32 DCM00003 REV. 07
Squealing sound during welding or when
test key is depressed.
Check plate screws and tighten or replace.
Check cover plate screws and tighten.
Reset gaps.
Re-square horn/tip and reset gaps.
Reset horn tip and gap.
Weld heights are inconsistent.
Re-calibrate encoders 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 arm moves sluggish.
Check air lines for contamination.
NOTE: 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.
Time, height and energy inconsistent.
Switch to energy mode & open height
window. Make some sample welds. Check
the time and the height of the welds for
consistency. If the time or weld thickness
varies greatly, check the air regulator.
Table 4.1 Troubleshooting Guide
Problem Solution
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