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Error Message Description Cause(s) Possible Solution(s)
Part detected before reach-
ing start sensing distance.
Force in excess of 50 lb (220 N) was
detected before reaching 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.
Press down travel limit
exceeded!
Lower travel limit switch activated. Press moved sufciently far down to
activate lower limit switch.
1. Lower bottom stop position.
2. Decrease weld or hold depth.
Servo actuator temperature
limit exceeded!
Servo actuator is too hot. 1. Welder duty cycle is too large.
2. Weld/hold times or forces are too
large.
3. Thruster fan not working.
4. Servo actuator or amplier 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.
Error detected at servo
press.
OR
Servo controller error!
One or more of servo-related error(s)
has occurred. This message is accom-
panied by one of the following error
types displayed in the Status area:
Amplier Error
Checksum Error
Command Error
Down Travel Limit
Force Duration Exceeded
Position Error
Servo Error
Trigger < Sensing start Distance
Up Travel Limit
See specic error type below. See specic error type below.
Amplier Error Error occurred with servo amplier. Faulty wiring or damaged amplier. 1. Restart press system.
2. Contact DUKANE service.
Checksum Error Servo controller hardware error. Problem with servo controller hardware. 1. Restart press system.
2. Contact DUKANE service.
Command Error Servo controller program error. Problem with servo controller hardware. 1. Restart press system.
2. Contact DUKANE service.
Down Travel Limit Lower travel limit switch activated. Press moved sufciently far down to
activate lower limit switch.
1. Lower bottom stop position.
2. Decrease weld/hold depth.
Force Duration Exceeded While in Teach mode, time allowed for
press to produce moderate/large forces
was exceeded.
Moderate/large press force was being
applied for an extended period of time,
resulting in servo amplier being auto-
matically powered off.
Reduce force and/or amount of time force is
applied while in Teach mode.
iQ Servo Press Error Messages Page 1 of 2
Table 6 - I Error Messages, Servo-related
Page 82
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual
Dukane Manual Part No. 403-575-00
- User's Manual 1
- Page ii 2
- Revision History 3
- Page iv 4
- Contents 5
- Contents Continued 6
- SECTION 1 7
- General User Information 9
- Press System Overview 10
- Key Generator Features 10
- SECTION 2 11
- General Considerations 13
- Plastics Health Notice 14
- Lifting the Equipment 16
- SECTION 3 17
- Page 12 18
- Before Installation 19
- Page 14 20
- Unpacking 21
- Placement 21
- Rack- Mounting 22
- Rack Mounting iQ Generator 22
- Continued from previous page 22
- Benchtop Mounting 23
- Rear Panel Layout Overview 24
- System I/O Panel 25
- 1 2 3 4 5 27
- 11 12 13 14 15 27
- Page 22 28
- System Outputs Connector 29
- Page 24 30
- Section 3 - Installation 31
- Page 26 32
- Ultrasound Output Connector 33
- Conguration Port Connector 33
- RFI Grounding 34
- Connecting Cables 35
- Three Congurations 36
- Pneumatic Press/Thruster 38
- Networking 43
- Recheck Connections 43
- Connect AC Power 43
- Page 38 44
- SECTION 4 45
- Page 40 46
- Overview 47
- Start-up 47
- Normal Conditions 48
- Emergency Conditions 48
- Numeric Pad and Keyboard 48
- Help System 49
- Quick Start - Servo Welder 50
- See Figure 4-7 51
- See Figure 4-8 51
- Linear Weld Joint (inches) 52
- Select Trigger 54
- Section 4 - Operation 55
- Advanced Users - NOTE 56
- Servo Step 13 - Set Amplitude 57
- Step 14 - Post Weld Settings 58
- Hold 59
- Page 54 60
- Process Limits Tab 60
- Servo Step 17 - Cycle Data 61
- Quick Start 62
- Page 60 66
- Air Cylinder Size 69
- Pounds of Force Comparison 69
- Continued from Page 62 70
- Page 66 72
- Page 70 76
- SECTION 5 77
- Page 72 78
- Operational Test of 80
- Error detected: 81
- Overload peak overload fault! 81
- Page 76 82
- Procedure for Cycling 83
- Page 78 84
- SECTION 6 85
- Page 80 86
- Troubleshooting 87
- Page 82 88
- Page 84 90
- Verifying Feature Operation 91
- Force Transducer (Load Cell) 92
- An Uninterrupted Cycle 93
- Premature Weld Termination 95
- Page 90 96
- The iQ Generator Won’t 97
- No Ultrasound 97
- Page 92 98
- SECTION 7 99
- Page 94 100
- Front and Rear Panels 101
- Page 96 102
- SECTION 8 103
- Page 98 104
- Electrical Safety 105
- Power Inlet Options 105
- AC Power Inlet Panel 106
- Press Interface Board 107
- Page 102 108
- SECTION 9 109
- Page 104 110
- Contacting Dukane 111
- Page 106 112
- SECTION 10 113
- Specications 113
- Page 108 114
- Page 109 115
- Section 10 - Specications 115
- Page 110 116
- Page 111 117
- Operating Environment 118
- AC Power Requirements 119
- Interpreting the Model Number 120
- Regulatory Agency Compliance 121
- CE Marking 121
- Page 116 122
- SECTION 11 123
- Appendices 123
- Page 118 124
- List of Figures 125
- Appendix A 125
- Appendix B 128
- List of Tables 128
- Page 123 129
- Page 124 130
- Continued 131
- Continued - Installation 132
- Page 128 134
- Dukane ISO 135
- Part No. 403 - 575 - 00 136
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