螺柱焊现场故障代码与报警.docx

1、螺柱焊现场故障代码与报警螺柱焊报警分析故障分类：螺柱焊故障，根据报警信息可以分为以下几大类。1.焊头故障2.送料器故障3.功率单元故障4.控制器故障5.通讯故障出现故障的部分会在报警信息中出现。在编程器的故障查询中会显示。常见故障报警:Fault1:“WeldheadremainsinR-position“故障1：焊枪不在起始位置Explanation:Afterasuccessfulweldstarttheweldheadsliderailremainsinbackposition(internalsliderailcontrol).解释：启动焊接信号后焊枪仍然停留在滑板起始位置（控制内部滑

2、轨）Cause:?Compressed-airsupplyinterrupted.原因：压缩空气供应中断?Feederfault(i.e.defectivemagneticsolenoidvalve).送料器故障（例如：电磁阀损坏了）?Weldheadfault(i.e.weldheadgotjammed).焊头故障（例如：焊头被卡住了）Remedy:?ResetFault.措施：故障复位?Checkcompressedairsupply.检查压缩空气供应?CheckfuseintheFeeder.检查送料器保险丝?Replacefeederorweldhead.更换送料器或焊头?Notify

3、serviceengineer!专业人员处理Fault2:“NoSOW“故障2:无接触信号Explanation:AfterasuccessfulweldstartSOWwasnotdetected.Thereforeweldingisnotpermitted.解释:启动焊接信号后无接触信号,导致无法焊接Cause:?Nostudincollet.原因:夹套里没有焊钉?Feederwithoutweldstuds.送料器里没有焊钉?Stabilizerincorrectlysetorcontaminated.支撑脚或喷嘴调整不当或太脏?Weldcircuitinterrupted.焊接回路中断

4、?Weldheadfault(i.e.weldheadgotjammed).焊头故障（例如：焊头被卡住了）?Colletdefective.夹持器损坏了Remedy:?Removeloadingfault.措施：排除送钉故障?Checkadjustingofstabilizer.检查支撑脚或喷嘴的调整状态?Checkweldingcircuit.检查焊接回路?Studfeeding.送一次钉?Repeatweldcycle.重复一次焊接?Replacecollet.更换夹持器?Notifyserviceengineer!专业人员处理Fault3:“Weldtoolnotinbackpositi

5、on“故障3：焊头没有在焊接位置Explanation:Proximityswitchforbackpositionnotconfigured,defectiveorpowersupplymissing.解释：焊接位置的接近开关没有被盖住或接近开关被损坏或者没有电压Cause:?Dropincompressed-airsupply.原因：压缩空气供应气压不足?Cablepackagedefective.管线总成损坏?Monitoringtimeafterweldingwasexceeded.焊接之后的检测时间超差?Weldheaddefective.焊头损坏?Feederdefective.送

6、料器损坏?Colletweldedtoworksurface.把夹持器焊在工件表面了Remedy:?Checkcompressedair.措施：检查压缩空气供应装置?Checkcablepackage.检查管线总成?Checkweldhead-sliderailmotion.检查焊头运动滑轨?Checkorreplaceweldhead.检查或更换焊头?Checkfeeder.检查送料器?CheckfeederfusesF1-F3.检查送料器保险丝F1-F3?Resetfault.故障复位?Replacecollet.更换夹持器?Notifyserviceengineer!专业人员处理Faul

7、t5:“Weldproceduresequencefault“故障5：焊接程序顺序故障Explanation:Duetoamalfunctiontheweldsequenceisnotterminatedcorrectly.解释：由于一个错误功能使焊接过程没有按照程序进行到底Cause:?FeederorSMPSmalfunction.原因：送料器或电源故障Remedy:?Resetfault.措施：故障复位?Checkwelding(ifnecessaryrepeatwelding).检查焊接（重新焊接）?Notifyserviceengineer!专业人员处理Fault6:“Program

8、noselected“故障6：缺少程序Explanation:Theweldunitdoesnotdetectanyprogramnumber.解释：焊接单元不识别程序号码Cause:?Programno.is0.原因：程序号码为0?Transfersignalhasnotbeenset.没有设置接受信号?Datalinedefective.数据线被损坏了Remedy:?Customerinterface(orinterfaceprogram)mustbeverified.措施：检查用户接口（或接口程序）是否编写?Notifyserviceengineer!专业人员处理Fault7:“Prog

9、ramnotactive“故障7：程序没有激活Explanation:Theselectedweldprogramisnotactiveandthereforecannotbeexecuted.解释：由于被选择的焊接程序没有被激活,因此无法实施焊接Cause:?Weldunitincorrectlyprogrammed.原因：焊接单元程序编写错误?Faultcustomercontrol.用户控制端错误?Datalinedefective.数据线被损坏了Remedy:?Checkweldprogramandactivateorselectanactiveweldprogram.措施：检查焊接程

10、序并激活或者选择一个已经激活的程序?Notifyserviceengineer!专业人员处理Fault13:“SMPS:Liftfault“故障13：电源：没有拉弧Explanation:Weldunitisunabletoidentifyliftviameasurementlines.解释：焊机通过它的测量线不能确定拉弧过程Cause:?Incorrectlysequenceofliftmovement.原因：拉弧过程的顺序不正确?Weldconditionsprohibitlift.焊接条件阻碍了拉弧?Cablepackagedefective.管线总成损坏?Weldheaddefecti

11、ve.焊头被损坏?Defectivefeeder.送料器被损坏?Internalprocesscyclefault.设备内部运行故障Remedy:?Checkweldconditions.措施：检查焊接条件?Checkweldhead.检查焊头?Checkfeeder.检查送料器?Studfeeding.送一次钉?Checkfeederconnection.检查送料器连接线?Repeatweldcycle.重复一次焊接?ForcedWC.启动焊接完成信号?Notifyserviceengineer!专业人员处理Fault15:“Dropdowntimeout“故障15：下落时间超时Explan

12、ation:Max.droptimewasexceededandweldingwasstopped.解释：下落时间超出最大允许值，焊接被中断Cause:?Airgapincorrectlyadjusted.原因：间隙调整错误?Weldcircuitresistancetoohigh.焊接回路电阻过高?Measurementline-groundmissing.没有连接地线测量线?SKK/PKdefective.自动焊头或焊枪损坏Remedy:?Resetfault.措施：故障复位?checkmeasurementline(ifnecessary,reduceweldcircuitresista

13、nce)检查测量线（降低焊接回路电阻值）?ChecksettingofSKK-/PK.检查自动焊头或焊枪状态?Notifyserviceengineer!专业人员处理Fault16:“Opencircuit,noarc“故障16：空载焊接Explanation:Extinguishingofthearcduringweld,resp.theweldcurrentisbelowI=80A.解释：焊接过程中拉弧被断开，或焊接回路电流小于80ACause:?Airgaptoolarge.原因：间隙过大?Gunwasremovedatthebeginningoftheweld.焊枪在开始焊接时被提起?

14、Extremelyimpureworksurface.焊接表面油污太多?FaultSMPS.电源故障Remedy:?Repeatweldcycle.措施：重复一次焊接?Studfeeding.送一次钉?Checkadjustingoftheweldgun.检查焊枪的调整?Checkweldingconditions.检查焊接条件?Checkworkpiececonditions.检查工件表面?Notifyserviceengineer!专业人员处理Fault17:“Measurementlinebroken“故障17：测量线中断Explanation:Measurementlinesignal

15、notanylongerdetected.解释：测量线信号没有被捕捉到Cause:?Measurementlinebrokenorincorrectlyconnected.原因：测量线损坏或连接错误?Reversedmeasurementline-groundandmeasurementline.地线测量线和测量线接反了?SOWpowerfailure.和工件的接触电压中断?Weldlineinterrupted.焊接电缆中断Remedy:?Checkfusesonfrontpanel.措施：检查面板上的保险丝?Resetfault.故障复位?Checkweldingcable.检查焊接线?C

16、heckmeasuringline.检查测量线?Checkground-measurementline检查地线测量线.?Checkfeederfuses.检查送料器的保险丝?Notifyserviceengineer!专业人员处理Fault23:“Handgunsequencenotfollowed“故障23：手枪焊接启动条件Explanation:Correctsequencewhenweldingwithagun(PK/PLM)wasnotobserved.解释:在用手枪焊接时没有遵守正确的焊接顺序Cause:?Angularityswitchby-passedorincorrectlya

17、djusted.原因：角度开关被桥接或调整错误?Triggerstartby-passed.启动开关被桥接?CorrectsequenceSOW-ANG-STARTnotobserved.没有遵守SOW(接触信号)-WS(角度开关)-START(焊接)的焊接顺序Remedy:?ObservesequenceSOW-ANG-START.措施：遵守SOW(接触信号)-WS(角度开关)-START(焊接)的焊接顺序?CheckPKforcorrectsettingofangularity.检查角度开关的调整情况?Releasetriggerandrestart.松开启动开关并重新启动?Notifys

18、erviceengineer!专业人员处理Fault25:“Wrongstudloaded“故障25：焊钉输送错误Explanation:Thesuppliedstudisnotthespecifiedstudrequiredbyunitcontrol.解释：所提供的焊钉不是焊机指定的焊钉Cause:?Theweldunitidentifiedanincorrectstudintheweldheadviatheliftmeasuringsystemorthestudverificationtest.原因：焊机只识别通过拉弧测量系统或者通过焊钉检验的焊钉的焊头Remedy:?Resetfault

19、.措施：故障复位?Repeatstudfeeding.重新送一次钉?Verifycorrectstudlengthinthefeeder.检验送料器里焊钉的长度?Checkprogramming.检查程序Fault30:“Weldoutoftolerance”故障30：焊接参数超差Explanation:Collectivefaultfortheexceededtolerances.解释：一般性超差Cause:?Thefollowingtolerancesareoutofparameter:weldcurrent,weldtime,Vp,Vw,Pen,Varcpeak,Varcdroporwe

20、ldenergy.原因：超出公差的参数：焊接电流，焊接时间，拉弧电压，焊接电压，焊接深度，电压峰值，电压降或焊接能量?DefectiveSMPSorweldingtool.电源或焊接工具损坏Remedy:?Resetfault.措施：故障复位?Checktolerances.检查公差设定值?Checkweldcircuitandweldconditions.检查焊接电流和焊接条件?CheckSMPSandweldingtool.检查电源和焊接工具Fault100:“Feeder:Nopowertoaux.supply“故障100：送料器：没有电压Explanation:Thefeederide

21、ntifiesnovoltagesupply.解释：送料器没有电压供应Cause:?Defectivefeederfuse.原因：送料器保险丝损坏?Defectivefeeder.送料器损坏Remedy:?Replacefeederfuse.措施：更换送料器保险丝?Checkfeeder.检查送料器?Notifyserviceengineer!专业人员处理ault102:“Feeder:Feedrailnotfilledintime“故障102：送料器：焊钉传送错误Explanation:Fillingoftherailwayisnotensured.解释：焊钉传送过程中出现故障Cause:?

22、Sufficientstudlevelintheseparatingdrumnotreached.原因：焊钉卡在了滑道上?Mechanicaldefectoftheescapementrails滑道上有机械故障?Wrongadjustingonthestudinletdish.焊钉口调整错误?WrongadjustedordefectiveproximityswitchMin.最小接近开关调整错误或损坏Remedy:?Checkadjusting.措施：检查送料器调整?Replenishweldstuds.加满焊钉?Removeblockage.清除滑道上焊钉?Adjustproximitys

23、witchor/andreplace.调整接近开关或更换?Notifyserviceengineer!专业人员处理Fault106:“Feeder:Feedtubelockingswitchopen“故障106：送料器：送料管被锁紧Explanation:Thesignalforfeedhoselockingatthestudfeederisnotconfigured.解释：送料器锁紧信号开关没有被盖上Cause:?Feedtubenotconnected(gun).原因：送料管没有连接?Nobridgeforfeedtubelocking(head).送料管锁紧开关没有连上?Defectiv

24、ecablepackage.管线总成损坏?DefectivefuseF5onPCBETFCPUE510.中央处理器E510电路板保险丝F5损坏Remedy:?Connectingfeedtube.措施：连接送料管?Checklockingswitch.检查紧锁开关?Checkcablepackage.检查管线总成?Replacefuse.更换保险丝?Notifyserviceengineer!专业人员处理Fault109:“Feeder:Feedcycletimeout“故障109：送料器：送料循环超时Explanation:Theweldunitindicatesanincorrectlyp

25、erformedfeedcycle.解释：焊机显示一个错误的送料循环Cause:?Thefeederdoesnotterminateafeedcycleinthemaximummonitoringtime.原因：送料器没有把送料循环锁定在最大的监控时间内Remedy:?Checkfeeder.措施：检查送料器?Repeatstudfeeding.重复一次焊接?Notifyserviceengineer!专业人员处理Fault118:“Feeder:+5VKeypadnotdetected“故障118：送料器：控制面板没有+5V电压供应Explanation:Thevoltagesupply5V

26、forthekeypadcommunicationismissing.解释：控制面板通信的+5V电压没有Cause:?DefectivefuseF3onPCBETFCPUE510.原因：中央处理器E510电路板保险丝F3损坏?DefectiveoptocoupleronthePCBETFCPUE510.E510电路板上的光耦合器损坏Remedy:?Replacefuse.措施：更换保险丝?ReplacePCBETFCPUE510.更换E510电路板?Notifyserviceengineer!专业人员处理Fault119:“Feeder:LM/Solenoidundervoltage“故障11

27、9：送料器：自动焊枪/电磁阀不足Explanation:Thevoltagesupplyforthelinearmotor/solenoidislessthan90Volt解释：直流电机/电磁阀的供电电压低于90VCause:?DefectivefuseF2onETFPCBAmplifierE512.原因：放大器E512 电路板保险丝F2损坏?DefectiveETFPCBamplifierE512.放大器E512电路板损坏Remedy:?ReplacefuseF2.措施：更换保险丝F2?ReplaceETFPCBAmplifierE512.更换放大器E512电路板?Notifyservice

28、engineer!专业人员处理Fault121:“Feeder:LM/Solenoidovervoltage“故障121：送料器：自动焊枪/电磁阀电压超出Explanation:ThevoltagesupplyforpcbE512isoutofthetolerancerange.解释：给电路板E512供电的电压超出公差范围Cause:?Transformerwrongconnected.原因：转换器连接错误?Defectivetransformer.转换器损坏Remedy:?Checkconnectiontransformer.措施：检查转换器连接?Exchangetransformer.更换

29、转换器?Notifyserviceengineer!专业人员处理Fault122:“LM/Solenoidnotdetected“故障122：自动焊枪/电磁阀故障Explanation:Theconnectedweldingtoolonthefeederhasnotlinearmotororsolenoid.解释：同送料器连接的焊接工具不是直线电机或电磁阀Cause:?Noweldingtoolconnected.原因：没有连接焊接工具?Defectivecablepackage.管线总成损坏Remedy:?Connectweldtool.措施：连接焊接工具?Checkcablepackage

30、.检查管线总成?Notifyserviceengineer!专业人员处理Fault167:“Feeder:+5Vnotdetected“故障167：送料器：+5V检测电压缺失Explanation:Thevoltagesupply+5Vforthemeasurementstretchlengthismissing.解释：测量拉伸长度的+5V电压缺失Cause:?Defectivecablepackage.原因：管线总成损坏?DefectivePCBintheweldhead.焊头里的电路板损坏?DefectiveoptocouplerontheETFCPUE510.E510里的光耦合器损坏Remedy:?Checkcablepackage.措施：检查管线总成?CheckPCBintheweldhead.检查焊头里的电路板?ReplacePCBETFCPUE510.更换E510电路板?Notifyserviceengineer!专业人员处理