Alarm Message
ALARM MESSAGE DESCRIPTION CORRECTIVE ACTIONS MEMORY ERROR!! Memory Trouble. Memory backup
battery is discharged. Program data may have been lost. TROUBLE output signal is generated at the I/O connector when power is turned on (refer to Appendix B).
Error Reset: Press the front panel RESET key.
Remedies: Check program data after reset. Restore data if wrong or missing.
Replace the lithium backup battery on the Power Supply printed circuit board (refer to Chapter 7).
OVER TEMPERATURE OF TRANSFORMER !!
Welding Transformer Thermostat is Open. The welding transformer has overheated and its protective thermostat has tripped. The system cannot start.
Error Reset: Close the RESET input signal at the I/O connector (refer to Ap-pendix B).
Remedies: Cool the welding transform-er to reset the thermostat.
Check the transformer cooling system.
Reduce the duty cycle or use a larger capacity weld-ing transformer.
OVER TEMPERATURE OF TRANSISTOR !!
Transistor Thermostat is Open. Pow-er transistors have ovPow-erheated and the protective thermostat has tripped. The system cannot start.
Error Reset: Close the RESET input signal at the I/O connector (refer to Ap-pendix B).
Remedies: Cool the power supply to reset the thermostat. Reduce the duty cycle.
OVER CURRENT!! Excessive Current. Power Supply peak output current exceeded 50 A for the IP-215A or 200 A for the IP-217A during the weld cycle.
Error Reset: Close the RESET input signal at the I/O connector (refer to Ap-pendix B).
Remedies: Check for a short circuit between the welding transformer out-put terminals or in the welding transformer output cable.
NO CURRENT !! No Current. During welding, weld cur-rent is less than 25 A for the IP-215A or 50 A for the IP-217A after 5 msec from the start of the weld cycle.
Welding has stopped and the system cannot be re-started.
Error Reset: Close the RESET input signal at the I/O connector (refer to Ap-pendix B).
Remedies: Check the welding trans-former secondary circuit and its internal toroidal coil for damaged wires and loose connections.
ALARM MESSAGE DESCRIPTION CORRECTIVE ACTIONS
NO VOLTAGE !! No Voltage. In the Constant Voltage or Constant Power control mode, sensed voltage is less than 0.05 V after 5 msec from the start of the weld cycle.
Error Reset: Close the RESET input signal at the I/O connector (refer to Ap-pendix B).
Remedies: Check for disconnected volt-age sensing leads or an open voltage sensing cable.
CURRENT ERROR !!
LOWER THAN LIMIT
Current Lower Limit Exceeded. The measured current value has gone below the current monitor lower limit setting.
MR = 0: END signal is output at I/O connector (refer to Appendix B). Next weld can begin.
MR = 1: END signal is not output at I/O
connector. Next weld cannot begin.
Error Reset:
MR = 0: Next START signal auto-matically clears error con-dition.
MR = 1: Close RESET input signal at I/O connector.
Remedies: Check for problems in the welding cables, work pieces, the weld head, and the AC input voltage source.
CURRENT ERROR !!
HIGHER THAN LIMIT
Current Upper Limit Exceeded.
When the weld is completed, the meas-ured current value has gone above the current monitor upper limit setting.
MR = 0: END signal is output at I/O connector (refer to Appendix B). Next weld can begin.
MR = 1: END signal is not output at I/O
connector. Next weld cannot begin.
Error Reset:
MR = 0: Next START signal auto-matically clears error con-dition.
MR = 1: Close RESET input signal at I/O connector.
Remedies: Check for problems in the welding cables, work pieces, and the weld head.
VOLTAGE ERROR !!
LOWER THAN LIMIT
Voltage Lower Limit Exceeded.
When the weld is completed, the measured voltage value between the electrodes has gone below the voltage monitor lower limit setting.
MR = 0: END signal is output at I/O connector (refer to Appendix B). Next weld can begin.
MR = 1: END signal is not output at I/O
connector. Next weld cannot begin.
Error Reset:
MR = 0: Next START signal auto-matically clears error con-dition.
MR = 1: Close RESET input signal at I/O connector.
Remedies: Check for problems in the welding cables, work pieces, and the weld head.
ALARM MESSAGE DESCRIPTION CORRECTIVE ACTIONS
VOLTAGE ERROR !!
HIGHER THAN LIMIT
Voltage Upper Limit Exceeded.
When the weld is completed, the measured vol-tage value between the electrodes has gone above the voltage monitor upper limit setting.
MR = 0: END signal is output at I/O connector (refer to Appendix B). Next weld can begin.
MR = 1: END signal is not output at I/O
connector. Next weld cannot begin.
Error Reset:
MR = 0: Next START signal auto-matically clears error con-dition.
MR = 1: Close RESET input signal at I/O connector.
Remedies: Check for problems in the work pieces and the weld head.
WATTAGE ERROR !!
LOWER THAN LIMIT
Power Lower Limit Exceeeded.
When the weld is completed, the measured power value has gone below the power monitor lower limit setting.
MR = 0: END signal is output at I/O connector (refer to Appendix B). Next weld can begin.
MR = 1: END signal is not output at I/O
connector. Next weld cannot begin.
Error Reset:
MR = 0: Next START signal auto-matically clears error con-dition.
MR = 1: Close RESET input signal at I/O connector.
Remedies: Check for problems in the welding cables, voltage sense cables, work pieces, the weld head, and the AC input voltage source.
WATTAGE ERROR !!
HIGHER THAN LIMIT
Power Upper Limit Exceeded. When the weld is completed, the measured power value has gone above the power monitor upper limit setting.
MR = 0: END signal is output at I/O connector (refer to Appendix B). Next weld can begin.
MR = 1: END signal is not output at I/O
connector. Next weld cannot begin.
Error Reset:
MR = 0: Next START signal auto-matically clears error con-dition.
MR = 1: Close RESET input signal at I/O connector.
Remedies: Check for problems in the work pieces and the weld head.
FULL WAVE !! Control Limit Exceeded. The control pulse width was 100% for more than 5 msec during the weld cycle.
Error Reset: Close the RESET input signal at the I/O connector or wait for the next START signal to
automatically clear the error condition.
Remedies: Check for problems in the welding cables, the work pieces, the weld head, and the AC input voltage source.
ALARM MESSAGE DESCRIPTION CORRECTIVE ACTIONS
(IP-217A Only) CURR SET ERROR !!
Current Setting Error. The IT-500A Welding Transformer is selected. At the START signal, the weld current setting is greater than 2.01 KA. An ERROR output signal is present at the I/O connector (refer to Appendix B).
The system cannot start.
Error Reset: Close the RESET signal input at the I/O connector (refer to Appendix B).
Remedies: Reduce the current setting below 2.01 KA or change the welding transformer to an IT-510A.
END OF WELD COUNT !! Note: This alarm is not the result of an error.
At the end of the last weld cycle, the number of good welds completed was equal to the value preset into the weld counter. The COUNT UP and END signals are output at the I/O connector (see Appendix B). The next weld can begin.
Alarm Reset: Press the front panel RESET and COUNT keys
simultaneously.