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7.3
Troubleshooting
This section shows how to fix some of the possible errors and problems which may occur
in normal use of the Ultraseal 20 welding system.
7.3.1
Weld Overload
Weld overloads are premature shut downs of the power supply. Overloads signify
excessive loads and must be corrected if continued reliability of the equipment is to be
maintained. Hardware internal to the supply are controlling this function and it can not be
defeated.
The control system analyzes the end of weld characteristics to check for overloads. If the
system determines an overload an alarm occurs. The control halts action until the system
is reset.
Some of the possible causes for overloads are:
• The tool clearances are too small, horn and anvil touch during welding
• Excessive air pressure with low amplitude
• Defective Stack assembly
• Defective Power Transistors in power supply
7.3.2
Low Air Pressure
The control system and its components were designed to run with a clean air supply of
from 90 to 120 psi. The control system monitors the air pressure from the low air pressure
switch (optional). The low pressure threshold is set from the controller. An alarm occurs
when incoming line pressure the drops below the set pressure.
7.3.3
Ready Check
The system undergoes a Ready Check operation at every startup, the end of every weld,
and at the exit of Setup mode. This procedure checks the height encoder position. If an
incorrect height value is returned, an alarm occurs.
Some of the possible causes of a Ready Check alarm are:
• The anvil 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 in to its connector
7.3.4
Troubleshooting Chart
Table 7.2 Troubleshooting Chart
System will not turn on
68
Problem
Solution
Power cable plugged in.
Power turned on at the outlet.
Check internal fuses on the Controller Line Board.
DCM00051 REV. 10
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