With the development of resistance welding technology, more and more spot welders are using medium frequency direct current welding technology, which requires the use of MFDC welding controllers. If you are using an MFDC spot welder or are about to use one, this article will guide you in making some judgments.
| 01 Air valve power supply voltage is low | interrupt alarm | non-resettable | |
| possible reason | Countermeasures | ||
| problem with the external DC24V | Check whether the DC24V on the air valve power supply X1 is normal | ||
| 02 Inverter drive failure | interrupt alarm | non-resettable | |
| possible reason | Countermeasures | ||
| During the inverter process, the IGBT device is over-current or the corresponding drive current is not working properly | – Check whether the main board and driver wiring are loose
– Check whether the wiring between the driver board and the IGBT is loose – IGBT device is damaged, replace the controller |
||
| 03 Heat sink overheated | interrupt alarm | Automatic reset after temperature drop | |
| possible reason | Countermeasures | ||
| – Cooling water inlet temperature is too high
– The duty cycle is too high – Insufficient cooling water flow – The temperature relay is damaged (normally closed, the main board X7 is the input of the temperature relay) |
-Reduce the cooling water inlet temperature
-Reduce controller duty cycle -Ensure that the cooling water is unobstructed -replace the temperature relay |
||
| 04 Abnormal primary current | interrupt alarm | resettable | |
| possible reason | Countermeasures | ||
| -Load short circuit (transformer primary short circuit or U, V line short circuit) causes inverter output current to be too large
-Transformer short circuit to ground – The two primary side transformers are asymmetrical – Main control board detection abnormality |
– Check if the load is short circuited
– Check transformer insulation -Replace the primary transformer -Replace the main control board |
||
| 05 Abnormal capacitor voltage | interrupt alarm | Non-resettable, automatically reset after the voltage is reached | |
| possible reason | Countermeasures | ||
| – Unstable power grid or lack of phase
– Abnormal charging of the capacitor |
-Ensure that the power grid is normal and stable without phase loss
-Replace the controller |
||
| 06 +5v power supply high | interrupt alarm | Non-resettable | |
| possible reason | Countermeasures | ||
| – Abnormal operating voltage of the motherboard | -Replace the motherboard | ||
| 07 +15V Power High | interrupt alarm | Non-resettable | |
| possible reason | Countermeasures | ||
| -The power supply of the motherboard is abnormal -The temperature control line of the transformer is connected to the high voltage | -Ensure that the mainboard power supply DC24V is normal
– Check the transformer temperature control line -Replace the motherboard |
||
| 08 -15V Power High | interrupt alarm | Non-resettable | |
| possible reason | Countermeasures | ||
| – The power supply of the motherboard is abnormal | -Ensure that the mainboard power supply DC24V is normal
-Replace the motherboard |
||
| 09 Transformer temperature is too high | interrupt alarm | Non-resettable, automatically reset when the temperature drops | |
| possible reason | Countermeasures | ||
| – Transformer cooling water inlet temperature is too high
– High duty cycle – Insufficient cooling water flow – The internal temperature relay of the transformer is damaged (normally normally closed, and the main board X5-3 is the input of the temperature relay) |
– Reduce cooling water inlet temperature
-Reduce duty cycle -Ensure that the cooling water is unobstructed -replace the temperature relay |
||
| 0a Main 24V power low | interrupt alarm | Non-resettable | |
| possible reason | Countermeasures | ||
| – The power supply of the motherboard is abnormal
– The power supply of the driver board is abnormal |
– Check whether the DC24V of the X2 terminal is normal, if it is normal, replace the main board,
– Otherwise, check whether the DC24V power supply on the driver board X2 is normal, if not, replace the driver board -Otherwise replace the controller |
||
| 0b Secondary current sensor short circuit | interrupt alarm | resettable | |
| possible reason | Countermeasures | ||
| – Abnormal connection wire of secondary current sensor
-Secondary current sensor damaged |
– Check the secondary current sensor wiring
– Replace the secondary current sensor |
||
| 0c Secondary current sensor is open | interrupt alarm | resettable | |
| possible reason | Countermeasures | ||
| – Abnormal connection wire of secondary current sensor
-Secondary current sensor damaged |
– Check the secondary current sensor wiring
– Replace the secondary current sensor |
||
| 0d (welding) current is too high | Reminder alarm à Interrupt alarm (optional) | resettable | |
| possible reason | Countermeasures | ||
| – current monitoring parameter setting is not suitable
-Transformer primary short circuit, U/V line short circuit (primary side detection) |
-Adjust current monitoring parameter settings (welding current monitoring related parameters)
– Check U/V line for short circuit – Check transformer primary |
||
| 0e (welding) current is too small | ）
Reminder alarm à Interrupt alarm (optional) |
resettable | |
| possible reason | Countermeasures | ||
| – current monitoring parameter setting is not suitable
– There is a problem with the welding secondary circuit |
-Adjust current monitoring parameter settings (welding current monitoring related parameters)
-Detect welding secondary circuit |
||
| 0f Continuous current low | Reminder alarm à Interrupt alarm (optional) | resettable | |
| possible reason | Countermeasures | ||
| – current monitoring parameter setting is not suitable
– There is a problem with the welding secondary circuit |
-Adjust current monitoring parameter settings (welding current monitoring related parameters)
-Detect welding secondary circuit |
||
| 10 Replacement Electrode Request | interrupt alarm | It can be reset, and the fault is cleared after being cleared | |
| possible reason | Countermeasures | ||
| – Welding gun electrode life has expired | – Replace the electrode, and input the electrode replacement signal from the X5 terminal after changing the electrode | ||
| 11 Reconditioning Electrode Request | interrupt alarm | It can be reset, and the fault is cleared after being cleared | |
| possible reason | Countermeasures | ||
| – Welding gun request grinding electrode | -Grind the electrode, and input step-by-step reset signal from X5 terminal after grinding the electrode | ||
| 12 Abnormal programming parameters | interrupt alarm | resettable | |
| possible reason | Countermeasures | ||
| – Parameter out of range in started weld specification | – Check for out-of-range parameters and modify | ||
| 13Abnormal calibration parameters | interrupt alarm | resettable | |
| possible reason | Countermeasures | ||
| – There is a problem with the main control board | -Replace the motherboard | ||
| 14 Abnormal water pressure detection | interrupt alarm | Can not be reset, automatically reset after normal | |
| possible reason | Countermeasures | ||
| Abnormal water pressure
There is a problem with the water pressure detection line |
Ensure that the water pressure is within the normal working range
Check water pressure detection wiring |
||
| 15 Abnormal air pressure detection | interrupt alarm | Can not be reset, automatically reset after normal | |
| possible reason | Countermeasures | ||
| abnormal air pressure
There is a problem with the air pressure detection line |
Make sure the air pressure is within the normal working range
Check air pressure detection wiring |
||
| 16 start inhibit | interrupt alarm | Resettable | |
| possible reason | Countermeasures | ||
| – the specification for the current start has been set to the disabled start mode | – Set the parameter “Prohibition to start” of the current starting specification to OFF | ||
| 17 emergency stop | interrupt alarm | Can not be reset, automatically reset after normal | |
| possible reason | Countermeasures | ||
| External emergency stop input disconnected | Access to external emergency stop | ||
| 18 Number of solder joints to | Reminder alarm à | Resettable | |
| possible reason | Countermeasures | ||
| -The number of actually monitored solder joints reaches the set maximum number of solder joints | – Just reset on the terminal or programmer | ||
| 19 production count | Interrupt alarm | Resettable | |
| possible reason | Countermeasures | ||
| -The actual monitoring production number reaches the set maximum production number | – Just reset on the terminal or programmer | ||
The following are the problems that may occur during the use of the medium-frequency welding power supply controller and the corresponding solutions. The resistance welding machines of AGERA can all refer to it. In addition, if you purchase AGERA’s equipment and encounter difficult-to-solve problems during use, you can contact our after-sales team. We are available 24 hours online and will quickly solve the current problems you are facing.
English 
Spanish 
Korean 
Russian 
French