Sonics E-Press - Manual (Page 33)

Sonics E-Press Manual Page 33
MAINTENANCE
TOC
Stepper Trouble-Shooting Guide
TOC :
The following list contains the most common problems associated with the stepper welding system and the
most probable cause. The potential problem is in
Bold Red
and the associated discussion should help lead to
a solution.
1. The
Weld seems to be cut short
and does not achieve the distance setpoint. Check the GX power
supply weld time settings, they must be programmed long enough for the E-Press system to complete all
programmed moves. If sonics is programmed OFF during the second move (Distance #2 and Velocity #2)
then the GX hold time must be long enough for the second move plus any desired Hold time. The
ultrasonic welder will be in HOLD when sonics shuts OFF.
2. The motor
starts to weld but there is a grinding sound
. Then it stops and stays in position. The system
has stalled for any one of several reasons causing the stepper motor to slip. This slipping makes clicking
noises but does not harm the motor. Use the RESET button on the E-Press front panel to reset the motor
system. The head assembly will move up to the home position. This condition could be caused by
excessive velocity settings or low ultrasonic amplitude. Check the velocity settings on the Stepper Screen
and verify that the ultrasonic amplitude is sufficient to melt plastic.
3. The
computer does not find the Stepper or GX controller
. These devices must be connected to the
two COMM Ports. They must be standard PC ports as COMM1 through COMM4 and each unit must be
wired with the proper cables. The stepper system must be in the ready screen: “SONICS & MATERIALS”
Press HOME or RESET to return to the ready screen. “SYSTEM READY“
4. The
head assembly does not find the home position
and keeps trying to run into the upper stop. This
could happen at initial startup or after a stall has taken place. The system has missed the upper limit home
signal and is trying to run until it finds it. Press the Emergency Stop button and physically move the
carriage down from the stop, approximately one inch. Restart or RESET the system and the HOME
position should be detected.
5. The System seems to find the parts but then
welds in the upward direction.
This can happen if Absolute
Welding mode has been selected and the parts tolerance settings are large. If the parts are found near
the end of the specified tolerance window (the sum of the upper and lower tolerance settings) and the
absolute weld setting is before that point, the system will weld in the reverse direction or up to the setting.
This would obviously be an incorrect application setup but it can be confusing. The part tolerances could
not meet the final desired depth after welding if they are already too short to be welded!
6. The machine seems to weld 10 or 15 pieces and then
stops in the middle of the weld while down on
the parts .
If the PC port is not connected with the stepper utility program running or the cable has been
disconnected without installing the terminator plug, the stepper controller can get into an internal buffer full
condition. Install the terminator connector or check the cables and run the utility program.