78 DCM00044 REV. 14
Excessive welding
• Reset parameters
• Reset amplitude
• Reset pressure
• Measure and re-calibrate amplitude display
Time limit error or peak power
error displayed after weld cycle
• Reset limits
• Check tip, rotate or replace if worn
• Check anvil for wear, rotate or replace if worn
• Check air pressure setting
• Check up stop for proper adjustment
• Process settings have to be opened up due to part
variance or limits should be adjusted according to
the part/wire being run
• Check anvil clamp for proper torque
Squealing sound during welding or
when test key is depressed
• Reset gaps
• Re-square horn/tip and reset gaps
• Reset horn tip and gap
Weld heights are inconsistent
• Re-calibrate encoder with 1mm gauge
• Ensure the connector for the encoder is tightly
plugged into the actuator card
Horn is stuck in down position
• Check air pressure
• Ensure air lines are installed properly
• Check for kinks in air lines
Air leaking from machine
• Ensure all air line connections are tight
• Check for cracked or broken air lines
Unusual sound during weld cycle
• Check tooling gap
• Check converter
• Check stack assembly
Squealing sound from power
supply when unit is turned on
• Check cooling fans in rear of unit
Maintenance counter alarm
• Reset maintenance counter
Actuator moves sluggish
• Check air lines for contamination
NOTICE
Air must be filtered to 5 microns and be oil and
water free.
• Check solenoid valve, replace if needed
• Check air regulator
System has READY CHECK
message
• The horn is stuck in the closed position
• Maintenance has moved the height encoder to an out
of limit condition
• Defective encoder or electronics
• Encoder not plugged into the actuator card
Table 7.1 Troubleshooting
Problem Solution
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