螺柱焊现场故障代码与报警.doc

资源描述

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: Fault 1: “Weld head remains in R-position“ 故障1：焊枪不在起始位置 Explanation: After a successful weld start the weld head slide rail remains in back position (internal slide rail control). 解释：启动焊接信号后焊枪仍然停留在滑板起始位置（控制内部滑轨） Cause: • Compressed-air supply interrupted. 原因：压缩空气供应中断 • Feeder fault (i.e. defective magnetic solenoid valve). 送料器故障（例如：电磁阀损坏了） • Weld head fault (i.e. weld head got jammed). 焊头故障（例如：焊头被卡住了） Remedy: • Reset Fault. 措施：故障复位 • Check compressed air supply. 检查压缩空气供应 • Check fuse in the Feeder. 检查送料器保险丝 • Replace feeder or weld head. 更换送料器或焊头 • Notify service engineer! 专业人员处理 Fault 2: “No SOW“ 故障2: 无接触信号 Explanation: After a successful weld start SOW was not detected. Therefore welding is not permitted. 解释: 启动焊接信号后无接触信号,导致无法焊接 Cause: • No stud in collet. 原因: 夹套里没有焊钉 • Feeder without weld studs. 送料器里没有焊钉 • Stabilizer incorrectly set or contaminated. 支撑脚或喷嘴调整不当或太脏 • Weld circuit interrupted. 焊接回路中断 • Weld head fault (i.e. weld head got jammed). 焊头故障（例如：焊头被卡住了） • Collet defective. 夹持器损坏了 Remedy: • Remove loading fault. 措施：排除送钉故障 • Check adjusting of stabilizer. 检查支撑脚或喷嘴的调整状态 • Check welding circuit. 检查焊接回路 • Stud feeding. 送一次钉 • Repeat weld cycle. 重复一次焊接 • Replace collet. 更换夹持器 • Notify service engineer! 专业人员处理 Fault 3: “Weld tool not in back position“ 故障3：焊头没有在焊接位置 Explanation: Proximity switch for back position not configured, defective or power supply missing. 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: • Drop in compressed-air supply. 原因：压缩空气供应气压不足 • Cable package defective. 管线总成损坏 • Monitoring time after welding was exceeded. 焊接之后的检测时间超差 • Weld head defective. 焊头损坏 • Feeder defective. 送料器损坏 • Collet welded to work surface. 把夹持器焊在工件表面了 Remedy: • Check compressed air. 措施：检查压缩空气供应装置 • Check cable package. 检查管线总成 • Check weld head - slide rail motion. 检查焊头运动滑轨 • Check or replace weld head. 检查或更换焊头 • Check feeder. 检查送料器 • Check feeder fuses F1-F3. 检查送料器保险丝F1-F3 • Reset fault. 故障复位 • Replace collet. 更换夹持器 • Notify service engineer! 专业人员处理 Fault 5: “Weld procedure sequence fault“ 故障5：焊接程序顺序故障 Explanation: Due to a malfunction the weld sequence is not terminated correctly. 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: • Feeder or SMPS malfunction. 原因：送料器或电源故障 Remedy: • Reset fault. 措施：故障复位 • Check welding (if necessary repeat welding). 检查焊接（重新焊接） • Notify service engineer! 专业人员处理 Fault 6: “Program no selected“ 故障6：缺少程序 Explanation: The weld unit does not detect any program number. 解释：焊接单元不识别程序号码 Cause: • Program no. is 0. 原因：程序号码为0 • Transfer signal has not been set. 没有设置接受信号 • Data line defective. 数据线被损坏了 Remedy: • Customer interface (or interface program) must be verified. 措施：检查用户接口（或接口程序）是否编写 • Notify service engineer! 专业人员处理 Fault 7: “Program not active“ 故障7：程序没有激活 Explanation: The selected weld program is not active and therefore cannot be executed. 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: • Weld unit incorrectly programmed. 原因：焊接单元程序编写错误 • Fault customer control. 用户控制端错误 • Data line defective. 数据线被损坏了 Remedy: • Check weld program and activate or select an active weld program. 措施：检查焊接程序并激活或者选择一个已经激活的程序 • Notify service engineer! 专业人员处理 Fault 13: “SMPS: Lift fault“ 故障13：电源：没有拉弧 Explanation: Weld unit is unable to identify lift via measurement lines. 解释：焊机通过它的测量线不能确定拉弧过程 Cause: • Incorrectly sequence of lift movement. 原因：拉弧过程的顺序不正确 • Weld conditions prohibit lift. 焊接条件阻碍了拉弧 • Cable package defective. 管线总成损坏 • Weld head defective. 焊头被损坏 • Defective feeder. 送料器被损坏 • Internal process cycle fault. 设备内部运行故障 Remedy: • Check weld conditions. 措施：检查焊接条件 • Check weld head. 检查焊头 • Check feeder. 检查送料器 • Stud feeding. 送一次钉 • Check feeder connection. 检查送料器连接线 • Repeat weld cycle. 重复一次焊接 • Forced WC. 启动焊接完成信号 • Notify service engineer! 专业人员处理 Fault 15: “Drop down timeout“ 故障15：下落时间超时 Explanation: Max. drop time was exceeded and welding was stopped. 解释：下落时间超出最大允许值，焊接被中断 Cause: • Air gap incorrectly adjusted. 原因：间隙调整错误 • Weld circuit resistance too high. 焊接回路电阻过高 • Measurement line-ground missing. 没有连接地线测量线 • SKK / PK defective. 自动焊头或焊枪损坏 Remedy: • Reset fault. 措施：故障复位 • check measurement line (if necessary, reduce weld circuit resistance) 检查测量线（降低焊接回路电阻值） • Check setting of SKK- / PK. 检查自动焊头或焊枪状态 • Notify service engineer! 专业人员处理 Fault 16: “Open circuit, no arc“ 故障16：空载焊接 Explanation: Extinguishing of the arc during weld, resp. the weld current is below I = 80A. 解释：焊接过程中拉弧被断开，或焊接回路电流小于80A Cause: • Air gap too large. 原因：间隙过大 • Gun was removed at the beginning of the weld. 焊枪在开始焊接时被提起 • Extremely impure work surface. 焊接表面油污太多 • Fault SMPS. 电源故障 Remedy: • Repeat weld cycle. 措施：重复一次焊接 • Stud feeding. 送一次钉 • Check adjusting of the weld gun. 检查焊枪的调整 • Check welding conditions. 检查焊接条件 • Check work piece conditions. 检查工件表面 • Notify service engineer! 专业人员处理 Fault 17: “Measurement line broken“ 故障17：测量线中断 Explanation: Measurement line signal not any longer detected. 解释：测量线信号没有被捕捉到 Cause: • Measurement line broken or incorrectly connected. 原因：测量线损坏或连接错误 • Reversed measurement line-ground and measurement line. 地线测量线和测量线接反了 • SOW power failure. 和工件的接触电压中断 • Weld line interrupted. 焊接电缆中断 Remedy: • Check fuses on front panel. 措施：检查面板上的保险丝 • Reset fault. 故障复位 • Check welding cable. 检查焊接线 • Check measuring line. 检查测量线 • Check ground- measurement line 检查地线测量线. • Check feeder fuses. 检查送料器的保险丝 • Notify service engineer! 专业人员处理 Fault 23: “Handgun sequence not followed“ 故障23：手枪焊接启动条件 Explanation: Correct sequence when welding with a gun (PK/PLM) was not observed. 解释: 在用手枪焊接时没有遵守正确的焊接顺序 Cause: • Angularity switch by-passed or incorrectly adjusted. 原因：角度开关被桥接或调整错误 • Trigger start by-passed. 启动开关被桥接 • Correct sequence "SOW-ANG-START" not observed. 没有遵守SOW(接触信号)-WS(角度开关)- START(焊接)的焊接顺序 Remedy: • Observe sequence "SOW-ANG-START". 措施：遵守SOW(接触信号)-WS(角度开关)- START(焊接)的焊接顺序 • Check PK for correct setting of angularity. 检查角度开关的调整情况 • Release trigger and restart. 松开启动开关并重新启动 • Notify service engineer! 专业人员处理 Fault 25: “Wrong stud loaded“ 故障25：焊钉输送错误 Explanation: The supplied stud is not the specified stud required by unit control. 解释：所提供的焊钉不是焊机指定的焊钉 Cause: • The weld unit identified an incorrect stud in the weld head via the lift measuring system or the stud verification test. 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: • Reset fault. 措施：故障复位 • Repeat stud feeding. 重新送一次钉 • Verify correct stud length in the feeder. 检验送料器里焊钉的长度 • Check programming. 检查程序 Fault 30: “Weld out of tolerance” 故障30：焊接参数超差 Explanation: Collective fault for the exceeded tolerances. 解释：一般性超差 Cause: • The following tolerances are out of parameter: weld current, weld time, Vp, Vw, Pen, Varc peak, Varc drop or weld energy. 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 • Defective SMPS or welding tool. 电源或焊接工具损坏 Remedy: • Reset fault. 措施：故障复位 • Check tolerances. 检查公差设定值 • Check weld circuit and weld conditions. 检查焊接电流和焊接条件 • Check SMPS and welding tool. 检查电源和焊接工具 Fault 100: “Feeder: No power to aux. supply“ 故障100：送料器：没有电压 Explanation: The feeder identifies no voltage supply. 解释：送料器没有电压供应 Cause: • Defective feeder fuse. 原因：送料器保险丝损坏 • Defective feeder. 送料器损坏 Remedy: • Replace feeder fuse. 措施：更换送料器保险丝 • Check feeder. 检查送料器 • Notify service engineer! 专业人员处理 ault 102: “Feeder: Feed rail not filled in time“ 故障102：送料器：焊钉传送错误 Explanation: Filling of the rail way is not ensured. 解释：焊钉传送过程中出现故障 Cause: • Sufficient stud level in the separating drum not reached. 原因：焊钉卡在了滑道上 • Mechanical defect of the escapement rails 滑道上有机械故障 • Wrong adjusting on the stud inlet dish. 焊钉口调整错误 • Wrong adjusted or defective proximity switch "Min". 最小接近开关调整错误或损坏 Remedy: • Check adjusting. 措施：检查送料器调整 • Replenish weld studs. 加满焊钉 • Remove blockage. 清除滑道上焊钉 • Adjust proximity switch or/and replace. 调整接近开关或更换 • Notify service engineer! 专业人员处理 Fault 106: “Feeder: Feed tube locking switch open“ 故障106：送料器：送料管被锁紧 Explanation: The signal for feed hose locking at the stud feeder is not configured. 解释：送料器锁紧信号开关没有被盖上 Cause: • Feed tube not connected (gun). 原因：送料管没有连接 • No bridge for feed tube locking (head). 送料管锁紧开关没有连上 • Defective cable package. 管线总成损坏 • Defective fuse F5 on PCB ETF CPU E510. 中央处理器E510电路板保险丝F5损坏 Remedy: • Connecting feed tube. 措施：连接送料管 • Check locking switch. 检查紧锁开关 • Check cable package. 检查管线总成 • Replace fuse. 更换保险丝 • Notify service engineer! 专业人员处理 Fault 109: “Feeder: Feed cycle timeout“ 故障109：送料器：送料循环超时 Explanation: The weld unit indicates an incorrectly performed feed cycle. 解释：焊机显示一个错误的送料循环 Cause: • The feeder does not terminate a feed cycle in the maximum monitoring time. 原因：送料器没有把送料循环锁定在最大的监控时间内 Remedy: • Check feeder. 措施：检查送料器 • Repeat stud feeding. 重复一次焊接 • Notify service engineer! 专业人员处理 Fault 118: “Feeder: +5V Keypad not detected“ 故障118：送料器：控制面板没有+5V电压供应 Explanation: The voltage supply 5V for the keypad communication is missing. 解释：控制面板通信的+5V电压没有 Cause: • Defective fuse F3 on PCB ETF CPU E510. 原因：中央处理器E510电路板保险丝F3损坏 • Defective optocoupler on the PCB ETF CPU E510. E510电路板上的光耦合器损坏 Remedy: • Replace fuse. 措施：更换保险丝 • Replace PCB ETF CPU E510. 更换E510电路板 • Notify service engineer! 专业人员处理 Fault 119: “Feeder: LM / Solenoid under voltage“ 故障119：送料器：自动焊枪/电磁阀不足 Explanation: The voltage supply for the linear motor / solenoid is less than 90 Volt 解释：直流电机/电磁阀的供电电压低于90V Cause: • Defective fuse F2 on ETF PCB Amplifier E 512. 原因：放大器E512 电路板保险丝F2损坏 • Defective ETF PCB amplifier E 512. 放大器E512电路板损坏 Remedy: • Replace fuse F2. 措施：更换保险丝F2 • Replace ETF PCB Amplifier E 512. 更换放大器E512电路板 • Notify service engineer! 专业人员处理 Fault 121: “Feeder: LM/Solenoid over voltage“ 故障121：送料器：自动焊枪/电磁阀电压超出 Explanation: The voltage supply for pcb E 512 is out of the tolerance range. 解释：给电路板E512供电的电压超出公差范围 Cause: • Transformer wrong connected. 原因：转换器连接错误 • Defective transformer. 转换器损坏 Remedy: • Check connection transformer. 措施：检查转换器连接 • Exchange transformer. 更换转换器 • Notify service engineer! 专业人员处理 Fault 122: “LM/Solenoid not detected“ 故障122：自动焊枪/电磁阀故障 Explanation: The connected welding tool on the feeder has not linear motor or solenoid. 解释：同送料器连接的焊接工具不是直线电机或电磁阀 Cause: • No welding tool connected. 原因：没有连接焊接工具 • Defective cable package. 管线总成损坏 Remedy: • Connect weld tool. 措施：连接焊接工具 • Check cable package. 检查管线总成 • Notify service engineer! 专业人员处理 Fault 167: “Feeder: +5V not detected“ 故障167：送料器：+5V检测电压缺失 Explanation: The voltage supply +5V for the measurement stretch length is missing. 解释：测量拉伸长度的+5V电压缺失 Cause: • Defective cable package. 原因：管线总成损坏 • Defective PCB in the weld head. 焊头里的电路板损坏 • Defective optocoupler on the ETF CPU E510. E510里的光耦合器损坏 Remedy: • Check cable package. 措施：检查管线总成 • Check PCB in the weld head. 检查焊头里的电路板 • Replace PCB ETF CPU E510. 更换E510电路板 • Notify service engineer! 专业人员处理专业文档供参考，如有帮助请下载。

展开阅读全文