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Table 7.2 Troubleshooting Chart
Low weld strength
Excessive welding
Time limit error or peak power
error displayed after weld cycle
Squealing sound during welding or
when test key is depressed
Weld heights are inconsistent
Anvil is stuck in down position
Air leaking from machine
DCM00051 REV. 10
Problem
Solution
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.
Reset parameters.
Reset amplitude.
Reset pressure.
Measure and re-calibrate amplitude display.
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.
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.
Re-calibrate encoders with 1mm gauge.
Ensure the connector for the encoder is tightly
plugged into the actuator card.
Check air pressure.
Ensure air lines are installed properly.
Check for kinks in air lines.
Ensure all air line connections are tight.
Check for cracked or broken air lines.
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