Chapter 9: Troubleshooting Chapter 9: Troubleshooting Page 9-1
Chapter 9: Troubleshooting (Rev. 8/98) 9.1 Abnormal Conditions. When an abnormal condition is detected, the system,halts with the ABNORMAL LED lit. For ease of troubleshooting the nature of the abnormal, the system provides an abnormal code in the [PARM/ABN] display and an abnormal sub-code in the [ANGL.SPNO] display. wAbnormal code display.
Chapter 9: Troubleshooting 9.2 (Rev. 8/98) Axis Unit Abnormal Help Screen Explanation After the applicable ABNORMAL CODE and ABNORMAL SUB CODE have been identified from the affected Axis unit a review of the following troubleshooting guide will identify the nature of the failure and the recovery method. Example: Abnormal code 1 with an Abnormal sub code of 0 can be found immediately following this example as "Code 1-0". The remainder of abnormal codes can be found in numerical order.
Chapter 9: Troubleshooting 9.3 (Rev. 8/98) Torque Transducer 9.3.1 code 1-0 TORQUE TRANSDUCER / ZERO VOLTAGE ERROR Zero level voltage error during power on initialization. This abnormal is caused from only 3 items. 1. When the tool transducer is sensing excessive torque due to pressure on the tool body. 2. If the controller or the transducer cable is located in an electric or magnetic noise field. 3. When the torque transducer, transducer (T/D) cable or the controller malfunctions. RECOVERY: 1.
Chapter 9: Troubleshooting (Rev. 8/98) This abnormal is caused from only 3 items. 1. When the tool transducer is sensing excessive torque due to pressure on the tool body. 2. If the controller or the transducer cable is located in an electric or magnetic noise field. 3. When the torque transducer, transducer (T/D) cable or the controller malfunctions. RECOVERY: 1. Check that the tool has no external force applied to it. 2.
Chapter 9: Troubleshooting 9.4 (Rev. 8/98) Preamplifier / Tool EEPROM 9.4.1 code 3-0 preamplifier / tool eeprom error Communications error between the tool preamplifier and the controller. This abnormal is caused from only 2 items. 1. If the controller or the transducer cable is located in an electric or magnetic noise field. 2. When the torque transducer, transducer (T/D) cable or the controller malfunctions. RECOVERY: 1.
Chapter 9: Troubleshooting 9.5 (Rev. 8/98) System Memory / Tool EEPROM 9.5.1 code 4-0 system memory error / tool eeprom write error Communications error between the tool preamplifier and the controller. This abnormal is caused from only 2 items. 1. If the controller or the transducer cable is located in an electric or magnetic noise field. 2. When the torque transducer, transducer (T/D) cable or the controller malfunctions. RECOVERY: 1.
Chapter 9: Troubleshooting 9.6 (Rev. 8/98) Servo Amplifier Response / Encoder 9.6.1 code 5-0 servo amplifier reply error / no reply from encoder The controller is trying to turn the tool assembly, but is not receiving any angle count back from the encoder to indicate that the tool is actually turning. This abnormal is caused from only 4 items. 1. The motor cable is damaged or not connected 2. If the encoder cable is damaged. 3. When the encoder, motor, or the controller malfunctions. 4.
Chapter 9: Troubleshooting 9.7 Servo Type 9.7.1 code 6-0 servo type error / servo type mismatch The servo amplifier does not match the connected motor type. Verify the servo type tag with the motor type tag. There are 4 type of servo amplifiers (controllers) available.
Chapter 9: Troubleshooting 9.8 (Rev. 8/98) Power voltage / Inside Power Supply 9.8.1 code 7-0 power voltage error / inside power supply abnormal The controller internal power supply circuit is not working properly. This abnormal is caused from only 3 items. 1. The controller internal power supply has failed 2. If the environment temperature is more than 113 degrees Fahrenheit ( 45 degree centigrade ) without any air flow. 3.
Chapter 9: Troubleshooting 9.9 (Rev. 8/98) Servo Amplifier / Encoder cable 9.9.1 code 8-0 servo amplifier error / encoder cable is broken The controller can not detect the presence of an encoder. This abnormal is caused from only 2 items. 1. If the encoder cable is damaged or disconnected. 2. When the encoder or the controller malfunctions. RECOVERY: 1. Connect the spare encoder cable to the existing tool. 2. Exchange tool and/or controller with known working units.
Chapter 9: Troubleshooting (Rev. 8/98) 9.9.4 code 8-3 servo amplifier error / servo is over heated The controller Servo circuit is not working properly. This abnormal is caused from only 3 items. 1. The controller servo drive circuit has failed 2. If the environment temperature is more than 113 degrees Fahrenheit(45 degree centigrade) without any air flow. 3. Source voltage is very close to the limit (253 volts ac) and the environment temperature is also close to the limit. RECOVERY: 1.
Chapter 9: Troubleshooting (Rev. 8/98) 9.9.7 code 8-6 servo amplifier error / source voltage abnormal The controller internal power supply circuit is not working properly or the input voltage is above the maximum limit. This abnormal is caused from only 2 items. 1. The controller internal power supply has failed 2. Source voltage is very close to the limit (253 volts ac) and the environment temperature is also close to the limit. RECOVERY: 1. Replace the controller 2.
Chapter 9: Troubleshooting 9.10 (Rev. 8/98) Preset Error 9.10.1 code 9-0 preset error / reverse speed does not exist The reverse speed preset is not setup or the wrong parameter number has been selected by the PLC. RECOVERY: 1. Verify that the parameter number that is being selected by the PLC is configured in the controller. 2. Check that the reverse speed preset is not <0> or out of the specified speed range of the tool. 9.10.
Chapter 9: Troubleshooting (Rev. 8/98) 9.10.5 code 9-4 preset error / system abnormal 3 The system controller experienced an internal processing error. This abnormal is caused from only 2 items. 1. If the controller is located in an electric or magnetic noise field. 2. When the controller malfunctions. RECOVERY: 1. Verify that the controller is not located near any high voltage transient power sources. Relocate as required and reinitialize the system. 2. Exchange the controller with known working unit.
Chapter 9: Troubleshooting 9.11 (Rev. 8/98) AFC1100 Axis Unit Fastening Faults and Causes 9.11.1 Accept Conditions THE ACCEPT LED will light for the three following reasons: 1. tHE RESET input is active on either the front panel or via a PLC input, and the reset condition (ZERO LEVEL) of the TRANSDUCER is within acceptable limits. 2. tHE CAL input is active on either the front panel or via a PLC input, and the calibration condition (CAL LEVEL) of the transducer is within acceptable limits. 3.
Chapter 9: Troubleshooting (Rev. 8/98) 9.11.3 ANGLE REJECT conditions THE ANGLe Reject LED will light for the following reasons: 1. A "REd" ANGLE Reject LED on the AXIS unit indicates a HIGH ANgle reject. THIS type of reject is caused when the degrees of rotation the fastener turns after sensing the Snug torque is in excess of the preset HIGH Angle limit as specified in the PARameters. MAy cause a LOW TORQue reject. CAUSES: EXCessive lubrication, thread obstacle, excessive joint compression. 2.
Chapter 9: Troubleshooting (Rev. 8/98) 9.11.5 TORQUE RATE REJECT conditions TorquE RAte (RAte) is defined as the change in torque divided by the change in degrees of rotation (ANgle) during a specific interval. 1ST RATE 1. A "RED" 1ST RATE Reject LED on the AXIS unit indicates that the Torque Rate, as measured from Threshold (THR) to 1st TORque, is above the high limit specified in the PARameters. May cause a LOW TOrque Reject. 2.
