Emerson DCX S - Table 8.17 Troubleshooting Weld Cycle Problems

132 100-412-183 REV. 13
8.6.4 Weld Cycle Problems
Table 8.17 Troubleshooting Weld Cycle Problems
Problem Check Solution
Full ultrasonic power
not delivered.
Unsuitable horn or booster
selection.
Contact Branson Applications
Lab
Plastic part material varies.
Mold release lubricant in weld
area.
Unsuitable joint design.
Unsuitable or misaligned part
fixture.
Amplitude setting Adjust if required.
No ultrasonic power
passed to horn.
Power supply overheating;
check fan and vents.
Replace improperly operating
fan. Remove dust and debris.
Alarm indicator
illuminates when you
press the Test key or
during the weld cycle.
Check converter-booster-
horn stack interface for
fretting corrosion.
See
8.2.2 Recondition the
Stack (Converter, Booster, and
Horn).
Check for loose or failed horn
converter or booster.
Tighten or replace as needed.
Check for loose or failed horn
or booster stud.
Failed RF cable Replace if failed.
Excessively warm
horn, booster, and
converter; occasional
overloads.
Check converter-booster-
horn stack mating surfaces
for fretting corrosion.
See 8.2.2 Recondition the
Stack (Converter, Booster, and
Horn).
Be certain proper cooling has
been provided.
Replace fan if required.