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Dukane 9001:2000 manual

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Table of contents for the manual

  • Page 1

    Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL +1–630–797–4900 • F AX +1–630–797–4949 Dukane Part No. 403–566-01 www .dukcorp.com/us User’ s Manual ISO 9001:2000 Dukane products ar e manufactur ed in ISO register ed facilities 04 05 06 07 08 09 10 11 12 13 14 15 16 17 [...]

  • Page 2

    Cop yright © 2003—2004 Dukane Cor poration Ultrasonics Division 2900 Dukane Dri ve St. Charles, IL 60174 USA Notice of Rights: All rights reser ved. No part of this manual including the inte- rior design, co ver design and icons ma y be reproduced , trans- mitted or utilized in an y for m or by an y means, electronic, mechanical, photocop ying, [...]

  • Page 3

    T able of Contents Dukane Manual Part No. 403-566-01 iii –00 Add information for EZ–Series Generator to DPC II Plus Manual. 2003–Sept–25 Added EZ Welder™ Key Featur es to Section 1. T able 3—1 references new DPC II Plus/EZ W elder manual. Figure 4–1B shows EZ Generator w/o Hot Key for P2 . Figure 4–8B added to show curr ent software[...]

  • Page 4

    iv Dukane Manual Part No. 403-556-01 DPC II Plus and EZ Welder System – User’ s Manual This pag e intentionally left blank[...]

  • Page 5

    T able of Contents Dukane Manual Part No. 403-566-01 v T ABLE OF C ONTENTS Section 1 – Introduction ........................................................... 1 Before Operating ................................................................................... 3 Read The Manual First .............................................................[...]

  • Page 6

    vi Dukane Manual Part No. 403-556-01 DPC II Plus and EZ Welder System – User’ s Manual Section 5 – Rear Connectors .................................................. 37 Rear Panel Layout ................................................................................ 39 System Input Connector ..................................................[...]

  • Page 7

    T able of Contents Dukane Manual Part No. 403-566-01 vii Press Mode Example ............................................................................ 77 Hot Keys ................................................................................................ 81 Process Control Recap ...............................................................[...]

  • Page 8

    viii Dukane Manual Part No. 403-556-01 DPC II Plus and EZ Welder System – User’ s Manual Section 11 – DPC Checkout .................................................. 117 Startup and Self–T est ......................................................................... 119 System T est ..........................................................[...]

  • Page 9

    T able of Contents Dukane Manual Part No. 403-566-01 ix Section 14 – Contacting Dukane ......................................... 141 Ultrasonics Division Main Office ....................................................... 143 Email Addresses .................................................................................. 144 T elephone Extensio[...]

  • Page 10

    x Dukane Manual Part No. 403-556-01 DPC II Plus and EZ Welder System – User’ s Manual This pa ge intentionally left b lank[...]

  • Page 11

    1 Dukane Manual Part No. 403–566–01 Section 1 – Introduction Befor e Operating ............................................ 3 Read The Manual First ............................................ 3 Caution and W arnings ........................................... 3 Drawings Labels ..................................................... 3 Manual Or[...]

  • Page 12

    2 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 13

    3 Dukane Manual Part No. 403 – 566 – 01 Section 1 – Introduction Important User Information Read This Manual First Before operating the DPC™ II Plus, read this User’ s Manual to become f amiliar with the sys- tem. This will ensure cor rect and safe operation. The manual is or ganized to allo w y ou to lear n ho w to safel y operate an ult[...]

  • Page 14

    4 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Section 1 – Intr oduction describes the manual or ganization and the ke y features of the Dukane DPC TM ( Dy- namic Process Controller ) II Plus Generator . Section 2 – Safety discusses OSHA re gulations and safety considerations. Section 3 ?[...]

  • Page 15

    5 Dukane Manual Part No. 403 – 566 – 01 Section 1 – Introduction Section 12 – T roub leshooting pro vides helpful tips on solv- ing the most common problems. Section 13 – Maintenance lists a schedule of suggested pre- venti ve maintenance items. Section 14 – Contacting Dukane pro vides information on contacting or obtaining suppor t fro[...]

  • Page 16

    6 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual DPC II Plus Overview The DPC ™ II Plus is the ne w est model in Dukane ’ s Dy- namic Process Controller product famil y . This system will accept a wide v ariety of optional modules and is designed for use with ultrasonic presses or applicatio[...]

  • Page 17

    7 Dukane Manual Part No. 403 – 566 – 01 Section 1 – Introduction DPC II Plus ™ Key Features • Timer Boar d option pro vides w eld and hold time control and stores up to eight setup f iles. • Pr ess Board option pro vides control for a Dukane ultrasonic press and thruster . • Multi–P oint Control Module option permits one DPC to hand[...]

  • Page 18

    8 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual • Dual Line–V oltage 1 Univ ersal P o w er Supply means that the DPC will operate w orldwide. Auto-Ranging means that adjustments b y the operator related to po w er input are unnecessar y . • Line V oltage Regulation automatically maintains[...]

  • Page 19

    9 Dukane Manual Part No. 403 – 566 – 01 Section 1 – Introduction Safety Tips • Health & Safety • RFI Considerations Dukane Corporation •• Ultrasonics Division S ECTION 2 Health & Safety Tips ...................................... 11 Plastics Health Notice ........................................... 12 Electrical Gr ounding Saf[...]

  • Page 20

    10 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 21

    11 Dukane Manual Part No. 403 – 566 – 01 Section 2 – Safety T ips Health and Safety Tips Please observe these health and safety recommen- dations for safe, ef f icient, and injury-free opera- tion of y our equipment. In this manual, the ter m system refers to a complete group of components associated with the w elding of plastic or metal par [...]

  • Page 22

    12 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Plastics Health Notice Before using an y Dukane ultrasonic welding sys- tem, be sure y ou are f amiliar with OSHA regula- tions from the U .S. Depar tment of Labor about the par ticular type of plastic(s) y ou are using. When plastic materials ar[...]

  • Page 23

    13 Dukane Manual Part No. 403 – 566 – 01 Section 2 – Safety T ips The po w er cable normally pro vided for inter na- tional use is compatib le with many po wer outlets (refer to Figure 2-3.) Ho w ev er , if your applica- tion requires another type of cab le, check with the local Dukane products representati ve, and fol- lo w local re gulation[...]

  • Page 24

    14 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 25

    15 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Unpacking & Installation Dukane Corporation •• Ultrasonics Division S ECTION 3 Shipping Carton Contents ............................ 17 DPC Placement ............................................. 17 Benchtop ................................................[...]

  • Page 26

    16 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 27

    17 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Shipping Contents Carefull y open the shipping container, and mak e sure it contains the items sho wn in T ab le 3 – I. In- spect the DPC for damage. Report any damage immediately to Dukane Ultrasonics Support/Ser - vice. DPC Placement Placement of the DPC depen[...]

  • Page 28

    18 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual F igure 3-2 sho ws the use of a bracket kit in mounting a DPC to a 19-inch equipment rack. (Contact Ultrasonic Sales at Dukane, and request P ar t Number US-1155.) The DPC illustrated has the standard , angled front panel of impact- resistant ABS[...]

  • Page 29

    19 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Rear AC Power Switch Slave Multi–Probe Controller Module Master Multi–Probe Controller Module Press Control Module Power Signal Output Module Remote Amplitude Control Module EEPROM Serial Programming Port Grounding Lug Model No. T ag Serial No. Ta g IEC AC Pow[...]

  • Page 30

    20 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Connect the Cables The instr uctions here and the diag rams in Figures 3 – 4 through 3 – 7 are meant to serve as a quick – start guide. The connectors and their pinouts are discussed in g reater detail in Section 5. Manual Pr obe System Ste[...]

  • Page 31

    21 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Ꮨ Ꮨ  DUKANE CORP ST. CHARLES, IL 60174 MADE IN USA SERIAL NUMBER US 10000 – W ARNING! – POWERLINE MUST BE GROUNDED AT OUTLET REMOVE ALL POWER BEFORE REMOVING COVER OR CONNECTING OR DISCONNECTING CABLES. ULTRASOUND OUTPUT SYSTEM OUT + – Power Monitor J[...]

  • Page 32

    22 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Ꮨ Ꮨ  DUKANE CORP ST. CHARLES, IL 60174 MADE IN USA SERIAL NUMBER US 10000 – W ARNING! – POWERLINE MUST BE GROUNDED AT OUTLET REMOVE ALL POWER BEFORE REMOVING COVER OR CONNECTING OR DISCONNECTING CABLES. ULTRASOUND OUTPUT SYSTEM OUT SYS[...]

  • Page 33

    23 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Figur e 3-7 DPC II Plus Automated Thruster Cable Connections Automated Thruster System Step 1. Ground the DPC II Plus and the Thruster as sho wn in Figure 3 – 7. Step 2. Attach the high v oltage RG62B/U coax cable from the rear -panel DPC II Plus connector J1 to[...]

  • Page 34

    24 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Ꮨ Ꮨ  DUKANE CORP ST. CHARLES, IL 60174 MADE IN USA SERIAL NUMBER US 10000 – W ARNING! – POWERLINE MUST BE GROUNDED AT OUTLET REMOVE ALL POWER BEFORE REMOVING COVER OR CONNECTING OR DISCONNECTING CABLES. ULTRASOUND OUTPUT SYSTEM OUT J90[...]

  • Page 35

    25 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Figur e 3-10 Rear Panel AC Breaker Switch Emergency Stop Switch Figure 3 – 9 is a simplif ied example that demon- strates the basic requirements to interface with the DPC II Plus on J902. This is e xcerpted from Ap- plication Note AN201 a v ailable on our w ebsi[...]

  • Page 36

    26 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pa ge intentionally left b lank[...]

  • Page 37

    27 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays Contr ols & Displays Dukane Corporation •• Ultrasonics Division S ECTION 4 Fr ont Panel Layout ........................................ 29 AC Power ..................................................... 30 Generator Status Panel ..............................[...]

  • Page 38

    28 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pa ge intentionally left b lank[...]

  • Page 39

    29 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays Fr ont Panel Layout This section describes the DPC II Plus and DPC EZ front panel controls, status, po w er output and menu displa ys. The DPC front panel is laid out in three sections as illustrated belo w in Figure 4-1A (DPC II Plus) and Figure 4 – 1B (DPC EZ). [...]

  • Page 40

    30 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual 1. AC Power Section The front-panel A C po w er section has a s witch and po w er indicator that is sho wn in Figure 4-2. ON/OFF The A C po wer s witch connects AC po w er to the generator . This breaker s witch is wired in series with the rear p[...]

  • Page 41

    31 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays System Status Display The System Status Displa y indicates one of the six system states. If that state is acti ve, the correspond- ing label is lit in the displa y . Figure 4-4 sho ws the System Status Displa y with the ON LINE state acti- vated. The six status cond[...]

  • Page 42

    32 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual System Power Output Display The tricolor System P o w er Output Displa y indi- cates the percentage of ultrasonic po w er being dra wn b y the load. Green Eight green vertical bars indicating 10% to 80% po w er output are dis- pla y ed during nor[...]

  • Page 43

    33 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays 3. Pr ocess Contr ol Panel Menu Function Keys The menu ke ys are sho wn in Figure 4 – 7. Their function is described going across each ro w start- ing at the upper left. Pressing the GEN. INFO k ey displa ys the DPC model, the f ir mw are version and the installed[...]

  • Page 44

    34 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Pressing the MODE ke y to ggles be- tw een the W eld mode (displays v al- ues for last w eld c ycle) and the Setup mode (displa ys main Process Setup menu). Pressing the right arrow k ey selects the ne xt digit to the right of a pa- rameter setti[...]

  • Page 45

    35 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays Pr ocess Control Menu Display The menu display is a backlit 4 – line LCD with 20 characters per line. The top line of the displa y con- tains the menu title (with a fe w exceptions). Selection Menus The selection menus ha ve a triangular cursor at the far right of[...]

  • Page 46

    36 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 47

    37 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays Rear Connectors Dukane Corporation •• Ultrasonics Division S ECTION 5 Rear Panel Layout ......................................... 39 System Input Connector ............................... 40 System Output Connector ............................ 42 Remote Amplitud[...]

  • Page 48

    38 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 49

    39 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Rear Panel Layout All of the connectors contained on the DPC II Plus and the optional modules are sho wn belo w in Figure 5 – 1. No generator will ha ve all the mod- ules sho wn. Specif icall y the Multi – Probe Control- ler and the Press Control Modules are mutuall y ex[...]

  • Page 50

    40 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual System Input Connector The System Input is a HD-15 (high-density , 15 contact) female connector . Pin assignments are sho wn in Figure 5 – 2. T able 5 — I below lists the pinout and signal name for the System Input con- nector . A complete de[...]

  • Page 51

    41 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Input Signal Description Pin 1 (+22V) This pin can suppl y +22VDC at up to 250mA to po w er the user's automation controls. Pin 2 (Gnd) Pin 2 and 7 are the 22VDC and Operate retur ns and are tied to the chassis ground. Pin 3 (Isolated Operate In) This pin is used to ini[...]

  • Page 52

    42 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual System Output Connector The System Output panel connector is a DB- 25 F emale type. Pin numbers are sho wn in F ig- ure 5 – 4 and pin assignments are gi ven in T able 5 — IV . Dukane cable assemb l y P/N 2 0 0 – 1302 is used to connect the [...]

  • Page 53

    43 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Output Signal Description Pin 1 (+22V) This pin can suppl y +22VDC to supply po w er for user automation controls. It is limited to 250mA. Pin 2 (Gnd) Pin 2 is the 22VDC and Status Out return. It is tied to the chassis ground. Pin 3 (Gnd) Pin 3 is the 22VDC and Status Out re[...]

  • Page 54

    44 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Pin 10 (ON LINE) An acti ve lo w output on pin 10 indicates the gen- erator is on line and is capab le of being triggered externall y . The front panel status display will indi- cate O N LINE . Pin 11 (Gnd) Pin 11 is the 22VDC and Status Out retu[...]

  • Page 55

    45 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Pin 18 (MPC Ready) 4 An acti ve lo w output on pin 18 indicates the MPC module (Multi – Probe Controller) is ready and will accept probe selection changes on the Remote Setup inputs. Pin 19 (Iso Power Fail) An acti ve lo w output indicates that AC po wer is within operatin[...]

  • Page 56

    46 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Remote Amplitude Contr ol Module Part No. 438 – 799 This optional module enab les remote control of output amplitude of the DPC II Plus. The control interface is a 4 – 20mA cur rent loop. The cur rent loop connector and fault indicator are sh[...]

  • Page 57

    47 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Power Signal Output Module Part No. 438 – 826 This optional module enab les the DPC II Plus to operate in the W eld – By – Energy mode. When installed , the DPC II Plus automatically detects the board and enables the ener gy options in the process control menu. The mod[...]

  • Page 58

    48 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Pr ess Control Module Part No. 110 – 3938 This optional module enab les the DPC II Plus to control a Dukane Model 210, 220 or 410 press or custom automation. This module is also installed on a EZ W elder ™ System. The module is illustrated in[...]

  • Page 59

    49 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors T able 5 — V on the previous page lists the pinout and signal description for J902 w hich is the Press Base connection. Note that there is an automation input on pin 8 w hich is electrically identical to pin 8 on the System Input connector . This per mits you to use J902 t[...]

  • Page 60

    50 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Multi – Pr obe Master Module Part No. 110 – 3954 This optional module enab les the DPC II Plus to acti vate an y one of four ultrasonic probes. Each probe can ha ve its o wn setup f ile which is selected by the Setup ID# (pins 12, 13 & 14[...]

  • Page 61

    51 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Jumper Block Options The DPC II Plus ma y be customized to y our spe- cif ic requirements by means of internal jumpers lo- cated on the main printed circuit board. Belo w is a list of the jumper blocks, their default factory set- tings and their alternate positions. Figures [...]

  • Page 62

    52 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual System Contr ol Inputs Jumper Block – SH707 JU724 - Non – Isolated Sink (F actor y Def ault) – Dry contact betw een input and DPC g round. JU725 - Non – Isolated Source – Dry contact be- tw een input and +22 VDC. JU726 - Isolated Source[...]

  • Page 63

    53 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors JU723 JU722 JU703 JU704 TIMER BD. ENABLE TIMER BD. BYPASS STATUS DRIVER NORMAL STATE NORMALLY OFF NORMALLY ON JU701 JU702 NON-ISO SOURCE NON-ISO SINK JU724 JU725 JU726 ISOLATED POWER SIGNAL OUTPUT BOARD CONTROL REMOTE BOARD ANY FAULT SYS FAULT OVERLOAD OVERTEMP U/S ACTIVE JU[...]

  • Page 64

    54 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 65

    55 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Menu Structur e Dukane Corporation •• Ultrasonics Division S ECTION 6 Pr ocess Setup ............................................... 57 Pr ocess Control ............................................. 58 Pr ocess Limits ............................................... 60 Ut[...]

  • Page 66

    56 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 67

    57 Dukane Manual Part No. 403 – 566 – 01 Section 6 – Menu Structur e Pr ocess Setup Menu This section deals with the o v erall menu str ucture. Each setup menu is later discussed in detail in its o wn section. Each time the DPC II Plus is po w ered up, the processor scans the system to determine w hich modules are installed and if a hand prob[...]

  • Page 68

    58 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Process Control, Limit Def inition or Utilities menu. Press the ENTER ke y to activ ate the selected menu. The Process Control Menu selects the trig- ger method , the w elding mode and sets the values for the w elding parameters. This menu ’ s [...]

  • Page 69

    59 Dukane Manual Part No. 403 – 566 – 01 Section 6 – Menu Structur e TRIGGER METHOD PROCESS CONTROL PROCESS SETUP PRESS TIMED PROBE MANUAL INITIA TE MODE AUTO MOMENT AR Y MAINT AINED TRIGGER TYPE ENABLE or DISABLE AUTO STOP WELD MODE 11 22 HOLD TIME PROCESS CONTROL AFTER – BURST WELD METHOD HOLD TIME PROCESS CONTROL AFTER – BURST RTW RTW [...]

  • Page 70

    60 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Limit Definition Menu The Limit Def inition menu has tw o classes of settings. The f irst class is the suspect limits and the second class is for bad part limits. When applicable, choices for time, ener gy , total time and total ener gy are av ai[...]

  • Page 71

    61 Dukane Manual Part No. 403 – 566 – 01 Section 6 – Menu Structur e Utilities Menu The Utilities menu has four dif ferent sections. The f irst section handles setup f ile operations. The sec- ond section accesses the par ts count functions. The third section conf igures the status output. The fourth section allo ws the operator to cycle the [...]

  • Page 72

    62 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pa ge intentionally left b lank[...]

  • Page 73

    63 Dukane Manual Part No. 403 – 566 – 01 Section 6 – Menu Structur e Pr ocess Contr ol Menu Dukane Corporation •• Ultrasonics Division S ECTION 7 Hand Pr obe .................................................. 65 Untimed Hand Probe ............................................ 66 Timed Hand Probe ............................................[...]

  • Page 74

    64 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 75

    65 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Pr ocess Contr ol Menu The Process Control Menu has a dynamic struc- ture. Its conf iguration is deter mined each time the DPC II Plus is turned on. The processor scans for installed modules and connected probes and con- f igures the user interf ace to match the install[...]

  • Page 76

    66 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Press the MODE k ey to displa y the Process Setup menu. In Process Setup, the cursor should be point- ing to Process Control as sho wn in Figure 7 – 5. If it is not, press the up – ar ro w and do wn – ar row k ey to na vigate the triangle p[...]

  • Page 77

    67 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu is reached , whiche ver comes f irst. Press ENTER and the data entry screen appears as sho wn in Figure 7 – 9. If a P ow er Output module is installed , then a W eld Method screen sho wn in Figure 7 – 8 is dis- pla yed f irst. Press the ENTER key to displa y the wel[...]

  • Page 78

    68 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual MPC Pr obe The cable connection diagram for connecting the Multi – Probe Controller module is sho wn in Sec- tion 3 in F igure 3 – 6. The flow chart for the Pro- cess Control menu with a Multi – Probe Controller installed is sho wn in Figur[...]

  • Page 79

    69 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Untimed MPC Probe – Pr obe Delay The probe dela y time value for untimed operation is sho wn in Figure 7 – 14. This parameter is typi- call y used in a single auto probe conf iguration w hich is co vered later in this section. F or MPC untimed operation, the suggest[...]

  • Page 80

    70 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual W eld Method – Energy If a P o w er Output module is installed , y ou can choose the Energy W elding method. The decision menu for choosing the W eld Method was sho wn in F igure 7 – 15. Use the down arro w key to mo ve the cursor next to WEL[...]

  • Page 81

    71 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu ture to function properl y , the f ixture must be elec- tricall y isolated from the horn suppor t and base as sho wn in F igure 7 – 19. The hor n is grounded and acts as a s witch closure when it contacts the f ix- ture. The g round detection is a cur rent limited +5V[...]

  • Page 82

    72 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual AUTO Pr obe The cable connection diagram for connecting an automated probe or an automated thruster is sho wn in Section 3 in F igures 3 – 5 and 3 – 7. The flo w chart for the Process Control menu using Auto Probe is sho wn in F igure 7 – 2[...]

  • Page 83

    73 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Untimed Auto Pr obe – Delay The generator is triggered b y e xter nal automa- tion equipment. The automation control pro vides the ultrasound start and stop signal. In cer tain operations, a dela y ma y be required to allo w the clamping head(s) to full y engage befor[...]

  • Page 84

    74 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual T o select an afterburst, mo v e the cursor down ne xt to ENABLE as sho wn in Figure 7 – 26 and press the ENTER key . T o setup the afterburst, the menu prompts y ou for tw o parameter v alues. The f irst is the afterburst dela y . This is the [...]

  • Page 85

    75 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu PRESS Mode The cab le connection diag ram for connecting a DPC II Plus to a Dukane press is sho wn in Sec- tion 3 in F igures 3 – 8. The flo w char t for the Pro- cess Control menu is sho wn in F igure 7 – 30. If a Press Control module is not installed , this menu w[...]

  • Page 86

    76 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual 3. If D ISABLE was selected in the AUTO STOP menu, t h e TRIGGER TYPE menu is displa yed next. This s elects whether the trigger which initiates the w eld cycle is momentary or must be maintained throughout the w eld cycle. 4. The SINGLE PRESSURE[...]

  • Page 87

    77 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu ing Energy for the f irst mode and T ime for the second mode or vice versa. Each of the b locks labeled Pressure 1 and Pressure 2 are equi valent to the Single Pressure W eld Method branch with- out Ground Detect. Note that the Auto Probe T rig- ger Method b ypasses the[...]

  • Page 88

    78 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual The menu changes to displa y the Initiate mode as sho wn in Figure 7 – 35. W e will assume a standard press conf iguration using the dual palm operate s witches. Since we will manuall y trigger the press, mo ve the cursor to MANUAL and press EN[...]

  • Page 89

    79 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Using the four ar ro w keys, enter the w eld time. Press the ENTER ke y when y ou hav e completed the data entry . This displa ys the W eld Method selection screen for Pressure T w o as sho wn in Figure 7 – 41. This time select WELD BY ENERGY and press the ENTER key .[...]

  • Page 90

    80 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual HOLD TIME 0.500 SEC PROCESS CONTROL WELD MODE HOLD TIME AFTERBURST AFTERBURST DISABLE ENABLE AFTERBURST DELAY 0.150 SEC AFTERBURST DURATION 0.250 SEC From here on, the menu follo ws the same logical sequence as Auto Probe. Hold Time is automatica[...]

  • Page 91

    81 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu W e ha ve no w def ined the w elding mode and set v alues for the necessar y parameters. Press the CANCEL key once to return to the root Process Setup menu sho wn in Figure 7 – 52 (the same as Figure 7 – 33). Press the MODE key to displa y the w elding pa- rameters [...]

  • Page 92

    82 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual cept the ne w value press the ENTER key . This will return you to the Process Setup menu sho wn in Figure 7 – 52. T o retur n to Process Setup without modifying the hold time, press the CANCEL key . The WELD P1 and WELD P2 hot ke ys function in[...]

  • Page 93

    83 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu TRIGGER METHOD PRESS TIMED PROBE MANUAL INITIA TE MODE AUTO MOMENT AR Y MAINT AINED TRIGGER TYPE ENABLE or DISABLE AUTO STOP WELD MODE 11 22 HOLD TIME PROCESS CONTROL AFTER – BURST WELD METHOD HOLD TIME PROCESS CONTROL AFTER – BURST RTW RTW RTW Step 1 Step 2 Step 3 [...]

  • Page 94

    84 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual T able 7 — I belo w summarizes the v arious method and mode menus and references their F igure num- ber . T able 7 – II on the next page lists the data en- tr y screens and references their F igure number . It also gi ves the minimum and maxi[...]

  • Page 95

    85 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Parameter Description Figure No. Weld Method Minimum Value Weld T ime Ultrasound Gate T ime 0.000 Second 7 – 8, 7 – 16 30.000 Seconds T weld Weld Energy T arget W elding Energy 0 Joules 7 – 10, 7 – 17 Energy Energy Ground Detect Ground Detect Untimed Probe Only [...]

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    86 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This page intentionall y left blank[...]

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    87 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Pr ocess Limits Menu Dukane Corporation •• Ultrasonics Division S ECTION 8 Pr ocess Limits Menu ...................................... 89 Limit Definition ............................................. 90 Suspect and Bad Limits ................................. 90 Pr[...]

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    89 Dukane Manual Part No. 403 – 566 – 01 Section 8 – Process Limits Menu Pr ocess Limits Menu The Process Limits Menu allo ws y ou to def ine upper and lo w er bounds for suspect par ts or for bad parts. The limits are a vailab le in both units of time and units of energy depending upon the w elding method chosen in Process Control setup. In [...]

  • Page 100

    90 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Limit Definition T o access the Limit settings, star t from the Pro- cess Setup menu sho wn in Figure 8 – 1. Select PROCESS LIMITS with the cursor and then press ENTER . This displa ys the LIMIT DEFINITION menu as sho wn in F igure 8 – 2. The[...]

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    91 Dukane Manual Part No. 403 – 566 – 01 Section 8 – Process Limits Menu F or a dual – pressure mode, both the nor mal limits and the total limits are displa yed as sho wn in Figure 8 – 5. In the flo wchar t, the single – pressure limits are on the right side and the dual – pressure total limits sec- tion are in the shaded area on the[...]

  • Page 102

    92 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual WELD ENERGY P1 MAXIMUM LIMIT 90 J PROCESS LIMITS WELD ENERGY P1 WELD ENERGY P2 After the minimum and maximum limit v alues ha ve been entered , the display returns to the Process Limit menu sho wn in F igure 8 – 3. Logical comparison en- sures [...]

  • Page 103

    93 Dukane Manual Part No. 403 – 566 – 01 Section 8 – Process Limits Menu TIME ENERGY TOT AL TIME TOT AL ENERGY PROCESS LIMITS WELD TIME P2 WELD TIME P1 PROCESS LIMITS WELD ENERGY P2 WELD ENERGY P1 TOT AL WELD TIME TOT AL WELD ENERGY LIMIT DEFINITION SUSPECT BAD LIMITS ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENT[...]

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    94 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 105

    95 Dukane Manual Part No. 403 – 566 – 01 Section 8 – Process Limits Menu Utilities Menu Dukane Corporation •• Ultrasonics Division S ECTION 9 Setup Utilities ............................................... 97 Select Setup ......................................................... 98 Copy A Setup ............................................[...]

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  • Page 107

    97 Dukane Manual Part No. 403 – 566 – 01 Section 9 – Utilities Menu Utilities Menu The Utilities Menu is the third option from the main Process Setup menu. It is di vided into four distinct menu g roups: 1. SETUP UTILITIES 2. PART COUNT 3. STATUS OUTPUTS 4. CYCLE PRESS OFF LINE The basic flo wchar t for the Utilities Menu was sho wn in Figure[...]

  • Page 108

    98 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Setup Utilities T o access the Utilities menu, start from the Process Setup menu sho wn in F igure 9 – 2. Mo ve the cursor do wn to select Utilities and press the ENTER key . PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES The Utilities [...]

  • Page 109

    99 Dukane Manual Part No. 403 – 566 – 01 Section 9 – Utilities Menu Copy A Setup Starting from the Utilities menu in Figure 9 – 4, mo ve the cursor do wn to Copy A Setup and press the ENTER key . The displa y f irst requests the source f ile number . This is shown in F igure 9 – 8. COPY FROM 1 # Use the increment and/or decrement ke y to [...]

  • Page 110

    100 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual T o erase all the stored setups, mo ve the cursor from ERASE CURRENT SETUP (see F igure 9 – 11) to do wn to ERASE ALL SETUPS and press ENTER . A conf irmation message is display ed. Mo ve the cur - sor do wn to YES as sho wn in Figure 9 – 14[...]

  • Page 111

    101 Dukane Manual Part No. 403 – 566 – 01 Section 9 – Utilities Menu Preset Par t Count This option allo ws you to preset a v alue (maxi- mum = 60,000) in the counter . Again from the part count selection menu, mo v e the cursor to the bot- tom line next to PRESET PART COUNT and press ENTER . A data entr y screen for presetting the v alue is [...]

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    102 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left b lank[...]

  • Page 113

    103 Dukane Manual Part No. 403 – 566 – 01 Section 9 – Utilities Menu Pr obes & Pr obe Stacks Dukane Corporation •• Ultrasonics Division S ECTION 10 The Ultrasonic Pr obe ................................... 105 Theory of Operation ........................................... 105 Probe Configuration ......................................[...]

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    104 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This page intentionall y left blank[...]

  • Page 115

    105 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks The Ultrasonic Probe Theory of Operation Plastic w elding is the most common application of ultrasonic assembl y . T o perfor m ultrasonic plas- tic w elding, the vibrating tip is brought into con- tact with one of the w ork pieces. Pressure is ap- plied and ultr[...]

  • Page 116

    106 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Ultrasonic Hor n The horn transfers the ultrasonic mechanical vi- brations (originating at the transducer in the probe housing) to the plastic par ts through direct ph ysi- cal contact. The horn is precision machined and designed to vibrate at e[...]

  • Page 117

    107 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks Stack Assembly Attaching A Replaceable Tip T o A Horn 1. Inspect all horn and tip surf aces for stress cracks, chips, or gouges. Any of these irregu- larities will af fect operation and could lead to further equipment damage. Contact the Du- kane Ultrasonics T oo[...]

  • Page 118

    108 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Attaching The Mounting Stud T o A Hor n Or A Booster 1. Inspect the stud for cracks or damaged threads. Replace the stud if it is cracked or otherwise damaged. 2. Remo ve an y foreign matter from the threaded stud and the mating hole. 3. Thread [...]

  • Page 119

    109 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks Attaching The Horn T o A Booster , Booster T o A Pr obe, Or Hor n T o A Probe 1. Inspect all surfaces to be joined for stress cracks, chips, or gouges. An y of these ir regu- larities will af fect operation and could lead to further equipment damage. Contact the [...]

  • Page 120

    110 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual mo ving the hor n from the booster or the booster from the probe. 6. Thread the components to gether and tighten to the follo wing torque specif ications using only the correct size wrenches. Use spanner wrenches on components with spanner wrenc[...]

  • Page 121

    111 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks HORN HORN HAND PROBE ASSEMBLY HAND PROBE HOUSING HAND PROBE HOUSING A SSEMBLY D ISASSEMBLY Output End Input End Spanner Wrench Holes Mounting Stud (Insert Into Horn First and Tighten to Torque Specs) Stack Disassembly Stack disassemb ly is required w hen changing[...]

  • Page 122

    112 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual The assemb ly and disassemb ly procedures for a hand probe sho wn in Figure 10 – 6. The same pro- cedure for a probe stack with booster is sho wn in Figure 10 – 7. It mak es no difference w hether the hor n is attached to the booster f irst,[...]

  • Page 123

    113 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks Separating Th e Hor n Fr om A Booster , Booster From A Pr obe Or Hor n Fr om A Probe On all transducers and horns with spanner wrench holes (see F igures 10 – 8), use only the cor rect size spanner wrench that came with y our system to pro- vide suf f icient to[...]

  • Page 124

    114 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Booster Notes How T o T ell The Booster Input End Fr om The Output 1. The depth of the threaded hole on the output end is al wa ys deeper than the threaded hole on the input end. 2. On an amplifying booster (gain > 1.0), the larger diameter e[...]

  • Page 125

    115 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks Mounting The Stack A probe-horn assembl y or probe-booster-horn as- semb ly (stack) can be mounted into a customer - pro vided machine to ensure stability and proper alignment during operation or for automated op- eration. A stack is secured in a machine by clamp[...]

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    116 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 127

    117 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks DPC Checkout Dukane Corporation •• Ultrasonics Division S ECTION 11 Startup and Self – T est .................................. 119 System T est ................................................. 120 System Operation ....................................... 1[...]

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  • Page 129

    119 Dukane Manual Part No. 403 – 566 – 01 Section 11 – DPC Checkout Startup and Self – T est 1. Push the rear panel A C breaker s witch to the ON position (see F igure 3 – 3 or 3 – 9 for the switch location.) 2. Push the front panel A C po wer s witch to the ON position (marked I on the s witch.) This is lab led A in Figure 11 – 1. 3.[...]

  • Page 130

    120 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual DPC System T est T o test the DPC II Plus system ’ s ultrasound signal deliv er y , perform the follo wing steps. 1. F or the initial test, the generator must be ON LINE . Refer to step 5 on the pre vious page. 2. P osition the probe so that i[...]

  • Page 131

    121 Dukane Manual Part No. 403 – 566 – 01 Section 11 – DPC Checkout System Operation 1. If the generator is not online, press the ON LINE ke y . This is labeled E in Figure 11 – 1. The g reen ON LINE status should light up (F in F igure 11 – 2). 2. Pro g ram the appropriate w eld method and time or ener gy to achiev e the desired welding [...]

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    122 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pa ge intentionally left b lank[...]

  • Page 133

    123 Dukane Manual Part No. 403 – 566 – 01 Section 12 – T roubleshooting No Ultrasonic Output ..................................... 125 Pr obe .................................................................... 125 Cable .................................................................... 125 Generator ........................................[...]

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    124 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pa ge intentionally left b lank[...]

  • Page 135

    125 Dukane Manual Part No. 403 – 566 – 01 Section 12 – T roubleshooting No Ultrasonic Output Pr obe Make sure that the probe coaxial cab le is connected to the generator Ultrasonic output connector J1 (see F igure 12 – 1). Make sure the probe stack w as as- semb led following the instructions in Section 10. Cables Make sure that both the U/[...]

  • Page 136

    126 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Generator The generator will not produce an output signal w hen triggered if it is OFF LINE. Make sure that the g reen po w er indicator [A] is lit. The status dis- pla y should indicate ON LINE which is mark ed as [B] in Figure 12 – 2. If the[...]

  • Page 137

    127 Dukane Manual Part No. 403 – 566 – 01 Section 12 – T roubleshooting Generator F AUL T s OVERLOAD If the generator OVERLOAD light comes on, it in- dicates e xcessiv e po w er is being drawn. This could be caused b y a mismatch between the ultrasonic signal and the resonant characteristics of the acous- tic stack. Improperl y assembled prob[...]

  • Page 138

    128 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Generator Err ors INPUT TEST Indicator Steady Red During po w er up, the INPUT TEST indicator should flash red for 5 – 10 seconds. This indi- cates the po w er-up test is running. When the test has successfull y completed , the INPUT TEST indi[...]

  • Page 139

    129 Dukane Manual Part No. 403 – 566 – 01 Section 12 – T roubleshooting INPUT TEST indicator lights up ? INPUT TEST flashes for 5 – 10 sec ? 1. Both the front and rear AC breaker switches on the DPC must be turned on (Figure 3 – 9 and 4 – 2). 2. Make sure the AC outlet has power . YES NO YES NO V erify that the AC voltage is within spec[...]

  • Page 140

    130 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual 1. Make sure correct probe is connected to generator . 2. Check the ultrasonic coaxial cable for shorts. 3. T ry changing the probe and/or cable. 4. Make sure probe stack is properly assembled. 1. If Press Module installed, check J902. 2. Check [...]

  • Page 141

    131 Dukane Manual Part No. 403 – 566 – 01 Section 12 – T roubleshooting Err or Messages TRIGGER LOST This er ror message is displa yed w hen the trigger type is set to MAINT AINED , and the trigger signal is inter r upted or lost. The w eld cycle is terminated. END OF WELD SIGNAL DETECTED At the star t of the cycle, one or both of the END OF [...]

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    132 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 143

    133 Dukane Manual Part No. 403 – 566 – 01 Section 13 – Care & Maintenance Fr ont Panel ................................................. 135 Rear Panel .................................................. 135 Chasis ........................................................ 135 Stack Surfaces ............................................ 136 S[...]

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    134 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This page intentionall y left blank[...]

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    135 Dukane Manual Part No. 403 – 566 – 01 Section 13 – Care & Maintenance Fr ont Panel Cleaning Do not use an y solvents or abrasi ve cleaners on the front panel. Do not spra y cleaner directl y onto the front panel. Apply a small amount of com- puter cleaner to a soft to w el f irst. Clean the panel with the moistened to w el. Do not spr[...]

  • Page 146

    136 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual T op Cover K eep the cov er on at all times. The chassis is ro- bust enough to hold considerable w eight. Ho w- e ver , a void placing e xcessivel y heavy objects on top of the chassis which ma y bend or dent the top co v er resulting in damage [...]

  • Page 147

    137 Dukane Manual Part No. 403 – 566 – 01 Section 13 – Care & Maintenance Cr owning A surface which is burnished only in the inner ring area around the stud , indicates the surface is con- ve x or cro wned. An example of this is sho wn in f igure 13 – 5. T o get an idea of amount of de via- tion from a flat surface, place a straight edg[...]

  • Page 148

    138 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Reconditioning Overview Stack components require reconditioning when the mating surfaces become unev en or cor roded. These conditions cause poor contact betw een the mating surfaces which w astes po w er . It also makes tuning the stack dif f i[...]

  • Page 149

    139 Dukane Manual Part No. 403 – 566 – 01 Section 13 – Care & Maintenance  CAUTION Use extreme care to keep the part level when moving it across the emery cloth. Be careful not to tilt the part. An uneven mating surface could leave the mating sur - face inoperative. Surface flatness is more im- portant than surface finish. mo ved acros[...]

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    140 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pa ge intentionally left b lank[...]

  • Page 151

    141 Dukane Manual Part No. 403 – 566 – 01 Section 14 – Contacting Dukane Ultrasonics Division Main Office .................. 143 Email Addresses .......................................... 144 T elephone Extensions .................................. 144 Contacting Dukane • Corporate Office • Extensions & eMails Dukane Corporation •?[...]

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    142 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

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    143 Dukane Manual Part No. 403 – 566 – 01 Section 14 – Contacting Dukane Department Phone Numbers Y ou can reach each department by dialing directl y A pplication Suppor t (630) 797 – 4930 F or applications and/or process technology questions. Engineering (630) 797 – 4950 F or engineering of standard and customized systems. Ser vice &[...]

  • Page 154

    144 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Applications: ............................. usapps@dukane.com Engineering: .............................. useng@dukane.com Food Processing: ....................... usfoodproc@dukane.com International Sales: ................... usintl@dukane.com [...]

  • Page 155

    145 Dukane Manual Part No. 403 – 566 – 01 Section 15 – Specifications Regulatory Compliance ............................... 147 Federal Communications Commission ................ 147 CE Marking (Conformit é Eur ope é ne) .................. 147 Dimensions ................................................. 148 Operating Enviornment ...........[...]

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    147 Dukane Manual Part No. 403 – 566 – 01 Section 15 – Specifications FCC The DPC II Plus complies with the follo wing F ed- eral Communications Commission regulations. • The limits for FCC measurement procedure MP-5, “ Methods of Measurement of Radio Noise Emissions from ISM Equipment ” , pur - suant to FCC Title 47 P ar t 18 for Ultra[...]

  • Page 158

    148 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Dimensions Operating Envir onment Operate the DPC II Plus within these guidelines: T emperatur e: 40 ° F to 100 ° F (+5 ° C to +38 ° C) Pressure: Ambient Air Particulates: Keep the DPC dr y . Minimize exposure to moisture, dust, dirt,smoke a[...]

  • Page 159

    149 Dukane Manual Part No. 403 – 566 – 01 Section 15 – Specifications Power Supply Requir ements The A C po w er requirements depend on the frequency and po wer rating of the generator . The tables belo w , list the nominal A C requirements (maximum current drawn be- fore o verload) and the service rating of the AC outlet each model of the DP[...]

  • Page 160

    150 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Interpr eting the DPC II Plus Model Number 2 2 0 0-LN 4-PE-L2 Generator Controller Le vel FREQUENCY 2 = 20 kHz 3 = 30 kHz 4 = 40 kHz 5 = 50 kHz 7 = 70 kHz PO WER RA TING 015 = 150 w 035 = 350 w 050 = 500 w 070 = 700 w 100 = 1000 w 120 = 1200 w 1[...]

  • Page 161

    151 Dukane Manual Part No. 403 – 566 – 01 Section 16 – W arranty Domestic warranty ...................................... 153 Inter national W arranty ................................ 154 W arranty • Domestic W arranty • International Warranty S ECTION 16 Dukane Corporation •• Ultrasonics Division[...]

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    153 Dukane Manual Part No. 403 – 566 – 01 Section 16 – W arranty Subject to the terms, limitations and exclusions set forth below , Dukane Corporation IAS Division (Dukane) warrants to the orig inal Purchaser , unless otherwise expressly agreed to in writing by Dukane, that all equipment and tooling designed and built by Dukane will be free f[...]

  • Page 164

    154 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Subject to the terms, limitations and exclusions set forth below , Dukane Corporation IAS Division (Dukane) warrants to the orig inal Purchaser , unless otherwise expressly agreed to in writing by Dukane, that all equipment and tooling designed [...]

  • Page 165

    155 Dukane Manual Part No. 403 – 566 – 01 Appendix A – List of Figures A PPENDIX A Dukane Corporation •• Ultrasonics Division List of Figur es Figure 2 – 1 120V olt, Gr ounded, 3-Prong Receptacle ......................................... 12 Figure 2 – 2 220V olt, Gr ounded, 3-Prong Receptacle ......................................... [...]

  • Page 166

    156 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Figure 6 – 1 DPC II Plus Startup Menu ............................................................... 57 Figure 6 – 2 DPC II Plus Configuration Menu ..................................................... 57 Figure 6 – 3 DPC II Plus Weld Cyc[...]

  • Page 167

    157 Dukane Manual Part No. 403 – 566 – 01 Appendix A – List of Figures Figure 7 – 42 Pr essure T wo Weld Energy Data Entr y ............................................. 80 Figure 7 – 43 Pr essure T wo Max W eld T ime Data Entry ........................................ 79 Figure 7 – 44 Dual Pressur e T ime Only Menus ...................[...]

  • Page 168

    158 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Figure 10 – 1 Hand Probe, Horn and Replaceable T ip ........................................ 105 Figure 10 – 2 Probe with Booster and Horn ....................................................... 106 Figure 10 – 3 Replaceable T ip Installat[...]

  • Page 169

    159 Dukane Manual Part No. 403 – 566 – 01 Appendix B – List of T ables Dukane Corporation •• Ultrasonics Division List of T ables T able 3 — I Contents of DPC II Plus Shipping Container ...................................... 17 T able 3 — II DPC II Plus AC Power Cord Part Numbers ......................................... 21 T able 5 ?[...]

  • Page 170

    160 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 171

    161 Dukane Manual Part No. 403 – 566 – 01 Appendix B – List of T ables Manual Switch Circuit ................................. 163 Automation Switch Cir cuits ......................... 164 Non – Isolated Switch Cir cuits ....................... 165 Curr ent Sink ....................................................... 165 Curr ent Source ...[...]

  • Page 172

    162 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 173

    163 Dukane Manual Part No. 403 – 566 – 01 Appendix C – User Supplied Circuitry DPC Switch Input DPC Ground System Input Cable Manual Control Switch User Supplied Switch Pin #8 – Operate or Pin #15 – F P Lockout Pin #2 or #7 DPC II Plus HD – 15 System Input Connector Figure C – 1 Manual Contr ol Switch NOTE The drawings and circuits sh[...]

  • Page 174

    164 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual User Supplied Relay User Supplied Transistor Driver Circuit HD – 15 System Input Connector HD – 15 System Input Connector HD – 15 System Input Connector HD – 15 System Input Connector Normally Open Contact To Automation Control Signal To[...]

  • Page 175

    165 Dukane Manual Part No. 403 – 566 – 01 Appendix C – User Supplied Circuitry   +22V DPC Internal Power Supply Current Limit Circuit 250mA max. Jumper Block SH707 Position JU724 (Refer to Figure 5 – 12) +24V Internal DPC II Plus Circuitry Optical Isolation Circuit Current Limit Circuit 12.5 mA max. 12.5 mA max 4 mA min Pin #2 or #7 I[...]

  • Page 176

    166 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual DPC II Plus +22V Power High-Side Switch Sources Current   DPC Ground +22V DPC Internal Power Supply Current Limit Circuit 250mA max. Jumper Block SH707 Position JU725 (Refer to Figure 5 – 12) +24V Internal DPC II Plus Circuitry Optical I[...]

  • Page 177

    167 Dukane Manual Part No. 403 – 566 – 01 Appendix C – User Supplied Circuitry Isolated Switch Cir cuit Isolated Current Sour ce Circuit Figure C – 5 illustrates a full y isolated circuit con- nected to the Isolated Automation Inputs. This re- quires an external po w er supply to dri ve the s witch. The SH707 jumper block needs to be placed[...]

  • Page 178

    168 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This page intentionall y left blank[...]

  • Page 179

    169 Dukane Manual Part No. 403 – 566 – 01 Index I NDEX A AC Power Indicator ....................................................................................... 29 AC Power Switch/Breaker ........................................................... 19, 25, 30, 39 AC Requirements ................................................................[...]

  • Page 180

    170 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Cable Schematics, System ....................................................................... 21 – 24 Cable T roubleshooting ............................................................................... 125 CANCEL Key ....................[...]

  • Page 181

    171 Dukane Manual Part No. 403 – 566 – 01 Index ENTER Key ............................................................................................... 34, 77 Enter New Setup ........................................................................................... 98 Erase Setups .............................................................[...]

  • Page 182

    172 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual I Increment Key ............................................................................................... 33 In-Dwell Status Output ................................................................................. 45 Indicator , AC Power .[...]

  • Page 183

    173 Dukane Manual Part No. 403 – 566 – 01 Index Maximum W eld Time .................................................................. 67, 70, 71, 79 Menu, Confirmation ..................................................................................... 35 Menu, Data Entry ........................................................................[...]

  • Page 184

    174 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Plug – and – W eld ............................................................................................... 7 Power , Definition .......................................................................................... 70 Power Indic[...]

  • Page 185

    175 Dukane Manual Part No. 403 – 566 – 01 Index Rear Panel Layout ................................................................................... 19, 39 Remote Amplitude Control Module ............................................................ 46 Replaceable T ips ...........................................................................[...]

  • Page 186

    176 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual System Output Connector ................................................................ 19, 39, 42 “ Power Output Display ..................................................................... 32 “ T est .....................................[...]

  • Page 187

    177 Dukane Manual Part No. 403 – 566 – 01 Index Weld Cycle Data ................................................................................ 57, 65, 81 Weld Ener gy ...................................................................................... 67, 70, 79 Weld Method ...................................................................[...]

  • Page 188

    178 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pag e intentionally left blank[...]

  • Page 189

    Dukane ISO ISO CER TIFICA TION Dukane chose to become ISO 9001:2000 cer - tified in order to demonstrate to our customers our continuing commitment to being a quality vendor . By passing its audit, Dukane can as- sure you that we have in place a well–defined and systematic approach to quality design, manufacturing, delivery and ser vice. This cer[...]

  • Page 190

    40356601 Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL +1–630–797-4900 • F AX +1–630–797–4949 Part No. 403–566–01 Printed in the United States of America $100.00 User's Manual – DPC II Plus and EZ W elder System www .dukcorp.com/us 1 2 3 5 5 6 6 6 Regional Office[...]