean spring and replace if needed
The measuring system (kit potentiometer) of the variable stud end stop is defective
Replace the measuring system (kit potentiometer)
The ribbon cable of the variable stud end stop is defective
Replace the cable harness of the ribbon cable
Fault 17013: TR: Error in the Controller of the rotation motor

Description A common fault in the controller of the rotation motor
The controller of the rotation motor is defective
Fault 17014: TR: Communication Error to the controller of the rotation Motor
Description The communication of the TR PCB to the controller of the rotation Motor has a failure
The cable harness between the TR PCB (E691) and the controller is defective
Check the cable harness and replace if needed
TR PCB (E691) is defective
Replace the TR PCB (E691)
Fault 17015: TR: Error during the reference run of the rotation motor
Description During the reference run an error was detected. The reference run is aborted.
76 26.11.2014
Faults
The control cable of the rotary motor is not wired correctly or is defective
Check the connector pin assignment and the control cable

You can find detailed information in the service manual
Fault 17016: TR: Rotation error - the angle was not reached
Description During the rotation an error appeared so that the preset angle was not reached
The specified angle is outside the valid range
Check the angle specification and correct if needed

The permissible angle range is: -17.0° to 273.0°
Fault 17017: Weld Tool: Maintenance weld tool (welds) required

programmed in the weld tool parameters. This counter is increased with each welding cycle.
The limit value of the preventative maintenance counter for the weld tool was reached

Fault 17018: Weld Tool: Maintenance slide rail required

Description The limit of the "slide rail maintenance counter" has been reached. The limit can be
programmed in the weld tool parameters. This counter is increased with each slide rail
movement.
26.11.2014 77
Faults
The limit value of the preventative maintenance counter for the slide was reached

Fault 17019: Weld Tool: Maintenance loading pin required

Description The limit of the "loading pin maintenance counter" has been reached. The limit can be
programmed in the weld tool parameters. This counter is increased with each loading pin
movement.
The limit value of the preventative maintenance counter for the loading pin was reached

Fault 17020: TR: Maintenance pick up station 1 required

Description The limit of the "pick up station 1 counter" has been reached. The limit can be programmed in
the weld tool parameters. This counter is increased with each feeding cycle into pick up
station 1.
The limit value of the preventative maintenance counter for the pickup station was reached

Fault 17021: TR: Maintenance pick up station 2 required

station 2.
78 26.11.2014
Faults
The limit value of the preventative maintenance counter for the pickup station was reached

Fault 17022: TR: The actual angle is not admitted for a slidemovement or a welding
Description For a slidemovement or a welding the actual angle is not admitted. There is a risk of
collusion with the pickup-stations.
Angle is too small
Move the rotary tool to a larger angle
Angle is too large
Move the rotary tool to a smaller angle
Fault 17023: TR: Studblock was pushed back during slide movement
Description During a slide move forward process the studblock was pushed back, even though it should
be clamped by a cylinder when the gripper is closed.
26.11.2014 79
Faults
Pneumatics on the clamping cylinder defective

Pneumatics on the clamping cylinder defective. The clamping cannot be properly vented due to a kinked
hose, thus the maximum clamping force is not reached.
Replace the pneumatic hose to the clamping cylinder

The potentiometer of the stud end stop is defective
Replace the potentiometer
The cable harness between the stud end stop and E690 is defective
Replace the cable harness
The control cables in the cable track are defective
Replace the cable track
Fault 17024: TR: Maintenance feeding tube pick up station 2 required

Description The limit of the "feeding tube pick up station 2 maintenance counter" has been reached. The
limit can be programmed in the weld tool parameters. This counter is increased with each
feeding cycle.
The limit value of the preventative maintenance counter for the feed tube of pickup station
2 was reached

Fault 17025: TR: Move slide forward is not allowed, because the rotation is not referenced.
Description Function not possible, because the rotation is not referenced, the current angle is unknown
and a save operation not garantied.
80 26.11.2014
Faults
The rotation is not referenced after switch-on
Use the manual functions or the customer interface to turn the rotary tool to any angle
Fault 17026: TR: Slowmotion controller detected a too fast rotation

Description The slowmotion controller was in slowmotion mode and detected a too fast rotation of the
motor.
Fault 17027: TR: Slowmotion controller has a system failure

Description The slowmotion controller generated an error because it detected a system failure
The input signals have an invalid status
Check the 4 slow-motion signals in the cable package and the TR cable harness
The slow-motion cable harness in the TE is defective
Check the cable harness; repair or replace

The slow motion controller is defective
Replace the slow motion controller
Fault 17028: TR: Rotation not possible, because slide is not in back-position
Description The slide is not in back-position, that is why a rotation is not possible.
26.11.2014 81
Faults
The air pressure in the weld tool is insufficient
Check the air pressure of the system and the weld tool
The weld tool slide was moved forward
Use the manual functions or the customer interface to move the slide backwards
The sensor for the slide position is shifted or defective
Replace or reset the sensor
Fault 17029: Weld tool: Gripper don't leave Closed Position

Description The Gripper don't leave the closed position. Both end position sensors are active, please
check sensors.
Clean the gripper

Fault 17030: Weld tool: Gripper don't leave Open Position

Description The Gripper don't leave the open position. Both end position sensors are active, please check
sensors.
Clean the gripper

82 26.11.2014
Faults
Fault 17031: Weld tool: Weldtool Don't Reach Front Position

Description The weld tool has not reached the front position. The requested position has not been
reached within the maximum allowed monitoring time.
26.11.2014 83
Faults
If the front position of the weld tool is detected via SOW, then no SOW is present
Check SOW
The sensor for detecting the front position of the weld tool is defective
Replace the sensor for detecting the front position of the weld tool
Air pressure is too low







Replace weld tool
Replace weld tool
84 26.11.2014
Faults
Fault 17032: Weld tool: extern üick up station is not ready for pick up process
Description The weld tool received a feed start from the TE system although the feeder reports that it is
not ready to feed studs.
Fault 17033: Weld tool: No fastener (stud) loaded

Description No fastener (stud) loaded, after feeding process.
When a fastener was transferred from an unknown pickup station, no fastener was
detected
Provide fastener
Fault 17034: Weld tool: No fastener (stud) leave the feeder

Description No fastener (stud) leave the feeder. No fastener (stud) loaded, after feeding process.
The stud departure and the stud arrival sensor don't detect a stud.
26.11.2014 85
Faults
Refill studs



Fault 17035: Weld tool: Stud-arrival sensor permanently active

Description The stud-arrival sensor is permanently active, please check the sensor.
86 26.11.2014
Faults
The feed tube coupling is not connected correctly
Press the feed tube into the pickup station until the coupling is locked
Sensor defective
Replace sensor
Sensor set incorrectly
Set sensor sensitivity and mode
Fault 17036: Weld tool: Loading pin don't leave back position
Description The loading pin don't leave the back position. Both end position sensors are active, please
check sensors.
Fault 17037: Weld tool: Loading pin don't leave front position
Description The loading pin don't leave the front position. Both end position sensors are active, please
check the sensors.
Fault 17038: Weld tool: The "Stud in gripper" senor is permanently active
Description The "Stud in gripper" senor is permanently active. Please check the sensor.
26.11.2014 87
Faults
Sensor defective
Replace sensor
The sensor is not mounted correctly
Mount sensor correctly
Fault 17039: TR: Pickup station 1: loading pin don't leave front position
Description The loading pin of the pickup station 1 don't leave the front position.

is defective
Fault 17040: TR: Pickup station 1: loading pin don't leave back position
Description The loading pin of the pickup station 1 don't leave the back position.
88 26.11.2014
Faults
is defective
Fault 17041: TR: Pickup station 1: rotation segment don't leave pick up position
Description The rotation segment of the pickup station 1 don't leave the pick up position.
defective

Fault 17042: TR: Pickup station 1: rotation segment don't leave feed position
26.11.2014 89
Faults
Description The rotation segment of the pickup station 1 don't leave the feed position.




defective

Fault 17043: TR: Pickup station 1: Stud-arrival sensor permanently active

Description The stud arrival sensor is checked at the beginning of every feed. If the sensor is
continuously on for a timeout of one second, the sensor must be inspected and, if needed,
the sensitivity set or the sensor exchanged.
90 26.11.2014
Faults
Sensor defective
Replace sensor
Fault 17044: TR: Pickup station 2: loading pin don't leave front position
Description The loading pin of the pickup station 2 don't leave the front position.
Supply air on the weld tool not connected or pressure insufficient
is defective
Fault 17045: TR: Pickup station 2: loading pin don't leave back position
Description The loading pin of the pickup station 2 don't leave the back position.
26.11.2014 91
Faults
is defective
Fault 17046: TR: Pickup station 2: rotation segment don't leave pick up position
Description The rotation segment of the pickup station 2 don't leave the pick up position.
defective

92 26.11.2014
Faults
Fault 17047: TR: Pickup station 2: rotation segment don't leave feed position
Description The rotation segment of the pickup station 2 don't leave the feed position.




defective

Fault 17048: TR: Pickup station 2: Stud-arrival sensor permanently active

Description The stud arrival sensor is checked at the beginning of every feed. If the sensor is
continuously on for a timeout of one second, the sensor must be inspected and, if needed,
the sensitivity set or the sensor exchanged.
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Faults
Sensor defective
Replace sensor
Fault 17049: Weld tool: No fastener (stud) in cage of the pick up station loaded and no stud
arrival sensor was detected
Description The feed cycle carried out could not be ended correctly. There is no fastener (stud) in the
pickup station cage after the feed cycle, and the stud arrival sensor was not triggered. The
fastener (stud) is in the feed tube.
The feed tube is kinked or defective

Programmed parameter "Maximum feed time" too short
Increase the "Maximum feed time"
Fault 17050: Weld tool: No fastener (stud) in cage of the pick up station loaded
Description The feed cycle carried out could not be ended correctly. There is no fastener (stud) in the
pickup station cage although the stud departure and stud arrival sensors triggered.
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Faults
Fastener (stud) fell out of the pickup station cage
Check the pickup station cage for damage and replace if needed
Set the throttle of the loading pin forward movement correctly
The fastener (stud) is between the stud arrival sensor and the rotation segment
Remove the fastener (stud) and feed again
Fault 17051: Weld tool: Absolute back pos. don't reached during move loading pin backward
Description Absolute back pos. don't reached during move loading pin backward. Check the sensor for
material pollution.
TODO: Contamination / double tension tongs system / O-ring / burnt loading pin...???


Replace sensor
Fault 17052: Weldtool: Wrong stud length before the welding

Description Before the welding a studlegth that is outside the tolerances was detected
26.11.2014 95
Faults
No stud in the gripper and gripper not calibrated correctly
Calibrate gripper
The Stud was manipulated
The calibrated stud values are borderline
Recalibrate stud values
Fault 17053: Weldtool: Wrong stud diameter before the Welding

Description Before the welding a stud diameter deviating from the reference value has been detected in
the gripper of the weld head.
No stud in the gripper and gripper not calibrated correctly
Calibrate gripper
The Stud was manipulated
The calibrated stud values are borderline
Recalibrate stud values
Fault 17054: TR: rotation motor reached iit-limit during weldprocess

Description The slide of the TR rotary tool was moved backwards, because the iit-limit was reached.
The slide moved forward but not backwards again
Move the slide backwards again on time
Fault 17055: TR: Studblock was pushed back during weld process
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Faults
Description During a weld process the studblock was pushed back, even though it should be clamped by
a cylinder when the gripper is closed. That has an effect on the welding (duration parameter)
so that the welding has to be checked.
One-time increased forces occurred due to the motor controller (LMC)

One-time increased forces occurred when the fastener was submerged in the weld pool
Check the fastener and acknowledge the fault

values is possible

Pneumatics on the clamping cylinder defective

Pneumatics on the clamping cylinder defective. The clamping cannot be properly vented due to a kinked
hose, thus the maximum clamping force is not reached.

The potentiometer of the stud end stop is defective
Replace the potentiometer
The cable harness between the stud end stop and E690 is defective
Replace the cable harness
The control cables in the cable track are defective
Replace the cable track
Fault 17056: TR: Pickup station 1: loading pin both sensors are aktive
Description During moving the loading pin back, both end position sensors are active, please check
sensors.
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Faults
One of the two sensors is defective
Check the sensors and replace the defective one
Contamination on the PCB of the pickup station
Clean the pickup stations with compressed air
Description During moving the loading pin forward, both end position sensors are active, please check
sensors.
Fault 17058: TR: Pickup station 1: rotation segment both sensors are aktive
Description During moving the rotation segment into feed position, both end position sensors are active,
please check sensors.
Description During moving the rotation segment into load position, both end position sensors are active,
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Faults
Description During moving the loading pin back, both end position sensors are active, please check
sensors.
Description During moving the loading pin forward, both end position sensors are active, please check
sensors.
Description During moving the rotation segment into feed position, both end position sensors are active,
Description During moving the rotation segment into load position, both end position sensors are active,
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Faults
Fault 17064: TR: Angle is not valid for pick up a stud out of an external pickup-station
Description For picking up a stud out of an external pickup station, the actual angle of the rotary tool is
not valid.
Angle is too small
Move the rotary tool to a larger angle
Angle is too large
Move the rotary tool to a smaller angle
Fault 17065: Weld tool: no feeding allowed

Description The bit "feeding allowed" is not set via the interface.
The "Feeding Allowed" signal is not set

The robot/higher-order PLC did not set the bit "Feeding Allowed". In the control panel, check the inputs of
the customer interface
Set the input signal "Feeding Allowed" on the customer interface
Fault 17066: TR: Enable of the rotation motor controllor failled

Description To rotate the rotary tool the controller must be enabled by a command and a hardware signal
The controller is missing the hardware release signal
Check the hardware signal from the E691 to the controller
Check the cable harness from the E691 to the controller
The cable harness between the TR PCB (E691) and the controller is defective
Check the cable harness and replace if needed
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Faults
Fault 17067: Weld tool: No fastener (stud) at the external pickup

Description At the external pickup the weldtool found no stud
No fastener (stud) provided by the external feeder
Fastener (stud) provided by the external feeder
The TR angle position is not correct to collect the fastener (stud) from the external feeder
Turn the TR to the correct angle

... with the customer interface or the manual functions
The weld tool is not positioned correctly to collect the fastener (stud) from the external
feeder
Position the weld tool correctly
Fault 17068: Weld tool: Absolute front pos. don't reached during move loading pin forward
Description After start loading pin forward is the senor for absolute front pos. not activ. Check the sensor
for material pollution.
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Faults

Fastener (stud) is blocking the loading pin

An insufficient loading pin delay or a fastener that springs back can cause the loading pin to jam.
Replace sensor
is defective
Fault 17069: Weld tool: Restriction front pos. don't reached during move loading pin forward
Description After start loading pin forward is the senor for restriction front pos. not activ or the senor for
absolute front pos. is activ . Check the sensors.
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Faults
The slider for the loading pin limiting is defective
Replace the slider for the loading pin limiting
Replace sensor
is defective
Fault 17070: Weld tool: Stud-arrival and stud-departure sensor detected no stud
Description The stud-arrival and stud-departure sensor detected no stud during a stud feeding process
Stud arrival sensor and stud departure sensor defective

The stud arrival sensor and stud departure sensor no longer works
Replace the stud arrival and stud departure sensor

Replace the stud arrival and stud departure sensor
Stud arrival sensor and stud departure sensor are not set correctly.
Stud stuck in the feeder.
Check the feeder.
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Faults
Fault 17071: Weld tool: protection gas flow rate not sufficient
Description Protective gas flow rate has fallen under the permitted value during the weld process
Insufficient or no pressure
Check proection gas supply

Check if the cable package is alright and the protection gas reaches the solenoid Valve inside the weld
tool
gas tubes to the front end defective
Check and change defective tubes
gas flow sensor not adjusted correctely
Adjust the Sensor mode and sensity
Flow through sensor defective
replace the sensor
Protection gas solenoid valve defective
Change defective solenoid valve
Defective weld tool PCB
Fault 20002: No SOW

Description The required signal SOW (stud on work) for starting a weld cycle is not recognized.
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Faults
No stud in the collet
The feeding process is programmed incorrectly
Check the feed parameters

This includes, among other things, the feed time and the load time
Replace the collet
The loading pin does not move smoothly
Replace the weld tool
Stud is too short
Remove studs
Check if the hopper or drum has been filled incorrectly
Worn, soiled or interrupted ground cables
Inspect the ground cables, ground hold-down device and the cable package for defects and
contamination and replace them if needed
Defective or incorrectly set weld tool
Replace the collet
The weld tool cannot reach the workpiece
Check the distance between the weld tool and the workpiece
Check the cable package

You can find the correct setting value for the input air pressure in the assembly instructions
(typical values are 5 to 8 bar).
The sustainer is not set correctly
Clean the sustainer
Check the sustainer setting

Ensure that the required stickout is present.
26.11.2014 The weld tool is defective 105

The weld cable is interrupted within the weld tool.
Faults
Fault 20003: Weld tool not in R position

Description The welder control detects that the weld tool is not in R position (rear position).
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Faults


The weld tool was manually moved into the front position
The weld tool is moved to the back position when the fault is acknowledged





Replace weld tool
Replace weld tool
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Faults
Fault 20004: SOW not reset

Description After a weld cycle the signal SOW (stud on work) is still detected.
The weld circuit was not opened after a weld was carried out
Weld spatter creates an electrical connection between the sustainer/mouthpiece and

the collet
Collet welded with the workpiece or fastener
Loosen the collet and replace
The workpiece follows the backwards movement of the weld tool
Fix the workpiece
Contamination in the transition between the receiver and the feed tube on the weld
tool
Replace weld tool

Fault 20006: DCPU-PM: Program not selected

Description The welder control does not detect a valid program number/Stud-ID from Robot/PLC or from
a welding gun with program select switch. NOTE: In the menu "Status customer interface" of
the control panel it can be checked which program number/Stud-ID had been s
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Faults
The program number/stud ID sent by the robot/PLC is not correct

When the program is selected via the mode "Program and Output" or "Number-ID", the sent program
number is zero or is outside the valid value range.
The size of the valid value range is displayed in the system status.
When the program is selected via the
Check the program number/stud ID activated by the robot/PLC
The program number/stud ID was not set by the robot/PLC on time

The program number/stud ID must already be provided by the robot/PLC before the associated start signal
is set (see impulse diagram in the customer interface description).
Check the sequence in the robot/PLC program
Wiring error between robot/PLC and the parallel customer interface of the weld unit
Inspect the wiring for correctness and cable break

Using the interface description (appropriate for the software version used on the customer interface),
identify the signal lines for transferring the program number and check them.
The setting parameter "Program selection" is not programmed correctly

The setting parameter "Program selection" is located in the system configuration. The value set here must
agree with the program selection used by the customer interface.
Adjust the setting parameter "Program Selection" in the system configuration
Program selection via stud ID: The selected stud ID not active in the weld unit
Re-create the stud ID (see programming instructions)
Program selection via stud ID: The setting parameter "Output" is not correct
The setting parameter "Output" must be identical to the output number for which the start signal was given.
Adjust the output assignment (see programming instructions)
The program number sent by the weld gun is not correct
Check the setting parameter "Program Selection Switch"

The setting parameter "Program selection switch" is located in the system configuration for the weld
output and should only be programmed to "Available", if a weld gun with a program pre-selection switch
is also connected.
Check the function of the weld gun

In the menu "Status Feeder/ Stud Divider" of the control panel, you can check the program number
preselected on the weld gun.
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The internal program pre-selection should be used, but multiple programs are active
With an internal program pre-selection, it is not necessary for the robot/PLC or the weld gun to specify the
Faults
Fault 20025: Wrong fastener (stud) loaded

Description At the beginning of the weld cycle with the function "Stud Length Check" an incorrect fastener
length has been recognized. Using units with stud divider it has been found that the stud
currently located in the weld tool does not comply with the "stud assi
110 26.11.2014
Faults
No stud in the weld tool
Feeder jammed or empty
Remedy the jam, fill up the studs and repeat the stud feeding process
Feed tube defective
Change the feed tube and repeat the stud feeding process
No feeding initiated
Check the setting parameter "Feeding"
Ensure that the start signal is given with external feeding
Stud with incorrect length in the weld tool
Check whether the right studs are in the feeder and exchange if needed
Base on the weld position contaminated
Check the base for weld spatter, stud, etc.
Stickout not correctly calibrated
Recalibrate stickout (see programming instructions)
The value for the tolerance of the stickout is too low
Increase the value for the tolerance (see programming instructions)
Divider application: Setting parameter "Stud assignment" programmed incorrectly
Adjust the setting parameter "Stud assignment" in the welding program (see programming instructions)
Divider application: The stud in the weld tool does not correspond to the stud assignment
External stud feeding: Check whether the robot/PLC feeds the right stud in advance
Internal stud feeding: Check the setting parameter "Next stud" (see programming instruction)
Weld tool defective
Replace weld tool
Fault 20028: No SOW - fastener (stud) has been not detected by stud-departure sensor
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Faults
Reason for the missing SOW signal:

The feeding cycle that was performed before the welding could not be completed correctly.
The fastener (stud) has been not detected by stud-departure sensor.
Refill studs



112 26.11.2014
Faults
Fault 20029: No SOW - fastener (stud) has been not detected by stud-arrival sensor
Reason for the missing SOW signal:

The feeding cycle that was performed before the welding could not be completed correctly.
The fastener (stud) has been not detected by stud-aarival sensor.
The feed tube is kinked or defective

Programmed parameter "Maximum feed time" too short
Increase the "Maximum feed time"
Fault 20030: DCPU-PM: Weld out of tolerance

Description One or more of the observed weld parameters are out of the programmed tolerance range.
This fault is caused by a timeout and indicates that the component which determined the
tolerance exceeding did not send the corresponding fault in the expected time.
Fault 20038: Data connection feeder

Description The communication between weld unit and feeder is disturbed.
Fault 20039: Internal connection customer interface
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Faults
Description The internal communication with the customer interface is disturbed.
Fault 20040: Fiber optic connection SMPS

Description The internal communication with the SMPS is disturbed.
LTF is defective
The communication connection (LTF) between the two affected components is defective.
Replace the LTF
SMPS is defective
CPM is defective
Replace the weld unit or the CPM PCB
Replace weld unit
Fault 20041: SMPS: Weld program parameters invalid

Description The weld program received by the SMPS contains invalid parameters.
Fault 20046: DCPU-PM: Feed cycle failed

Description The weld tool reported a failed feeding cycle.
Protective circuit or emergency stop during the feed cycle
Repeat the feed cycle (e.g. via restart)
No fastener in the collet
Repeat the feed cycle (e.g. via restart)
Fault 20058: DCPU-PM: Weld start signal invalid during current operation state
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Faults
Description A weld start signal has been set by the customer interface or a weld gun with the weld unit
being in an operation state that does not allow processing of start signals.
Reset was set while the weld unit was not ready to operate
Protective circuit/emergency switching off active
Ensure that the protective circuit/emergency switching off is not active (e.g., check the protective
door)
SMPS is not ready after protective circuit/emergency switching off
Wait until the SMPS is ready (approximately 4 seconds)
Wait until the weld unit is ready to operate again and repeat the restart
Robot/PLC sets start signals, but the weld unit is not ready to operate
Check the robot/PLC program

Only set start signals when the weld unit signals that it is ready to operate
Change the operating status and resend the start signal using the restart function
Test mode is active

Test functions are carried out in the control panel or TEVisu.
End test mode

Exit corresponding function in the control panel or TEVisu.
Fault 20103: CPM: Air pressure not sufficient

Description Input air pressure to the TE has fallen under the permitted value.
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Faults

Check the compressed-air supply of the weld unit
Replace weld unit or pressure control device
CPM is defective
Replace the weld unit or the CPM PCB
Replace weld unit
Fault 20109: Feeder: Timeout feeding tube

Description The weld unit signals a feeding cycle that has been carried out in an improper manner.
The stud arrival sensor did not detect a stud with stud feeding optimization active
If the stud feeding optimization is switched on, then the system waits for the signal of the stud arrival sensor
during the stud feed cycle. This returns a signal as soon as the stud passes the sensor on the weld head.
Check whether a stud arrival sensor is available on the weld head while the stud feeding optimization is
switched on
The stud arrival sensor is an option on the weld head. This must be available in order to use the stud
feeding optimization. If no stud arrival sensor is available, this must be deactivated.
Check whether the stud arrival sensor is supplied with voltage

If the stud arrival sensor is present, then you can check the power supply via the green control LED
when the system is switched on.
Check if the stud arrival sensor switches

The yellow LED on the stud arrival sensor illuminates when the sensor detects a stud in the tube. You
can check if the sensor still switches by feeding a stud.
Fault 20112: CPM: Pressure monitor protective gas

Description The CPM signals that the protective gas pressure has fallen below the limit value.
116 26.11.2014
Faults
Supply of protective gas is faulty
Check supply of protective gas
Protecive gas container is empty
Plug new protecive gas container
Pressur of protecive gas is not set in a correct
Check setting of protective gas and correct if necessary
A weld start was set for a program with activated protective gas function although the
system does not support this
Deactivate the protective gas function in the program
Set the weld start for the program without activated protective gas function
Fault 20160: DCPU-PM: Color marking not possible

Description The feeder doesn't recognize the color marking box.
The colour marking box is not connected correctly

The colour marking box is not connected correctly to the X17 on the feeder
Connect the colour marking box to the feeder

Connect the colour marking box to the X17 connector of the feeder
The crimp contacts in the connectors have become pushed back

The crimp contacts in the connectors have become pushed back, so the identifier of the colour marking box
is not detected by the feeder.
Check the crimp contacts of the connector

Check whether a connector crimp contact was pressed back. Both on the X17 of the feeder and on the
plug of the colour marking box.
Fault 20168: DCPU-PM: TR Angle position not achieved

Description The selected angle position of the TR hasn't been achieved.
Timeout when moving to the angle position (ZCPU)
Fault 20325: DCPU-PM: Timeout robot retreating to weld position
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Faults
Description The weld unit signals a timeout during "restart" of a weld with a TR weld head as the signal
"robot retreating to weld position" hasn't been set by the customer interface.
Fault 20345: DCPU-PM: Continuing weld cycle after e-stop/protection circuit not possible
Description After the end of an emergency stop or protection circuit, the weld was interrupted due to
these matters cannot be continued automatically.
Fault 21000: CPM: Phase monitor

Description The phase monitor signals a failure of the power supply.
Fault 21001: DCPU-PM: Changing of operation state not allowed

Description A component tried to change the operation state of an outlet, but this is not allowed under the
current system conditions.
Fault 21002: CPM: USB-Module not available

Description The USB-Module of the CPM board is not available. Check and insert the USB-Module of the
CPM board.
Fault 21003: CPM: Faulty firmware configuration

Description The configuration of the DCPU firmware is not correct. Check and retry DCPU firmware
installation.
Fault 21004: CPM: Faulty hardware configuration

Description The hardware configuartion of the DCPU was faulty and reset to default. Check and
reconfigure harwdare configuration.
118 26.11.2014
Faults
Fault 21008: DCPU-PM: Weldtool number not assigned

Description While initialization phase there was a weldtool detected, which was connected never before.
The user must assign a toolnumber to this weldtool.
Fault 21009: UNUSED: DCPU-PM: Component type changed

Description The type of the connected component changed. The initialization of this component has been
paused. The user can confirm the change and has the system proceed with the initialization
process of the component.
Fault 21010: DCPU-PM: Initialization failed - Unacknowledged exchange of component

Description The type of the connected component changed. The initialization of this component has been
paused. The user can confirm the change and has the system proceed with the initialization
process of the component.
Fault 21011: DCPU-PM: Initialization failed - the datamanagement component didn't react within
the expected span of time
Description There was a read or write request for the data management component, but the expected
response has not been received within the expected span of time.
Fault 21012: DCPU-PM: Initialization failed - component didn't sent the configuration parameter
set
Description The initialization process was canceled.
The component didn't sent a configuration parameter set within the expected span of time.
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Faults
Fault 21013: DCPU-PM: Initialization failed - Touchpad wasn't initialized

Description The touchpad isn't connected or couldn't be initialized within the expected span of time. In
order to initialize a weldtool, which has never been connected to the system before, the
touchpad must be connected, so the user is able to assign a tool number t
Fault 21014: DCPU-PM: Initialization failed - programmable parameter set couldn't be saved
Description The initialization failed. The programmable parameter set couldn't be saved. The
datamanagement returned an error.
Fault 21016: DCPU-PM: Initialization failed - schema set for configuration parameter set
couldn't be saved
Description The initialization failed. The schema for the configuration parameter set couldn't be saved.
The datamanagement returned an error.
Fault 21017: DCPU-PM: Initialization failed - schema set for programmable parameter set
couldn't be saved
Description The initialization failed. The schema for the programmable parameter set couldn't be saved.
The datamanagement returned an error.
Fault 21018: DCPU-PM: Initialization failed - configuration parameter set couldn't be saved
Description The initialization failed. The configuration parameter set couldn't be saved. The
datamanagement returned an error.
Fault 21019: DCPU-PM: Initialization failed - component did not complete initialization
Description The component didn't send complete message within expected span of time.
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Faults
Fault 21030: DCPU-PM: Missing Component

Description The heartbeat signal of a component is missing. The status of this component has been set
to status "NOT ATTACHED" now.
Fault 21031: Data connection weld tool

Description The communication between weld unit and weld tool is disturbed.
Fault 21032: DCPU-PM: Whole weld cycle canceled due to missing LMC
Description The currently running weld process has been canceled due to missing of the LMC. The
communication with the component which is needed for the whole weld cycle has failed.
Fault 21033: DCPU-PM: Whole weld cycle canceled due to missing feeder
Description The currently running weld process has been canceled due to missing of the selected feeder.
The communication with the component which is needed for the whole weld cycle has failed.
Fault 21034: DCPU-PM: Whole weld cycle canceled due to missing weld tool
Description The currently running weld process has been canceled due to missing of the selected weld
tool. The communication with the component which is needed for the whole weld cycle has
failed.
Fault 21035: DCPU-PM: Timeout weld head rotation cycle

Description The currently running weld head rotation process has been canceled due to a timeout. An
attached component didn't answered within the expected period of time.
Fault 21036: DCPU-PM: Weld head rotation canceled
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Faults
Description The current weld head rotation was canceled because the start signal of the rotation was
withdrawn before the rotation was finished.
Fault 21037: DCPU-PM: Weld head rotation cycle canceled due to a start signal during a
operation state that does not allow a rotation start
Description A start signal has been set with the weld unit being in an operation state that does not allow
processing of rotation start signals.
door)

Test mode is active

End test mode

Fault 21038: DCPU-PM: Timeout weld tool gripper move cycle

Description The currently running weld tool gripper move process has been canceled due to a timeout.
An attached component didn't answered within the expected period of time.
Fault 21039: DCPU-PM: Weld tool gripper move cycle canceled due to a start signal during a
operation state that does not allow a gripper movement
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Faults
Description A start signal has been set with the weld unit being in an operation state that does not allow
processing of gripper move start signals.

Test mode is active

End test mode

Fault 21040: DCPU-PM: Weldhead couldn't be moved due to a timeout

Description Weldhead couldn't be moved
Fault 21041: DCPU-PM: weld head couldn't be moved due to a cancel request
Description The initiator of the move process itself canceled the request.
Fault 21042: DCPU-PM: Timeout move cycle wait for rotation

Description The currently running move process has been canceled due to a rotation process of the weld
head which took a longer time than expected.
Fault 21043: DCPU-PM: Request for weldstart canceled while weld cycle is running
Description One of the following reasons caused a cancelation of the currently running weld cycle:
- the current operation state isn't one of the following states:
- S130_MANUAL_MODE_WELDING,
- S160_AUTOMATIC_MODE,
- S150_AUTOMATIC_WITHOUT_P
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Faults
Fault 21044: DCPU-PM: Main weld cycle canceled due to a timeout

Description The currently running weld process has been canceled due to a timeout. An attached
component didn't answered within the expected period of time.
The internal monitoring of the weld process detected a timeout
If additional faults are active when this fault occurs, then check the subsequent procedure using these
faults
The further procedure for removal of the fault depends on the detailed fault message that is displayed.
Check the weld and acknowledged the fault with Restart or Forced WC
Fault 21045: DCPU-PM: Whole weld cycle canceled due to a timeout

Description The currently running weld process has been canceled due to a timeout. An attached
The internal monitoring of the weld process detected a timeout
If additional faults are active when this fault occurs, then check the subsequent procedure using these
faults
The further procedure for removal of the fault depends on the detailed fault message that is displayed.
Fault 21046: LMC: Lift program parameters invalid

Description The lift program received by the LMC contains invalid parameters.
Fault 21047: DCPU-PM: Unkown weld mode

Description The currently running weld process has been canceled due to unkown weld mode. The
customer interface has sent a unkown weld mode.
Fault 21048: Fiber optic connection LMC

Description The communication between weld unit and LMC is disturbed.
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Faults
Fault 21049: DCPU-DM: Measurement data could not be saved

Description So the current weld process has been terminated abnormally.
Fault 21050: DCPU-PM: Weld head move start signal invalid during current operation state
Description A weld head move start signal has been set with the weld unit being in an operation state that
does not allow processing of start signals.

Test mode is active

End test mode

Fault 21051: DCPU-PM: Wrong stud length (stickout)

Description The measured stud length is not the same as the programmed stud length.
Fault 21053: DCPU-PM: Feeder not selected

Description The welder control does not detect a valid feeder or program number/Stud-ID to start feeding.
Fault 21054: DCPU-PM: Start weld not permitted

Description The sender of the current weld start is not permitted to start a welding under the current
conditions (e.g. the weld start for a weld gun can only be send from the weld gun itself).
Fault 21055: DCPU-PM: Component not ready for welding
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Faults
Description The weld process was canceled because the SMPS or LMC is not ready for welding.
Linear motor temperature monitoring blocks the weld to protect the motor
Press Restart to restart the welding
The run-up phase of the SMPS is not yet completed
Press Restart to restart the welding
Fault 21056: DCPU-PM: Timeout stud length check

Description The currently running weld process has been canceled due to a timeout. The result of the
stud length check was not received in the expeceted time.
Fault 21057: DCPU-PM: Timeout for acknowledge of process parameters

Description The currently running weld process has been canceled due to a timeout. The SMPS or LMC
did not acknowledge the process parameters in the expeceted time.
Fault 21058: No fastener (stud) loaded

Description At the beginning of the weld cycle no fastener (stud) has been recognized in the weld tool.
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Faults
No stud in the weld tool
Feeder jammed or empty
Remedy the jam, fill up the studs and repeat the stud feeding process
Feed tube defective
Change the feed tube and repeat the stud feeding process
No feeding initiated
Check the setting parameter "Feeding"
Ensure that the start signal is given with external feeding
Fault 21059: DCPU-PM: Rotation angle not valid for welding

Description The currently running weld process has been canceled due to a rotation angle that is not valid
for welding.
Fault 21060: SysUpdate: Corrupt update of SMPS

Description The software update of SMPS was canceled due to a timeout. The current status of the
component's software is undefined.
Fault 21061: SysUpdate: Corrupt software update of feeder

Description The feeder software update has been canceled due to a timeout. The status of the
component is undefined.
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Faults
Fault 21062: SysUpdate: Corrupt software update of LMC

Description The LMCsoftware update has been canceled due to a timeout. The status of the component
is undefined.
Fault 21063: SysUpdate: Corrupt software update of weldtool

Description The weldtool software update has been canceled due to a timeout. The status of the
component is undefined.
Fault 21064: DCPU-PM: Whole weld cycle canceled due to a missing component
Description The currently running weld process has been canceled due to a missing component. The
communication with a component which is needed for the whole weld cycle has failed.
Fault 21065: DCPU-PM: Feed start signal invalid during current operation state
Description A feed start signal has been set with the weld unit being in an operation state that does not
allow processing of start signals.
128 26.11.2014
Faults
door)

Test mode is active

End test mode

Fault 21066: DCPU-PM: Self-resetting fault during weld process

Description A self-resetting fault has occured during a weld process. This fault ensures that the according
weld process ends with an fault. The causal fault can be found in the fault history.
A self-resetting function occurred during the welding process and was reset again
Retrace the causal self-resetting fault using the fault memory
Fault 21067: SysUpdate: No valid software in control board of LMC

Description The control board of LMC has no runnable software. Please update LMC software.
Fault 21068: SysUpdate: No valid software in control board of SMPS

Description The control board of SMPS has no runnable software. Please update SMPS software.
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Faults
Fault 21069: SysUpdate: No valid software in control board of weldtool

Description The control board of weldtool has no runnable software. Please update weldtool software.
Fault 21070: SysUpdate: No valid software in control board of feeder

Description The control board of the feeder has no runnable software. Please update the feeder software.
Fault 21071: SysUpdate: No valid software in control board of ICPU

Description The control board of ICPU has no runnable software. Please update ICPU software.
Fault 21082: DCPU-PM: Feed cycle canceled due to missing LMC

Description The currently running feeding process has been canceled due to missing of the associated
LMC. The communication with the component which is needed for the feed cycle has failed.
Fault 21083: DCPU-PM: Feed cycle canceled due to missing feeder

Description The currently running feeding process has been canceled due to missing of the selected
feeder. The communication with the component which is needed for the feed cycle has failed.
Fault 21084: DCPU-PM: Feed cycle canceled due to missing weld tool
Description The currently running feeding process has been canceled due to missing of the selected weld
tool. The communication with the component which is needed for the feed cycle has failed.
Fault 21085: DCPU-PM: Timeout feed cycle wait for rotation
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Faults
Description The currently running feed process has been canceled due to a rotation process of the weld
head which took a longer time than expected.
Fault 21086: DCPU-DM: Database of statistical data damaged

Description The database of statistical data is damaged and couldn't be repaired automatically.
Restore an old backup of the database or delete the database of the statistical data.
Database not initialized

The database was not completely initialized during generation. This can happen if you start a system that
does not yet have a database or whose database was recently deleted and the power supply is interrupted
immediately.
Delete database
Import a backup of an older database.
Fault 21087: DCPU-DM: Database of programmable data damaged

Description The database of programmable data is damaged and couldn't be repaired automatically.
Restore an old backup of the database or delete the database of the programmable data.

immediately.
Delete database
Fault 21088: DCPU-DM: Database of statistical data has been automatically restored
Description The data management has automatically restored the database due to a detected corruption
of the data.
Fault 21089: DCPU-DM: Database of programmable data has been automatically restored
Description The data management has automatically restored the database due to a detected corruption
of the data.
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Faults
Fault 21090: DCPU-DM: Fault storage cleared

Description All content of fault storage has been deleted.
Fault 21091: DCPU-DM: Version of database ist newer than version of the installed CPM-
software
Description A downgrade of the database isn't supported.
The databse can't be opened. The system can't be used correctly.
An older CPM software version was imported or a database backup was used to restore
the database of the newer version
Import a newer CPM software version

1. Import a newer CPM software version
Import an old database backup again

1. Create a backup of the current database
2. Restore an older backup of the database.
Completely reprogram the unit by hand

1. Create a backup of the current database.
2. Empty the current database
3. Reconfigure the entire system by hand
Fault 21092: DCPU-DM: database of programmable data has been recreated

Description The user has executed a command which has deleted the database with all the
programmable data.
The database has been recreated afterwards. All following data has been cleared:
- programmable parameter sets of all components
- associations of weldtools
-s
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Faults
Fault 21093: DCPU-DM: database of quality data has been recreated

Description The user has executed a command which has deleted the database with all the
programmable data.
The database has been recreated afterwards. All following data has been cleared:
- measurement data
- fault storage
- graphical measurement data
- longtime-drif
Fault 21094: DCPU-DM: databases have been recreated

Description The user has executed a command which has deleted the databases.
The databases have been recreated afterwards. All following data has been cleared:
- programmable parameter sets of all components
- associations of weldtools
- system- and outlet-dependent
Fault 21095: DCPU-DM: Damaged Database

Description The database is damaged and couldn't be repaired automatically. Restore an old backup of
the database or delete database.

immediately.
Delete database
Fault 21096: DCPU-PM: Stud-ID difference weld and feed cycle

Description The currently running weld process has been canceled due to the usage of different Stud-IDs
for the last feed and the current weld cylce.
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Faults
Change of the stud ID applied on the customer interface during both of the affected cycles
The affected cycles must be started with the same stud ID
Fault 21097: DCPU-PM: Stud-ID difference weld and rotation cycle

Description The currently running weld process has been canceled due to the usage of different Stud-IDs
for the last rotation and the current weld cylce.
Change of the stud ID applied on the customer interface during both of the affected cycles
The affected cycles must be started with the same stud ID
Fault 21098: DCPU-PM: Wrong fastener (stud) loaded

Description The feeding process was canceled due to the detection of a wrong fastner in the pickup
station. The current feeding command deals with a fastner which differs to the one currently
in the pickup station.
Fault 21100: DCPU-PM: Timeout rotation cycle wait for feeding

Description The currently running weld head rotation process has been canceled due to a feeding
process of the weld tool which took a longer time than expected.
Fault 21101: DCPU-PM: Timeout rotation cycle wait for weld head move
Description The currently running weld head rotation process has been canceled due to a move slide
process of the weld head which took a longer time than expected.
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Faults
Fault 21102: DCPU-PM: Weld head not ready for rotation

Description The currently running weld head rotation process has been canceled because the weld head
is not ready for rotation.
Fault 21103: DCPU-PM: Reset of active faults failed

Description Not all active faults could be reset within the defined time span.
Fault 21104: DCPU-PM: Timeout Automatic Teaching

Description The currently running automatic teaching process during weld process has been canceled
due to a timeout. An attached component didn't answered within the expected period of time.
Fault 21105: DCPU-PM: Stick out measurement failed during automatic teaching
Description The currently running automatic teaching process has been canceled due to a failure during
measurement of the stick out.
Fault 21110: DCPU-PM: Following Stud-ID not selected

Description Double ball welding: The selected following Stud-ID is not available.
Please check the assignment of the following Stud-ID in the weld program programming.
Following Stud-ID has been deleted
Select a existing following Stud-ID

The selection of the follwoing Stud-ID has to be done in the weld programm programming.
Restore backup
Fault 21111: DCPU-PM: Following Stud-ID on different outlet
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Faults
Description Double ball welding: The selected following Stud-ID is assigned to an different outlet then the
Stud-ID of the first process.
Please check the assignment of the following Stud-ID in the weld program programming.
Wrong Stud-ID as following Stud-ID selected
Select the correct following Stud-ID

The selection of the follwoing Stud-ID has to be done in the weld programm programming.
Following Stud-ID is assigned to the wrong outlet
Select the correct outlet in the following Stud-ID
Fault 21140: DCPU: UPS not charged

Description The buffer module (E674) of the DCPU could not be charged correctly.
Check the wiring of the buffer module (E674) and replace pcb if necessary.
This message could be deactivated via the button "Ignore".

In Emergency state the device is still fully operational.
Das Puffermodule (E674) der DCPU hat nicht den korrekten Ladezustand erreicht.
Verkabelung des Puffermoduls (E674) prüfen und ggf. Platine austauschen.
Diese Störung kann über die Schaltfläche "Ignore" abgeschaltet werden.

Die Anlage ist im Notbetrieb weiterhin betriebsbereit.
Fault 21141: DCPU: UPS power supply error
136 26.11.2014
Faults
Description The buffer module (E674) of the DCPU has detected an error of the power supply.
Check the wiring of the buffer module (E674) and replace pcb if necessary.
This message could be deactivated via the button "Ignore".

In Emergency state the device is still fully operational.
Das Puffermodul (E674) der DCPU hat eine Störung der Spannungsversorgung festgestellt.
Verkabelung des Puffermoduls (E674) prüfen und ggf. Platine austauschen.
Diese Störung kann über die Schaltfläche "Ignore" abgeschaltet werden.

Die Anlage ist im Notbetrieb weiterhin betriebsbereit.
Fault 21150: DCPU-PM: Timeout tool check

Description The currently running weld tool check process has been canceled due to a timeout. An
attached component didn't answered within the expected period of time.
Fault 21151: DCPU-PM: Wrong weld tool docked

Description The tool check process has determined that the currently docked weld tool does not match
the selection of the active Stud-ID.
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Faults
Incorrect weld tool docked
Connect the correct weld tool

The currently selected and required weld tool can be retraced in the programming of the active stud ID.
Incorrect stud ID applied
Apply correct stud ID from the robot/PLC
Programming of the stud ID incorrect

The correct weld tool was not selected in the welding program of active stud ID.
Select the correct weld tool in the welding program
Tool number assignment for the weld tool not correct

The assigned tool number for the currently connected weld tool is not correct.
Assign the correct tool number
Fault 21152: DCPU-PM: No weld tool docked

Description The tool check process has determined that no weld tool is currently connected on the outlet
selected by the active Stud-ID.
Weld tool not connected
Connect weld tool
Incorrect stud ID applied
Apply correct stud ID from the robot/PLC
Programming of the stud ID incorrect

The correct output was not selected in the welding program of the active stud ID.
Select the correct output in the welding program

Replace weld tool
138 26.11.2014
Faults
Fault 21153: DCPU-PM: Tool check start signal invalid during current operation state
Description A tool check start signal has been set with the weld unit being in an operation state that does
not allow processing of start signals.

Fault 21200: DCPU-PM: Timeout short circuit test SMPS

Description The currently running test process has been canceled due to a timeout. An attached
Fault 21201: DCPU-PM: Timeout feeding test cycle

Description The currently running test process has been canceled due to a timeout. An attached
Fault 21202: DCPU-PM: Start short circuit test invalid during current operation state
Description A test start was triggert with the weld unit being in an operation state that does not allow
processing of such start signals.
Ensure that the protective circuit/emergency switching off is not active (e.g., check the protective door)
Fault 21203: DCPU-PM: Start feeding test cycle invalid during current operation state
Description A test start was triggert with the weld unit being in an operation state that does not allow
processing of such start signals.
Ensure that the protective circuit/emergency switching off is not active (e.g., check the protective door)
Fault 21210: DCPU-PM: Mean value of slider movement time (forward) excceeds tolerated limits
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Faults
Description The measured value of slider movement time (forward) excceeds permanently the
programmed tolerated limits.
Fault 21211: DCPU-PM: Mean value of slider movement time (backward) excceeds tolerated
limits
Description The measured value of slider movement time (forward) excceeds permanently the
Fault 21212: DCPU-PM: Mean value of feeding time excceeds tolerated limits
Description The measured value of feeding time excceeds permanently the programmed tolerated limits.
Fault 21213: DCPU-PM: Wrong software version DCPU

Description The software version of the DCPU differs from the target version given with the last installed
software package.
Fault 21214: DCPU-PM: Wrong software version feeder

Description The software version of a feeder differs from the target version given with the last installed
software package.
Fault 21215: DCPU-PM: Wrong software version LMC

Description The software version of the LMC differs from the target version given with the last installed
software package.
Fault 21216: DCPU-PM: Wrong software version weld tool
140 26.11.2014
Faults
Description The software version of the docked weld tool differs from the target version given with the last
installed software package.
Fault 21217: DCPU-PM: Wrong software version DCPU-OS

Description The software version of DCPU operation system differs from the target version given with the
last installed software package.
Fault 21218: DCPU-PM: Wrong software version ICPU

Description The software version of the ICPU differs from the target version given with the last installed
software package.
Fault 21219: DCPU-PM: Wrong software version SMPS

Description The software version of the SMPS differs from the target version given with the last installed
software package.
Fault 23000: DCPU-CI: Start weld signal from robot invalid during current operation mode
Description A start weld signal has been set by the robot with the weld unit being in an operation mode
that does not allow processing this start signal.

Test mode is active

End test mode

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Faults
Fault 23001: DCPU-CI: Start feed signal from robot invalid during current operation mode
Description A start feed signal has been set by the robot with the weld unit being in an operation mode
that does not allow processing this start signal.

Test mode is active

End test mode

Fault 23002: DCPU-CI: Restart signal from robot invalid during current operation mode
Description Restart signal has been set by the robot with the weld unit being in an operation mode that
does not allow processing this signal.
Fault 23003: DCPU-CI: Forced WC signal from robot invalid during current operation mode
Description A forced weld complete signal has been set by the robot with the weld unit being in an
operation mode that does not allow processing this signal.
Fault 23004: DCPU-CI: Activate protective gas signal from robot invalid during current
operation mode
Description Activate protective gas has been set by the robot with the weld unit being in an operation
mode that does not allow processing this signal.
Fault 23005: DCPU-CI: Set color mark signal from robot invalid during current operation mode
Description Set color mark signal has been set by the robot with the weld unit being in an operation mode
that does not allow processing this signal.
142 26.11.2014
Faults
Fault 23006: DCPU-CI: Move weld tool signal from robot invalid during current operation mode
Description A move weld tool signal has been set by the robot with the weld unit being in an operation
mode that does not allow processing this signal.
Fault 23007: DCPU-CI: Communication failure with customer interface

Description Main Processor (DCPU) is not able to communicate with interface CPU (ICPU).
Supply voltage for ICPU is missing
Fault 23008: DCPU-CI: Customer Interface Protocol Type not selected

Description The customer interface protcol type has not been selected in the system configuration yet.
Without this parameter, a connection to robot can not be established.
Pelease select a protocol type in the system configuration.
Fault 23009: DCPU-CI: Customer Interface parameter are incorrect

Description The connection parameter for the customer interface are incorrect
Fault 23010: DCPU-CI: Customer Interface Protocol Type is incompatible

Description The customer interface protocol type is incompatible with the customer interface hardware
(e.g. protcol type requires more IO's than hardware can transfer)
Fault 23011: DCPU-CI: Customer interface configuration failure

Description Main Processor (DCPU) is not able to configure the customer interface
The power supply for the ICPU is missing
26.11.2014 143
Faults
Fault 23012: DCPU-CI: Weldstart handshake error

Description The weldstart signal was cleared before the weld cycle had been completed. The weld start
signal should be present until the weld complete signal (FK) is generated.
The power supply for the ICPU is missing
Fault 23045: DCPU-CI: Start weld cycle not reset

Description The signal "Start weld cycle" has been set:
> Before start of system

> Before or during a self resetting fault
> Before or during a partial operation stop
For safety reasons, weld starts active when the unit is switched on are not carried out.
The signal "Start weld" was set:
> Before the weld unit is switched on

> During a self-resetting fault
TODO: Protective circuit, user protection? > Before or during a partial operating interruption
The fault can be reset by setting the signal Restart or Forced WC
Fault 23046: DCPU-CI: Weld without current

Description Info for PLUS system not displayed in the user terminal or link software
Fault 23047: DCPU-CI: Parity Error in Stud-ID

Description Parity error in Stud-ID
Fault 23048: DCPU-CI: Parity Error in Action Code

Description Parity error in Stud-ID
144 26.11.2014
Faults
Fault 23050: DCPU-CI: Weld start initiated while the signal StudID valid was not active
Description A weld start had been initiated while the signal "StudID valid" was not active.
26.11.2014 145
Faults
146 26.11.2014
Warnings
2 Warnings
Feeder: Maintenance user counter required

Description The limit of the "user counter" has been reached. The limit can be programmed in the
feederparameters. This counter is increased with each feeding cycle.
Feeder: Maintenance feeding tube required

Feeder: Separation fault - stud has not left feeder

Description The stud-departure sensor on the feeding tube has not detected a stud during the feeding
cycle.
26.11.2014 147
Warnings
The air pressure on the feeder is too low


For the procedure, see the operating instructions of the feeder.
The air throttle for the stud feeder is set incorrectly
Set the air throttle
Jammed stud between slider and separation guide
Remove jammed stud and check the distance between the slider and the separation guide; set as
needed
Separation block jammed due to a stud in the separation chamber
Open the separation chamber and remove the stud
The programmed parameter "Time rear isolating blade" too short
Increase the "Time rear isolating blade"
The beginning of the feed tube is not correctly attached or not cut straight
Check the beginning of the tube and, if needed, re-cut it and place it correctly
Refill studs
The initiator on the beginning of the tube is defective
Check that the initiator on the beginning of the hose is functioning and replace it necessary
Extern pickup station: Stud-arrival sensor detected no stud

Description the Stud-arrival sensor detected no stud during a stud feeding process
148 26.11.2014
Warnings


Feeder: Maintenance feeder required

Description The limit of the "feeder maintenance counter" has been reached. The limit can be
Feeder: Fault during stud separation

Description The feed rail of the feeder was not filled.
Refill studs
Stud in the feeder jammed while the separation guide was being filled
Remove jammed stud
Replace fuse (feeder PCB control)
Defective motor driver PCB
Defective proximity switch in the separation guide
Replace the defective switch
Only TF12, TE46, TF47:
Vibrating conveyor set incorrectly (hopper and/or vibrating bowl)
Adjust programming on the touchpad
26.11.2014 149
Warnings
Feeder: Maintenance feed rail required

Description The limit of the "feed rail maintenance counter" has been reached. The limit can be
Feeder: Maintenance divider feeding tube required

Description The limit of the "feeding tube after divider maintenance counter" (feeding tube after the
divider, which is direct connected to the feeder) has been reached. The limit can be
programmed in the feederparameters. This counter is increased with each feeding
Extern Pickup station: Maintenance Extern Pickup station required

Description The limit of the "extern pickup station maintenance counter" has been reached. The limit can
be programmed in the feederparameters. This counter is increased with each feeding cycle.
Feeder: Stud fill level is low

Description Please refill studs.
Feeder: Stud door is not locked

Description Please close and lock the door.
Feeder: Stud-departure sensor permanently active

Description The stud-departure sensor is permanently active, please check the sensor.
150 26.11.2014
Warnings
There are studs in the feed tube
Remove studs
Weld Tool: Maintenance user counter required

Description The limit of the "user counter" has been reached. The limit can be programmed in the weld
tool parameters. This counter is increased with each feeding cycle.
Weld Tool: Maintenance collet/gripper required

Weld Tool: Maintenance weld tool (feeds) required

Weld Tool: Maintenance feeding tube required

Weld tool: Stud-arrival sensor detected no stud

Description The stud-arrival sensor detected no stud during a stud feeding process.
Attention: Feeding time is increased to 5 seconds!
26.11.2014 151
Warnings


Stud arrival sensor is not set correctly.
Weld Tool: Maintenance weld tool (welds) required

programmed in the weld tool parameters. This counter is increased with each welding cycle.
Weld Tool: Maintenance slide rail required

Description The limit of the "slide rail maintenance counter" has been reached. The limit can be
programmed in the weld tool parameters. This counter is increased with each slide rail
movement.
Weld Tool: Maintenance loading pin required

Description The limit of the "loading pin maintenance counter" has been reached. The limit can be
programmed in the weld tool parameters. This counter is increased with each loading pin
movement.
TR: Maintenance pick up station 1 required

station 1.
TR: Maintenance pick up station 2 required
152 26.11.2014
Warnings
station 2.
TR: Maintenance feeding tube pick up station 2 required

Description The limit of the "feeding tube pick up station 2 maintenance counter" has been reached. The
limit can be programmed in the weld tool parameters. This counter is increased with each
feeding cycle.
Weld tool: Loading pin don't leave front position

Description The loading pin don't leave the front position. Both end position sensors are active, please
check sensors.
Weld tool: Absolute front pos. reached during move weldtool forward
Description Absolute front pos. reached during move weldtool forward. It could be a problem during the
stick-out measuring.
The sensor for detecting the front position of the weld tool is set incorrectly
Correctly set the sensor for detecting the front position of the weld tool
The sensor for detecting the front position of the weld tool is defective
Replace the sensor for detecting the front position of the weld tool
Weld tool: Absolute front pos. don't reached during move loading pin forward
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Warnings
Description After start loading pin forward is the senor for absolute front pos. not activ. Check the sensor
for material pollution.
Replace sensor
is defective
Weld tool: Absolute back pos. don't reached during move loading pin backward
Description After start loading pin backward is the senor for absolute back pos. not activ. Check the
sensor for material pollution.
154 26.11.2014
Warnings
Replace sensor
TR: Pickup station 1: Feed stud-arrival sensor timeout

Description No stud was detected by the stud arrival sensor during the feed process. Thus the blow air
was switched off after the timeout time expired and the feed process was brought to a close.
TR: Pickup station 2: Feed stud-arrival sensor timeout

Description TR: Pickup station 2: Feed stud-arrival sensor timeout
TR: Pickup station 1: The Rotation did not reach load position during a feeding cycle
Description During a feeding cycle the rotation did not reach load position. The rotation is moved to feed
position and afterwards to load position again to fix the problem automatically.
26.11.2014 155
Warnings
TR: Pickup station 2: The Rotation did not reach load position during a feeding cycle
Description During a feeding cycle the rotation did not reach load position. The rotation is moved to feed
position and afterwards to load position again to fix the problem automatically.
Weld Tool: Premaintenance warning collet/gripper required

Weld tool: Weld tool don't leave the front position

Description The weld tool don't leave the front position. Both end position sensors are active, please
check sensors.
TR: Gripper value not valid at the first measurement

Description During a feeding process the gripper value of the stud was out of tolerance at the first
measurement. The second measurement after a timeout of 1sec was successful. If this
warning appears more often there migth be a cable break.
TR: Studblock value not valid at the first measurement

Description During a feeding process the studblock value of the stud was out of tolerance at the first
measurement. The second measurement after a timeout of 1sec was successful. If this
warning appears more often there migth be a cable break.
TR: rotation motor reached iit-limit

Description The slide of the TR rotary tool was moved backwards, because the iit-limit was reached.
156 26.11.2014
Warnings
TR: The Clamping of the variable studblock does not work correctly
Description During the slide move in front process the studblockpoti was pushed back, even though it
should be clamped by a cylinder when the gripper is closed.
CPM: The battery of the clock is low

Description Please replace the batterie on the CPM board.
CPM: Faulty configuration USB-Module

Description The system has a faultily configured USB-Module detected. Exchange or reconfigure the
USB-Module quick as possible.
CPM: Faulty configuration SD-Card

Description The system has a faultily configured SD-Card detected. Exchange or reconfigure the SD-
Card quick as possible.
CPM: Mean value of slider movement time (forward) excceeds tolerated limits
Description A measured value of slider movement time (forward) excceeds permanently the programmed
tolerated limits.
CPM: Mean value of slider movement time (backwards) excceeds tolerated limits
Description The measured value of slider movement time (backwards) excceeds permanently the
CPM: Mean value of feeding time excceeds tolerated limits

Description The measured value of feeding time excceeds permanently the programmed tolerated limits.
26.11.2014 157
Warnings
DCPU-PM: Wrong software version DCPU

Description The software version of the DCPU differs from the target version given with the last installed
software package.
DCPU-PM: Wrong software version feeder

Description The software version of a feeder differs from the target version given with the last installed
software package.
DCPU-PM: Wrong software version LMC

Description The software version of the LMC differs from the target version given with the last installed
software package.
DCPU-PM: Wrong software version weld tool

Description The software version of the docked weld tool differs from the target version given with the last
installed software package.
DCPU-PM: Wrong software version DCPU-OS

Description The software version of DCPU operation system differs from the target version given with the
last installed software package.
DCPU-PM: Wrong software version ICPU

Description The software version of the ICPU differs from the target version given with the last installed
software package.
158 26.11.2014
Warnings
DCPU-PM: Wrong software version SMPS

Description The software version of the SMPS differs from the target version given with the last installed
software package.
CPM: Authorization failed

Description An attempt to authorize the current user failed due to unknown reason.
CPM: Authorization failed - user unknown

Description The user isn't registered in the system.
CPM: Authorization failed - wrong password

Description The password is wrong.
CPM: Authorization failed - unknown key

Description The used key isn't registered in the system.
CPM: Authorization failed - timeout

Description Internal error: timeout
CPM: Authorization failed - internal error

Description
26.11.2014 159
Warnings
CPM: Authorization failed - list of registered users not available

Description The list of registered users isn't available. There is no way to check, if the given key is
allowed.
CPM: Authorization failed - error in EKS reader

Description The EKS reader reports an error.
CPM: Authorization failed - unknown privilege level

Description The key is using a privilege level, which is unknown in the system.
CPM: Authorization failed - Customer not selected

Description The customer must be selected in the hardware configuration of the CPM, before the used
key could be authenticated.
CPM: Authorization failed - key has expired

Description The key has expired.
CPM: Authorization failed - EKS reader not available

Description Do you have plugged-in the EKS reader ?
CPM: Authorization failed - key is not valid for this production area
Description You can check the required production area under "System Settings".
160 26.11.2014
Warnings
DCPU-PM: Feed start signal invalid during current operation state

Description A feed start signal has been set e.g. by the start feed button or control panel with the weld
unit being in an operation state that does not allow processing of start signals.
DCPU: TR Slow Motion active

Description Slow motion is active for the TR. This results in an increase of the cycle time.
DCPU: UPS not charged

Description The UPS pcb (E674) of the DCPU could not be charged correctly.
Check the wiring of the UPS pcb (E674) and replace pcb if necessary.
DCPU: UPS power supply error

Description The UPS pcb (E674) of the DCPU has detected an error of the power supply.
Check the wiring of the UPS pcb (E674) and replace pcb if necessary.
DCPU-CI: Weldstart removed while weld process has not been completed
Description Weldstart removed while weld process has not been completed
DCPU-NI: The ProFeP System kann not be activated

Description The ProFeP system could not be started.
26.11.2014 161
Warnings
DCPU-NI: ProFeP invalid DNS server information

Description A DNS server IP has not been configured. ProFeP could not be started.
DCPU-NI: ProFeP DNS request failed

Description A DNS request to resolve the computername of NTP server failed. ProFeP could not be
started.
DCPU-NI: ProFeP DNS request failed

Description A DNS request to resolve the computername of ProFeP server failed. ProFeP could not be
started.
162 26.11.2014

EMHART-Trouble Shooting Guide

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EMHART-Trouble Shooting Guide

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Fault notifications

Table of Contents .......................................................................................................................................................3

Fault 13060: LMC: Error while reading EEProm data ...........................................................................................32

Fault 16304: TR: Undervoltage rotation motor ......................................................................................................58

Fault 20025: Wrong fastener (stud) loaded .........................................................................................................110

Fault 21040: DCPU-PM: Weldhead couldn't be moved due to a timeout ...........................................................123

Fault 23048: DCPU-CI: Parity Error in Action Code ............................................................................................144

DCPU-PM: Wrong software version DCPU .........................................................................................................158

Fault 8000: Unknown Message

Update the receiver components

Fault 10005: Weld procedure sequence fault

The internal monitoring of the weld process detected a problem.

Check welding program

Check the software version in weld unit

Fault 10013: SMPS: Lift fault

The collet is worn or defective

Replace the collet

Weld tool is heavily contaminated

Clean weld tool

Replace weld tool

Inspect component for contamination and clean as needed

Lift movement is not smooth

Replace weld tool

Defective cable package between weld unit and weld tool

Check the cable package for correct function

Replace cable package

Weld tool defective

Replace weld tool

Replace weld unit or SMPS

Fault 10014: Short-circuit weld

Weld parameter not correct

Check lift height in welding program and adjust as needed

Check weld current in welding program and adjust as needed

Check collet for wear and replace as needed

Fix the workpiece using the counter bearing

Incorrectly positioned weld tool

Check distance and adjust as needed

Air supply of the loading pin not correct

Check the air supply of the weld tool

Check the cable package for correct function

Pressure loss due to defective pneumatic connector

Replace defective components

Pressure loss due to kinked or defective pneumatic lines

Replace defective components

Fault 10015: weld time timeout

Incorrectly connected ground measurement cable on the workpiece

Inspect connection or laying of the ground measurement cable

Insufficient ground connection to workpiece

Check ground connection to workpiece

Clean ground contact and set as needed

Replace weld unit or SMPS

Burn-up on fastener too large

Inspect programmed drop time and adjust as needed

Inspect programmed lift height and adjust as needed

Inspect weld parameter in welding program and adjust as needed

Fault 10016: Open circuit, no arc

Insufficient ground connection to workpiece

Check ground connection to workpiece

Clean ground contact and set as needed

Fix the workpiece using the counter bearing

Weld gun was moved during the welding

Weld head was moved during the welding

Check the mounting of the weld head