MT861EN KA01d

iBox AW/SW
Medium Frequency Inverter

with Built-In WCC
Quick Reference Guide
Type KA Issue 01 (Ethernet IP)
iBox Front Face

or
Pocket Terminal
MT861EN_KA01d
Revision Index
Date
Documentation
reference
11/2012
MT861FR
Creation of original (KA00)
01/2013
MT861EN
Creation of English translation
Type of change
Update KA00c XD01007
02/2013
03/2013
MT861FR
Update KA00d XD01008
03/2013
MT861FR
Update KA01 XD02000
06/2013
MT861EN
Update KA01b XD02005
06/2013
MT861EN
Update KA01c XD02006
07/2013
MT861EN
Update KA01d XD02007
07/2013
MT861EN
Update XD02008
08/2013
MT861EN
Update XD02009
08/2013
MT861EN
Update XD02010
ARO Welding Technologies S.A.S. 1, avenue de Tours 72500 Chteau du Loir France
+33 (0)2 43 44 74 00 +33 (0)2 43 44 74 01
www.arotechnologies.com
This document is a translation from French. Only the original document is the reference.
MT861EN_KA01d
ARO Welding Technologies S.A.S. 1, avenue de Tours BP 40161 72500 CHATEAU-DU-LOIR France (+33) (0)2 43 44 74 00
Table of Contents
MT861EN_KA01d
iBox Front Fa ce Presentation .................................................................................................................................. 7

Pock et Progra mming T erminal Presentation ............................................................................................................ 8
Activating the Pocket Terminal .............................................................................................................................................................. 9
Accessing the Menus ............................................................................................................................................................................... 9
Browsing Menus ...................................................................................................................................................................................... 9
Deactivating the Pocket Terminal ........................................................................................................................................................... 9
Operation ............................................................................................................................................................. 10
Operating Screens .................................................................................................................................................................................. 10
Fault or Alarm Screens .......................................................................................................................................................................... 10
Menu s .................................................................................................................................................................. 11
Main Menu ............................................................................................................................................................................................. 11
Sub-Menus.............................................................................................................................................................................................. 11
Progra mming Screens ........................................................................................................................................... 12
Process ................................................................................................................................................................. 17
Process Sub-Menu ................................................................................................................................................................................. 17
Service Screens ...................................................................................................................................................................................... 17
Specialty Process Screens...................................................................................................................................................................... 18
Input a nd Output Dia gnostics Screens .................................................................................................................. 19
Controls ............................................................................................................................................................... 20
Controls Sub-Menu ................................................................................................................................................................................ 20
Force Control Screen ............................................................................................................................................................................. 20
Current Control Screen .......................................................................................................................................................................... 20
History ................................................................................................................................................................. 21
History Sub-Menu .................................................................................................................................................................................. 21
Fault History Screens ............................................................................................................................................................................. 21
Spot History Screens .............................................................................................................................................................................. 21
Signature History Screens ..................................................................................................................................................................... 22
Identification Screens ........................................................................................................................................... 25
Expert or Operator Mode Choice Screens ............................................................................................................. 26
Diagnostic ............................................................................................................................................................ 27
Diagnostic Sub-Menu ............................................................................................................................................................................ 27
Timer Diagnostics Screen...................................................................................................................................................................... 27
Slave Bus Diagnostics Screens ............................................................................................................................................................. 27
Thermal Current Diagnostics Screens .................................................................................................................................................. 28
Welding Axis Diagnostics Screens ....................................................................................................................................................... 28
Ethernet Diagnostics Screens ................................................................................................................................................................ 29
Datakey Diagnostics Screens ................................................................................................................................................................ 30
Maintenance ......................................................................................................................................................... 31
Maintenance Sub-Menu ......................................................................................................................................................................... 31
Parameter Reset Screens ........................................................................................................................................................................ 31
Dressing Grinder Counter Reset Screen ............................................................................................................................................... 32
Copy Parameters Screen ........................................................................................................................................................................ 32
Configuration ....................................................................................................................................................... 34
Configuration Sub-Menu ....................................................................................................................................................................... 34
General Configuration Screens ............................................................................................................................................................. 34
Gun Configuration Screens ................................................................................................................................................................... 35
AW Learning Configuration Screens ................................................................................................................................................... 37
Robot Communication Configuration Screen ...................................................................................................................................... 37
Calibration ........................................................................................................................................................... 38
Calibration Sub-Menu ........................................................................................................................................................................... 38
Ongoing Assistant Screen...................................................................................................................................................................... 38
Gun and Learning Choice Screen ......................................................................................................................................................... 39
Force Calibration Screens...................................................................................................................................................................... 39
Gun Opening Calibration Screens ........................................................................................................................................................ 40
Current Measurement Calibration Screens........................................................................................................................................... 40
MF Learning Screens ............................................................................................................................................................................. 40
Resistance Calibration Screen ............................................................................................................................................................... 41
AW Learning Screens ............................................................................................................................................................................ 41
Fault Definition .................................................................................................................................................... 43
Ala rm Definition .................................................................................................................................................. 53
iBox Front Face Presentation
iBox Front Face Presentation
5
9
4
8
3
7
2
No.
TYPE
1
2
4
5
FUNCTION
Display
LCD, 4 lines of 20 characters.
key
key
key
key
+ key
key
Move to the previous column (Program, Gun ) or to the previous menu.
enter key
F1 key
F2 key
F3 key
To validate the entered information and to go to next field on same page.
0 to 9
clear key
Use the number pad to directly enter a digital value.
esc key
menu key
Cancels any modifications made that have not been saved (after confirmation from the user).
Keys
7
8
9
menu
key
for 750 ms
MT861EN_KA01d
Move to the next column (Program, Gun ) or to the next menu.

Move to the previous page in the same column (Configuration, Program, Gun ).
Move to the next page in the same column (Configuration, Program, Gun ).
In a list, the + and - keys scroll all possible values. For these fields, the cursor is placed on the first
character in the field.
For a numerical value, the + or - keys increment or decrement the value. For these fields, the cursor is
placed on the least significant digit.
Function keys. A name is displayed on the lower line in block capitals only to show that the function key is
valid. The first character shows the key number. The name has up to five characters; if it is four characters or
less, the name is separated from the digit (1, 2 or 3) by a - e.g. 2-RST assigned to Key F2.
Left
F1
Centre
F2
Right
F3
For a digital value, deletes the least significant digit, shifts the other digits right by one character and replaces
the most significant digit with a 0.
From an execution, fault or alarm screen, displays the main menu.

From a parameter setting screen, displays the main menu.
From the main menu screen, displays the execution, fault or alarm screen.
From another menu screen, displays the main menu.
From an execution, fault or alarm screen, displays the last parameter setting screen.
From a parameter setting screen, displays the last execution, fault or alarm screen.
Pocket Programming Terminal Presentation

1
7
6
10
12
F1 F2
14
F3 F4
16
F5 F6
F7
9
13
15
No
TYPE
FUNCTION
1
2
Display
LCD, 4 lines of 20 characters.
key
Move to the previous column (Program, Gun ) or to the previous menu.
key
Move to the next column (Program, Gun ) or to the next menu.
key
Move to the previous page in the same column (Configuration, Program, Gun ).
key
Move to the next page in the same column (Configuration, Program, Gun ).
3
4
5
6
7
8
key
key
11
key
F1 key
F2 key
F3 key
12
F4 key
13
F5 key
14
F6 key
F7 key
9
10
15
16
key
(MENU)
11
In a list, the + and - keys scroll all possible values. For these fields, the cursor is positioned on the first
character in the field.
For a numerical value, the + or - keys increment or decrement the value. For these fields, the cursor is
positioned on the digit to be modified (initially the least significant digit).
To validate the entered information and to go to next field on same page.

Function keys. A name is displayed on the lower line in block capitals only to show that the function key is
valid. The first character shows the key number. The name has up to five characters; if it is four characters or
less, the name is separated from the digit (1, 2 or 3) by a - e.g. 2-RST assigned to Key F2
Left
F1
Centre
F2
Right
F3
For a numerical value, the cursor shifts left by one digit. Then the cursor returns to the right hand digit if it was
on the left most digit.
Cancels the current modifications and returns to the main menu (with user confirmation if the data is not
saved).
Not used.
From an execution, fault or alarm screen, displays the last parameter setting screen.
From a parameter setting screen, displays the last execution, fault or alarm screen.
From an execution, fault or alarm screen, displays the main menu.
From a parameter setting screen, displays the main menu.
From the main menu screen, displays the execution, fault or alarm screen.
From another menu screen, displays the main menu.
MT861EN_KA01d
Activating the Pocket Terminal
Connect the SUB D connector on the Pocket terminal to the "RS232" port on the Medium Frequency
inverter or on the cabinet. If the cabinet is powered up, an execution (or fault or alarm) screen is
displayed by the pocket terminal.
The Pocket terminal and the iBox front face cannot be used simultaneously. If the iBox front face is
present, the following screen is displayed by the pocket terminal:
iBox MMI present.

Pocket not available!
Accessing the Menus

From an execution, fault or alarm screen, press the
(Menu) key. The main menu is displayed.
Browsing Menus
A menu allows the selection of a group of parameters or data to be displayed or the selection of actions
to be performed.
Each screen of a menu allows up to three selections.
Menu with more than three choices. Pressing or displays the rest of the menu.
Main Menu
<>
Main Menu
<>
Main Menu
<>
1= Programming
1= Controls
1= Expert
2= Process
2= History
3= Inputs Outputs
3= Identification
Menu with three choices at most. Keys or are inactive.
Controls
1= Gun force
2= Current
In all cases, a menu is selected via function keys F1, F2, F3.
Deactivating the Pocket Terminal
MT861EN_KA01d
Any change made but not saved will be lost. To save it, return to (RUN) by pressing the
key or
change the column being edited by pressing the or button before deactivating the terminal.
Deactivating the Pocket terminal by disconnecting the "RS232" connector: the Pocket terminal display is
cleared and backlighting switched off.
Operation
Operation
Operating Screens
X1
X01 W G Prg
Imeasured= . kA
% PWM
= . %
Voltage = . V
X2
X02 W G Prg
Welding time
Command = ms
Time
= ms
Mode AW or SW; gun number; program number
X03 W G Prg
AW Learning
State spot
Mode AW; gun number; program number

Learning number assigned to the program
AW state spot
X3

Measured current
% PWM (--.- % if mode AW)
Effective secondary voltage level measured (-.--- V if SW mode)
Programmed welding time

Effective welding time (---- ms if SW mode)
Screen X3 is accessible in AW mode.

Spot state:
OK
Bad
Expulsed
Short-circuit
Constant resistor
X4
X04 W G Prg
Command
Measure
I .
. kA
F + daN

Command mode I or %; Current setting or %PWM; current measurement or %
Force setting (+ squeeze compensation force); force measurement (---- if no force sensor)
In SW and "%PWM" modes, line 3 = "% 00.0
00.0 %
"
If the squeeze compensation mode is off, "+000" does not appear on the fourth line.
X05 W G Prg
WC seg.
Spots Dres

Before EOL
X6
X06 W G Prg
Indentation . mm
Time
ms
Surface . mm.ms

Maximum indentation value
Indentation time in relation to start of welding
Indentation surface
Screen X6 is only accessible when indentation control is on.
X7
X07 W G Prg
Expansion
. mm
Time
ms
Surface . mm.ms

Maximum expansion value
Expansion time in relation to the start of welding
Expansion surface
Screen X7 is only accessible when expansion control is on.
X8
X08 W G Prg
Final pos. . mm

Final spot position
X5
Segment number (- in mode AW); spot counter; dressing counter

Spots remaining before end of life; Dressing before electrode replacement
Screen X8 is only accessible when final position control is on.
Fault or Alarm Screens

Dnn
Wnn
D07-000
Transformer
overheating
1-ACQ
Type 1
3->
F1 to acknowledge the fault; F3 to view the next fault

Alarm number; tool involved (if alarm linked to tool)
Fault name (on two lines)
A04
DC bus loading
3->
10
Fault number and cause number; type of fault

Fault description (on two lines)
F3 to view the next alarm
MT861EN_KA01d
Menus
Menus
Main Menu
Operator mode:
Main Menu
<>
1= Programming
2= Process
3= Inputs Outputs
Main Menu
<>
1= Controls
2= History
3= Identification
Main Menu
1= Expert
<>
Expert mode:
Main Menu
<>
1= Programming
2= Process
3= Inputs Outputs
Main Menu
<>
1= Controls
2= History
3= Identification
Main Menu
1= Expert
2= Diagnostic
3= Maintenance
<>
Main Menu
1= Configuration
2= Calibration
<>
Sub-Menus
Process
1= Service
2= Process
Controls
1= Gun force
2= Current
History
1= Faults
2= Spots
3= Signatures
Diagnostic
1= Timer
2= Slave Bus
3= Thermal
<>
Diagnostic
1= Welding axis
2= Ethernet
3= Datakey
<>
Maintenance
1= Reset parameters
2= Reset counter
3= Copy Parameters
Configuration
1= Common
2= Gun
3= AW
<>
Calibration
<>
1= Gun/lear. choice
2= Gun force
3= Opening
Configuration
1= Robot
Calibration
<>
1= Current measure
2= MF Learning
3= Resistance
Calibration
1= AW Learning
MT861EN_KA01d
<>
<>
11
Programming Screens
Programming Screens
Accessible by choosing Programming from the main menu
If access to the parameters is password protected, the programming screen may display a password prompt:
P01
Password
Number
1-VISU
Prg
=
=
3MODIF
View the current program number

Enter the password that protects access to parameters
Choice of the program number to call up
Choose mode: visualize or modify
For the visualization or view mode (F1 key), there is no need to enter the access code.
When F3 is pressed, the access code is compared with the parameter password:
Correct code Modify program parameters shown on line 3.
Incorrect code Access rejected (the display remains on the code entry screen).
When changing the program or exiting the programming screens with a changeover from SW mode to AW mode (P1 screen), the converter notifies you
before quitting the screen currently edited that the AW mode is not authorized if there is no datakey or if there is an SW datakey:
P
Prg
AW not available
Continue?
1-YES
3-NO
Gun number
F1 to confirm changeover to AW mode; F3 to return to the edited program
Note: The fault 83 -039 appears when activating a cycle start if the program is in
unauthorized AW mode (start not authorized if AW option is not available).
P1
P01
Gun
=
Learning
Prg
Program number (0 to 255)

Gun number (0 to 7)
Working mode: "AW mode" or "SW mode"
Learning number assigned to the program (not accessible --- if SW mode)
P2
P02
Prg
With current
:
Program number
With current cycle: "Yes" or "No"
P3
P03
Prg
Current
"%PWM
"Without control
Program number
P04
Prg
Force
"Without regulation
"Without control
Program number
P05
Prg
Maximum time
Squeeze
= ms
Program number
P4
P5
Current regulation mode

Current control mode
Screen P3 is accessible if "SW mode" (Screen P1).
Possible current regulation modes =
% PWM
Current regulation
Possible current control modes:
Without control
Current control
Curr. and %control (if "Current Regulation" mode)
Force control mode (only if "SW mode" in Screen P1)

Current control mode
Possible current regulation modes =
Without regulation
With regulation
(if gun motor has force sensor)
Possible current control modes =
Without control
Force control
(if gun motor has force sensor)
Envelope control
(if sensor and number of force steps 1)
Maximum period allowed between start of closure and start of force

Note: Exceeding the maximum time triggers Fault 82.
12
MT861EN_KA01d
Programming Screens
P6
P06
Force steps
Prg
=
Program number
Number of force steps
Screen P6 accessible if "SW mode" (Screen P1).

Prg
Welding Hold
Time = ms
Force = daN
Program number
P8
P08
Prg
P1= ms
P2= ms
P3= ms
daN
daN
daN
Program number
Duration and force of 1st force step
Duration and force of 2nd force step
Duration and force of 3rd force step (not accessible "----", if "Force steps" = 2)
Screen P8 accessible if "SW mode" (Screen P1) and if "Force steps" 1 (Screen P6).
P9
P09
Prg
P4= ms
P5= ms
P6= ms
daN
daN
daN
Program number
Duration and force of 4th force step
Duration and force of 5th force step (not accessible "----", if "Force steps" < 5)
Duration and force of 6th force step (not accessible "----", if "Force steps" < 6)
Screen P9 accessible if "SW mode" (Screen P1) and "Force steps" > 3 (Screen P6).
P7
P07
Welding and holding duration

Welding and holding force
Screen P7 accessible if "SW mode" (Screen P1) and "Force steps = 1" (Screen P6).
Hold force = 0 The hold phase is performed with the same force setting as the welding phase.
P10
P10
T1=ms
T2=ms
T3=ms
Prg
T4=ms
T5=ms
T6=ms
Program number
Transition time to step 1; Transition time to step 4
Screen P10 accessible if "SW mode" (Screen P1), "Force steps" 1 (Screen P6) and gun motor defined
with a force sensor.
Parameter T3 is not accessible ("----") if "Force steps" = 2.
Parameter T4 is not accessible ("----") if "Force steps" < 4.
P11
P11
Welding
Step
Delay
Prg
= ms
=
= ms
Program number
Welding time
Welding step
Welding delay time
Screen P11 accessible if "SW mode" (Screen P1) and "Force steps" 1 (Screen P6).
P12
P12
Gun
Command
Spt
"%
40.0
P13
P13
Gun Prg
Control
Segment
%
40.0 --.- %
I 003.00---.-- kA
MT861EN_KA01d
Prg
Segment

--.- %
Gun number; Program number

Wear compensation segment number
Start segment spot number; end segment spot number
Type setting % or I; Start segment setting; End segment setting; Setting unit
Start segment spot number = Previous segment end spot number
Start segment current = Previous segment end current
Setting type and unit depending on current regulation mode defined in screen P3:
" %
40.0 --.- % " (setting %) if regulation mode = "%PWM"
" I 003.00---.-- kA" (setting kA) if regulation mode = "Current Regulation"

Gun number; Program number
Wear compensation segment number
Type setting % or I; Start segment setting; End segment setting; Setting unit
Type control I or %; Start segment control; End segment control; Control unit
Start segment setting = End previous segment setting
Start segment control = End previous segment control
Screen P13 accessible if "SW mode" (Screen P1) and if:
Regulation mode = "%PWM" and control mode = "Current control (Screen P3):
line 3 = " %
40.0 --.- % " (setting and unit %)
line 4 = " I 003.00 ---.-- kA" (current control and unit kA)
or Regulation mode = "Current regulation" and control mode = "Int. and %" control:
line 3 = " I 003.00 ---.-- kA" (setting I and unit kA)
line 4 = " %
40.0 --.- % " (control and unit %)
13
Programming Screens
P14
P14 I Toler. Prg

High +%
Low -%
Repet. thresh. -%
Nr of repetitions
Program number
High threshold; Low threshold
Repetitive threshold
Number of repetitions
Screen P14 accessible if "SW mode" (Screen P1) and if current control mode = "Current Control" or
"Curr. and % control" (Screen P3).
Faults generated for this control mode:
23 if I Measured > ThresHigh
24 if I Measured < ThresLow
25 if ThresRepeat > IMeasured >= ThresLow n + 1 times (n = number of repeats)
P15
P15 % Toler. Prg

High +% Low -%
Repet. thresh. +%
Nr of repetitions
Program number
High threshold; Low threshold
Repetitive threshold
Number of repetitions
Screen P15 accessible if "SW mode" (Screen P1) and if current control mode = "Curr. and % control"
(Screen P3).
Faults generated for this control mode:
8 if %PWMMeasured > ThresHigh
28 if %PWMMeasured < ThresLow
29 if ThresRepeat < %PWMMeasured <= ThresHigh n times (n = number of repeats)
P16
P16
Prg
Tolerance = . mm
Thickness = . mm
Program number
Workpiece tolerance
Workpiece thickness
Note: Tolera nce = 010.0 mm No control.
P17
P18
P17
Prg
Force tolerances
High + Low - daN
Filter
ms
Program number
P18
Prg
Opening end of cycle
. mm
Program number
Force control high threshold; Force control low threshold

Force error filter
Screen P17 is accessible if force regulation mode = "With regulation " (Screen P4).
The "Filter" parameter is not accessible ("---") if force control mode "Envelope control" (Screen P4)
or if "Force steps" = 1 (Screen P6).
End of cycle opening setting.

Screen P18 is accessible if "Opening end of cycle" = "Used programmed opening"
(ARODMS/ARONET).
P19
P19
Prg
Nr of pulsations
Interval
ms
Program number
Number of pulsations
Pulsation interval
P20
P21
14
P20
Prg
Slope :Up
Down
Time :
ms
Comm.
Program number
P21
Prg
Pre-heat. = ms
Command
=
Cold
= ms
Program number
Pre-heat time
Pre-heat command; unit setting
Cold time (between pre-heating and welding)
Setting type and unit (3rd line) depending on the current regulation mode (Screen P3):
"Command = 40.0 % " (unit %) if regulation mode = "%PWM"
"Command = 03.00 kA" (unit kA) if regulation mode = "Current Regulation".
Upslope duration; downslope duration

Start upslope setting; end downslope setting; setting units
Setting type and unit (4 th line) depending on the current regulation mode (Screen P3):
Command 40.0 40.0 % " (unit %) if regulation mode = "%PWM"
Command 03.00 03.00 kA" (unit kA) if regulation mode = "Current Regulation"
MT861EN_KA01d
Programming Screens
P22
P22
Cooling
Time
Prg
= ms
Program number
Cooling time
P23
P24
P25
P26
P27
P28
P29
P30
P31
P32
P23
Prg
Annealing
Time
= ms
Command
=
Program number
P24
Prg
Equalizing
With EV =
Command = %
Program number
P25
Prg
Compensation
Squeeze
=
Program number
P26
Prg
Indentation
With control
=
Program number
P27
Prg
Indentation
Mini = . mm
Maxi = . mm
Program number
P28
Prg
Indentation time
Mini = ms
Maxi = ms
Program number
P29
Prg
Indentation surface
Mini = . mm.ms
Maxi = . mm.ms
Program number
P30
Prg
Expansion
With control
=
Program number
P31
Prg
Expansion
Mini = . mm
Maxi = . mm
Program number
P32
Prg
Expansion time
Mini = ms
Maxi = ms
Program number
MT861EN_KA01d
Annealing time
Annealing time command; unit setting
Setting type and unit (4 th line) depending on the current regulation mode (Screen P3):
"Command = 40.0 % " (unit %) if regulation mode = "%PWM"
"Command = 03.00 kA" (unit kA) if regulation mode = "Current Regulation".
Equalizing With EV: "No" or "Yes"

Equalizing Setting
With squeeze compensation: "No" or "Yes"
With indentation control: "No" or "Yes"
Minimum indentation
Maximum indentation
Screen P27 accessible if a program with indentation control is selected (Screen P26).
Indentation control not performed if Min = 0 and Max = 0 are set but measurements are made.
Minimum indentation time

Maximum indentation time
Indentation time control not performed if Min = 0 and Max = 0 are set but measurements are made.
Minimum indentation surface

Maximum indentation surface
Indentation surface control not performed if Min = 0 and Max = 0 are set but measurements are made.
With expansion control: "No" or "Yes"
Minimum expansion
Maximum expansion
Screen P31 accessible if a program with expansion control is selected (Screen P30).
Expansion control not performed if Min = 0 and Max = 0 are set but measurements are made.
Minimum expansion time

Maximum expansion time
Expansion time control not performed if Min = 0 and Max = 0 are set but measurements are made.
15
Programming Screens
P33
P34
P35
P36
P33
Prg
Expansion surface
Mini = . mm.ms
Maxi = . mm.ms
Program number
P34
Prg
Final position
With control
=
Program number
P35
Prg
Final position
Mini = . mm
Maxi = . mm
Program number
P36
Prg
Save measures
Program number
2-SAVE
P37
P38
Minimum expansion surface

Maximum expansion surface
Expansion surface control not performed if Min = 0 and Max = 0 are set but measurements are made.
With final position control: "No" or "Yes"
Minimum end position

Maximum end position
Screen P35 accessible if a program with final position control is selected (Screen P34).
Final position control not performed if Min = 0 and Max = 0 are set but measurements are made.
Function performed by F2 (only displayed if a cycle has been performed).

Screen P36 accessible if a program with indentation control (Screen P26), expansion control (Screen P30)
or final position control (Screen P34) is selected.
Pressing F2 saves the measurements from the last cycle in the Min and Max settings for the controls that
are performed.
P37
Prg
Measures thresholds
Start
=
ms
Stop
=
%
Program number
P38
Sampling
Period
Program number
Prg
= ms
Start current measurement function

Percentage of the current setting level below which no measurements may fall as a consequence this
measurement is no longer taken into account
Sampling period used for the oscilloscope function: 1, 2, 5 or 10 milliseconds

16
MT861EN_KA01d
Process
Process
Process Sub-Menu
Accessible by choosing Process from the main menu
Process
1= Service
2= Process
If access to process parameters is password protected, the programming screen may display a password prompt:
PS1 Services
Password
=
Enter the password that protects access to the process
1-VISU
or
PM1 Process
Password
1-VISU
3MODIF
Enter the password that protects access to the process
3MODIF
For the visualization or view mode (Key F1), there is no need to enter the password.
When F3 is pressed, the password entered is compared with the process password set:
Password correct
access to editing service or process settings.
Password incorrect
Access denied (the password prompt screen remains displayed).
Service Screens
Accessible by choosing Service from the Process sub-menu
PS1
PS1 Services
Unavailable screen
in automatic mode
Screen PS1 displayed if automatic mode selected.
PS2
PS2 Services
No selection
XXXXXXXXXXXXXXXXXXXX
Service name
Possible value for the selected service
Screen PS2 accessible if mode MANU.
Possible service (line 2) + value (line 3):
No selection
Initialization
Welding
Close gun
Open gun
Dressing
Change
Equalizing
Opening request
Tape init
Initialization 2
MT861EN_KA01d
+ Program Nr
+ Command
+ Command
: 000
: 000
: 000
17
Process
Specialty Process Screens

Accessible by choosing a specialty Process from the Process sub-menu
PM1
PM1 Process
With water
No
2ACTIV
PM2
18
PM2 Process
Control mode
With current
Release brake
Process with water indication: "No " or "Yes"

A function of key F2 "2ACTIV" or "2INACT"
:No
:Yes
:No
Control mode: "No " controls are inhibited

With or without current
Release motor brake (excluding motion)
Screen PM2 is accessible if MAN mode selected.
MT861EN_KA01d
Input and Output Diagnostics Screens
Input and Output Diagnostics Screens

Accessible by choosing Inputs Outputs from the main menu
DT1
DT1 General I.
AU= AUTO= SER=
TH= ASI= CDE=
CPA= ECNT=
DT3
DT3 EqBox I.
EPRT= EOUS= EMOT=
ERET= EPOS= EINI=
With current control

Water flow control
Air pressure control
Equalizing module ready
Wear order OK
Motor temperature OK
Retract OK
Pre-pos OK
Init OK
DT4
DT4 General O.
VCE= EVD= EVE=
PRT= DEF= VDS=
CNT= APUI=
DT6
DT6 EqBox O.
EVE=
Screen DT3 is accessible if EqBox electrical balancing cassette selected (ARODMS/ARONET).
Digital input assignments (X2)

WLD
17
1
AU
CDE
18
2
AUTO
CPA
19
3
SER
EPRT
20
4
EOUS
21
5
EMOT
22
6
ERET
23
7
EPOS
24
8
EINIT
25
9
26
10
TH
27
11
ECNT
28
12
29
13
30
14
31
15
32
16
Transformer thermostat
Contactor state
Screen DT6 is accessible if EqBox electrical balancing cassette selected (ARODMS/ARONET).

Wear value = 4 x EUE4 + 2 x EUE2 + 1 x EUE1
Electrode wear x 1 (EqBox)

MT861EN_KA01d
Emergency stop
Auto / Man
Manual cycle execution
Digital output assignments (X1)

17
1
18
2
19
3
20
4
21
5
22
6
23
7
VCE
EUE1
24
8
EVD
EUE2
25
9
EVE
EUE4
26
10
SWR
27
11
DEF
28
12
VDS
29
13
CNT
30
14
APUI
31
15
32
16
Water cut off valve

Equalizing
Balancing
Cabinet ready
Fault
Service request light
Contactor control
Power activation
19
Controls
Controls
Controls Sub-Menu
Accessible by choosing Controls from the main menu
Controls
1= Gun force
2= Current
If the process password has been set, the control screen may display a password prompt:
CE1 Force control
Password
=
Password to access controls
1-VISU
3MODIF
ou
CC1 Current control

Password
=
Password to access controls
1-VISU
3MODIF
For the visualization or view mode (F1 key), there is no need to enter the password.
If you press the F3 key, the access code will be compared to the process password:
Password correct access granted to the controls screen.
Password incorrect access denied (the password prompt screen is still displayed).
Force Control Screen

Accessible by choosing Gun force from the Controls sub-menu
CE1
CE1 Force control

Thickness = . mm
Command
= daN
2CYCLE
Dynamometer thickness
Force setting
Possible action: start ("2CYCLE") or cancel ("2CANCE") the control cycle
Procedure
Enter the dynamometer thickness
Enter the force setting
Press F2 to start the force control cycle: The F2 key becomes 2CANCE
Run a manual clamping cycle by triggering the service input (SER) and use a dynamometer to
measure the force obtained
When the gun opens, the F2 becomes 2CYCLE
To run the control cycle again, restart from 1, 2 or 3

Remar ks:
When screen CE1 appears manual cycle execution is blocked: fault 83-032 is displayed when the
service input (SER) is triggered.
It is impossible to exit the screen if the control cycle is active: to disable the control cycle
without triggering the service input (SER), press F2 which becomes 2CYCLE
Current Control Screen

Accessible by choosing Current from the Controls sub menu
CC1
CC1 Current control

Force
= daN
Command = . kA
2CYCLE
Force setting
Current setting
Possible action: start ("2CYCLE") or cancel ("2CANCE") the control cycle
Procedure
Enter the force setting
Enter the current setting
Press F2 to start the current control cycle: The F2 key becomes 2CANCE
Run a manual welding cycle by triggering the service input (SER) and use a calibrated kiloammeter to measure the current level achieved (Settings: welding 200ms; holding 200ms)
When the gun opens, the F2 becomes 2CYCLE
To run the control cycle again, restart from 1, 2 or 3

Remar ks:
When screen CC1 appears manual cycle execution is blocked: fault 83-032 is displayed when the
service input (SER) is triggered.
It is impossible to exit the screen if the control cycle is active: to disable the control cycle
without triggering the service input (SER), press F2 which becomes 2CYCLE
20
MT861EN_KA01d
History
History
History Sub-Menu
Accessible by choosing History from the main menu
History
1= Faults
2= Spots
3= Signatures
Fault History Screens

Accessible by choosing Faults from the History sub-menu
HD1
HD1 Faults
// ::
Gun
Prg
AW Learning
HD2
HD2 Faults
Fault
Cause
Number of fault signature (0 = the newest; 099 = the oldest)

Fault number; cause number
Number of fault signature (0 = the newest; 099 = the oldest)

Date and time of the spot signature
Gun number; program number
Learning number assigned to the program (--- if SW mode fault signature)
Remar k:
The list of 100 fault recordings includes the signatures for Power off, the signatures for Power on and
the fault signatures.
Spot History Screens

Accessible by choosing Spots from the History sub-menu
S1
S01
// ::
Gun
Prg
AW Learning
S2
S02
State spot=
I measured=. kA
Force
= daN
S3
S03
Welding time
Command
= ms
Measure
= ms
ms
ms
daN
S5:
S05
Thickness
Measured = . mm
Error
= . mm

Effective welding duration (if spot signature in AW mode, "----" else)
Thickness measured
Thickness error
MT861EN_KA01d
Signature type, number (0 = the newest; 249 = the oldest)

Squeeze time
Holding time
Measured force ("---- daN" if gun without force sensor)
S06
Cycle time = ms
Spots =/
Dressing =/
S6
S04
Squeeze
=
Hold
=
Force
=

Spot state
Measured current
Spot state (2nd line):
"OK
"
"Bad
"
"Expulsed "
"Short-C. "
"Const. R "
"SW mode " (if spot signature in SW mode)
S4

Date and time of the signature
Gun number; selected program number
Learning number assigned to the program (--- if spot signature in SW mode)

Cycle time
Spot counter; absolute spot counter (SW) or number of spots before dressing (AW)
Dressing counter; programmed number of dressings
21
History
S7
S07
Initialization =
Dressing
=
Change
=
S8
S08
Bus voltage = V
Sec voltage =. V
S9
S09
Force compensation
squeeze
= daN
S11
S11
Expansion
=.mm
Time
=ms
Surface =.mm.ms
S12
S12
Final pos. =.mm
Force applied to compensate for workpiece squeeze

Expansion measured
Expansion time
Expansion surface
Screen S11 is accessible if expansion control is selected (Screen P30).

Final position
S13
Fault Cause
Screen S9 is accessible if squeeze compensation is selected (Screen P25).

Indentation measured
Indentation time
Indentation surface
Screen S10 is accessible if indentation control is selected (Screen P26).
S13
S10
Indentation =.mm
Time
=ms
Surface =.mm.ms

DC bus voltage (--- V if the spot signature is in AW mode)
Average secondary voltage ("-.--- V" if the spot signature is in SW mode)
S10

Initialisation: "No" or "Yes"
Dressing request "No" or "Yes"
Change request "No" or "Yes"
Screen S12 is accessible if final position control is selected (Screen P34).
Note: If there is no spot recording in the 250 signature history, then only screen S13
is a ccessible.
Signature History Screens

Accessible by choosing Signatures from the History sub-menu
S1
22
S01
// ::
Gun
Prg
AW Learning

Date and time of the signature
Gun number; Selected program number
Learning number assigned to the program
Signature type (1st line):
"AW spot
"
"SW spot
"
"Counter
"
"Fault
"
"Acknowledge "
"Switch off "
"Switch on
"
"Dressing ok "
"Dress not ok"

The 3rd line does not appear for "Switch off" or "Switch on" signatures
The 4th line is only visible for "AW spot" signatures
MT861EN_KA01d
History
S2
S02
State spot=
I measured=. kA
Force
= daN
S3
S03
Welding time
Command
= ms
Measure
= ms
S04
Squeeze
=
Hold
=
Force
=
ms
ms
daN
S5
S05
Thickness
Measured = . mm
Error
= . mm
S7
S07
Initialization =
Dressing
=
Change
=
S8
S08
Bus voltage = V
Sec voltage =. V
S06
Cycle time = ms
Spots =/
Dressing =/

Effective welding duration (if spot signature in AW mode, "----" else)
Screen S3 is accessible for "AW spot", "SW spot", "Counter" and "Fault" signatures.
Signature types (1st line): Identical to Screen S1.

Squeeze time
Holding time
S6
S4

Spot state
Measured current
Spot status (2nd line):
"OK
"
"Bad
"
"Expulsed "
"Short-C. "
"Const. R "
"SW mode " (if spot signature in SW mode)
Thickness measured
Thickness error

Cycle time
Spot counter; Absolute spot counter (SW) or number of spots before dressing (AW)
Dressing counter; Programmed number of dressings

Initialisation request: "No" or "Yes"
Dressing request "No" or "Yes"
Change request "No" or "Yes"

DC bus voltage (--- V if signature type = AW spot)
Average secondary voltage (-.--- V if signature type "AW spot")
Screen S8 is accessible for "AW spot", "SW spot", "Counter" and "Fault".
S9
S09
Force compensation
squeeze
= daN

Force applied to compensate for workpiece squeeze
Screen S9 is accessible if squeeze compensation is selected (Screen P25).
For "AW spot", "SW spot" and "Fault" signatures.
S10
S10
Indentation =.mm
Time
=ms
Surface =.mm.ms
MT861EN_KA01d

Indentation measured
Indentation time
Indentation surface
Screen S10 is accessible if indentation control is selected (Screen P26).
23
History
S11
S11
Expansion
=.mm
Time
=ms
Surface =.mm.ms
S12
S12
Final pos. =.mm
S13
Fault
Cause
Screen S12 is accessible if final position control is selected (Screen P34).


Fault number; cause number
24

Final position
S13

Expansion measured
Expansion time
Expansion surface
Screen S11 is accessible if expansion control is selected (Screen P30).
Screen S13 is accessible for "Fault" and "Acknowledgement" signatures.

MT861EN_KA01d
Identification Screens
Identification Screens
Accessible by choosing Identification from the main menu
I1
I2
I3
I4
I5
I6
I01 Identification
MF converter
Vers=KA01d-XD.02.010
SN=
MF converter type: AW or SW according to the datakey type

Reference of the factory configuration and firmware
Inverter serial number
I02 Identification
Welding firmware
Vers=HB03d
DSP firmware
I03 Identification
Drive firmware
Vers=LXA16a
SN=
Servo-controller firmware
Servo-controller serial number
I04 Identification
iBox HMI firmware
Vers=IA01001
SN=
iBox HMI firmware

iBox HMI serial number
I05 Identification
MF converter
MFDC
I06 Identification
Variant/series
MT861EN_KA01d
MF converter type: AW or SW according to the datakey type

Inverter model
WCC or cabinet name (defined with ARONET or ARODMS)
Inverter models managed:
"MFDC1200"
(MFDC1200, water cooled)
"MFDC560"
(MFDC560, water cooled)
"MFDC560A-N-V" (MFDC 560, air cooled by natural convection)
"MFDC800"
(MFDC800 water cooled)
"MFDC560A-V-F" (MFDC 560 air cooled with forced ventilation)
"MFDC2400"
(MFDC 2400 water cooled)
Gun number
Gun variant number
Gun serial number
25
Expert or Operator Mode Choice Screens
Expert or Operator Mode Choice Screens

Accessible by choosing Expert from the main menu
E1
E01 Expert
Expert mode
Expert mode No or Yes
The inverter is initially in operator mode.

To activate expert mode (access to all parameters), choose "Yes" ( + or key) and press the
Screen E02 is displayed to ask for confirmation.
To return to operator mode, choose "No" and press : you are not asked to confirm.
E2
E02 Expert
Do you want to pass
in expert mode?
1-YES
3-NO
key:
Confirm choice of expert mode or not:
F1 to confirm; F3 cancels the expert mode request

Remar ks:
26
Expert mode is disabled automatically after 10 minutes without pressing a keyboard key. The
display changes if the current screen is not accessible in operator mode.
Pressing F1 or F3 returns you to the E01 screen.
MT861EN_KA01d
Diagnostic
Diagnostic
Diagnostic Sub-Menu
Accessible by choosing Diagnostic from the main menu (if the expert mode is active)
Diagnostic
1= Timer
2= Slave Bus
3= Thermal
<>
Diagnostic
1= Welding axis
2= Ethernet
3= Datakey
<>
Timer Diagnostics Screen

Accessible by choosing Timer from the Diagnostic sub-menu
H1
H01 Timer
::
//
Current time
Current date
F2 2MODIF to modify; F2 2VALID to validate the time update
Slave Bus Diagnostics Screens

Accessible by choosing Slave Bus from the Diagnostic sub-menu
SB1
SB2
SB1 Slave Bus

Ethernet/IP Word
SB2 Slave Bus

Inputs
WCE(0:0) = 0
Type of slave bus and word number to display

Input state
Output state
Input name; Word and bit numbers; Input state

Possible inputs (selected by pressing + or ):
Weld Enabled (0:0)=0 (WCC activated)
Rob. In Teach(0:1)=0 (robot in manual mode)
Fault Reset (0:3)=0 (fault acknowledgement)
With Weld
(0:4)=0 (With/without current)
PS Input
(0:5)=0 (start welding cycle)
NTSR
(0:12)=0 (electrode change acknowledgement)
DTSR
(0:13)=0 (electrode dressing acknowledgement)
BPilot(0:14-1:5)=000 (program number selection)
Tip Water
(1:7)=0 (water present)
XFMR temp. (1:12)=0 (transformer temperature OK)
SERVO temp. (1:13)=0 (motor temperature OK)
ReqPos(4:0-15)=00000 (gun opening command)
JOG+
(5:9)=0 (open slow speed)
JOG(5:10)=0 (close slow speed)
Go Req. Pos.(5:11)=0 (opening request)
MT861EN_KA01d
27
Diagnostic
SB3
SB3 Slave Bus

Outputs
Output name; Word and bit numbers; Output state
Possible outputs (selected by pressing + or ):
In Weld Cycle(0:0)=0 (welding cycle running)
Weld Complete(0:1)=0 (end of cycle)
Mainten. Req.(0:2)=0 (maintenance required)
Timer fault (0:3)=0 (WCC fault)
New Tip
(0:4)=0 (change reset done)
Dressed Tip (0:5)=0 (dressing reset done)
Fault (0:14-1:4)=00 (fault code)
IAvail. Hi/Lo(1:9)=0 (current fault active)
TipDress ROK(1:11)=0(dressing test OK)
Tip Chg. Req.(2:0)=0 (change request)
Tip Chg. War.(2:1)=0 (change alarm)
AW Enabled
(2:5)=0 (AW mode)
Comm. OK
(2:6)=0 (communication OK)
GunPos(4:0-15)=00000 (gun opening)
TipWear(5:0-10)=0000 (electrode wear)
At ReqGunPos(5:11)=0 (opening reached)
GunRequ. rez(5:12)=0 (electrode wear)
ServoG fault(5:13)=0 (drive error)
G fully open(5:14)=0 (large opening)
Gun opened (5:15)=0 (small opening)
Thermal Current Diagnostics Screens

Accessible by choosing Thermal from the Diagnostic sub-menu
TH1
TH2
TH1 Welding th. (kA)

2s=. 30s=.
15s=. s=.
Cycle s=.
Welding thermal current 2 and 30 seconds

Welding thermal current 15 seconds; duration (60 to 240 seconds) and thermal current
Welding cycle duration and thermal current
TH2 Motor th. (A)

15s=. 2mn=.
Motor thermal current for 15 seconds and over 2 minutes
Welding Axis Diagnostics Screens

Accessible by choosing Welding axis from the Diagnostic sub-menu
DV1
DV2
DV3
DV4
DV1 Opening
New el.
=
Actu. el. =
Wear
=
. mm
. mm
. mm
New electrode opening

Current electrode opening
Electrode wear
DV2 Drive
Digital I/O
In=
Out=
Drive analogue inputs

Drive analogue outputs
DV3 Drive
Analog I/O 1-2
In=. V . V
Out=. V . V
Voltage on analogue input 1; voltage on analogue input 2

Voltage on analogue output 1; voltage on analogue output 2
DV4 Drive
State:
Fault number =
Axis state
Fault number
Possible axis states:
Drive init
Axis init
Elec. init
Calibration
Axis ready
Fault
28
MT861EN_KA01d
Diagnostic
DV5
DV6
DV7
DV5 Drive
Mot. current =.A
Mot. voltage =.V
DC voltage
=.V
Motor current
Motor voltage
DC voltage
DV6 Drive
Speed
= rpm
Max torque =.Nm
Motor speed
Max. torque
DV7 Opening
New el.
=
Actu el. =
Wear
=
Position of new electrodes on wedge

Current position of electrodes on wedge
Electrode wear on wedge (electrode of the upper arm)
. mm
. mm
. mm
Ethernet Diagnostics Screens

Accessible by choosing Ethernet from the Diagnostic sub-menu
ET1
ET2
ET1 Ethernet
@IP =...
Answer
: ms
2-PING
IP address to test
Ping response time
A function of key F2
Procedure
Enter an IP address
Press function key F2. The ICMP protocol Ping request is sent to the IP address to be tested.
The response time is displayed (---- if no response).
ET2 Ethernet
Select the counter to display

Value corresponding to the selection
Counters (select by pressing + or ):
"Incoming packets
"
"Incoming with errors"
"Incoming lost
"
"Sent packets
"
"Sending error
"
"Outgoing lost
"
"Unknown protocol
"
ET3
ET3 Ethernet
@MAC=000A46.
@IP =...
Map MAC address

Current IP address
Note: The current IP address is the one from screen CO2 on power up. This may be
different from the one defined in the CO2 screen.
ET4
ET4 Signatures
Waiting
=
Lost
=
2RESET
MT861EN_KA01d
Number of signatures waiting for transfer to the PC

Number of signatures not sent to the ARONET PC
Key F2 is used to reset the lost signature counter
29
Diagnostic
Datakey Diagnostics Screens

Accessible by choosing Datakey from the Diagnostic sub-menu
DK1
30
DK1 Datakey
AW mode =
@IP =...
TCP/IP Port =
Datakey status
AW or SW mode
IP address of the datakey ("---.---.---.---" if not available)
TCP/IP port of the datakey ("-----" if not available)
Datakey status:
if datakey exists without fault
Missing
Write er
Error
CRC err.
AW or SW mode display:
No if there is an SW type datakey or if there is no datakey
Yes if there is an AW type datakey
MT861EN_KA01d
Maintenance
Maintenance
Maintenance Sub-Menu
Accessible by choosing Maintenance from the main menu (if the expert mode is active)
Maintenance
1= Reset parameters
2= Reset counter
3= Copy Parameters
If access to the parameters is password protected, the maintenance screen may display a password prompt:
RP1 Reset parameters
Password
=
1-VISU
3MODIF
or
RC1 Reset counter

Password
=
1-VISU
3MODIF
or
CP1 Copy Parameters

Password
=
1-VISU
3MODIF

For the visualization or view mode (Key F1), there is no need to enter the access code.
Correct code Access to the maintenance screen.
Incorrect code Access rejected (the display remains on the code entry screen).
Parameter Reset Screens

Accessible by choosing Reset parameters from the Maintenance sub-menu
RP1

All areas
2RESET
Function key F2
Procedure
1.
Press F2 to start the procedure to completely reset all of the inverter parameters
or

Clear all
parameters?
1APPLY 2CANCE
Function keys F1 and F2

Procedure (cont'd)
2.
Press F1 to continue the procedure to completely reset all of the inverter parameters
3.
Press F2 to cancel this procedure
or

Clear
2CANCE 3-ALL

Procedure (cont'd)
4.
Press F2 to cancel this procedure
5.
Press F3 to confirm the compete reset of all inverter parameters
CAUTION: All of the data stored in the inverter will be lost.
MT861EN_KA01d
31
Maintenance
RP2

2RESET
Area type; area number

Press F2 to reset the parameters for the selected area
Procedure:
1.
Select the type of area (selected by pressing + or ):
Configuration 000
Gun
000
SW Program
000
MF Learning
000
AW Learning
000
Service
000
Cutters
000
2.
Enter the area number to reset (if area type configuration)
3.
Press F2 to reset all of the parameters in the selected area
CAUTION: All of the data in the selected area will be lost .
Dressing Grinder Counter Reset Screen

Accessible by choosing Reset counter from the Maintenance sub-menu
RC1
RC1 Reset counter

Blade counter
2RESET
Blade counter number

Function key F2
Procedure:
1.
Select the blade counter number
2.
Press F2 to reset the selected counter
Copy Parameters Screen

Accessible by choosing Copy parameters from the Maintenance sub-menu
CP1
CP2
CP3
32
CP1 Copy Parameters

Standard program
-->
2-COPY
CP2 Copy Parameters

AW Learning
-->
2-COPY
CP3 Copy Parameters

Gun
-->
2-COPY
Source program number; target program number

Function key F2 (only displayed if source target)
Procedure:
1.
Select the source
2.
Select the target
3.
Press function key F2. The source Standard Welding program is then fully copied to the target
Standard Welding program.
AW source learning numbers; AW target learning numbers

Procedure:
1.
Select the source
2.
Select the target AW learning number
3.
Press function key F2. The source AW learning is then fully copied to the target AW learning
Source gun number; target gun number

Procedure:
1.
Select the source gun number
2.
Select the target gun number
3.
Press function key F2. The source gun parameters are fully copied to the target gun.
MT861EN_KA01d
Maintenance
CP4
CP5
CP4 Copy Parameters

Service
-->
2-COPY
CP5 Copy Parameters

Blade
-->
2-COPY
MT861EN_KA01d
Source service number; target service number

Procedure:
1.
Select the source service number
2.
Select the target service number
3.
Press function key F2. The source service is then fully copied to the target service
Source blade number; target blade number

Procedure:
1.
Select the source blade number
2.
Select the target blade number
3.
Press function key F2. The source blade parameters are then fully copied to the target blade.
33
Configuration
Configuration
Configuration Sub-Menu
Accessible by choosing Configuration from the main menu (if the expert mode is active)
Configuration
1= Common
2= Gun
3= AW
<>
Configuration
1= Robot
<>
If access to parameters is protected by a password, the configuration screen can display the password prompt:
C01 Station
Password
1-VISU
=
3MODIF

or
G01
Password
Gun
=
1-VISU
3MODIF
Visualize the current gun number

or
A01 AW learn
Password
=
Number
=
1-VISU
3MODIF
Visualize the current learning number

Choose the learning number to reach
or
RO1 Robot
Password
1-VISU
3MODIF

For the visualization or view mode (Key F1), there is no need to enter the access code.
Code correct
Access to modify parameters for configuration, gun or selected AW learning.
Code incorrect
Access denied (the password prompt screen remains displayed).
General Configuration Screens

Accessible by choosing Common from the Configuration sub-menu
C1
C01 Station
Language
01 English
Language number; Language name

Languages available =
00 Franais
01 English
C2
C3
C02 Ethernet
@IP ...
SNM ...
Gate ...
C03 Ethernet
TCP/IP Port =
For
IP address
Subnet mask
Gateway address
further details on these parameters, see ARONET documentation
TCP/IP Port
For further details on these parameters, see ARONET documentation

C4
C04 Options
Starting init
34
Force gun initialisation on start up: "No" or "Yes"
MT861EN_KA01d
Configuration
C6
C8
C06 Station
Sector voltage =0V
Choose mains voltage (in 10 volt increments)
C08 Common
Programmable fault
Number =
Type
=
Fault number selection (by pressing + or )

Fault type (0 to 4, not modifiable from the MMI)
Note: Only configurable faults can be accessed.
C9
C10
C11
C09 Common
Auto repetition
Number =
C10 Password
Pass
Param. =
Process=
C11 Common
WC time
IWC-WC Delay =
Number of automatic spot repetitions
Time
mn
mn
Parameters password (0 password not used) and its validity time

Process password (0 password not used) and its validity time
Time = 0: The password (when used) is required for every access and remains valid without any time
limit.
Time 0: The password (when used) is only requested for every access if the validity time has expired
(no action on the keyboard during the set time); Password entry is automatically requested once the
validity time has expired.
ms
Duration of the welding cycle (WC = weld complete)
ms
Period of time between the IWC (in weld cycle) and WC (weld complete) field bus signals
Gun Configuration Screens

Accessible by choosing Gun from the Configuration sub-menu
The change of gun (0 to 3) is performed by keys and (previous and next).
When changing the program or exiting the gun configuration screens with a changeover from SW mode to AW mode (G1 screen), the converter notifies
you that the AW mode is not authorized if there is no datakey or if there is an SW datakey:
G
Gun
AW not available
Continue?
1-YES
3-NO
Gun number
F1 to confirm changeover to AW mode; F3 to return to gun configuration

Note: The fault 83 -039 appears when activating a cycle start if the gu n is in
unauthorized AW mode (start not authorized if AW option is not available).
G1
G01
Gun
Welding type
=
Max force
=daN
Gun number
Welding type
Force on the electrodes not to exceed
Welding:
G4
G5
AW
SW
G04 Gain
Coil calibration
Ratio
= .
Gun number
G05 Measures
Type =
Gun number
Measurement channel used "Secondary " or "Primary
Current measurement calibration coefficient
"
Screen G05 accessible if the gun is in SW mode (Screen G01).
MT861EN_KA01d
35
Configuration
G6
G7
G06 Transfo.
transfo/diodes type
Coils number =
Gun number
G07 Transfo.
Water flow = l/min

Water temp = C
Gun number
Cooling water flow
Temperature of the water on the inlet to the welding transformer
Transformer and diode set

Number of windings for the current measurement
Transformer and diode set:
"56kVA with 2 diodes "
"180kVA with 4 diodes"
"360kVA with 4 transf"
"Unknown
": Transformer not referenced by ARO .
Cooling water flow:
4 litres per minute
6 litres per minute
8 litres per minute

G8
G9
G10
G08 Transfo.
Thermal current
Duty factor
=
Itherm. time = s
Gun number
G09 Transfo.
Transformation
Ratio
= .
Offset = . kA
Gun number
G10 Option serv.
Gun number
Alignment ctrl. =
Activate the transformer duty factor control or not

Thermal rating integration duration
Transformation ratio slope

Transformation ratio offset
Screen G09 is accessible if the transformer/diode set is unknown (Screen G06).
Alignment control
G17
G17 Chang. serv.
Opening
= .mm
Force
= daN
Tolerance = . mm
G18
G18 Chang. serv.
Alignment monitor
Opening
= . mm
Gun number
Gun number
Opening for manual change
New cap insertion force
Tolerances for checking new caps
Opening for alignment monitoring

Screen G18 is accessible if alignment monitoring (Screen G10) and manual change (Screen G16) are
selected.
G21
G21 Init serv.
Spts btw init. =

Spt before fault=
G24
G24
Regulation
coefficient
Gun
Gun number
Number of spots before initialisation request
Number of spots between initialisation request and fault
Gun number
Coefficient to set the current regulation algorithm
Increase the parameter to reduce the overshoot (requested current exceeded).
Decrease the parameter to reduce the slope control time.
G25
G25
Gun
Wedge thickness
Gun number
Thickness of the wedge to initialize gun number 2.
G26
36
G26
Gun
Resistance tolerance
%
Gun number
Tolerance in % on the resistance measurement during the dressing test
MT861EN_KA01d
Configuration
G27
G27
Gun
Gun opened =
mm
Gun fully opened
=
mm
Gun number
Value of the small opening position
Value of the large opening position
G28
G28
Gun
Maxi gun opening
Gun number
mm
Maximum gun opening
AW Learning Configuration Screens

Accessible by choosing AW from the Configuration sub-menu
The change of learning (0 to 255) is performed by keys and (previous and next).
A1
A01 AW learn
Learning
Not realized
Learning number
Screen A1 is the only one accessible if AW learning is poor or not done.

A2
A3
A4
A02 AW learn
Time
Hold
= ms
Learning number
A03 AW learn
Welding
Command
= %
Max time
= ms
Learning number
A04 AW learn
Expulsion fault
Spots =
Learning number
Holding time
Welding setting adjustment (as a % of the AW learning setting)

Maximum welding duration
Number of spiting events before activating fault 13.
Robot Communication Configuration Screen

Accessible by choosing Robot from the Configuration sub-menu
RO1
RO1 Robot
Common
Master words
MT861EN_KA01d
= 06
Number of words managed by the master (02 to 10)
37
Calibration
Calibration
Calibration Sub-Menu
Accessible by choosing Calibration from the main menu (if the expert mode is active)
Calibration
<>
1= Gun/lear. choice
2= Gun force
3= Opening
Calibration
<>
1= Current measure
2= MF Learning
3= Resistance
Calibration
1= AW Learning
<>
If the process password has been set, the calibration screen may display a password prompt:
CX1 Gun/lear. choice
Password
=
Password to access calibration
1-VISU
3MODIF
ou
CF1 Force
Password
Gun
=
1-VISU
3MODIF

ou
CO1 Opening
Password
1-VISU
Gun
=
3MODIF

Ou
CT1 Coil
Password
Gun
=
1-VISU
3MODIF

Ou
MF1 MF learn Gun

Password
=
1-VISU
3MODIF
Ou
CA1 AW learn Gun

Password
=
1-VISU
3MODIF
For the visualization or view mode (F1 key), there is no need to enter the password.
If you press the F3 key, the access code will be compared to the process password:
Password correct
Access granted to modify the calibration parameters.
Password incorrect
Access denied (the password prompt screen is still displayed).
Ongoing Assistant Screen

This screen is displayed if an option from the Calibration sub-menu is selected if the ARODMS assistant is enabled.
Ongoing assistant
2CLOSE
38
Function key F2 to quit the screen
MT861EN_KA01d
Calibration
Gun and Learning Choice Screen

Accessible by choosing Gun/lear. choice from the Calibration sub-menu
CX1
CX1 Gun/lear. choice

Gun number
=
AW Lear number =
Gun number used for calibration

AW learning number to perform
Function key F2
Procedure:
Select the Gun number
Select the AW learn number
Press F2 2CYCLE which becomes 2CANCE briefly then returns to 2CYCLE. Then the other
Calibration menu sub-menus can be used.
Force Calibration Screens

Accessible by choosing Gun force from the Calibration sub-menu
CF1
CF2
CF1 Force
Gun
Calibration
Force
Sensor
Gun number chosen from screen CX1
CF2 Force
Squ. speed

Squeeze speed
Gun
=rpm
2CYCLE
CF3
CF3 Auto.
Function key F2
Pressing F2 transfers the parameter to the servo-controller.
Gun
Sensor :
1-OPEN 2CYCLE
CF4
CF4 Manual
Gun
Force meas.= daN

1-OPEN 2CYCLE 3APPLY
MT861EN_KA01d
Force calibration state

Sensor calibration state
Calibration states:
"Realized
"
"Not realized"
Sensor selection
Sensor selection:
"Motor
"
"Reference"
Procedure:
Press F1: To open the gun via the service (SER) input
Press F2: 2CYCLE becomes 2CANCE
Trigger the service (SER) input to run the calibration cycle (it must be held for the entire cycle.
Enter the manual force sensor measurement

Function keys F1, F2 and F3
Procedure:
Press F1: To open the gun via the service (SER) input
Trigger the service (SER) input to run the calibration cycle
Read the measurement from the dynamometer
Enter this measurement (3rd line)
Press F3: To validate this measurement.
Resume from Point No. 3 so long as F2 displays 2CANCE
39
Calibration
Gun Opening Calibration Screens

Accessible by choosing Opening from the Calibration sub-menu
CO1
CO1 Opening
Gun
Measured opening
: . mm
3APPLY

Opening measured by the operator
Initially: F2 visible F3 not visible
Procedure:
Trigger the service (SER) input: The servo-controller controls gun initialisation then a 10 mm
opening
Measure the actual gun opening
Enter the opening measured and press ENTER ( on the Pocket terminal), F3 is displayed
showing 3VALID
Press F3 to save the opening calibration.
To exit gun opening calibration, press Menu.
Current Measurement Calibration Screens

Accessible by choosing Current measure from the Calibration sub-menu
CT1
CT1 Coil
Gun
Comm %PWM =. %
Reference =.kA
3APPLY

Welding setting in %PWM for the current coil calibration cycle
Current measured by the calibration kilo-ammeter
Current measurement calibration procedure:
Select the welding setting (%PWM) for the current calibration cycle
Trigger the service (SER) input, measure the current on the electrodes using a calibrated kiloammeter, then release the SER input.
Enter the current measured by the calibrated kilo-ammeter and press ENTER ( on the Pocket
terminal): 3VALID is displayed
Press F3 to display screen CT2
CT2
CT2 Coil
Gun
WCC measure=.kA
Reference =.kA
Adjust
=.

Current measured by the DC MF inverter
Current measured by the calibrated kilo-ammeter
Calibration coefficient resulting from the calibration performed
To exit current measurement calibration, press Menu.
MF Learning Screens
Accessible by choosing MF Learning from the Calibration sub-menu
MF1
MF1 MF learn Gun

Command 1 = %
Command 2 = %

Welding setting (%PWM) for the first pulsation in the MF learning cycle
Welding setting for the second cycle pulsation
Function key F2
MF learning procedure:
Enter the welding setting (%PWM) for the first cycle pulsation
Press key , the setting for the second pulsation is automatically changed setting2 = setting1 + 10 %)
Press which becomes 2CANCE
Trigger the service (SER) input; The cycle runs (two weld pulsations); Release the SER input when
the gun opens; Screen MF2 is displayed.
MF2
MF2 MF learn Gun

State

MF learning state
MF learning state:
Finished:
the cycle ran correctly
Error:
Incorrect cycle (no current or the SER input was released before the first welding pulsation)
To exit the MF learning mode, press Menu.
40
MT861EN_KA01d
Calibration
Resistance Calibration Screen

Accessible by choosing Resistance from the Calibration sub-menu
CR1
CR1 Resistance
Old
=
Actual
=
O
O
Previous resistance value

New resistance value
Function key F2
AW Learning Screens
Accessible by choosing AW Learning from the Calibration sub-menu
If there is no datakey or the datakey is the SW type, only the CA1 screen is accessible (upon entering the process password if applicable) to notify that
AW learning is not authorized.
If there is an AW datakey, the CA2 screen can be accessed directly (upon entering the process password if applicable).
CA1
CA1 AW learn Gun

AW not available
Function key F2
2CANCE
Press the F2 key to quit AW learning (return to normal operation).

To authorize AW learning, enter an AW type datakey before accessing the AW learning screens.
CA2
CA2 AW learn Gun

Force
Step number
=

Number of force steps
Force regulation mode
Possible force regulation modes =
Without regulation
With regulation
(only for gun motors with a force sensor)
CA3 AW learn Gun

Welding Hold
Time = ms
Force = daN
CA4
CA4
S1=
S2=
S3=
AW learn Gun
ms daN
ms daN
ms daN

Duration and force of 1st force step
Duration and force of 2nd force step
Duration and force of 3rd force step (not accessible "----", if "Step number" = 2)
ScreenCA4 is accessible if the number of force steps 1 (Screen CA2).
CA5
CA5
S4=
S5=
S6=
AW learn Gun
ms daN
ms daN
ms daN

Duration and force of 4th force step
Duration and force of 5th force step (not accessible "----", if "Step number" < 5)
Duration and force of 6th force step (not accessible "----", if "Step number" < 6)
Screen CA5 is accessible if the number of force steps > 3 (Screen CA2).
CA6
CA6 AW learn Gun

T1=ms T4=ms
T2=ms T5=ms
T3=ms T6=ms

Transition time 1; Transition time 4
Screen CA6 is accessible if the number of force steps 1 (Screen CA2) and if the gun motor is configured
with a force sensor (ARODMS).
Parameter T3 is not accessible ("----") if "Step number" = 2.
Parameter T4 is not accessible ("----") if "Step number" < 4.
CA7
CA7 AW learn Gun

Welding
= ms
Step
=
Delay
= ms

Welding time
Number of force step when welding starts
Delay in starting welding in relation to start of force step
Screen CA7 is accessible if number of force steps > 1 (Screen CA2).
CA3
MT861EN_KA01d
Welding duration; Holding duration

Welding force; Holding force
Screen CA3 is accessible if the number of force steps = 1 (Screen CA2).
41
Calibration
CA8
CA8 AW learn Gun

Thickness = . mm
Current
= . kA
3APPLY

Welding thickness
Reference current setting
Procedure
If necessary, adjust the settings (+ Screens CA3 or CA4/CA5/CA6/CA7)
Press F2 2CYCLE which becomes 2CANCE to allow the expulsed weld search cycle
Trigger the service (SER) input to run the welding cycle to find the expulsed weld search limit
After the welding cycle, F2 becomes 2CYCLE and F3 becomes visible 3VALID
If the parameters are not suitable, restart the procedure from 1
If the parameters are suitable: Press F3 to confirm. Screen CA9 is displayed.
CA9
CA9 AW learn Gun

Spots
= /10
I measured= . kA
State

Number of spots done; number of spots to do
Current measured during last cycle
AW learning state:
AW learning state:
State Not realized (initial state no spots welded)
State in progress
(less than 10 spots done)
State OK
(10 spots done and AW learning valid)
State Bad
(10 spots done and AW learning invalid)
To exit AW learning, press Menu.
42
MT861EN_KA01d
Fault Definition
Fault Definition
Fault and Possible Causes
Troubleshooting Actions
0 Emergency stop
Input ARS (XC2) or AU (X2) open.
Close ARS (XC2) and AU (X2) inputs.
1 Power unit fault
Short-circuit at inverter output.
Check that the power cable on the output from

the inverter is not short-circuited.
2 MF converter overheating
Inverter thermostat open: One of the

internal thermostats is open or the TH
output on XC2 is open.
Check inverter cooling.

Check fan operation.
Inverter cooling fault.

Capacitor heating.
Faulty thermostat or connection leads
cut or disconnected
3 Start actuated
03-252: DCY and selection nil.
Input DCY is active.
Release DCY (Start button) before

acknowledging.
Bad selection of a program number.
Release the DCY (Start button) before

acknowledging and select a program number
that is valid.
03-253: Before the system is ready.

03-254: Before the system is waiting.
4 Selection fault
5 Invalid parameter in schedule

05-001: Excessive dressing force.
Correct the clearly identified cause.
05-002: Nil dressing time.

05-003: Cap dresser too thick.
05-004: Nil heating current with duty cycle check.
05-005: Nil transformer ratio with unknown type of transformer.
05-007: Excessive JOG increment.
05-008: Dressing force regulation with motor and no force sensor.
05-010: Program in AW mode and gun configured for primary regulation.
05-020: Force steps too great.
05-021: Excessive end of cycle opening.
05-022: Workpiece thickness exceeds end of cycle opening.
05-023: Welding increments exceed number of steps.
05-024: Welding delay time exceeds step duration.
05-025: Force regulation with motor not fitted with a force sensor.
05-026: Force control with motor not fitted with a force sensor.
05-027: Nil welding time.
05-034: Force regulation without performing learning.
05-035: Current setting exceeds inverter limits.
05-036: Preheating setting exceeds inverter limits.
05-037: Upslope setting exceeds inverter limits.
05-038: Downslope setting exceeds inverter limits.
05-039: Annealing setting exceeds inverter limits.
05-040: Incoherence between force time and current time.
05-041: Current time too long for a step.
05-042: Force cycle exceeds 2 seconds.
05-045: Cannot check welding quality.
05-046: Start welding during a force step.
05-047: Transition time less than minimum time.
05-048: Program learning not performed with program gun.
05-049: Welding setting > 20 kA in AW mode.
MT861EN_KA01d
43
Fault Definition
7 Transformer overheating
07-001: Hardware overheating
The welder thermostat On/Off input is

open (X2-10).
If the fault will not acknowledge:
07-022: Software overheating
The XFMR bus input of the robot has the

state 0.
Check thermal duty cycle.
Check water circulation.
Cooling fault.
Check TH connection on welding

transformer.
Transformer or welder duty cycle

exceeded
Check the condition of the XFMR bus

input coming from the robot.
Faulty thermostat or connection leads cut

or disconnected
The IGBT conduction rate (%PWM)
Check the welding gun (secondary
exceeds the upper tolerance limit allowed
connections, secondary loop, shortto ensure the requested welding current.
circuits).
8 Exceeding positive % tolerance
Welder impedance damage.
If necessary, check % reference

programming.
Check the current measurement sensor.
The criteria stored during AW training have

not been reached.
9 Bad welding spot
Check that the AW training used is

compatible with the welded assembly.
10 Electrode end of life

10-001: NORMAL WC
10-002: WC MAX TIME
10-003: AW WC MAX NBR AFTER ALARM
10-004: NO R VARIATION
10-005: WC INCORRECT DRESSING
10-007: FORCED REPLACEMENT
11 Waiting acknowledgement
11-001: CAUSE_CYCLE_OKNOK
11-002: CAUSE_CYCLE_BAD
11-003: CAUSE_AU_RESTART
11-004: CAUSE_LOSS_PULSE
12 Dressing not perform

12-001: NORMAL WC
12-002: AW WC MAX TIME
12-003: AW WC MAX NBR AFTER ALARM
12-004: NO R VARIATION
12-005: WC INCORRECT DRESSING
12-006: NEW ELECTRODE DRESSING REQUEST
12-007: FORCED DRESSING
The number of spitting events detected is
excessive.
13 Expulsion fault
Check the location of the spot weld.

Check electrode condition.
Check the welding parameters used.
Welding voltage does not match the mains

voltage parameter or the phase is
disconnected or the inverter module faulty.
Configure the mains voltage used.
17 Converter duty factor exceeded
The permanent current level required from

the inverter exceeds its capacity.
Reduce the rate so that the permanent current

level becomes acceptable.
18 Secondary current measurement
No secondary current measurement signal

is reaching the inverter.
Check the measurement coil using an

ohmmeter. Its resistance level should be
between 20 and 30 ohms for a gun and
approx. 100 ohms for a machine.
16 DC voltage out of limits
Measurement coil unserviceable or

connecting wires cut or disconnected.
Check the power connections.
The welding board input stage has failed.

19 Secondary voltage measurement
No secondary current measurement signal

is reaching the inverter.
Connecting wires cut or disconnected.
Check the measurement points on the gun and

the voltage measurement connections back to
the inverter.
The welding board input stage has failed.
44
MT861EN_KA01d
Fault Definition
20 Machine too powerful
This fault appears if the Current

regulation option was programmed.
Check that programmed parameters are

correct.
The requested welding current level is less

than the minimum level generated by the
machine.
Check the calibration factor for the

measurement coil.
This fault may also be caused by a current

measurement coil fault that generates a
value that is greater than the true one.
21 Machine too weak
This fault appears if the Current

regulation option was programmed.
Check current programming in relation to

the welder's capacity.
The requested current value exceeds the

welder's capacity.
If correct, check that the welder is

providing its full performance: quality of
secondary links, transformer overheating
and secondary links.
This fault may also be caused by a current

measurement coil fault that generates a
value that is less than the true one.
The average effective current level during the
welding time exceeds the maximum threshold
allowed.
23 Current too high
- Check the calibration factor.

Acknowledge the fault then continue
welding. If the fault persists, adjust the
control threshold (+ 3% by default).
If % surveillance mode is used, readjust the
conduction rate in % terms, if necessary, to
bring it back within the required current
tolerances.
Mean rms current during the welding time is

lower than minimum tolerated threshold.
24 Current too low
Acknowledge the fault. Repeat the welding

spot.
Check the quality of workpiece squeeze.
If the fault persists, adjust the control
threshold (- 3% by default).
If % surveillance mode is used, readjust the
conduction rate in % terms, if necessary, to
bring it back within the required current
tolerances.
Mean rms current during welding time is

lower than tolerated recurrence threshold.
The threshold has been exceeded several
times in succession and more often than the
number of acceptable repeats.
25 Low recurrence current
Check the quality of the squeeze and the

location of the weld spot and, if necessary,
adjust the number of repetitions or the
control threshold.
Check the welder power connections.
measurement coil.
26 Gun duty factor exceeded

26-001: Thermal 2 seconds exceeded
26-004: Thermal N seconds exceeded
27 Diode duty factor exceeded
28 Exceeding negativ % tolerance
The duty cycle control option was

programmed and the WCC detected that the
permanent current level exceeded the
programmed maximum level. Welding
current level or rate too high in relation to
machine capacity.
Check the type of transformer configured.
The diode thermal control option is set and

the current levels required are too high
compared to what the selected transformer's
diodes can handle and they may become
damaged.
Reduce the rate so that the permanent

current level becomes acceptable.
In current regulation mode with %PWM

control, the %PWM setting is too low to
reach the programmed current level.
Check the current measurement sensor.
Change welder impedance.

29 Exceeding positiv recurrence %
In current regulation mode with %PWM

control, the %PWM setting is too high to
reach the programmed current level. The
threshold has been exceeded a number of
times in succession and more often than
the number of acceptable repeats.

Check the type of transformer

programmed.
If necessary, check % PWM reference

programming.
Check the welder secondary circuit.
Check the current measurement coil
connection.
measurement coil.
Change welder impedance.
MT861EN_KA01d
45
Fault Definition
30 Primary current overload
31 Cycle duty factor exceeded
32 Primary current measurement not OK
The primary current level has exceeded the

limit allowed for the MF inverter.
Check the connections from the

transformer to the inverter.
Welding transformer saturation
Check the welding request if necessary.
Thermal rating over cycle exceeded: Ith cycle

exceeded over the last N seconds of the cycle
defined. Welding current or rate too high.

The power circuit is open between the

inverter and the gun.
Check the power cable between the inverter

and the gun. This includes proper cable
clamping on the gun and inverter and no
cable failure.
Faulty internal current measurement sensor

or measurement system.
Check cycle max. thermal rating

programming: Max. thermal rating and
cycle duration.
Check that the gun squeezes correctly onto

the assembly.
Check that there is no insulation on the
assembly.
Check that the welding cycle has been
correctly programmed.
Check the second phase contact.
Spitting was detected during the last weld

spot.
34 Expulsed spot
Check the location of the spot weld.

Check workpiece squeeze conditions.
Check the compatibility of the welded
assembly.
35 Welding voltage too high
The measured secondary voltage exceeds the

programmed threshold.
Check that the welded assembly is

compatible with the program used.
Adjust threshold if necessary.
36 Welding voltage too low
The measured secondary voltage is below the

programmed threshold.
Check that the welded assembly is

compatible with the program used.
Check the connection for the welder
secondary voltage takeoff.
Adjust threshold if necessary.
37 Indentation out of limits

37-001: Indentation too big
The indentation characteristics exceed the set

limits.
Check the programmed thresholds.
The expansion characteristics exceed the set

limits.
37-002: Indentation too small

37-003: Indentation time too long
37-004: Indentation time too short
37-005: Indentation surface too big
37-006: Indentation surface too small
38 Expansion out of limits
38-001: Expansion too big
38-002: Expansion too small
38-003: Expansion time too long
38-004: Expansion time too short
38-005: Expansion surface too big
38-006: Expansion surface too small
39 Final position out of limits

39-001: Final position too big
39-002: Final position too small
44 Cutters end of life
Dressing tool end of life counter limit

reached.
Change the dressing cutter and

acknowledge this change.
Check parameterizing for Cutters end of
life.
46
MT861EN_KA01d
Fault Definition
45 Incorrect water flow
45-001: Valve not controlled
45-002: Water flow rate controller
45-003: Water flow rate controller of the robot
The water cutoff valve is not controlled or the

water flow rate is not within the range
allowed by the flow controller or the
information coming from the robots field bus
does not have the state 1.
Check flow meter setting.
Check that the installation is properly
supplied with water.
Check that there are no leaks in the water
circuit.
Check that there is nothing blocking the
water circuit.
Check the connection of the water cutoff
valve.
Check the state of the TW input on the bus
coming from the robot.
The pressure sensor does not detect the

selected air pressure.
46 Air pressure fault
Check that there is air in the circuit.

Check the pressure sensor setting.
Check the pressure sensor setting.
47 Fault opening gun parameters

47-001: Small opening exceeds maximum opening
The settings of the guns opening positions

are incorrect.
Make sure that the opening positions are

consequentially set.
Max. speed.
Internal run error.
Check the gun.

Check the ground connections, wiring
47-002: Large opening exceeds maximum opening

47-003: Small opening exceeds large opening
48 Drive error
48-000
48-001 to 48-011
Shutdown the cabinet and restart it.

If the problem persists, contact ARO.
48-011
48-012
Motor cable short circuit or current level too

high on motor.
One of the motor phases is taken to ground or
current level too high on motor.
48-015
Servo-controller duty cycle exceeded.
48-020
Servo-controller DC bus overvoltage.
Check the cable. If the problem persists, use a

shorter cable or a better quality one.
Check the motor and servo-controller (power
part). If the problem persists, use a shorter
cable or a better quality one.
Make sure that no mechanical blockage is
causing excess power consumption (bad
lubrication, hard point...).
Reduce the cycle time.
Check the mains supply voltage (max.
allowed: 528V).
Check the servo-controller input filter.
48-050 or 48-054
Servo-controller temperature too high.
Check for proper heat sink ventilation.

Check that the heat sink is clean.
Check that the servo-controller is properly
mounted on the heat sink.
48-053 or 48-057
Motor temperature level exceeded (motor

with thermistance): the limit allowed is
150 .
Check that the motor type is correctly

filled-in.
Check the motor cooling circuit.
48-058
Motor temperature level exceeded (motor

with thermostat).
Check that the motor type is correctly

filled-in.
Check the thermostat connection (inputs
T1/T2).
48-062 to 48-066
Error on servo-controller CAN.
48-070
Overvoltage on the internal 15V circuit in the

servo-controller.
Internal run error.
48-071 to 48-080
Check the wiring on X4 servo-controller,

terminator resistors (120), PE.
Check power supplies (24 V between X5-39
and X5-59).
48-082
48-086
MT861EN_KA01d
Resolver error.
Measured temperature is incorrect (motor
with thermistance).
Check the resolver and resolver wiring.

Check the thermistance connection (between
X7-8 and X7-9; ~600 at ambient
temperature).
47
Fault Definition
48-087
Encoder error.
48-110
Faulty heat sink temperature sensor.
48-111
Faulty servo-controller internal temperature

sensor.
Internal run error.
48-112 to 48-119
Check the encoder and the encoder wiring (if
the motor is fitted with an encoder).
Check that the servo-controller heat sink is
not dirty and is correctly ventilated.
Contact ARO.
49 Gun initialization error
The initialisation cycle is not performed

correctly for one of the following reasons:
One of the stops (gun open or electrode
contact) is not detected,
An obstacle is detected while searching for
the electrode contact.
Check that there are no obstacles along the

trajectory (force sensor).
Check that the corresponding gun file has
been loaded.
Check the gun.
Check opening calibration.
50 Open command faulty
51 Force command faulty
At least one open settings cannot be reached:

Opening too large.
Check that the gun file that corresponds to

the gun has been loaded.
Opening too small if the last initialization

was performed using a force sensor.
Repeat gun initialization.
A force setting for one of the six steps

exceeds the gun's maximum force level.
Check the gun's max. force level.
Check that the requested opening is less

than the gun's maximum opening.

been loaded.
Check the force settings.
52 Force measurement faulty
No force measurement signal is seen by the Check the force sensor and wiring.
servo-controller or the voltage level present
Check that the force required is acceptable
on the input to the servo-controller is too
for the gun (max. gun force level)
high (>10 V).
Sensor failure or connection wire cut or
disconnected.
Recalibrate the gun.
Faulty servo-controller measurement stage.

53 Error gun parameters
One of the following positions cannot be

reached:
end of cycle opening for the current
program

been loaded.
program sheet thickness
Check that the following parameters are

correct:
cap dresser thickness
End of cycle opening.

Sheet thickness.
Cap dresser thickness.
54 Squeezing fault
Without force regulation: The max. torque

level allowed is exceeded during squeeze.
With force regulation: The requested
squeeze force is not reached after 200 ms.
55 Following error
The motor cannot follow the motions

requested:
excess load,
torque too low,
acceleration too high.
Repeat force sensor calibration.

Check the "Squeeze force" parameter.
Check gun state: motor braking jammed,

electrodes stuck...
Recalibrate after opening the gun to the
maximum.
Reduce gun acceleration.
Increase the value of the "Max. movement
torque" parameter.
48
MT861EN_KA01d
Fault Definition
The measured sheet thickness is less than the
programmed thickness less the programmed
tolerance.
56 Thickness too low
Check sheet thickness parameterizing
Check welded sheets.
If necessary, increase the sheet thickness
tolerance.
Check force calibration.
The measured sheet thickness is more than the Check sheet thickness parameterizing
programmed thickness less the programmed
Check welded sheets.
tolerance.
57 Thickness too high
If necessary, increase the sheet thickness

tolerance.
Check force calibration.
When opening the gun after a spot, the torque
level required is too high. The deduction is
that the electrode on the arm has become
stuck.
58 Electrodes stuck
Check that the electrodes are really stuck.

If so, check cooling, check welding
current
Check that the requested force setting is not
too low.
Recalibrate after opening the gun to the
maximum.
If necessary, increase the "Electrode
unsticking tolerance" or the "Max.
movement torque level".
The detected rotor position is outside of

acceptable limits.
60 Position overflow
Check that the gun is not broken.

Check opening calibrationCheck the
maximum electrode wear (Electrode
parameters, Advanced parameters tab,
Electrode wear control heading).
61 2 mn duty factor exceeded
The motor load during the last two minutes

exceeds that allowed and may cause damage.

Check (and if necessary) increase cycle
times.
62 15s duty factor exceeded
The motor load during the last 15 seconds

exceeds that allowed and may cause damage.
63 Tightening too long
The tightening time before welding

authorization is too long (> 1s).
Acknowledge and start again.

If the problem persists shutdown the
cabinet and try again.
The force profile was run correctly but the

internal mechanism did not allow the gun to
open within the set length of time (duration =
3s instead of 1.5).
64 Cycle too long
The force measured exceeds the expected

value.
65 Force too high
Check the calibration of the gun.

Check that the equalization is set correctly.
Check the programmed tolerances and
filter value.
Check the calibration.
The force measured is less than the expected

value.
The system cannot reach the set force level.
66 Force too low

67 Force regulation error
Check the force sensor and wiring.

Check the force settings.
68 Cannot restart (gun moved) - init gun
MT861EN_KA01d
The restart system without initialization

option is set:
On power up, the motor position is different
from the one recorded on power down. The
system cannot continue without performing
an initialization.
Free the gun from the part to weld and

perform initialization before restarting the
system. Only manual mode opening is
possible.
49
Fault Definition
69 Equalizing fault
Input X2-20 = 0
Using the MMI, press RESET to reset the

equalization cassette. Then acknowledge
the fault.
Check the equalizing cassette wiring.
70 Equalizing automatism fault
Input USUREOK = X2-21
Check the wiring.

Check the equalizing cassette.
71 Equalizing thermostat fault
Cassette thermostat input = X2-22

Cassette motor thermostat.
Slow the workrate.
72 Motor overheating
SERVO input on the field bus coming from

the robot
Check the state of this input.
73 Equalizing actuator fault
Input X2-24.
The cassette is not equalised after 1 second.
Repeat cassette initialisation in manual

mode (Process menu | Service from the
MMI).
74 Equalizing init. fault
Input X2-25 = INITOK.

The cassette has lost its parameters.
Check the wiring.

Check the equalizing cassette.
75 No stepper reset
A maintenance cycle (program 30 to 38) has

been activated without any NTSR or DTSR
signal.
After executing a maintenance cycle, activate

one of the signals on the NTSR or DTSR bus.
78 Pilot closed
The DCY has not been activated within

150 ms after the selection of the program or
the selection is not reset to 0 after the
execution end of the selected program.
Selection automation problem on robot side.
70-001: USUREOK input set to 1

70-002: USUREOK input set to 0
78-001: selection not nil

78-001: waiting for start
Contact your ARO representative stating the

fault number.
80 Memory corrupted
81 Automatism fault
The contact is not engaged before welding,
The squeeze time exceeds the max. squeeze

time programmed (if not 0).
Check the parameters in ARODMS:

Program parameters, Checks and
thresholds tab, Squeeze time heading.
Check gun state: lubrication
81-005: Contact not closed before welding.

82 Squeeze time exceeded
Check the state of input X2-11 (ECNT).

Check the state of output X1-13 (CNT).
Check the good operation of the contact.
83 Start not authorized

83-001: Calibration without current.
83-002: Welding in AW mode without AW calibration.
83-003: Welding without calibration.
83-004: Regulation without teaching.
83-005: Bus workload.
83-006: AW teaching finished.
83-010: Teaching incoherent with voltage configuration.
83-011: Teaching incoherent with number of windings configuration.
83-012: Teaching incoherent with typical transformer configuration.
83-013: Teaching incoherent with typical measurement configuration.
83-014: Assistant running.
83-015: Opening before init.
83-016: Welding in init request mode.
83-017: Dressing in init request mode.
83-018: Dressing without calibration.
83-019: Electrode replacement without calibration.
83-020: Calibration with sensor gain not programmed (0).
83-021: Servo-controller not valid.
83-023: Calibration before init.
83-025: Change in init request.
83-026: Change without calibration.
83-032: Manual cycle request not allowed.
83-039: AW option not available.
83-040: JOG+ or JOG- cycle request in manual mode of the robot
84 Gun initialization to do
50
The number of spots planned between two

Inits has been reached. An Init is required.
Perform the initialization cycle.

Change the parameterizing of the regular
initialization request in: Electrode
parameters, Services tab, Initialisation
service heading.
MT861EN_KA01d
Fault Definition
85 Incorrect caps change
The check on cap position after a cap change

results in a value outside of the tolerances.
Check that the tips were correctly

replaced.
Check the parameters in Electrode
parameters, Services tab, Initialisation
service heading.
86 Welding without water
A spot weld has just been welded with the

water cooling circuit shutdown.
This fault does not inhibit welding but is

generated at the end of every cycle without
water. So that this does not recur, restart the
cooling circuit.
87 Water flow closed
The cap replacement cycle was interrupted

while the water cooling circuit was shutdown
and before finishing the cap insertion phase.
The water circuit was not therefore
reactivated.
Check that the electrodes are correctly pressed

home, then go to the screen to request water
activation from the MMI.
88 Dressing test
Bad electrode dressing detected.
88-010: RESISTANCE ABOVE TOLERANCE

88-011: RESISTANCE BELOW TOLERANCE
Check the dressing quality.
89 Dressing test not saved
There is no reference resistance saved.
Check whether or not dressing has been

executed.
Save a resistance as reference value.
Communications with the field bus are not
operational.
90 Fieldbus
Contact your ARO representative stating the

fault number.
91 System bus
91-011: Communication impossible with servocontroller
91-012: Communication impossible with iBox
MMI
Check the following parameters:

Configuration parameters, Peripherals tab,
Cap dressers heading.
Electrode parameters, Services tab,
Dressing service heading.
92 Parameter fault
92-000: Incoherent electrode program
92-001: Motor selection
92-002: Incoherent electrode axis program
92-003: Incoherent electrode WCC program
If CAN module option.
93 CAN module error
Check field bus connection.

Check the communication speed and slave
number.
Check the master configuration.
Check CAN module connection.

Acknowledge the fault. If the problem
persists, contact your ARO representative
with the Fault and Cause numbers.
94 Board bus fault

94-003: Write WCC parameters
94-004: Read WCC parameters without tools
94-005: Read WCC parameters with tools
94-012: Communication impossible with DSP
94-020: DSP
95 External No Weld fault
A welding cycle without current has been

executed from the field bus.
Activate the bit with current on the field bus

(Robot).
96 Internal error
Internal run error. A cycle was unable to run

or finish correctly.
Acknowledge the fault. If the problem

persists, contact your ARO representative
with the Fault and Cause numbers.
The inverter command card temperature

exceeds limits.
Check the inverter fan for correct

operation.
If the problem persists, contact your ARO
representative with the Fault and Cause
numbers.
96-001: Servo-controller parameter setting

96-002: Awaiting WCC results
96-003: Awaiting end of servo-controller cycle
97 Board temperature too high
97-xxx: MPC temperature (system
microprocessor); xxx = temperature measured
97-020: DSP temperature (welding
microprocessor)
MT861EN_KA01d
51
Fault Definition
Problem with the Data Key.
98 Datakey error
98-000: "NO TOKEN"
98-001: Data Key missing
98-002: Write error
98-003: "ACKNOWLEDGE"
98-004: Bad checksum from the data zone
98-005: Bad data size
98-006: Bad registry number
98-007: Bad AW_SW data serial number
98-008: Bad size for AW_SW data
98-009: Data Key busy
98-010: Done
98-011: Error
98-012: Time-out
98-013: Function call not supported
99 Manufacturer config incoherence
99-004: The type of inverter selected does not exist.
Check that the Data Key is correctly
positioned.
Contact your ARO representative with the

Fault and Cause numbers.
99-005: Gun servo-controller number exceeds the number of servo-controllers defined in the
factory configuration.
99-006: Incoherent match between max. motor number in the gun and the max motor number
defined in the factory configuration.
99-007: Incoherent match between the number of guns and the max. gun number in the program.
99-008: Invalid type of software between firmware and factory configuration (software type
comparison).
99-009: Invalid software version between firmware and factory configuration (software version
comparison).
99-010: No opening instruction and opening number on the fieldbus.
99-011: Presence (simultaneously) of an opening instruction and opening number on the fieldbus.
99-012: Invalid type of servo-controller software between firmware and factory configuration.
99-013: Module type not valid according to manufacturer configuration.
52
MT861EN_KA01d
Alarm Definition
Alarm Definition
No
Meaning
Details
Dressing warning
You need to perform electrode dressing.
Alarm maintenance required
You need to perform electrode replacement.
ELCB Test Warning
You need to perform a circuit breaker test.
DC Bus Loading
Wait until the alarm condition is no longer active (the MFDC

bus is loading).
System bus initialization
Wait until the alarm condition is no longer active (the

DACopen internal bus is starting up).
Peripherals initialization
Wait until the alarm condition is no longer active (the

peripherals are initializing).
Gun initialization
You need to perform an initialisation.
Motor power inhibited
Causes:
Electrode cap replacement cycle in progress,
Gun disconnected (tool changer case),
In other cases, check that power is active on the servocontroller.
10
Cutters end of life
You will need to replace the dressing cutters.
11
Waiting gun connection (for a

system comprising a tool changer)
Run the gun connection cycle.
12
Caps change authorized
In the electrode change cycle, the gun is in its safe position

(power and water cut off) so that the operator can change the
electrodes.
13
Alarm water down
The water was cut off outside of an electrode change cycle.

Executing a welding cycle will trigger fault 87-000.
14
Caps change in progress
During the electrode change cycle, the emergency stop input

was opened.
15
Battery low
Contact ARO with the alarm name.
17
Caps alignment
In the electrode caps replacement service, this is the electrode

cap alignment check phase.
19
WCC disabled
The WCE (weld control enable) field bus input coming from
the robot is disabled.
20
Initialisation two-step
Initialization of gun 2 running.
24
Internal bus running
Wait until the alarm condition is no longer active (the internal

bus is starting up).
25
Assistant not ready:

A start cycle condition is active when you
pressed the Qualify the spot button.
Release the start cycle condition.
26
Fieldbus initialization
Wait until the alarm condition is no longer active (the field

bus is starting up).
MT861EN_KA01d
53

MT861EN KA01d

Uploaded by

Copyright:

Available Formats

MT861EN KA01d

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

MT861EN KA01d

Uploaded by

Copyright:

Available Formats

What information is provided in the document tables of contents?

What information is provided in the document tables of contents?

What types of faults and alarms are described in the document?

What types of faults and alarms are described in the document?

iBox AW/SW

Medium Frequency Inverter

Quick Reference Guide

Type KA Issue 01 (Ethernet IP)

iBox Front Face

Creation of original (KA00)

Creation of English translation

Update KA00c XD01007

Update KA00d XD01008

Update KA01 XD02000

Update KA01b XD02005

Update KA01c XD02006

Update KA01d XD02007

iBox Front Fa ce Presentation .................................................................................................................................. 7

iBox Front Face Presentation

iBox Front Face Presentation

LCD, 4 lines of 20 characters.

Move to the previous column (Program, Gun ) or to the previous menu.

To validate the entered information and to go to next field on same page.

Use the number pad to directly enter a digital value.

Move to the next column (Program, Gun ) or to the next menu.

From an execution, fault or alarm screen, displays the main menu.

Pocket Programming Terminal Presentation

Pocket Programming Terminal Presentation

LCD, 4 lines of 20 characters.

Move to the previous column (Program, Gun ) or to the previous menu.

Move to the next column (Program, Gun ) or to the next menu.

To validate the entered information and to go to next field on same page.

Pocket Programming Terminal Presentation

Activating the Pocket Terminal

iBox MMI present.

Accessing the Menus

(Menu) key. The main menu is displayed.

Deactivating the Pocket Terminal

Mode AW or SW; gun number; program number

Mode AW; gun number; program number

Mode AW or SW; gun number; program number

Programmed welding time

Screen X3 is accessible in AW mode.

Mode AW or SW; gun number; program number

Mode AW or SW; gun number; program number

Mode AW or SW; gun number; program number

Mode AW or SW; gun number; program number

Mode AW or SW; gun number; program number

Segment number (- in mode AW); spot counter; dressing counter

Screen X8 is only accessible when final position control is on.

Fault or Alarm Screens

F1 to acknowledge the fault; F3 to view the next fault

Fault number and cause number; type of fault

F3 to view the next alarm

View the current program number

Program number (0 to 255)

Current regulation mode

Curr. and %control (if "Current Regulation" mode)

Force control mode (only if "SW mode" in Screen P1)