Dukane Ultrasonic Generator 403-575-00 - Manual (Page 89)

Error Message
Description
Cause(s)
Possible Solution(s)
Position Error
Allowable servo position following error was exceeded.
1. Force required to maintain pro
-
grammed speed(s) is too large. 2.
Trigger Distance or Sensing Start
Distance is too large, causing premature contact of horn with part. 3. Press motion is obstructed.
1a. Reduce weld/hold speed(s). 1b. Increase weld amplitude to increase melt rate. 2. Reduce
Trigger Distance or Sensing start
Distance. 3. Check for and remove any obstructions to press motion.
Servo Error
General servo error
.
Multiple causes possible.
1. Restart press system. 2. Contact DUKANE service.
Trigger<Sensing Start Distance
Force or Power
Trigger occurred before
press reached Sensing Start Distance.
1. Sensing Start Distance is too large. 2. Part(s) not properly loaded.
1. Decrease Sensing Start Distance. 2. Check part placement.
Up T
ravel
Limit
Lower travel limit switch activated.
Press moved sufficiently far up to acti
-
vate upper limit switch.
Jog press down.
Up T
ravel
Limit
Lower travel limit switch activated
Press moved sufficiently far up to activate upper limit switch.
Jog press down.
Overload (average) at xxx msecs. Power above generator rating.
Power from ultrasonic stack sent to the part exceeds power rating of generator
.
1. Excessive pressure applied to the part. 2. Booster size is too large.
1. Decrease pressure applied to part. 2. Reduce size of booster
.
Overload (peak) at xxx msecs. Check stack.
1. Component failure in the stack. 2. Improper stack assembly
.
3. Incorrect
Advanced Hardware settings.
1. Check functionality of stack components. 2. Disassemble and reassemble stack. 3. Check the generator's
Advanced Hardware
settings.
Over temperature fault!
Generator's internal temperature ex
-
ceeds 158º F (70º Celsius).
1. W
elder duty cycle is too large.
2. W
eld/hold times or forces are too
large. 3.
Thruster fan not working.
4. Servo actuator or amplifier is dam
-
aged.
1. Reduce cycle rate. 2. Change setup to reduce weld/hold forces or decrease weld duration. 3. Check if fan is obstructed; contact DUKANE service for replacement. 4. Contact DUKANE service.
Overload (frequency) at xxx msecs. Check stack, cable or validate ramp up time.
Generator is unable to lock to the reso
-
nant frequency of the ultrasonic stack.
1. Improper stack assembly
.
2. Defective ultrasound cable. 3. Ramp up time is too short.
1. Disassemble and reassemble stack. 2. Replace ultrasound cable. 3. Increase ramp up time.
Overload (frequency) at xxx msecs. Check for coupling between stack and part.
Generator correctly locks to the resonant frequency of the ultrasonic stack, but loses the lock at a point later in the weld cycle.
Horn comes in contact with the part nest or anvil.
Make adjustments to thruster and part nest.
Power fault. Check
AC line.
AC line voltage drops below 190 V
AC on
240 V
AC systems, and below 95 V
AC on
120 V
AC systems.
Fluctuations in
AC power
.
Check the incoming
AC line power
.
iQ
Servo
Press
Error
Messages
Page 2 of 2
Table 6 - I Error Messages, Servo-related (continued)
Page 83
Dukane Manual Part No. 403-575-00
Section 6 - Troubleshooting