Fronius TPS Error Codes

-St | oP-: Robot not ready

What it means: Shown when the power source is run with a robot interface or a field bus and the robot control has not signalled that the robot is ready.^[1]

Likely causes

• Robot ready signal not set by the robot control

First checks, in this order

1. Set the Robot ready signal from the robot control.
2. With a ROB 5000 robot interface or a field bus coupler for robot control, also send the Source error reset signal.

dsP | A21: LHSB link lost during parallel or TimeTwin operation

What it means: Only in parallel operation or TimeTwin Digital mode. The power source is set for parallel operation (setup parameter P-C = ON) or TimeTwin Digital (setup parameter T-C = ON), and the LHSB link was disconnected or became faulty while the power source was switched on.^[1]

Device response: Reset by switching the power source off and back on.

Likely causes

• LHSB link unplugged while the power source was on
• Faulty LHSB link

First checks, in this order

1. Switch the power source off and back on to reset the code.
2. If needed, restore or repair the LHSB link.

dSP | Axx, Cxx, Exx, Sy, nSy: Fault in the central control and regulation unit

What it means: The power source reports an internal fault in its central control and regulation unit. Fronius prints the same text for dSP | Axx, dSP | Cxx, dSP | Exx, dSP | Sy and dSP | nSy.^[1]

Likely causes

• Internal fault in the central control and regulation unit

First checks, in this order

1. Fronius only lists one remedy: contact After-Sales Service.
2. Note the code, the serial number and the configuration of the power source, then contact Fronius After-Sales Service with a detailed description.

E-S | toP: External stop has tripped

What it means: Only with the External stop or External stop with inching enabled options. The external stop input has tripped and the machine is stopped.^[1]

Device response: Acknowledge via the robot control unit and re-apply the 24 V SELV safety voltage.

Likely causes

• External stop circuit opened
• 24 V SELV safety voltage on the external stop removed

First checks, in this order

1. Find and clear whatever tripped the external stop.
2. Acknowledge the code from the robot control unit.
3. Re-apply the 24 V SELV safety voltage.

EFd | 8.1, EFd | 8.2: Fault in the wire feed system (overcurrent in wire-feed unit drive)

What it means: The wire-feed drive is drawing too much current. Fronius prints the same text for the general code EFd | xx.x.^[1]

Likely causes

• Hosepack laid with tight bends
• Kinks or dirt in the inner liner
• Wrong contact pressure on the 2-roller or 4-roller drive
• Wire-feed unit motor sticking or defective

First checks, in this order

1. Lay the hosepack in as straight a line as possible.
2. Check the inner liner for kinks and dirt.
3. Check the contact pressure on the 2-roller or 4-roller drive.
4. Check the wire-feed unit motor and replace it if it sticks or is defective.

EFd | 9.1: External supply voltage below tolerance range

What it means: The external supply voltage has dropped below the tolerance range.^[1]

Likely causes

• External supply voltage too low
• Wire-feed unit motor sticking or defective (listed by Fronius as a second cause)

First checks, in this order

1. Measure the external supply voltage.
2. Check the wire-feed unit motor and replace it if it sticks or is defective.

EFd | 9.2: External supply voltage above tolerance range

What it means: The external supply voltage has risen above the upper limit of the tolerance range.^[1]

Likely causes

• External supply voltage too high

First checks, in this order

1. Measure the external supply voltage.

EFd | 12.1: No actual speed value from the wire-feed unit motor

What it means: The power source receives no actual rotational speed value from the wire-feed unit motor.^[1]

Likely causes

• Faulty actual-value pick-up on the wire-feed motor
• Damaged cable or connection to the pick-up

First checks, in this order

1. Check the actual-value pick-up and the cable connections to and from it.
2. Replace the pick-up or cable if faulty.

EFd | 12.2: No actual speed value from the push-pull unit motor

What it means: The power source receives no actual rotational speed value from the push-pull unit motor.^[1]

Likely causes

• Faulty actual-value pick-up on the push-pull motor
• Damaged cable or connection to the pick-up

First checks, in this order

1. Check the actual-value pick-up and the cable connections to and from it.
2. Replace the pick-up or cable if faulty.

EFd | 15.1: Wire buffer empty

What it means: The wire buffer has run empty.^[1]

Device response: Acknowledge with the Feeder inching button once the cause is fixed.

Likely causes

• Counter lever on the main wire-feed unit open
• Main wire-feed unit slipping
• End of wire reached

First checks, in this order

1. Close the counter lever on the main wire-feed unit.
2. Check the wearing parts of the wire-feed unit, use suitable feed rollers, reduce the wire brake force and increase the contact pressure on the main wire-feed unit.
3. Check that enough wire is left.
4. Acknowledge the code with the Feeder inching button.

EFd | 15.2: Wire buffer full

What it means: The wire buffer is full.^[1]

Device response: Acknowledge with the Feeder inching button once the cause is fixed.

Likely causes

• Counter lever on the push-pull unit open
• Push-pull unit slipping
• Arc not igniting because of a poor ground (earth) connection
• Arc not igniting because the wrong welding program is selected

First checks, in this order

1. Close the counter lever on the push-pull unit.
2. Check the wire feed wearing parts, use suitable feed rollers and increase the contact pressure on the push-pull unit.
3. Check the ground (earth) connection.
4. Select the welding program that matches the wire diameter and material in use.
5. Acknowledge the code with the Feeder inching button.

EFd | 15.3: No wire buffer available

What it means: The power source cannot find the wire buffer.^[1]

Likely causes

• Connection to the wire buffer missing

First checks, in this order

1. Check the connection to the wire buffer.
2. Check the wire buffer control line.

EFd | 30.1: LHSB connection to power source missing

What it means: The wire-feed system has lost its LHSB connection to the power source.^[1]

Likely causes

• LHSB connection to the power source unplugged or faulty

First checks, in this order

1. Check the LHSB connection to the power source.

EFd | 30.3: LHSB connection to CMT drive unit missing

What it means: The LHSB connection to the CMT drive unit is missing. Only on systems with a CMT drive unit.^[1]

Likely causes

• LHSB connection to the CMT drive unit unplugged or faulty

First checks, in this order

1. Check the LHSB connection to the CMT drive unit.

EFd | 31.1: Rotor calibration on the CMT drive unit failed

What it means: The rotor calibration of the CMT drive unit did not succeed. Only on systems with a CMT drive unit.^[1]

Likely causes

• Rotor calibration of the CMT drive unit failed

First checks, in this order

1. Switch the power source off and back on.
2. If EFd | 31.1 remains, switch the power source off, disengage the CMT drive unit and switch the power source back on.
3. If it still appears, contact Fronius After-Sales Service.

EFd | 31.2: Rotor calibration on the CMT drive unit is running

What it means: Status message: the CMT drive unit is performing its rotor calibration.^[1]

Likely causes

• Rotor calibration in progress

First checks, in this order

1. Wait for the rotor calibration to finish.

EiF XX.Y: Interface error

What it means: An error reported by the robot interface. The values XX and Y are explained in the operating instructions of the robot interface.^[1]

Likely causes

• Fault reported by the robot interface

First checks, in this order

1. Look up XX and Y in the operating instructions for the robot interface and follow the remedy given there.

Err | 049: Phase failure

What it means: The power source has detected that a mains phase is missing.^[1]

Likely causes

• Blown mains fuse
• Damaged mains lead
• Faulty mains plug

First checks, in this order

1. Check the mains fuse.
2. Check the mains lead.
3. Check the mains plug.

Err | 050: Intermediate circuit balance error

What it means: The power source reports a balance error in its intermediate (DC link) circuit.^[1]

Likely causes

• Internal fault in the intermediate circuit

First checks, in this order

1. Fronius only lists one remedy: contact After-Sales Service.
2. Note the code, the serial number and the configuration of the power source, then contact Fronius After-Sales Service with a detailed description.

Err | 051: Mains undervoltage

What it means: The mains voltage has fallen below the tolerance range of the power source.^[1][5]

Also on: TransSteel 3500 / 5000 Syn shows the same condition as Err | 51 (Fronius adds: contact After-Sales Service if it keeps recurring).

Likely causes

• Mains voltage too low

First checks, in this order

1. Measure and check the mains voltage.

Err | 052: Mains overvoltage

What it means: The mains voltage has risen above the tolerance range of the power source.^[1][5]

Also on: TransSteel 3500 / 5000 Syn shows the same condition as Err | 52 (Fronius adds: contact After-Sales Service if it keeps recurring).

Likely causes

• Mains voltage too high

First checks, in this order

1. Measure and check the mains voltage.

Err | 054: Wire stuck in the solidifying weld pool

What it means: The wire-stick control function has detected the wire electrode sticking in the solidifying weld pool within 750 ms after the end of welding. Available when a robot interface or field bus system is connected.^[1]

Device response: Output after the end of welding; the code does not need to be acknowledged. The power source is ready again once the wire is cut free.

Likely causes

• Wire electrode stuck in the weld pool at the end of the seam

First checks, in this order

1. Make sure the Arc on signal is not set while you fix it, otherwise welding starts again as soon as the wire is freed.
2. Cut off the sticking end of the wire electrode.

Err | 056: Wire end detected or VR 1500 / VR 1530 wire-feed protection tripped

What it means: The Wire-end check option has detected the end of the wire electrode, or a protection on a VR 1500 - 11 / 12 / 30 or VR 1530 wire-feed unit has tripped.^[1]

Device response: Wire feed halts when the wire-end sensor triggers, either at once or after the current seam depending on the FCO setup parameter (with the noE setting, field bus only, the alarm goes only to the robot control). Acknowledge with the Store button.

Likely causes

• End of wire electrode reached (Wire-end check option)
• Additional fan filter of the VR 1500 - 11 / 12 / 30 contaminated, so the power electronics overheat and their temperature switch trips
• Ambient temperature too high at the VR 1500 - 11 / 12 / 30
• Motor current too high on the VR 1500 - 11 / 12 / 30, for example from wire feed problems
• VR 1530 wire-feed unit cover open or interlock release handles not snapped into place

First checks, in this order

1. Fit a new wirespool and feed the wire electrode into the hosepack.
2. Clean or replace the additional fan filter of the VR 1500.
3. Lower the ambient temperature or move the welding machine to a cooler place.
4. Check the wire feed conditions and correct any faults.
5. Close the VR 1530 cover properly with the interlock handles engaged.
6. Acknowledge Err | 056 with the Store button.

Err | 062: TP 08 remote control overheated

What it means: The TP 08 remote control has overheated. E62 is shown on the TP 08 at the same time.^[1]

Likely causes

• Overheating of the TP 08 remote control

First checks, in this order

1. Let the TP 08 remote control cool down.

Err | 069: Illegal mode change during welding

What it means: A mode change was attempted while welding, for example changing from a MIG/MAG job to a TIG job.^[1]

Likely causes

• Mode or job type changed during welding

First checks, in this order

1. Start the welding action again.
2. Do not switch between job types (for example MIG/MAG and TIG) while welding.

Err | 70.x: Fault in digital gas sensor

What it means: The digital gas sensor reports a fault: Err 70.1 gas sensor not found, Err 70.2 no gas, Err 70.3 calibration error, Err 70.4 solenoid valve faulty, Err 70.5 solenoid valve not found.^[1]

Likely causes

• Gas sensor not found (70.1)
• No gas (70.2)
• Gas sensor calibration error (70.3)
• Gas solenoid valve faulty (70.4)
• Gas solenoid valve not found (70.5)

First checks, in this order

1. Check the gas supply.
2. Note the sub-code (70.1 to 70.5) to narrow down the cause.

Err | 71.x: Set limits exceeded or not reached

What it means: The welding current or voltage left the limits that were set: Err 71.1 current limit exceeded, Err 71.2 current limit not reached, Err 71.3 voltage limit exceeded, Err 71.4 voltage limit not reached.^[1]

Likely causes

• Welding current above or below the set limit (71.1, 71.2)
• Welding voltage above or below the set limit (71.3, 71.4)

First checks, in this order

1. Check the quality of the weld seam.
2. Note the sub-code to see which limit was crossed.

Err | 77.x: Wire-feed motor current limit exceeded

What it means: The current limit set for a wire-feed motor has been exceeded: Err 77.7 wire-feed unit motor current exceeded, Err 77.8 PPU (push-pull unit) motor current exceeded.^[1]

Likely causes

• Too much resistance in the wire feed path (feed rollers, inner liner, inlet or outlet nozzles)

First checks, in this order

1. Check the wire-feed components: feed rollers, inner liner, inlet and outlet nozzles.
2. Check the quality of the weld seam.

Err | bPS: Fault in power module

What it means: The power source reports a fault in its power module.^[1]

Likely causes

• Internal fault in the power module

First checks, in this order

1. Fronius only lists one remedy: contact After-Sales Service.
2. Note the code, the serial number and the configuration of the power source, then contact Fronius After-Sales Service with a detailed description.

Err | Cfg: No LHSB link after switch-on (parallel or TimeTwin)

What it means: Only in parallel operation or TimeTwin Digital mode. The power source is set for parallel operation (P-C = ON) or TimeTwin Digital (T-C = ON), but after switch-on it could not establish an LHSB link because the link was detached or faulty.^[1]

Device response: Reset by switching the power source off and back on.

Likely causes

• LHSB link detached before switch-on
• Faulty LHSB link

First checks, in this order

1. Switch the power source off and back on to reset the code.
2. If needed, restore or repair the LHSB connection.

Err | IP: Primary overcurrent

What it means: The power source has detected an overcurrent in its primary (mains side) circuit.^[1][5]

Also on: TransSteel 3500 / 5000 Syn prints Err | IP with a different meaning: primary overvoltage. There, check the mains voltage, switch off for 10 seconds and back on, and contact After-Sales Service if it persists.

Likely causes

• Internal fault on the primary side of the power source

First checks, in this order

1. Fronius only lists one remedy: contact After-Sales Service.
2. Note the code, the serial number and the configuration of the power source, then contact Fronius After-Sales Service with a detailed description.

Err | PE: Earth current watchdog tripped

What it means: The earth current watchdog has triggered the safety cut-out of the power source.^[1][5]

Also on: TransSteel 3500 / 5000 Syn: same code and meaning; that manual also says to place the power source on an insulating surface and to connect the grounding cable to a part of the workpiece closer to the arc.

Device response: Safety cut-out of the power source; switch off, wait 10 seconds, switch on.

Likely causes

• Welding current flowing through an unintended earth path

First checks, in this order

1. Switch the power source off, wait 10 seconds and switch it back on.
2. If the error keeps coming back after several tries, contact Fronius After-Sales Service.

Err | tJo: JobMaster torch temperature sensor faulty

What it means: The temperature sensor in the JobMaster welding torch is faulty.^[1]

Likely causes

• Faulty temperature sensor in the JobMaster torch

First checks, in this order

1. Fronius only lists one remedy: contact After-Sales Service.
2. Note the code, the serial number and the configuration of the power source, then contact Fronius After-Sales Service with a detailed description.

hot | H2O: Cooling unit thermostat has tripped

What it means: The thermostat on the cooling unit has tripped because the coolant is too hot.^[1][5]

Also on: TransSteel 3500 / 5000 Syn: same code (coolant temperature too high); that manual adds cleaning the cooler and checking that the cooling unit fan works.

Device response: Clears by itself once the coolant has cooled down.

Likely causes

• Coolant temperature too high

First checks, in this order

1. Wait until the cooling phase ends and hot | H2O is no longer displayed.
2. With a ROB 5000 or a field bus coupler for robot control, set the Source error reset signal before welding again.

no | Arc: Arc break

What it means: The arc break watchdog has switched the machine off: the arc broke and no current started flowing again within the time set in the Setup menu (parameter Arc, factory setting OFF).^[1]

Device response: The system cuts out automatically; press the torch trigger again to start welding.

Likely causes

• Wire stick-out too long
• Dirty workpiece surface
• Arc break watchdog enabled with a short time setting

First checks, in this order

1. Shorten the wire stick-out.
2. Clean the surface of the workpiece.
3. Press the torch trigger again to restart.

no | GAS: No gas pressure (gas watchdog)

What it means: The Gas watchdog option has detected a loss of gas pressure.^[1][5]

Also on: TransSteel 3500 / 5000 Syn: same code and meaning; there it is reset by pressing any button.

Device response: Acknowledge with the Store button once gas pressure is back.

Likely causes

• Gas cylinder empty
• Cylinder valve or pressure regulator closed

First checks, in this order

1. Connect a new gas cylinder.
2. Open the gas cylinder valve and the pressure regulator.
3. Acknowledge no | GAS with the Store button.

no | IGn: Ignition time-out

What it means: The Ignition time-out function is active and no current started flowing before the length of wire set in the Setup menu (parameter Ito) had been fed, so the safety cut-out tripped. E55 is shown on the JobMaster torch and on the field bus module.^[1][5]

Also on: TransSteel 3500 / 5000 Syn: same code and meaning.

Device response: Safety cut-out; press the torch trigger again for a new ignition attempt.

Likely causes

• Wire stick-out too long
• Dirty workpiece surface
• Ito wire length set too short for the application

First checks, in this order

1. Shorten the wire stick-out.
2. Press the torch trigger again.
3. Clean the surface of the workpiece.
4. If needed, increase the Ito setting in Setup menu level 2.

no | H2O: Cooling unit flow watchdog triggered

What it means: The flow watchdog of the cooling unit has been triggered because coolant flow is too low. The setup parameter C-t sets the time from the flow watchdog triggering until no | H2O is shown.^[1][5]

Also on: TransSteel 3500 / 5000 Syn: same code (coolant flow rate too low).

Device response: Acknowledge with the Store button once flow is restored.

Likely causes

• Coolant level too low
• Air in the cooling circuit
• Fault in the cooling unit

First checks, in this order

1. Check the cooling unit.
2. Top up the coolant and bleed the water flow if needed (see the cooling unit operating instructions).
3. Acknowledge the error with the Store button.

no | Prg: No preconfigured program selected

What it means: No preconfigured program has been selected, so the power source has no welding program to run.^[1][5]

Also on: TransSteel 3500 / 5000 Syn: same code and meaning.

Likely causes

• No preconfigured program has been selected

First checks, in this order

1. Select a configured program.

r | E30: r calibration: no contact with the workpiece

What it means: During measurement of the welding circuit resistance r the machine cannot make contact with the workpiece.^[1]

Likely causes

• Grounding (earthing) cable not connected
• Contact tube not touching the workpiece firmly

First checks, in this order

1. Connect the grounding (earthing) cable.
2. Make a tight connection between the contact tube and the workpiece.

r | E31: r calibration interrupted by repeated torch trigger

What it means: The welding circuit resistance measurement was interrupted because the torch trigger was pressed repeatedly.^[1]

Likely causes

• Torch trigger pressed more than once during the measurement

First checks, in this order

1. Make a tight connection between the contact tube and the workpiece.
2. Press the torch trigger once only.

r | E32: r calibration: ground cable, current cable or hosepack defective

What it means: The measured welding circuit resistance is below 0.5 milliohm or above 30 milliohm, which points to a defective cable or hosepack.^[1]

Likely causes

• Defective grounding (earthing) cable
• Defective current cable
• Defective hosepack

First checks, in this order

1. Check the grounding (earthing) cable, the current cable and the hosepack, and replace if needed.

r | E33, r | E34: r calibration: poor contact between contact tube and workpiece

What it means: The welding circuit resistance measurement found poor contact between the contact tube and the workpiece. Fronius prints the same text for r | E33 and r | E34.^[1]

Likely causes

• Dirty contact point
• Loose contact tube
• Poor grounding (earthing) connection

First checks, in this order

1. Clean the point of contact.
2. Tighten the contact tube.
3. Check the grounding (earthing) connection.

tJO | xxx: JobMaster welding torch overheating

What it means: The JobMaster welding torch is overheating; xxx is a temperature value. E66 is shown on the JobMaster at the same time.^[1]

Device response: Acknowledge with the Store button after the torch has cooled.

Likely causes

• Overheating of the JobMaster welding torch

First checks, in this order

1. Let the torch cool down.
2. Acknowledge the error with the Store button.

tP1 to tP6 | xxx: Overtemperature in the primary circuit

What it means: Overtemperature in the primary circuit of the power source; xxx is a temperature value. Fronius prints the same text for tP1, tP2, tP3, tP4, tP5 and tP6.^[1]

Device response: Thermostatic safety cut-out stops welding current; the power source comes back on by itself after the cooling phase.

Likely causes

• Overload: duty cycle exceeded
• Limited supply of cooling air
• Faulty fan in the power source

First checks, in this order

1. Let the power source cool down; it comes back on by itself after the cooling phase.
2. Take the duty cycle into account.
3. Remove the air filter at the rear of the housing from the side and clean it, and keep the cooling air ducts free.
4. If the fan is faulty, contact Fronius After-Sales Service.

tS1 to tS3 | xxx: Overtemperature in the secondary circuit

What it means: Overtemperature in the secondary circuit of the power source; xxx is a temperature value. Fronius prints the same text for tS1, tS2 and tS3.^[1]

Device response: Thermostatic safety cut-out stops welding current; the power source comes back on by itself after the cooling phase.

Likely causes

• Overload: duty cycle exceeded
• Limited supply of cooling air
• Faulty fan in the power source

First checks, in this order

1. Let the power source cool down; it comes back on by itself after the cooling phase.
2. Take the duty cycle into account.
3. Clean the air filter at the rear of the housing and keep the cooling air ducts free.
4. If the fan is faulty, contact Fronius After-Sales Service.

tSt | xxx: Overtemperature in the control circuit

What it means: Overtemperature in the control circuit of the power source; xxx is a temperature value.^[1]

Likely causes

• Overload: duty cycle exceeded
• Limited supply of cooling air
• Faulty fan in the power source

First checks, in this order

1. Let the power source cool down.
2. Clean the air filter at the rear of the housing and keep the cooling air ducts free.
3. If the fan is faulty, contact Fronius After-Sales Service.

Err | Eto: Incorrect measurement during push-pull calibration

What it means: A measurement went wrong while the push-pull unit was being calibrated with the drive units disengaged (open-circuit calibration).^[1]

Likely causes

• Incorrect measurement during calibration

First checks, in this order

1. Repeat the push-pull calibration.

St1 | E 1 to St1 | E 6: Push-pull open-circuit calibration: no actual speed value

What it means: During open-circuit push-pull calibration (drive units disengaged) a motor gave no actual rotational speed value: at minimum wire feed speed for E 1, E 3 and E 4, at maximum wire feed speed for E 2, E 5 and E 6.^[1]

Likely causes

• Motor delivers no actual speed value during calibration

First checks, in this order

1. Repeat the push-pull calibration; if the message appears again, contact Fronius After-Sales Service.

St1 | E 16, St2 | E 16: Push-pull calibration interrupted by quick-stop

What it means: The push-pull calibration was interrupted because quick-stop was activated by pressing the torch trigger.^[1]

Likely causes

• Torch trigger pressed during calibration

First checks, in this order

1. Repeat the push-pull calibration without pressing the torch trigger.

St2 | E 7: Open-circuit push-pull calibration not done

What it means: The engaged push-pull calibration was started before the open-circuit calibration (drive units disengaged) had been carried out.^[1]

Likely causes

• Open-circuit calibration skipped

First checks, in this order

1. Carry out the push-pull calibration with the drive units disengaged (open-circuit) first, then the engaged calibration.

St2 | E 8, St2 | E 12: Push-pull engaged calibration: no actual speed value from wire-feed motor

What it means: During engaged push-pull calibration the wire-feed unit motor gave no actual rotational speed value, at minimum wire feed speed (E 8) or maximum wire feed speed (E 12).^[1]

Likely causes

• Wire-feed unit motor delivers no actual speed value

First checks, in this order

1. Repeat the push-pull calibration; if the message appears again, contact Fronius After-Sales Service.

St2 | E 9, St2 | E 13: Push-pull engaged calibration: no actual speed value from push-pull motor

What it means: During engaged push-pull calibration the push-pull unit motor gave no actual rotational speed value, at minimum wire feed speed (E 9) or maximum wire feed speed (E 13).^[1]

Likely causes

• Push-pull motor delivers no actual speed value
• Faulty actual-value pick-up (named by Fronius for E 13)

First checks, in this order

1. Repeat the push-pull calibration; if the message appears again, contact Fronius After-Sales Service.

St2 | E 10, St2 | E 14: Push-pull engaged calibration: wire-feed motor current out of range

What it means: During engaged push-pull calibration the motor current of the wire-feed unit motor was outside the permitted range, at minimum wire feed speed (E 10) or maximum wire feed speed (E 14).^[1]

Likely causes

• Wire-feed motors disengaged
• Wire feed problems

First checks, in this order

1. Engage the drive units of both wire-feed motors.
2. Lay the hosepack in as straight a line as possible.
3. Check the inner liner for kinks or dirt.
4. Check the contact pressure on the 2-roller or 4-roller drive of the push-pull unit.
5. Repeat the push-pull calibration; if the message appears again, contact Fronius After-Sales Service.

St2 | E 11, St2 | E 15: Push-pull engaged calibration: push-pull motor current out of range

What it means: During engaged push-pull calibration the motor current of the push-pull unit was outside the permitted range, at minimum wire feed speed (E 11) or maximum wire feed speed (E 15).^[1]

Likely causes

• Wire-feed motors disengaged
• Wire feed problems

First checks, in this order

1. Engage the drive units of both wire-feed motors.
2. Lay the hosepack in as straight a line as possible.
3. Check the inner liner for kinks or dirt.
4. Check the contact pressure on the 2-roller or 4-roller drive of the push-pull unit.
5. Repeat the push-pull calibration; if the message appears again, contact Fronius After-Sales Service.

6451: Phase error (incorrect power supply)

What it means: A phase error has occurred, meaning the welding machine has an incorrect power supply. Fronius names error numbers 6451 and 6515 for this; the number is shown on the welding machine display and sent to the robot as the Error number signal.^[4]

Also on: Fronius gives 6515 for the same phase error.

Likely causes

• Incorrect mains power supply to the welding machine, for example a missing phase

First checks, in this order

1. Check the mains supply to the welding machine.
2. On a robot cell, the Mains voltage status signal on the interface shows the phase error; on a TWIN system it goes High when either welding machine has a phase error, so check both.

6515: Phase error (incorrect power supply)

What it means: A phase error has occurred, meaning the welding machine has an incorrect power supply. Fronius names error numbers 6451 and 6515 for this; the number is shown on the welding machine display and sent to the robot as the Error number signal.^[4]

Also on: Fronius gives 6451 for the same phase error.

Likely causes

• Incorrect mains power supply to the welding machine, for example a missing phase

First checks, in this order

1. Check the mains supply to the welding machine.
2. On a robot cell, the Mains voltage status signal on the interface shows the phase error; on a TWIN system it goes High when either welding machine has a phase error, so check both.

1334: Short circuit between contact tip and welding ground during active WireSense/teach process

What it means: During a WireSense or teach movement the torch was moved so far toward the workpiece that the contact tip made an electrical connection to it.^[4]

Device response: The wire is retracted 40 mm and the error message is set.

Likely causes

• Torch moved too close to the workpiece during WireSense or teach
• Movement outside the WireSense length limits

First checks, in this order

1. Move the torch back so the contact tip stays clear of the workpiece.
2. Check the robot path against the WireSense measuring range and length limits.

1340: Maximum number of movement cycles on isolating materials achieved

What it means: In WireSense Isolated mode more than 30 continuous movement cycles were made on non-conductive material, for example slag, silicate or oxide on the seam. At a slow search speed of 30 cm/min this is a silicate width of about 5 mm.^[4]

Device response: The process stops automatically.

Likely causes

• Searching across slag, silicate or oxide deposits
• WireSense started on a non-conductive section
• Unstable wire feed in Isolated mode (see warning 16680), which can trigger 1340 incorrectly

First checks, in this order

1. Start the WireSense process on a conductive section.
2. Remove slag from the component or seam; the Slaghammer function only removes silicate on the wire tip.
3. Check the logbook for warning 16680 before this error.

16680: Increased motor force / unstable wirefeed process detected during isolated mode

What it means: In WireSense Isolated mode the welding machine saw unusual motor forces or wire speed profile, so the WireSense process is no longer running properly. If operation continues, error 1340 may be triggered incorrectly.^[4]

Device response: Warning only; the running process is not aborted.

Likely causes

• Special torch types, for example very long or special torch geometries
• Special filler metals, for example CuMn13Al8
• Unsuitable inner liner or inner liner not matched to the wire diameter
• Uncommon wire diameters, for example 0.8 mm or 1.6 mm

First checks, in this order

1. Check that the inner liner suits the wire diameter.
2. Check the torch and filler metal against the cases Fronius lists.
3. Clarify with Fronius Technical Support whether another system setup is possible or whether WireSense Isolated mode can be used.

19: Lower voltage limit undershot

What it means: Limit Monitoring error message: the actual voltage stayed below the lower voltage limit longer than the set reaction time (monitored per weld seam or job, in the main current phase). Fronius lists this number under Limit Monitoring for the TPS/i.^[4]

Device response: With the Limit reaction set to Error the welding machine stops welding, makes a logbook entry, marks the affected parameters red and outputs the error number at the interface. With Warning it keeps welding, makes a logbook entry and marks the parameters red, but outputs no warning number at the interface.

Likely causes

• Actual voltage outside the limits defined in the job
• Limits set from set values instead of measured actual values
• Job parameters changed without adjusting the limits

First checks, in this order

1. Check the weld seam. If it is OK, review and adjust the limits; if it is not OK, check and adjust the welding parameters.
2. Set limits from measured actual values (display, SmartManager or WeldCube Premium), not from set values.

20: Upper voltage limit exceeded

What it means: Limit Monitoring error message: the actual voltage stayed above the upper voltage limit longer than the set reaction time (monitored per weld seam or job, in the main current phase). Fronius lists this number under Limit Monitoring for the TPS/i.^[4]

Device response: With the Limit reaction set to Error the welding machine stops welding, makes a logbook entry, marks the affected parameters red and outputs the error number at the interface. With Warning it keeps welding, makes a logbook entry and marks the parameters red, but outputs no warning number at the interface.

Likely causes

• Actual voltage outside the limits defined in the job
• Limits set from set values instead of measured actual values
• Job parameters changed without adjusting the limits

First checks, in this order

1. Check the weld seam. If it is OK, review and adjust the limits; if it is not OK, check and adjust the welding parameters.
2. Set limits from measured actual values (display, SmartManager or WeldCube Premium), not from set values.

21: Lower current limit undershot

What it means: Limit Monitoring error message: the actual current stayed below the lower current limit longer than the set reaction time (monitored per weld seam or job, in the main current phase). Fronius lists this number under Limit Monitoring for the TPS/i.^[4]

Device response: With the Limit reaction set to Error the welding machine stops welding, makes a logbook entry, marks the affected parameters red and outputs the error number at the interface. With Warning it keeps welding, makes a logbook entry and marks the parameters red, but outputs no warning number at the interface.

Likely causes

• Actual current outside the limits defined in the job
• Limits set from set values instead of measured actual values
• Job parameters changed without adjusting the limits

First checks, in this order

1. Check the weld seam. If it is OK, review and adjust the limits; if it is not OK, check and adjust the welding parameters.
2. Set limits from measured actual values (display, SmartManager or WeldCube Premium), not from set values.

22: Upper current limit exceeded

What it means: Limit Monitoring error message: the actual current stayed above the upper current limit longer than the set reaction time (monitored per weld seam or job, in the main current phase). Fronius lists this number under Limit Monitoring for the TPS/i.^[4]

Device response: With the Limit reaction set to Error the welding machine stops welding, makes a logbook entry, marks the affected parameters red and outputs the error number at the interface. With Warning it keeps welding, makes a logbook entry and marks the parameters red, but outputs no warning number at the interface.

Likely causes

• Actual current outside the limits defined in the job
• Limits set from set values instead of measured actual values
• Job parameters changed without adjusting the limits

First checks, in this order

1. Check the weld seam. If it is OK, review and adjust the limits; if it is not OK, check and adjust the welding parameters.
2. Set limits from measured actual values (display, SmartManager or WeldCube Premium), not from set values.

23: Lower wirefeeder limit undershot

What it means: Limit Monitoring error message: the actual wirefeeder speed stayed below the lower wirefeeder limit longer than the set reaction time (monitored per weld seam or job, in the main current phase). Fronius lists this number under Limit Monitoring for the TPS/i.^[4]

Device response: With the Limit reaction set to Error the welding machine stops welding, makes a logbook entry, marks the affected parameters red and outputs the error number at the interface. With Warning it keeps welding, makes a logbook entry and marks the parameters red, but outputs no warning number at the interface.

Likely causes

• Actual wirefeeder speed outside the limits defined in the job
• Limits set from set values instead of measured actual values
• Job parameters changed without adjusting the limits

First checks, in this order

1. Check the weld seam. If it is OK, review and adjust the limits; if it is not OK, check and adjust the welding parameters.
2. Set limits from measured actual values (display, SmartManager or WeldCube Premium), not from set values.

24: Upper wirefeeder limit exceeded

What it means: Limit Monitoring error message: the actual wirefeeder speed stayed above the upper wirefeeder limit longer than the set reaction time (monitored per weld seam or job, in the main current phase). Fronius lists this number under Limit Monitoring for the TPS/i.^[4]

Device response: With the Limit reaction set to Error the welding machine stops welding, makes a logbook entry, marks the affected parameters red and outputs the error number at the interface. With Warning it keeps welding, makes a logbook entry and marks the parameters red, but outputs no warning number at the interface.

Likely causes

• Actual wirefeeder speed outside the limits defined in the job
• Limits set from set values instead of measured actual values
• Job parameters changed without adjusting the limits

First checks, in this order

1. Check the weld seam. If it is OK, review and adjust the limits; if it is not OK, check and adjust the welding parameters.
2. Set limits from measured actual values (display, SmartManager or WeldCube Premium), not from set values.

47: Lower energy limit not reached

What it means: Limit Monitoring error message: the actual energy input stayed below the lower energy limit longer than the set reaction time (monitored over the weld seam). Fronius lists this number under Limit Monitoring for the TPS/i.^[4]

Device response: With the Limit reaction set to Error the welding machine stops welding, makes a logbook entry, marks the affected parameters red and outputs the error number at the interface. With Warning it keeps welding, makes a logbook entry and marks the parameters red, but outputs no warning number at the interface.

Likely causes

• Actual energy input outside the limits defined in the job
• Limits set from set values instead of measured actual values
• Job parameters changed without adjusting the limits

First checks, in this order

1. Check the weld seam. If it is OK, review and adjust the limits; if it is not OK, check and adjust the welding parameters.
2. Set limits from measured actual values (display, SmartManager or WeldCube Premium), not from set values.

48: Upper energy limit exceeded

What it means: Limit Monitoring error message: the actual energy input stayed above the upper energy limit longer than the set reaction time (monitored over the weld seam). Fronius lists this number under Limit Monitoring for the TPS/i.^[4]

Device response: With the Limit reaction set to Error the welding machine stops welding, makes a logbook entry, marks the affected parameters red and outputs the error number at the interface. With Warning it keeps welding, makes a logbook entry and marks the parameters red, but outputs no warning number at the interface.

Likely causes

• Actual energy input outside the limits defined in the job
• Limits set from set values instead of measured actual values
• Job parameters changed without adjusting the limits

First checks, in this order

1. Check the weld seam. If it is OK, review and adjust the limits; if it is not OK, check and adjust the welding parameters.
2. Set limits from measured actual values (display, SmartManager or WeldCube Premium), not from set values.

50: Lower welding time limit not reached

What it means: Limit Monitoring error message: the actual welding time stayed below the lower welding time limit longer than the set reaction time (monitored over the weld seam). Fronius lists this number under Limit Monitoring for the TPS/i.^[4]

Device response: With the Limit reaction set to Error the welding machine stops welding, makes a logbook entry, marks the affected parameters red and outputs the error number at the interface. With Warning it keeps welding, makes a logbook entry and marks the parameters red, but outputs no warning number at the interface.

Likely causes

• Actual welding time outside the limits defined in the job
• Limits set from set values instead of measured actual values
• Job parameters changed without adjusting the limits

First checks, in this order

1. Check the weld seam. If it is OK, review and adjust the limits; if it is not OK, check and adjust the welding parameters.
2. Set limits from measured actual values (display, SmartManager or WeldCube Premium), not from set values.

51: Upper welding time limit exceeded

What it means: Limit Monitoring error message: the actual welding time stayed above the upper welding time limit longer than the set reaction time (monitored over the weld seam). Fronius lists this number under Limit Monitoring for the TPS/i.^[4]

Device response: With the Limit reaction set to Error the welding machine stops welding, makes a logbook entry, marks the affected parameters red and outputs the error number at the interface. With Warning it keeps welding, makes a logbook entry and marks the parameters red, but outputs no warning number at the interface.

Likely causes

• Actual welding time outside the limits defined in the job
• Limits set from set values instead of measured actual values
• Job parameters changed without adjusting the limits

First checks, in this order

1. Check the weld seam. If it is OK, review and adjust the limits; if it is not OK, check and adjust the welding parameters.
2. Set limits from measured actual values (display, SmartManager or WeldCube Premium), not from set values.