Error codes

In error situations, the web UI displays the number and title of the error.

Error
Code	Title	Possible cause	Proposed action
1	Power source not calibrated	Power source calibration has been lost.	Restart the power source. If problem persists, contact Kemppi service.
2	Too low mains voltage	Voltage in mains network is too low.	Restart the power source. If problem persists, contact Kemppi service.
3	Too high mains voltage	Voltage in mains network is too high.	Restart the power source. If problem persists, contact Kemppi service.
4	Power source is overheated	Too long welding session with high power.	Do not shut down, let the fans cool the machine. If fans are not running, contact Kemppi service
5	Internal 24V voltage is too low	Power source contains an inoperative 24V power supply unit .	Restart the power source. If problem persists, contact Kemppi service.
7	Wire feeder not found	Wire feeder is not connected to power source or connection is faulty.	Check the control cable and its connectors.
8	Initialization error in FPGA card	Control card is faulty or software fails in power source.	Restart the power source. If problem persists, contact Kemppi service.
9	Measurement cable failure	Voltage sensing cable is not connected to the work piece or measurement cable connection is faulty.	Connect voltage sensing cable to the work piece and check the measurement cable and its connectors.
11	FET unit failure	Power source contains an inoperative FET unit.	Restart the power source. If problem persists, contact Kemppi service.
12	Welding cable failure	Plus and minus cables are connected together.	Check the connections of welding cable and earth return cable.
13	IGBT overcurrent	Inoperative mains transformer in power source.	Restart the power source. If problem persists, contact Kemppi service.
14	IGBT overheated	Too long welding session with high power or high ambient temperature.	Do not shut down, let the fans cool the machine. If fans are not running, contact Kemppi service.
17	Phase is missing from mains supply	One or more phases are missing from the mains supply.	Check the mains cable and its connectors. Check the voltage of mains supply.
20	Power source cooling failure	Cooling capacity is reduced in the power source.	Clean the filters and clear any dirt from the cooling channel. Check that the cooling fans are running. If not, contact Kemppi service.
24	Cooling liquid overheated	Too long welding session with high power or high ambient temperature.	Do not turn off the cooler. Let the liquid circulate until the fans cool it down. If fans are not running, contact Kemppi service.
26	Cooling liquid not circulating	No cooling liquid or circulation is blocked.	Check the liquid level in the cooler. Check hoses and connectors for blockage.
27	Cooler not found	Cooling is turned on in the settings menu, but cooler is not connected to power source or cabling is faulty.	Check the cooler connections. Ensure that the cooling is turned off in the settings menu, if the cooler is not in use.
33	Welding cable calibration failure	Welding cable calibration failed.	Check the welding system cables and their connections.
40	VRD error	Open circuit voltage exceeds the VRD limit.	Restart the power source. If problem persists, contact Kemppi service.
41	Wire feeder not calibrated	Wire feeder calibration has been lost.	Restart the welding system. If problem persists, contact Kemppi service.
42	High current in wire feeder motor	There may be too much pressure in the wire feed rolls or dirt in the wire line.	Adjust the feed roll pressure. Clean the wire line. Change worn parts in the welding torch.
43	Overcurrent in wire feeder motor	There may be too much pressure in the wire feed rolls or dirt in the wire line.	Adjust the feed roll pressure. Clean the wire line. Change worn parts in the welding torch.
44	Wire speed measurement is missing	Faulty sensor or wiring in wire feeder.	Restart the welding system. If problem persists, contact Kemppi service.
50	Welding program error	Required welding program is not installed.	Contact Kemppi service for installing welding programs.
51	Rear drive roll slipping	Wire feeder’s rear drive roll is slipping.	Adjust the feed roll pressure. Clean the wire lines.
53	Collision detected	Welding torch has collided with an object.	Move the welding torch away from the collision and check the torch for any damage.
56	Wire feeder hardware fault	There is an internal hardware fault in wire feeder.	Check wire feeder connections and restart the welding system. If problem persists, contact Kemppi service.
57	Low shielding gas flow	Shielding gas flow is below the warning level or missing.	Check and adjust the shielding gas flow.
58	Assistive wire feeder was disconnected	Connection to assistive wire feeder was lost during operation.	Check the connection of assistive wire feeder and ensure that it is operational.
59	Gas sensor unit missing	Faulty gas sensor unit or wiring in the wire feeder. Functions related to the gas sensor are not available.	Check the external cable connections of the wire feeder and restart the welding system. If problem persists, contact Kemppi service.
60	Welding torch speed signal missing	Disconnected push-pull welding torch control cable, or faulty wiring or sensor.	Check the push-pull welding torch control cables, and the push-pull welding torch control cable connector on the wire feeder.
61	Operation not allowed	Subfeeder is connected, but it has not been selected in the system settings.	Go to the system settings menu on the control panel and select your subfeeder model and type.
62	Power source not found	No power source is connected to the wire feeder, or connection is faulty.	Check the control cable and its connectors.
64	Robot control device lost	Wire feeder lost connection to the robot control device.	Check the robot control device and interconnection cables. If problem persists, contact Kemppi service.
65	Subfeeder not allowed	Use of subfeeder is not allowed with selected welding process.	Remove the subfeeder or change the welding process.
81	Welding program data missing	Welding program data has been lost.	Restart the power source. If problem persists, contact Kemppi service.
103	Empty memory channel	Robot tried to start welding using a nonexistent memory channel.	Check the memory channel selected by the robot.
129	Filler wire stuck	Filler wire is stuck to the weld.	Ensure that welding has stopped, and cut the filler wire. Exercise caution around hot surfaces.
130	RCM hardware fault	There is an internal hardware failure within the RCM.	Check any external I/O connections, optional add-on cards and add-on card power supplies, if applicable. If problem persists, contact Kemppi service.
131	Fieldbus initialization failed	RCM failed to initialize the fieldbus module. Either the module is unsupported or it is faulty.	Remove the fieldbus module and check if it is supported by the RCM.
132	Robot not responding	There is a communication problem between robot and the RCM.	Check fieldbus cabling, connectors and the fieldbus module.
133	Stop switch pressed	Welding system has been stopped because the stop switch is pressed.	Release the stop switch.
134	Gate door open	Gate door has been opened.	Close the gate door.
141	High current in welding torch motor	There may be too much pressure in the wire feed rolls or dirt in the wire line. This may cause degraded welding performance.	Adjust the feed roll pressure in the welding torch. Clean the wire line. Change worn parts in the welding torch.
142	Overcurrent in welding torch motor	There may be too much pressure in the wire feed rolls or dirt in the wire line. The push-pull welding torch control cable may be damaged.	Adjust the feed roll pressure in the welding torch. Clean the wire line. Change worn parts in the welding torch. Check the welding torch control cables, and the push-pull welding torch control cable connector on the wire feeder.
161	High current in assistive wire feeder motor	There may be too much pressure in the wire feed rolls or dirt in the wire line.	Adjust the feed roll pressure. Clean the wire line. Change worn parts in the welding torch.
162	Overcurrent in assistive wire feeder motor	There may be too much pressure in the wire feed rolls or dirt in the wire line.	Adjust the feed roll pressure. Clean the wire line. Change worn parts in the welding torch.
163	Wire speed measurement from assistive wire feeder is missing	Faulty sensor or wiring in wire feeder or mechanical obstacle in wire feed mechanism.	Restart the welding system. Check the wire feed mechanism. If problem persists, contact Kemppi service.
164	Main wire feeder is not supported by the assistive wire feeder	Main wire feeder is not supported by the assistive wire feeder.	Check the user manual for supported wire feeder models. Check that the assistive wire feeder has the latest firmware version.
165	Assistive wire feeder hardware fault	There is an internal hardware fault in the assistive wire feeder.	Check the assistive wire feeder connections and restart the welding system. If problem persists, contact Kemppi service.
166	Assistive wire feeder feed rolls slipping	Assistive wire feeder's feed rolls are slipping or the assistive wire feeder ran out of wire.	Adjust the feed roll pressure. Clean the wire lines. Check the wire source.
171	Gas sensor unit not calibrated	The gas sensor unit is not calibrated or the calibration data cannot be loaded.	Restart the welding system. If problem persists, contact Kemppi service.
238	Power source serial number is missing	Communication to serial number card failed.	Restart welding system. If problem persists, contact Kemppi service.
244	Internal memory failure	Initialization failed (%sub:%device).	Restart welding system. If problem persists, contact Kemppi service.
250	Internal memory failure	Memory communication failed.	Restart welding system. If problem persists, contact Kemppi service.
255	Unsupported hardware	RCM hardware is not supported by the current firmware.	Update the RCM firmware.