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Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschwe

Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstr. 7-19, 58285 Gevelsberg Troubleshooting Guide Stud Welding Unit N3 Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstr. 7-19, 58285 Gevelsberg TABLE OF CONTENTS 1. General Information ................................................................................... 5 1.1 System Components............................................................................................... 6 1.2 N3 Power Unit Functions......................................................................................... 7 1.3 N3 Power Unit Components .................................................................................... 8 1.4 Inverter Engine...................................................................................................... 9 1.5 Micro Processor.....................................................................................................10 1.6 Power Unit Control Card ........................................................................................11 1.7 FSE Feeder Control Card........................................................................................12 1.8 HMI Control Card ..................................................................................................13 1.9 FSE 100 Feeder Functions......................................................................................14 1.10 System Architecture ..............................................................................................15 2. Wrong Stud Error...................................................................................... 16 2.1 Feeding Problem...................................................................................................17 2.2 Studs builds up on the side walls of FSE 100 ...........................................................18 2.3 Chuck Problem......................................................................................................19 2.4 Referenz Methode.................................................................................................20 2.5 Push Test / Push Test ++......................................................................................21 2.6 Isolation Tube ......................................................................................................23 2.7 No Contact Error...................................................................................................24 2.8 No Arc..................................................................................................................25 2.9 Contact Light Always "On" .....................................................................................26 2.10 Arc Voltage Lost....................................................................................................27 2.11 Weld Cycle interrupted ..........................................................................................28 2.12 Safety Circuit Error................................................................................................29 2.13 Low Current NIO Error in Process Monitor ...............................................................30 2.14 NIO ARC Voltage...................................................................................................31 2.15 Error in Gun / Head Movement...............................................................................32 2.16 Head not retracted Position....................................................................................33 2.17 Current Level error................................................................................................34 2.18 Can Bus Error .......................................................................................................35 3. Components.............................................................................................. 36 4. Fuse Problems........................................................................................... 37 4.1 Fuse in Feeder is blown (90V) ................................................................................37 4.2 Fuse (F1, F2, F3) in N3 power supply board are blown.............................................38 4.3 Fuse (F4, F5, F6) in N3 power supply board are blown.............................................39 4.4 Fuse (F 10) in N3 power supply board is blown........................................................40 4.5 Fuse (F 11) in N3 power supply board is blown........................................................41 4.6 Fuse (F 12) in N3 power supply board is blown........................................................42 4.7 F1 in Inverter Module............................................................................................43 5. Error Messages ......................................................................................... 44 5.1 Error Classes ........................................................................................................44 5.2 Error List ..............................................................................................................45 5.3 Internal Errors Feeder ...........................................................................................49 Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstr. 7-19, 58285 Gevelsberg 6. Hardware Errors Code 0x10-0x1F ............................................................ 50 6.1 Code: 0x10 Line contactor OFF! .............................................................................50 6.2 Code: 0x11 Protective grid open.............................................................................51 6.3 Code: 0x12 Switch protective grid ..........................................................................52 6.4 Code: 0x13 Temperature too high! .........................................................................53 6.5 Code: 0x14 Phase under voltage! ...........................................................................54 6.6 Code: 0x15 Power supply unit error!.......................................................................56 6.7 Code: 0x16 SPI-bus! .............................................................................................59 6.8 Code: 0x17 Battery undervoltage! ..........................................................................60 6.9 Code: 0x1D Protective circuit relay .........................................................................61 6.10 Code: 0x1E Short-circuit / overload! .......................................................................63 6.11 Code: 0x1F No voltage supply!...............................................................................65 7. System Errors Code 0x00-0x0F ................................................................ 66 7.1 Code: 0x01 System Reset! .....................................................................................66 7.2 Code: 0x02 Fast ram!............................................................................................67 7.3 Code: 0x03 Low power ram! ..................................................................................68 7.4 Code: 0x04 Dual port ram!.....................................................................................69 7.5 Code: 0x05 Dual port ram (init)!.............................................................................70 7.6 Code: 0x06 Dual port ram (Watchdog)! ..................................................................71 7.7 Code: 0x07 No configuration data! .........................................................................72 7.8 Code: 0x08 Sytem IRQ (error!!!) ............................................................................73 7.9 Code: 0x09 No communication with user panel........................................................74 7.10 Code: 0x0A Inverter card!......................................................................................76 7.11 Code: 0x0B Bus address! .......................................................................................77 7.12 Code: 0x0C No EEProm data!.................................................................................78 8. Parameter Errors Code 0x20-02F ............................................................. 79 8.1 Code: 0x20 No welding program! ...........................................................................79 8.2 Code: 0x21 Data pool welding programs full! ..........................................................80 8.3 Code: 0x22 Write error configuration data!..............................................................81 9. Welding Cycle Errors Code 0x30-0x3F...................................................... 82 9.1 Code: 0x30 NIO weld! ...........................................................................................82 9.2 Code: 0x31 No contact! .........................................................................................83 9.3 Code: 0x32 Current threshold ................................................................................84 9.4 Code: 0x33 Arc voltage lost ...................................................................................85 9.5 Code: 0x34 No arc! ...............................................................................................87 9.6 Code: 0x35 Welding cycle interrupted!....................................................................89 9.7 Code: 0x36 Synchronisation error!..........................................................................90 9.8 Code: 0x37 Welding process active!........................................................................91 9.9 Code: 0x38 Welding process error!.........................................................................92 9.10 Code: 0x39 Timeout welding process !....................................................................93 9.11 Code: 0x3A No measured values! ...........................................................................94 9.12 Code: 0x3B Plunge obstruction!..............................................................................95 9.13 Code: 0x3C Protective gas failure ...........................................................................96 9.14 Code: 0x3D Simulation ..........................................................................................97 Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstr. 7-19, 58285 Gevelsberg 10. Infeed Errors Code 0x40-0x4F.................................................................. 98 10.1 Code: 0x40 No R-position! .....................................................................................98 10.2 Code: 0x41 No V-position! .....................................................................................99 10.3 Code: 0x42 Timeout infeed!.................................................................................100 10.4 Code: 0x43 Infeed error! .....................................................................................101 10.5 Code: 0x4A Angular position NIO .........................................................................102 11. Welding Tool Errors Code 0x50-0x5F ..................................................... 103 11.1 Code: 0x50 Servo controller defective!..................................................................103 11.2 Code: 0x51 Servo init. faulty!...............................................................................104 11.3 Code: 0x52 Servo error input! ..............................................................................105 11.4 Code: 0x53 Servo overload current!......................................................................106 12. Feeder Errors Code 0x60- 0x6F .............................................................. 107 12.1 Code: 0x60 Rail filling level min.!..........................................................................107 12.2 Code: 0x61 Feeder filling level min.! .....................................................................108 12.3 Code: 0x62 Bunker filling level min.!.....................................................................109 12.4 Code: 0x63 Feeder cover open!............................................................................110 12.5 Code: 0x64 Lack of compressed air! .....................................................................111 12.6 Code: 0x65 Feeder key switch!.............................................................................112 13. Feed Errors Code 0x70-0x7F................................................................... 113 13.1 Code: 0x70 No stud fed!......................................................................................113 13.2 Code: 0x71 Wrong stud!......................................................................................114 13.3 Code: 0x72 Incorrect stud! ..................................................................................120 13.4 Code: 0x73 Feed fault loading pin! .......................................................................121 13.5 Code: 0x74 Förderstörung optischer Sensor! .........................................................122 13.6 ode: 0x75 Feed fault optical sensor! .....................................................................123 13.7 Code: 0x76 Stud feed protective circuit open!........................................................124 13.8 Code: 0x77 Stud/program allocation.....................................................................125 14. CAN Errors Code 0x80-0x8F ................................................................... 126 14.1 Overview CAN BUS Errors ....................................................................................126 14.2 Code: 0x80 CAN-message faulty!..........................................................................127 14.3 Code: 0x81 CAN-Message Timout!........................................................................128 14.4 Code: 0x82 CAN transmission FIFO full!................................................................129 14.5 Code: 0x83 CAN 1 bus error! ...............................................................................130 14.6 Code: 0x84 CAN 1 bus OFF!.................................................................................131 14.7 Code: 0x85 CAN 1 bus error! ...............................................................................132 14.8 Code: 0x86 CAN 1 bus error! ...............................................................................133 14.9 Code: 0x87 CAN 2 bus error! ...............................................................................134 14.10 Code: 0x88 CAN 2 bus OFF!.................................................................................135 14.10.1 Code: 0x89 CAN 2 bus error! ...........................................................................136 14.11 Code: 0x8A CAN 2 bus error! ...............................................................................137 14.12 Code: 0x8B CAN bus monitoring...........................................................................138 Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstr. 7-19, 58285 Gevelsberg 15. External Communication Errors Code 0x90-0x9F................................... 139 15.1 Code: 0x90 No program selection!........................................................................139 15.2 Code: 0x95 Incorrect interface module .................................................................140 15.3 Code: 0x96 Bus initialisation error! .......................................................................141 15.4 Code: 0x97 No bus communication!......................................................................142 15.5 Code: 0x98 Bus Idle!..........................................................................................143 15.6 Code: 0x99 Bus reset! .........................................................................................144 16. Process Errors, Code 0xA0-0xAF............................................................. 145 16.1 Code: 0xA0 Unacknowledged error!......................................................................145 16.2 Code: 0xA1 Process fault .....................................................................................146 17. Facility Errors, Code 0xB0-0xBF ............................................................. 147 17.1 Code: 0xB0 Feeder configuration error!.................................................................147 17.2 Code: 0xB1 Tool configuration error! ....................................................................148 17.3 Code: 0xB2 Maintenance 80.................................................................................149 17.4 Code: 0xB3 Maintenance 100...............................................................................150 17.5 Code: 0xB4 Maintenance .....................................................................................151 17.6 Code: 0xB5 Error frequency .................................................................................152 17.7 Code: 0xBA Ethernet ON......................................................................................153 17.8 Code: 0xBB Ethernet OFF ....................................................................................154 17.9 Code: 0xBC Ethernet ...........................................................................................155 17.10 Code: 0xBF Facility configuration..........................................................................156 Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstr. 7-19, 58285 Gevelsberg Page 5 1. General Information The error description section serves as a help for the analysis and rectification of problems which may occur during the commissioning or operation of the stud welding unit. Error messages have the following structure: • Error class • Error code • Error information 1 • Error information 2 • Error information 3 • Error time All errors are assigned to error classes which signal the severity of the error (refer to the Error Classes subsection). The errors as well as the respective information are explained in the following description. The error code is displayed or output in hexadecimal form. The error code is output on the internal 7-segment displays of the N3 stud welding unit and in the system components, if available. In the operating panel of the N3 stud welding unit, the error messages are displayed in plain text, including the error time (refer to the N3 Programming Manual). The N3 stud welding unit continuously logs 50 consecutive errors in an error buffer. The occurring errors are saved in a manner protected against mains failure. Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstr. 7-19, 58285 Gevelsberg Page 6 1.1 System Components N3 Power Unit FSE 100 Stud Feeder KSE 100 Weld Head Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstr. 7-19, 58285 Gevelsberg Page 7 1.2 N3 Power Unit Functions • Central Controller of Peripheral Devices • Develops and Controls Weld Current • HMI for Data Input and Feedback • Provides Interface with PLC/Robot Controller Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstr. 7-19, 58285 Gevelsberg Page 8 1.3 N3 Power Unit Components The N3 can be broken down into 2 major systems: Inverter Engine Control (Micro Processors) Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstr. 7-19, 58285 Gevelsberg Page 9 1.4 Inverter Engine The Inverter Engine can also be broken down into 2 components: Secondary Side Primary Side Low Voltage – High Current Diode Pack (Rectifier) Filter Capacitors Pilot Circuit Output SCR High Voltage Rectifier Storage Capacitors IGBT’s (high voltage transistors) Snubbers (noise filter) High Frequency Transformer Troubleshooting Guide Stud welding unit N3 As of: 29.11.2007 Nelson Bolzenschweiß-Technik GmbH & Co. KG, Flurstr. 7-19, 58285 Gevelsberg Page 10 1.5 Micro Processor A typical N3 System has 4 micro processor and 1 additional processor for each output that is added to a system. The CPU’s communicate to one another via a CAN Bus network. Power Unit Control Card has 2 CPU’s FSE Feeder Control Card has 1 CPU uploads/S4/ n3-troubleshooting-guide.pdf