DCM00044 REV. 14 77
Plant fuse fails or circuit breaker
trips during weld cycle
• Check current rating of the plant fuse or the circuit
breaker, replace if failed
Line fuse fails
• Check fuse current rating, replace if incompatible
• Check fan motor, replace if failed
Horn will not move down or up
• System not connected to air supply
• Air not turned on
Get Emergency Stop when system
is turned on
• Check Emergency Stop Switch
• All cables properly connected
• Twist red switch on foot pedal (if system is equipped
with one)
No Sonics when test button is
pressed
• RF Cable connected
• Check RF cable for broken wire
• Ribbon cable in power supply between SPM and
programmer unplugged
No sonics during weld cycle
• Check all cable connections
• Check start cable for broken wires
• Check inside power supply for loose start cable from
rear of unit to programmer board
• Check thermal switch in power supply
Overloads when welding
• Stack not tuned properly
• Tooling not set up properly
• Crash gap not set properly
• Tip nut cracked, replace if needed
• Check weld parameters
• Check stack interfaces for fretting
• Check for loose or failed horn or booster, tighten or
replace as necessary
When touching the system you get
a slight electrical shock
• Inspect power cord, replace if needed
• Inspect system ground, repair if needed
Tooling heats up after machine
runs a while
• Cooling air is not turned on or is not on long enough
• Cooling air is not directed at tooling
Low weld strength
• Check weld parameters
• Check tooling gaps
• Check knurl on tooling
• If worn replace tooling
• Increase Energy
• Check the Down stop adjustment
• Check for part contamination
• Ensure all hardware is tight
Table 7.1 Troubleshooting
Problem Solution
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