Failure analysis structure

Error No. Deutsch English Troubleshooting

When a terminal is clamped by the operator and then the reset button is pressed, this
77 Benutzerabbruch: Teil entfernen! User Abort: Remove Part!
message appears on the screen

Bitte prüfen, ob die korrekte PLC-Version

79 Please check if the correct PLC-Version is installed Please check if the correct PLC-Version is installed
installiert ist

101 DATEI: Datei schon vorhanden DATA FILE: Data file already exists If required store the data using a different file name

102 DATEI: Datei nicht vorhanden DATA FILE: Data file does not exist File missing

After reaching the downward counter, the message must be acknowledged and, if
103 ABWARTSZÄHLER erreicht! DOWNWARD-COUNTER reached!
necessary, the next number entered

105 Eingabe: Wert ungültig! Input: Value invalid! Please enter a valid value

107 Wartung: Diagnose -> Diagnose! Maintenance: Diagnosis -> diagnosis! Please perform diagnostics of the machine according to the maintenance schedule.

108 Wartung: Reinigen -> Diagnose! Maintenance: Clean -> diagnosis! Please clean the machine according to the maintenance schedule.

109 Wartung: Abschmieren -> Diagnose! Maintenance: Lubrication -> diagnosis! Please lubricate the machine according to the maintenance schedule.

110 Sequenzdefinition nicht komplett! Sequence-definition is not complete! Please recreate the sequence
111 Knoten der Sequenz fehlt! Splice of the sequence is lacking! Please recreate the weld in teach mode / save the sequence again
112 Statistik nicht möglich! Statistics are not possible! Please perform a weld in production mode to get statistic values
115 Eingabefehler: Bereich Anzahl input error: starting no. > final no. Please enter a valid number
116 Eingabefehler: Startdatum > Enddatum input error: starting date > final date Please enter a valid date
117 Eingabefehler: Startzeit > Endzeit input error: starting time > final time Please enter a valid time
118 Eingabefehler: Zeit ungültig input error: time invalid Please enter a valid time
119 Eingabefehler: Datum ungültig input error: date invalid Please enter a valid date

Check the files on the hard disk, delete files that are no longer needed or transfer
120 Festplatte voll Hard disk area complete
them to another storage device

File: Error Code Liste DS20-II & LS-C Ausgabedatum 20.05.2022

 Failure analysis structure
Check the files on the hard disk, delete files that are no longer needed or transfer
121 Festplatte voll - Stopp Stat.-Protokoll Hard disk area complete - stop stat.-record
them to another storage device

Check the files on the hard disk, delete files that are no longer needed or transfer
122 Festplatte fast voll Hard disk area nearly complete
them to another storage device

123 Datei vorhanden -> Überschreiben? Data file already exists -> overwrite? Overwrites a file that already exists

124 Datei löschen? Delete data file? Delete a file that already exists

Please check the correctly mounting of the sound insulation and the mechanical
201 FEHLER: Timeout Schallschutz schließen ERROR: Close timeout sound insulation
movement

202 FEHLER: Timeout Druck ERROR: Timeout pressure Make sure, that the input-pressure is set to 6.5 Bar

Please check the correctly mounting of the sound insulation and the mechanical
204 FEHLER: Timeout Schallschutz öffnen ERROR: Open timeout sound insulation
movement

Please check the error message on the generator display and check this error message
205 FEHLER: Generator ERROR: Generator
with description of the operation manual.

206 FEHLER: Versorgungsspannung fehlt ERROR: Main voltage is lacking Check the emergency stop and switch on the machine

The ERROR: Compacting height can occur by various criteria, for example, wrong cable
208 FEHLER: Pressmaß ERROR: Compacting height inserted, cable depth, not all strands in the welding area, new charge of wires, faulty
diagnosis etc.

The ERROR: Welding Height can occur after compacting by various criteria, for
209 FEHLER: Schweissmaß ERROR: Welding height example, wrong cable inserted, cable depth, not all strands in the welding area, new
charge of wires, faulty diagnosis etc.

The Welding time error message occurs when the weld in the production mode differ
210 FEHLER: Schweißzeit überschritten ERROR: Welding time crossed to the reference weld. Please check the following points: Wrong cable inserted, cable
depth, new charge of wires, new charge of terminals, etc.

File: Error Code Liste DS20-II & LS-C Ausgabedatum 20.05.2022

 Failure analysis structure
The ERROR: compacting height external limit reached can be determined by various
221 FEHLER: Pressmaß statische Grenze compacting height external limit reached criteria, for example, wrong cable inserted, cable depth, not all strands in the welding
area, new charge of wires etc.

The ERROR: welding height external limit reached can be determined by various
222 FEHLER: Schweissmaß statische Grenze welding height external limit reached criteria, for example, wrong cable inserted, cable depth, not all strands in the welding
area, new charge of wires etc.

Problem with connection between PC and PLC. Please check the connections from PC
223 Datenübertragung Steuerung ERROR: Data transmission Controller
to PLC and look if the PLC is still powered on.

This error message appears if the sonotrode does not reach the lower position in a
237 Sonotrode nicht unten Sonotrode not down
specified time. Please check if the sonotrode moves down correctly.

This error message appears if the input pressure does not reach the preset value
249 FEHLER: Druckverlust ERROR: Line Pressure
(according to MIC 6.5 bar), drops or fluctuates

If this error message appears check the correct position and the sensor from the down
261 Timeout Niederhalter Timeout Down Holder
holder

This error message appears if the crimparm is not in home position. Please check the
264 Timeout Crimparm Timeout Crimper
correct position and the sensor from crimper

This error message appears if the sonotrode does not reach the upper position in a
265 Timeout Sonotrode oben Timeout Sonotrode up
specified time. Please Check the sensor for sonotrode up.

The ERROR: Energy can occur after welding by various criteria, for example, wrong
392 FEHLER: Energie ERROR: Energy cable inserted, cable depth, not all strands in the welding area, new charge of wires
etc.

File: Error Code Liste DS20-II & LS-C Ausgabedatum 20.05.2022

 Failure analysis structure
There was probably another error message before. Error 399 will pop up if the “all
reset could not be finished” (height sensor counter could not stop in the upper
399 Initialisierung fehlgeschlagen Initialization failed position, automatic back pressure calibration could not be set correctly). By pressing
the “reset” button a backpressure calibration will be performed if it could not be
finished before.

This error message appears after the "Afterburst Cycle". Please check if there is an
418 FEHLER: Nachschallzyklus Leistung ERROR: Afterburst cycle power error code on the generator. Please check the setting in the software function
"Afterburst"

419 FEHLER: Nachschallzyklus Weg ERROR: Afterburst cycle distance Please check the setting in the software function "Afterburst"

This error occurs during the power monitoring. Please check the settings of the power
451 Leistungswert hat den Grenzwert unterschritten Power value below critical limit
monitoring feature.

In case of this error, first check if everything is inserted correctly (Wire / Terminal).
This message is machine specific and depends on the application. If you would like to
538 Teil falsch eingelegt Part incorrectly inserted
have more information about this, we need the machine number on which the error
currently occurs

The left gliding jaw has not reached the forward / backward position within the
801 Timeout Schieber links vorne Timeout Jaw left forward
specified time. Please check the correct movement and the sensor setting

The right gliding jaw has not reached the forward / backward position within the
802 Timeout Schieber rechts vorne Timeout Jaw right forward
specified time. Please check the correct movement and the sensor setting

The left gliding jaw has not reached the lower / upper position within the specified
803 Timeout Schieber links unten Timeout Jaw left down
time. Please check the correct movement and the sensor setting

File: Error Code Liste DS20-II & LS-C Ausgabedatum 20.05.2022

 Failure analysis structure
The right gliding jaw has not reached the lower / upper position within the specified
804 Timeout Schieber rechts unten Timeout Jaw right down
time. Please check the correct movement and the sensor setting

Timeout Litzenanschlag - Terminal/Kontaktteil The wire stop has not reached the working / home position within the specified time.
805 Timeout wire stop - check terminal/contact position!
Position prüfen! Please check the correct movement and the sensor setting

The wire gripper up has not reached the working / home position within the specified
806 Timeout Kabelklemme oben Timeout wire gripper up
time. Please check the correct movement and the sensor setting

The wire gripper closed has not reached the working / home position within the
807 Timeout Kabelklemme zu Timeout wire gripper closed
specified time. Please check the correct movement and the sensor setting

The terminal damper closed has not reached the working / home position within the
808 Timeout Terminaldämpfung Timeout terminal damper
specified time. Please check the correct movement and the sensor setting

The crimp unit has not reached the working / home position within the specified time.
815 Timeout Crimpeinheit Timeout Crimp-unit
Please check the correct movement and the sensor setting

The cutting unit has not reached the working / home position within the specified
816 Timeout Schneideinheit Timeout Cutting-Unit
time. Please check the correct movement and the sensor setting

This error message appears if there is no vacuum. Please check if the parts are
819 Timeout Vakuum Timeout Vacuum
inserted correctly

The damping unit has not reached the working / home position within the specified
820 Timeout Dämpfung Timeout Dampening
time. Please check the correct movement and the sensor setting

The fixture has not reached the working / home position within the specified time.
821 Timeout Einlegemaske Timeout Fixture
Please check the correct movement and the sensor setting

File: Error Code Liste DS20-II & LS-C Ausgabedatum 20.05.2022

 Failure analysis structure
Tools are not in home position. Please press reset button and check the further error
827 Resetknopf drücken Press Reset Button
messages.

The "Timeout pressure sensor" error can appear if there is a difference between the
975 Timeout Drucksensor Timeout Pressure Sensor target and measured actual pressure value (welding pressure). Please perform a
pressure diagnosis.

The "Timeout force sensor" error can appear if there is a difference between the
980 Timeout Kraft Sensor Timeout Force Sensor target and measured actual force value (welding force). Please perform a force
diagnosis.

The "Timeout safety stop" error can appear if the cylinder of the safety stop is not
981 Timeout Sicherheitsstopp Timeout safety stop
correctly retracted / extended

The ERROR: Upper external limit reached PowerMonitoring2 can be determined by

1148 Statische obere Grenze PowerMonitoring2 Upper external limit reached PowerMonitoring2 various criteria, for example, wrong cable inserted, cable depth, not all strands in the
welding area, new charge of wires etc.

The ERROR: Lower external limit reached PowerMonitoring2 can be determined by

1149 Statische untere Grenze PowerMonitoring2 Lower external limit reached PowerMonitoring2 various criteria, for example, wrong cable inserted, cable depth, not all strands in the
welding area, new charge of wires etc.

The ERROR: Upper limit reached PowerMonitoring2 can be determined by various

1150 Obere Grenze PowerMonitoring2 Upper limit reached PowerMonitoring2 criteria, for example, wrong cable inserted, cable depth, not all strands in the welding
area, new charge of wires etc.

The ERROR: Lower limit reached PowerMonitoring2 can be determined by various

1151 Untere Grenze PowerMonitoring2 Lower limit reached PowerMonitoring2 criteria, for example, wrong cable inserted, cable depth, not all strands in the welding
area, new charge of wires etc.

1412 Störung Start Malfunction Start Please check the function of the start button
1457 Bitte Terminal entfernen und Start betätigen Remove Terminal and press start Please remove Terminal and press start

File: Error Code Liste DS20-II & LS-C Ausgabedatum 20.05.2022

 Failure analysis structure

Please perform the force calibration again over diagnosis menu. If the error message
1458 Fehler: Kraftsensor Kalibrierung ERROR: Force sensor calibration
comes up again, please contact service Department from Schunk Sonosystems

The poka yoke function has not reached the working / home position within the
1459 Poka Yoke-1 Poka Yoke-1
specified time. Please check the correct movement and the sensor setting

The poka yoke function has not reached the working / home position within the
1460 Poka Yoke-2 Poka Yoke-2
specified time. Please check the correct movement and the sensor setting

In case of this error, first check if everything is inserted correctly (Wire / Terminal).
This message is machine specific and depends on the application. If you would like to
1461 Leitung falsch eingelegt Incorrect wire position
have more information about this, we need the machine number on which the error
currently occurs

In case of this error, first check if everything is inserted correctly (Wire / Terminal).
This message is machine specific and depends on the application. If you would like to
1462 Leitungsposition 1 Wire position 1
have more information about this, we need the machine number on which the error
currently occurs

In case of this error, first check if everything is inserted correctly (Wire / Terminal).
This message is machine specific and depends on the application. If you would like to
1463 Leitungsposition 2 Wire position 2
have more information about this, we need the machine number on which the error
currently occurs

In case of this error, first check if everything is inserted correctly (Isolation unit). This
message is machine specific and depends on the application. If you would like to have
1464 Isolierstück falsch eingelegt Incorrect isolation unit
more information about this, we need the machine number on which the error
currently occurs
2165 Fehler Kühlung ERROR: Cooling Please check the provided cooling unit

File: Error Code Liste DS20-II & LS-C Ausgabedatum 20.05.2022