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Table 7.2 Troubleshooting Chart
Plant fuse fails or circuit breaker
trips when plugging the unit into an
electrical outlet
Plant fuse fails or circuit breaker
trips during weld cycle
Line fuse fails
Anvil will not move down or up
Get Emergency Stop when system
is turned on
No Sonics when test button is
pressed
No sonics during weld cycle
Overloads when welding
When touching the system you get
a slight electrical shock
Tooling heats up after machine runs
a while
DCM00051 REV. 10
Problem
Solution
Inspect power cord, replace if shorted.
Check line filter, replace if failed.
Check current rating of the plant fuse or the
circuit breaker, replace if failed.
Check fuse current rating, replace if
incompatible.
Check fan motor, replace if failed.
System not connected to air supply.
Air not turned on.
Check Emergency Stop Switch.
All cables properly connected.
Twist red switch on foot pedal. (if system is
equipped with one)
RF Cable connected.
Check RF cable for broken wire.
Ribbon cable in Controller between SPM and
programmer unplugged.
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.
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.
Inspect power cord, replace if needed.
Inspect system ground, repair if needed.
Cooling air is not turned on or is not on long
enough.
69
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