Dukane SVB051 User`s manual

Intelligent Assembly Solutions
MICROLOGIC
CONTROLLER
SPIN WELDER
SVB031 – 3 HP
SVB051 – 5 HP
User’s Manual
Dukane Part No. 403 - 547- 03
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949
ISO 9001:2008
Dukane products are manufactured in ISO
registered facilities.
www.dukane.com/us
Spin Welder User’s Manual
Copyright © 2011
Dukane Intelligent Assembly Solutions
2900 Dukane Drive
St. Charles, IL 60174 USA
Notice of Rights:
All rights reserved. No part of this manual including the interior design, cover design and icons
may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical,
photocopying, recording, or by any information storage and retrieval system, without written
permission from Dukane Corporation.
Notice of Liability:
The information contained in this manual is distributed on an “as is” basis, without warranty.
While every precaution has been taken in the preparation of this manual, Dukane Corporation
shall not have any liability to any person or entity with respect to any liability, loss, or damage
caused or alleged to be caused directly or indirectly by the instructions contained in this manual,
or by the hardware products described herein.
Specifications are subject to change without notice.
This user’s manual documents product features, hardware, and controls software available
at the time this user's manual was published.
Printed in the United States of America.
Dukane Part Number: 403 - 547- 03
Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents:
(* = Inactive)
3,780,926 * 4,131,505* 4,277,710* 5,798,599 5,880,580 6,984,921
7,819,158
Page ii
7,225,965
7,475,801 and,
Dukane Manual Part Number 403-547-03
Revision History
Revision Revision
NumberHistory
Date
– 00
Original release
2001-Sept-11
– 01
Corrected Fig 11-3 Side View Dimensions
2002-Feb-14
– 02
Clarify Counterbalance Regulator description on page 41.
2004-Sept-30
Elaborate counterbalance adjustment on page 52.
Added warning regarding excessive
counterbalance force setting on page 55.
New Division and 24–Hour Service Phone Numbers.
New Consolidated Domestic and Intn'l Warranty.
Updated ISO Certification to 9001:2000
Revised web address, and Dukane contacts.
2010-July-02
Revised Figure 4-2 Tool Mounting Hub Dimensions.
2010-Nov-15
Corrected typographical errors: pages 30, 33, 43, and 45.
2011-Oct-19
– 03
Updated copyright page content, page i.
Updated ISO Certification to 9001: 2008
Removed warranty pages, and renumbered pages and page references.
Dukane Corporation •
Dukane Manual Part Number 403-547-03
• Ultrasonics Division
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Dukane Manual Part Number 403-547-03
Table of Contents
Table of Contents
Section 1 – Introduction............................................................ 1
Important Information.............................................................................. 3
Read This Manual First..................................................................................... 3
Notes and Tips.................................................................................................. 3
Cautions and Warnings.................................................................................... 3
Drawings and Tables........................................................................................ 3
Manual Organization................................................................................. 4
Key Features............................................................................................... 5
Section 2 – Unpacking............................................................... 7
Unpacking System...................................................................................... 9
Packing List................................................................................................. 9
System Requirements............................................................................... 10
Physical Space................................................................................................. 10
Electrical.......................................................................................................... 10
Pneumatic....................................................................................................... 10
Major Components.................................................................................. 10
Spin Welder Rear View................................................................................... 11
Spin Welder Front View................................................................................. 12
Section 3 – Safety.................................................................... 13
Safety Regulations................................................................................... 15
Plastics Health Notice..................................................................................... 15
Palm Switches................................................................................................. 15
General Safety................................................................................................ 15
Electrical Safety........................................................................................ 16
AC Power........................................................................................................ 16
Grounding....................................................................................................... 17
Mechanical Safety.................................................................................... 17
Pneumatic Safety...................................................................................... 17
Section 4 – Installation............................................................ 19
Work Area................................................................................................ 21
Securing to Work Table........................................................................... 21
Bench Capacity............................................................................................... 21
Leveling........................................................................................................... 21
Mounting Holes.............................................................................................. 21
Tooling Attachment................................................................................. 21
Compressed Air ....................................................................................... 22
Control Cables.......................................................................................... 22
Base Interface Cable....................................................................................... 22
Top–Of–Stroke Cable...................................................................................... 23
AC Power.................................................................................................. 23
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Spin Welder User’s Manual
Section 5 – Theory of Operation............................................ 25
Spin Welding Process............................................................................... 27
Material Considerations........................................................................... 28
Control Parameters.................................................................................. 28
Axial Pressure.................................................................................................. 28
Surface Velocity.............................................................................................. 29
Weld Time....................................................................................................... 29
Hold Time........................................................................................................ 30
Initial Settings........................................................................................... 30
Axial Pressure.................................................................................................. 30
RPM................................................................................................................. 31
Weld Time....................................................................................................... 33
Hold Time........................................................................................................ 33
Part Size.................................................................................................... 33
Section 6 – Control Functions................................................. 35
AC Power.................................................................................................. 37
AC Switch........................................................................................................ 37
AC Fuses.......................................................................................................... 37
Operate Controls...................................................................................... 38
Palm Switches................................................................................................. 38
Emergency OFF............................................................................................... 39
Status Display.................................................................................................. 39
Pneumatic Controls.................................................................................. 40
Air Pressure Regulator................................................................................... 40
Regulator Gauge............................................................................................ 40
Down Speed Control...................................................................................... 41
Counterbalance Regulator............................................................................. 41
Controller Interface.................................................................................. 41
Display............................................................................................................. 41
Keypad............................................................................................................ 41
Number Keys........................................................................................................... 42
Function Keys.......................................................................................................... 42
Display/Format Keys................................................................................................ 42
Motor Speed Control............................................................................... 43
Mechanical Controls................................................................................. 43
Height Adjustment......................................................................................... 43
Dovetail Locks................................................................................................. 44
Bottom Stop.................................................................................................... 44
Bottom Stop Lock........................................................................................... 45
Section 7 – Operational Setup................................................ 47
Terminology.............................................................................................. 49
Pre–Spin.......................................................................................................... 49
Pre–Load......................................................................................................... 49
Weld Time....................................................................................................... 49
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Dukane Manual Part Number 403-547-03
Table of Contents
Hold Time........................................................................................................ 49
Weld by Time.................................................................................................. 49
Weld by Distance............................................................................................ 50
Tooling Capacity....................................................................................... 50
Upper Hub...................................................................................................... 50
Lower Fixture.................................................................................................. 50
Fixture Height................................................................................................. 50
Setup Checklist......................................................................................... 51
1. Attach Tooling........................................................................................... 51
2. Disable System........................................................................................... 51
3. Base Interface Cable.................................................................................. 51
4. Connect AC Power..................................................................................... 51
5. Connect Compressed Air........................................................................... 51
6. Turn Power ON.......................................................................................... 52
7. Front Panel Regulator............................................................................... 52
8. Down Speed Adjustment.......................................................................... 52
9. Counterbalance Regulator........................................................................ 52
10. Enable System........................................................................................... 52
Height Adjustment................................................................................... 52
Stroke Adjustment................................................................................... 53
Stop Lock......................................................................................................... 53
Bottom Stop Adjustment............................................................................... 53
Start–Of–Weld................................................................................................ 54
End–Of–Weld.................................................................................................. 54
Pneumatic Adjustments........................................................................... 54
Front Regulator.............................................................................................. 54
Counterbalance Regulator............................................................................. 55
Down Speed Adjustment............................................................................... 56
Motor Speed Control............................................................................... 56
User Interface........................................................................................... 57
Power Up Sequence....................................................................................... 57
Operating Menus........................................................................................... 58
SETUP.............................................................................................................. 58
RUN Menu....................................................................................................... 60
MODIFY Menu................................................................................................ 61
Input Parameters...................................................................................... 62
PART PICKUP................................................................................................... 62
PICKUP TIME................................................................................................... 62
PRE–LOAD TIME.............................................................................................. 62
MAX. TIME LIMIT............................................................................................ 62
PREV and NEXT Keys................................................................................ 63
PREV Key......................................................................................................... 63
NEXT Key......................................................................................................... 63
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Spin Welder User’s Manual
Section 8 – Maintenance......................................................... 65
User Interface Panel................................................................................. 67
Cleaning.......................................................................................................... 67
Display............................................................................................................. 67
Control Keys.................................................................................................... 67
AC Power Cord......................................................................................... 67
Weekly Maintenance............................................................................... 68
Pre–Filter......................................................................................................... 68
Exhaust Diffuser............................................................................................. 68
Visual Inspection............................................................................................. 68
Monthly Maintenance............................................................................. 68
Slides & Motor Shaft...................................................................................... 68
Rear Counterbalance...................................................................................... 68
Annual Maintenance............................................................................... 69
Gas Spring....................................................................................................... 69
Lubricate Slides............................................................................................... 70
Section 9 – Troubleshooting................................................... 71
Welding Process....................................................................................... 73
Material Choices............................................................................................. 73
Parameter Effects........................................................................................... 73
Surface Velocity....................................................................................................... 73
Axial Pressure.......................................................................................................... 73
Weld Time................................................................................................................ 73
Hold Time................................................................................................................ 73
Welder Troubleshooting.......................................................................... 74
Pneumatics...................................................................................................... 74
Mechanical...................................................................................................... 74
Electrical Power.............................................................................................. 74
Base Interface Cable....................................................................................... 74
AC Motor Controller...................................................................................... 76
User Interface................................................................................................. 76
Section 10 – Contacting Dukane............................................ 79
Identify Equipment........................................................................................ 81
Our Website.................................................................................................... 81
Ultrasonics Division Location......................................................................... 81
Ultrasonics Division eMail Address................................................................ 81
Ultrasonics Division Phone Numbers............................................................. 81
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Dukane Manual Part Number 403-547-03
Table of Contents
Section 11 – Specifications...................................................... 83
Energy Requirements............................................................................... 85
Pneumatic....................................................................................................... 85
AC Power........................................................................................................ 85
Operating Environment........................................................................... 85
Dimensions............................................................................................... 86
Identification Numbers............................................................................ 87
Welder Model and Serial Number................................................................. 87
Base Model and Serial Number..................................................................... 88
Appendix A – List of Figures & Tables.................................... 89
Appendix B – Electrical Schematic.......................................... 93
Index........................................................................................ 97
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Dukane Manual Part Number 403-547-03
Section 1 – Introduction
Section 1
Introduction
• Important Information
• Manual Organization
• Key Features
Important User Information..........................3
Read This Manual First................................... 3
Notes and Tips................................................ 3
Caution and Warnings................................... 3
Drawings and Tables...................................... 3
Manual Organization.....................................4
Spin Welder Key Features..............................5
Dukane Corporation •
Dukane Manual Part Number 403-547-03
• Ultrasonics Division
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Dukane Manual Part Number 403-547-03
Section 1 – Introduction
Important User Information
Read This Manual First
Before operating the Spin Welder read this User’s
Manual to become familiar with the system. This
will ensure correct and safe operation. The manual is
organized to allow you to learn how to safely operate a spin–welding system. The examples given are
chosen for their simplicity to illustrate basic setup
procedure.
Notes and Tips
Throughout this manual we use NOTES to provide
information that is important for the successful application and understanding of the product. A NOTE
block is shown to the right.
Cautions and Warnings
In addition, we use special notices to make you
aware of safety considerations. These are the CAUTION and WARNING blocks as shown here. They
represent increasing levels of important information.
These statements help you to identify and avoid hazards and recognize the consequences. One of three
different symbols also accompany the CAUTION and
WARNING blocks to indicate whether the notice pertains to a condition or practice, an electrical safety
issue or a hand protection issue.
NOTE
Note statements provide additional information or highlight procedures.
CAUTION
Caution statements identify conditions or practices
that could result in damage to the equipment or
other property.
Drawings and Tables
WARNING
Warning statements
point out conditions
or practices that could
result in personal injury
or loss of life.
The figures and tables are identified by the section
number followed by a sequence number. The sequence number begins with one in each section. The
figures and tables are numbered separately. Figure
4-2 is the second illustration in section four. Table
4-2 is the second table in section four, and is not
associated with Figure 4-2.

Condition
or Practice
Dukane Manual Part Number 403-547-03
Electrical
Hazard
Hand
Hazard
Page 3
Spin Welder User’s Manual
Manual Organization
Section 1 – Introduction gives a general explanation of the Dukane Spin Welder.
Section 2 – Unpacking and Major Components
gives unpacking instructions and
identifies major Spin Welder components.
Section 3 – Safety discusses safety considerations
and regulations.
Section 4 – Installation describes the setup sequence and external connections necessary for operation.
Section 5 – Theory of Operation describes the
Spin Welding process and gives guidelines for part size.
Section 6 – Controls and Their Functions describes all the controls and their function or purpose.
Section 7 – Operational Setup describes basic
system checkout, adjustment and operation.
Section 8 – Maintenance gives a schedule of suggested preventive maintenance.
Section 9 – Troubleshooting provides helpful tips
for identifying and solving the most
common problems.
Section 10 – Contacting Dukane provides information on obtaining support from the
Dukane support team.
Section 11 – Specifications gives the Spin Welder
dimensions and power requirements.
Appendices
A
–
List of Figures and Tables
B
–
Electrical Schematic
Page 4
Dukane Manual Part Number 403-547-03
Section 1 – Introduction
Spin Welder Key Features
• Computer Controlled Motor with digital RPM
setting. DC Braking or optional Dynamic Braking
stops the motor quickly.
• Column–Mounted direct drive 3 or 5 HP motor
for solid, reliable welding operation.
• Digital Timer for Weld Time and Hold Time gives
precise control of the Spin Welding process.
• Keypad Programmer with backlit 2–line LCD
Display for operator convenience and ease of
setup.
• Industry Standard Logic Controller and Motor
Controller assures replacement parts are readily
available.
• Fixture throat depth is 7.6” to 8.5” depending
upon part geometry. The generous 20.94” tool hub
height can be increased an additional 6” with a
special order assembly request. The hub can easily
accommodate up to 12” diameter tooling.
• Photoelectric Start–Of–Weld and End–Of–Weld
switches for trouble–free and reliable operation.
• Built–in Air Pressure Gauge and Regulator means
the Spin Welder is ready to operate.
• Pneumatic Operation with adjustable 7” stroke
assures quiet operation and is environmentally
safe.
• Counterbalanced thruster for easy height
adjustment with rack–and–pinon gearing.
• Ultra–Rigid square support column for precise
and repeatable operation.
• Factory Installed lifting ring for easy
placement.
• ISO 9001 Certification means that the Spin
Welder is manufactured to exacting quality
standards.
• 24–Month domestic warranty assures you of
reliability and quality construction.
Dukane Manual Part Number 403-547-03
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Dukane Manual Part Number 403-547-03
Section 2 – Unpacking
Section 2
Unpacking
• Unpacking System
• Packing List
• System Requirements
• Major Components
Unpacking System.......................................... 9
Packing List.....................................................9
System Requirements...................................10
Physical Space............................................... 10
Electrical........................................................ 10
Pneumatic..................................................... 10
Major Components......................................11
Rear View...................................................... 11
Front View.................................................... 12
Dukane Corporation •
Dukane Manual Part Number 403-547-03
• Ultrasonics Division
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Dukane Manual Part Number 403-547-03
Section 2 – Unpacking
Unpacking System
The Spin Welder is normally packed in a corrugated
carton resting on a wooden shipping pallet. To unpack the Spin Welder follow these steps.
1. Remove the straps from the carton.
2. Open the top of the carton. Carefully remove any
packing materials, cables and documentation.
3. Cut the tape at the bottom corners and unfold
the flaps.
4. Remove the corrugated carton, but leave the Spin
Welder on the pallet.
5. Leave the power cable wrapped to the column
until after the Spin Welder has been placed in its
working area and you are ready to begin hooking
up power and air.

WARNING
DO NOT LIFT the Spin
Welder manually. Lifting and/or moving the
welder manually could
result in personal injury.
Use mechanical means
to move and place the
Spin Welder.
6. If you are supplying your own tooling, the Spin
Welder is shipped with the dovetail slide locking levers tightened (see Figure 2–3 or Figure
6–7). If you ordered custom tooling with your
Spin Welder, it may be installed with a sample
part under the tool hub for shipping. Leave the
locking levers tightened until the Spin Welder
has been installed in its work area.
Packing List
After removing the shipping container, check that
you have the items listed in Table 2–1. Inspect the
Spin Welder for damage. Report any damage immediately to the carrier and to Dukane Ultrasonics
Service at 1-800-231-8404. Also see Section 10 for
information on contacting Dukane. Save all shipping
and packing materials so they can be inspected in
processing any claims that may arise.
Dukane Manual Part Number 403-547-03
Qty
Item
Part Number
1
Spin Welder
SVB031 (3hp)
SVB 051 (5hp)
1
Base Interface
to Press Cable
200-1064
1
Spin Welder
User’s Manual
403-547-XX
Table 2–1 Spin Welder Shipping Contents
Page 9
Spin Welder User’s Manual
System Requirements
Physical Space
Allow sufficient area on either side of the Spin
Welder to accommodate current and future parts
and fixtures. Also be aware that under extreme spin
welding conditions, small droplets of molten plastic
may be ejected by the spinning upper part.
Electrical
The Spin Welder requires a 240VAC – 3 phase outlet
rated at 20 Amps. Both the 3HP and 5HP model use
the same power cord and plug. The cable connector
is a NEMA L15–20P configuration 4–prong plug
and is shown in Figure 2–1. The corresponding wall
receptacle is illustrated in Figure 2–2. Note that the
geometry of the 240VAC 20A 3Ø plug is slightly
different from a 120/240VAC 20A 1Ø (NEMA
L14–20P) configuration and also from a 480VAC
20A 3Ø (NEMA L16–20P) configuration. All three
geometries are incompatible with each other to
prevent accidental overloads.
Figure 2–1 240VAC L15-20 Plug
Pneumatic
Additionally, the Spin Welder requires a clean, dry,
compressed air supply of 100 psi (6.9 bar) nominal.
See Section 11 – Specifications for the upper and
lower limits on the electrical and compressed air
supply.
Major Components
Figure 2–2 240VAC L15-20 Receptacle
Figures 2–3 and 2–4 identify the major components
to help you familiarize yourself with the Spin Welder. These illustrations may be referenced throughout
this manual.
Page 10
Dukane Manual Part Number 403-547-03
Section 2 – Unpacking
1
Lifting Ring
2 Compressed Air Inlet
3 Top–Of–Stroke Connector
4 Base Interface Connector (J8)
5 Air Exhaust Diffuser
6 Spin Welder Serial Number
7
Spin Welder Model Number
8 Counterbalance Regulator
9 AC Power To Press
10 Upper Dovetail Lock
11 Main AC Disconnect
and Fuse Enclosure
12 AC Power Switch & Lockout
13 AC Enclosure Lockout
14 Lower Dovetail Lock
15 Press Height
Adjustment Crank
16 AC Power Cord
240VAC 3–Phase
17 Base Serial Number
18 Base Interface Connector (J35)
19 Base Grounding Lug
Figure 2–3 Spin Welder Major Components Rear View With Callouts
Dukane Manual Part Number 403-547-03
Page 11
Spin Welder User’s Manual
User Interface 20
Display & Keypad
Pressure Regulator Gauge 21
Pressure Regulator 22
Adjustment
Down Speed Adjustment 23
Motor Speed Control 24
Front Access Panel 25
Upper Press Housing 26
Bottom Stop Indicator Flags 27
Lower Motor Housing 28
Tooling Hub 29
Height Adj. Rack Gear 30
Height Adj. Gas Spring 31
Bottom Stop Adjustment 32
Bottom Stop Adj. Lock 33
Base Platen 34
Left Palm Switch 35
Status Display 36
Left Mounting Hole 37
Emergency OFF Switch 38
Right Mounting Hole 39
Right Palm Switch 40
Figure 2–4 Spin Welder Major Components Front View With Callouts
Page 12
Dukane Manual Part Number 403-547-03
Section 2 – Unpacking
Section 3
Safety
• Safety Regulations
• Electrical Safety
• Mechanical Safety
• Pneumatic Safety
Safety Regulations....................................... 15
Plastics Health Notice................................... 15
Palm Switches............................................... 15
General Safety.........................................15
Electrical Safety............................................16
AC Power...................................................... 16
Grounding.................................................... 16
Mechanical Safety........................................17
Pneumatic Safety..........................................17
Dukane Corporation •
Dukane Manual Part Number 403-547-03
• Ultrasonics Division
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Dukane Manual Part Number 403-547-03
Section 3 – Safety
Safety Regulations
Plastics Health Notice
Before using any Dukane plastic welding system,
make sure you are familiar with applicable regulations regarding the particular type(s) of plastic you
are using. In the USA, check with the U.S. Department of Labor.
When plastic materials are being processed, they
may emit fumes and/or vapors that could be hazardous (e.g. PVC – Polyvinyl Chloride can emit
chlorine gas under certain processing conditions).
Make sure you use proper ventilation whenever
these plastics are processed.
Palm Switches
The dual safety palm switches comply with OSHA
safety regulations. Using a foot switch in place of
the dual palm activation buttons violates OSHA
regulations.
General Safety
Before performing any maintenance or service on
the Spin Welder, locks and tags should be applied
to all energy isolating switches. Anything that might
restore energy to the Spin Welder must be locked
out.
You may be required to add accessories to bring the
system into compliance with applicable regulations
for operator safety. In the United Sates, these regulations are administered by OSHA (Occupational
Safety and Health Administration).
Do not make any unauthorized modifications to the
Spin Welder or base. Unauthorized modifications
could cause equipment damage and injury to the
operator. In addition, unauthorized modifications
will void the equipment warranty.
Dukane Manual Part Number 403-547-03
Page 15
Spin Welder User’s Manual
Follow the installation instructions to ensure the
Spin Welder is properly installed. Do not operate
the Spin Welder until after it has been properly and
securely installed.
Electrical Safety
AC Power
For safety and reliability, the power cords on the
Dukane Spin Welder have a grounded Twist–Lock
NEMA configuration plug. This should be connected
to a NEMA L15–20R configuration receptacle (see
Figure 2–2).
The AC power switch has a provision to lockout
the handle in the OFF position during any maintenance or servicing. The cover can also be locked to
prevent unauthorized access. Figure 3–1 shows the
AC power switch and the two lockouts. Before performing any service or tests, turn off the AC power
switch, disconnect the AC power cord from the AC
receptacle and lock the switch handle in the OFF
position. Never attempt to lockout the AC power
by pulling the fuses.
WARNING
Always turn the AC power
OFF before opening the AC
switch enclosure. Disconnect the AC power cord
and lockout the switch
handle before performing any tests or maintenance on
the fuses. The voltage inside the
enclosure is dangerous.

Always lockout the compressed air
before performing any electrical
maintenance or service.
Switch Lockout
Cover Lockout
Figure 3–1 AC Power Enclosure, Switch and Lockouts
Page 16
Dukane Manual Part Number 403-547-03
Section 3 – Safety
If a fuse has blown, determine the cause and repair
the defect before replacing the fuse. Replace the
fuses only with fuses of the same type and rating.
Grounding
It is important for operator safety that the receptacle
grounding wire be installed properly and securely
attached to an effectively grounded rod. The function of the ground wire is to keep the Spin Welder
base and housing at earth potential. In the event of
a short circuit from one of the three AC phases to
the case, the fuse(s) will blow, protecting the equipment and operator.

WARNING
If there is any question
about the effectiveness
of your electrical grounding, have it checked by a
qualified electrician.
A grounding lug is also provided on the back of the
base (Item 19 in Figure 2-3). You should connect
a separate 14 AWG* ground wire to an effectively
grounded metal pipe. This will minimize any external electrical interference from leaking into the
spin welder control circuitry. This will not compromise the safety of the power ground.
* 14 AWG wire has a diameter of 1.63mm or 0.064”
Mechanical Safety
The Spin Welder is capable of developing substantial
torque and high rotational velocity. Keep your hands
and body away from the tool head during operation.
The spinning head is capable of inflicting serious
injury. Never attempt to retrieve a part from a spinning tool head. Always wear safety glasses when
operating the spin welder. Be extremely careful not
to let long sleeves, necklaces or long hair become
entangled in the spin welder during operation.
WARNING
Never touch the tool
head while the Spin
Welder is operating. The
spinning head is capable
of inflicting cutting and
crushing injuries.
Pneumatic Safety
In the United States, you will have to add a device
capable of isolating and locking out the compressed
air supply to comply with OSHA regulations. Always lockout the compressed air when performing
any maintenance or service on the Spin Welder.
Dukane Manual Part Number 403-547-03
Page 17
Spin Welder User’s Manual
Compressed air can develop a considerable amount
of force. This force is large enough to inflict serious
injury if one places their hand or other limb under the
tool head. The Spin Welder uses a 3–inch (76–mm)
diameter air cylinder which converts the air pressure
to mechanical movement and has a force multiplication factor of seven. This means that at the full 100 psi
(6.9 bar), the air cylinder is capable of exerting 700
pounds (318 kg) of force. This much force can result
in serious injury to the operator.
Page 18

WARNING
Tighten all compressed
air connections securely. A loose fitting can
cause injury if it detaches
from the compressed air
connection and whips
around.
Dukane Manual Part Number 403-547-03
Section
Section
4 – Installation
3 – Safety
Section 4
Installation
• Secure to Work Table
• Tooling Attachment
• Compressed Air
• Control Cable
• AC Power Connection
Work Area......................................................21
Secure to Work Table......................................21
Bench Capacity............................................... 21.
Leveling.......................................................... 21
Mounting Holes.............................................. 21
Tooling Attachment........................................21
Compressed Air Connection...........................22
Control Cables................................................22
Base Interface Cable....................................... 22.
Top–Of–Stroke Cable...................................... 23
AC Power Connection....................................23
Dukane Corporation •
Dukane Manual Part Number 403-547-03
• Ultrasonics Division
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Dukane Manual Part Number 403-547-03
Section 4 – Installation
Work Area
Allow sufficient area on either side of the Spin
Welder for handling material, work pieces and fixtures. Provide ample room so that the movement
of an operator or helper does not interfere with the
work of another. Also be aware that under extreme
conditions, small droplets of molten plastic may be
spun off from the upper part.
Securing to Work Table
Bench Capacity
The Spin Welder weighs approximately 500 lbs.
(225 kg). It should be mounted on a table or bench
capable of supporting 750 lbs. (340 kg) to accommodate the additional force imposed by the vertical
movement of the motor and slide during spin welding operation.
Two 1/2" Holes
Figure 4–1 Base Mounting Hole Location
3.00 inch Bolt Circle
Leveling
We recommend that the Spin Welder be leveled to
within one degree. This can be accomplished using
a carpenter’s level. One degree corresponds to approximately one–quarter of an inch (6 mm) deviation
across the 16 inch (406 mm) width of the platen.
Mounting Holes
The base of the Spin Welder has two mounting holes
in the front as shown in Figure 4–1. The two holes
will accept either 12mm or 7/16” diameter bolts. We
recommend that you securely attach the Spin Welder
base to the work table using these mounting holes.
0.328 inch Dia.
8 Holes
Equally Spaced
on Bolt Circle
Tooling Attachment
The upper tooling attaches to a 3.5–inch diameter
hub using 5/16” cap screws. Figure 4–2 gives the
measurements of the tooling hub. The base fixture
attaches to the platen using M10–1.5 cap screws.
See Figure 11–3 in the Specifications Section for the
Dukane Manual Part Number 403-547-03
0.188
1.000
+ 0
- .002
3.50
Figure 4–2 Tool Mounting Hub Dimensions
Page 21
Spin Welder User’s Manual
detailed measurements of the fixture mounting holes
in the platen.
Compressed Air
The Spin Welder requires a clean, dry supply of
compressed air at a nominal pressure if 100 psi (6.9
bar). The air supply should be capable of delivering
1 SCFM and at least 80 psi (5.5 bar) and not greater
than 110 psi (7.6 bar). The air is attached to the rear
of the press using a standard 3/8” NPT fitting. The
location is shown in Figure 4–3. A sintered metal
diffuser is attached to the exhaust port directly below
the air connection. If your compressed air supply
contains any oil or moisture, you should attach a
pre–filter between the compressed air supply line
and the Spin Welder.
O
Figure 4–3 Compressed Air Connection
Control Cables
Base Interface Cable
Directly to the right of the compressed air exhaust
diffuser is the press control input connector (J8).
Page 22
Dukane Manual Part Number 403-547-03
Section 4 – Installation
The Base Interface to Press cable (Part No. 200–
1064) is a supplied part and is included with the
Spin Welder (see Table 2–1). The cable is connected
between J8 on the press and J35 on Base Interface
connector. This connection is illustrated in Figure
4–4. Both J8 and J35 are 14–contact female connectors with 7 active contacts. The control cable carries
the operate and emergency stop signals from the
palm operate and abort switches on the base. If you
are using custom automation, you will have separate
operate and abort switches. These still connect to J8,
the press control input of the Spin Welder.
Panel
Connector
View
Panel
Connector
pinout is
the same
for both
J8–Press
and
J35–Base
J8
Top–Of–Stroke Cable
BLK
WHT
1
Part No. 200–1064
Directly above the press control input connector
is a 4–contact connector for the optional Top–Of–
Stroke cable (Dukane Part No. 438–528). This
connection utilizes the Top–Of–Stroke output from
the spin welder controls and is only required if you
are using the custom automation feature. This is a
normally–open contact which closes at the top of the
stroke. It is limited to a maximum of 24 Volts and 1
Amp. The cable pinout is shown in Figure 4–5.
J35
Figure 4–4 Base Interface to Press Connection
3
Figure 4–5 Top–Of–Stroke Cable
AC Power
The AC power cord is permanently attached to
the main AC power switch box. This cable has a
4-prong twist–lock plug and requires 240 VAC
3–phase power rated at 20 Amps. This plug should
be connected to a NEMA L15–20R configuration
receptacle (see Figure 4–6). Inside the power
Dukane Manual Part Number 403-547-03
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Spin Welder User’s Manual
switch enclosure are three fuses for the 240 VAC
three–phase power rated at 20 Amps. The power
switch and fuses are identical on both the 3 HP and
5 HP models. The AC power switch has a provision
to lock the handle in the OFF position during any
maintenance or servicing. The cover can also be
locked to prevent unauthorized access.
240V
240V
GND
240V
Note that X is
narrower than
Y or Z
X
G
Y
Z
Figure 4–6 240VAC 3–Phase Receptacle Wiring
Page 24
Dukane Manual Part Number 403-547-03
Section 5Section
– Theory
4 –ofInstallation
Operation
Section 5
Theory of Operation
• Spin Welding Process
• Material Considerations
• Control Parameters
• Initial Settings
• Part Size
Spin Welding Process......................................27
Material Considerations..................................27
Control Parameters.........................................28
Axial Pressure.................................................. 28
Surface Velocity (RPM).................................... 29
Weld Time...................................................... 29
HoldTime........................................................ 30
Initial Settings.................................................30
Axial Pressure.................................................. 30
RPM (Surface Velocity).................................... 31
Weld Time...................................................... 33
HoldTime........................................................ 33
Part Size..........................................................33
Dukane Corporation •
Dukane Manual Part Number 403-547-03
• Ultrasonics Division
Page 25
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Page 26
Dukane Manual Part Number 403-547-03
Section 5 – Theory of Operation
Spin Welding Process
Dukane Manual Part Number 403-547-03
on
iti
e
III
IV
V
ol
H
d
Ti
m
St
dy
ea
St
II
el
M
tin
g
Tr
a
at
e
ns
s
tin
tic
le
ea
rP
ar
lH
na
W
ea
tio
I
ic
Fr
The spin welding process is divided into 5 distinct
phases as shown in Figure 5–1. In Phase I, the rotational friction generates heat. Frictional heating is
intensified with both axial pressure and joint surface
velocity. In Phase II, the friction results in abrasive
forces which strip off surface roughness, generating
wear particles causing the surfaces of the polymer
to begin to melt. As the polymer reaches its crystalline melting point or glass transition temperature, it
enters Phase III. This is an unsteady state in which
the temperature quickly increases and viscous flow
is initiated resulting in a large increase in melt thickness. This is accompanied by a sharp rise in the
melt (weld) penetration velocity. Once the melting
process is initiated, heat is then generated by internal
friction within the molten region. This continues in
Phase IV until a steady state equilibrium is reached
and the penetration velocity stalls. In Phase IV,
the heat loss through the wall and flash expelled
approaches the heat being generated. Here the temperature of the molten layer remains relatively constant. Because plastics are poor conductors of heat,
the surface heat is transferred slowly to the interior
and much of it remains localized. At this point, the
rotation is stopped and we enter Phase V where the
molten material is allowed to cool under pressure
for a short period called the Hold Time.
g
The formal definition of spin welding is “An assembly process in which thermoplastic parts with
rotationally–symmetric mating surfaces are joined
together under pressure using unidirectional circular
motion. The heat generated during the rotational
contact melts the plastic in the heat–affected zone
forming a weld upon cooling” Note that the parts
do not have to be circular, only the mating surfaces
to be welded have to be circular.
Weld
Penetration
Velocity
Weld
Penetration
Depth
t1
t2
t3
t4
t5
Figure 5–1 Penetration Depth and Velocity as a
Function of Time During the Five Phases
of Spin Welding.
Page 27
Spin Welder User’s Manual
Material Considerations
Materials that can be friction (i.e. vibration) welded
can also be joined with by spin welding. The semicrystalline thermoplastics are more readily joined
using spin welding than ultrasonics. Using compatible polymers, spin welding is capable of making
reliable hermetic seals. Far–field welding is easier
with spin welding than with ultrasonic welding. Additional parts can be entrapped between the upper
and lower pieces during spin welding.
Joining of dissimilar polymers is possible using the
spin weld process although it generally produces
lower strength weld joints. By designing the weld
joint with an undercut, the polymer with the lower
melting temperature will flow into the undercut,
creating a mechanical union.
Material filler and surface contaminants (e.g. mold
release agent) are two factors that will affect consistency and weld repeatability. Spin welding is more
tolerant of contaminants than ultrasonic welding.
Spin welding is also less affected by hygroscopic
polymers, although they may still require special
handling for critical applications. The moisture
content can lead to bubble formation in the joint
resulting in decreased weld strength.
NOTE
Common hygroscopic thermoplastics: ABS/Polycarbonate (Cycoloy)
Polyoxymethylene (Acetal, Delrin)
Polyamides (Nylon, Zytel)
Polycarbonate (Lexan)
Polycarbonate/Polyester (Xenoy)
Polysulfone (Udel)
Control Parameters
Axial Pressure
There are three primary process control variables
that determine the weld penetration. They are
the axial pressure on the weld joint, the surface
velocity of the weld joint and the weld time.
An increase in each yields an increase in weld
penetration. The effects of pressure and velocity are also highly nonlinear. The axial pressure
required is determined by the material strength
and wall thickness (how much pressure the part
can safely sustain), surface weld joint area and
partially by the surface velocity. Larger joint
Page 28
Dukane Manual Part Number 403-547-03
Section 5 – Theory of Operation
areas require more pressure. Higher pressure not
only increase the weld penetration depth, it also increases the penetration velocity. Mass reduction – a
measure of the amount of wear particles and flash
– is not significantly affected by increased pressure,
especially at high rotation speeds. A slower surface
velocity (i.e. small diameter weld joints) requires
higher pressure. Higher axial pressure may also be
required to force any contaminants or bubbles out of
the weld joint. The combination of speed and pressure must be controlled but be high enough to cause
melting at the interface as opposed to grinding.
Surface Velocity (RPM)
For a fixed rotational speed, surface velocity increases with weld joint diameter. For a fixed weld
joint diameter, surface velocity increases with motor RPM. Smaller diameter parts therefore usually
require more RPM than larger parts and typically
cannot tolerate as much axial pressure. However, the
same percentage change in axial pressure has a larger
effect than the same percentage change in RPM in
determining the time required to initiate weld formation and the depth to which the weld penetrates. The
previous statement is a generalization, and is meant
to imply that axial pressure has a greater effect
than motor RPM. Mass reduction shows an almost
exponential increase with rotational velocity.
Weld Time
Welding time is the third process variable. It is the
time the axial pressure and surface velocity are
applied to achieve the desired uniform weld penetration depth. Increasing the weld time results
in an almost linear increase in weld penetration.
Weld penetration beyond the critical threshold
does not significantly increase weld strength.
The total welding time is dependent upon loading pressure, rotational velocity and desired
weld penetration depth. Once the desired weld
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Spin Welder User’s Manual
penetration has been achieved, we want to stop
the rotation as quickly as possible. Too long of a
deceleration time will allow the polymer to solidify
and subsequently shear reducing the weld strength.
Higher axial pressure may help stop the rotation
sooner on large diameter parts.
Hold Time
During Phase V, a holding time allows the plastic
to solidify before removing pressure from the joint.
Larger weld joints take longer for the plastic to
solidify due to the larger mass and poor thermal
conductivity of plastic.
Initial Settings
The following information is presented for informational purposes only and is in no way meant to
serve as a rule or formula. The information is collected from publicly available books and papers. It is
presented here to provide customers with a general
guideline for setting the initial parameters.
Axial Pressure
TIP
Change only one parameter at a time.
Record your settings. This will make it
easier to arrive at correct settings, until you become familiar with the Spin
Welder.
This is the most difficult parameter to estimate.
You will require less pressure with an electric motor spin welder than with an inertial welder due to
the inertial welder’s loss of kinetic energy. A rough
estimate can be derived from a specific pressure of
1.7 MPa (1.7x106 Nt–m-2) of projected joint area.
This translates to roughly 250 pounds per inch2 of
weld surface area (total wetted surface area). The
spin welder uses a 3” diameter air cylinder to supply
pressure and it has a boost factor of 7x, so a pressure reading on the regulator of 35 psi translates to
250 pounds of force. Again remember that the 250
pounds per inch2 of weld surface area is only a starting estimate and differs from values used in inertial
spin welders. Depending upon the joint design, your
application may require 2x more or 0.5x less pressure. Axial pressure typically also has a larger effect
on the weld initiation process than the RPM setting.
Page 30
Dukane Manual Part Number 403-547-03
Section 5 – Theory of Operation
RPM (Surface Velocity)
Maximum weld strength occurs at an optimum pressure and speed. Higher rotation speeds decrease the
weld initiation time, but to a lesser extent than axial
pressure. This means that you will typically need to
make larger percentage changes in motor speed to
see a noticeable difference in the weld properties
than you would in axial pressure. The basic expression commonly seen is:
600
=
25
00
R
41 PM
.7
M
RP
00 0
15 25.
=
N
N
35
N = 00 R
PM
58.
3
Surface Velocity (inch/sec)
v = πDNwhere v is surface velocity (inch/sec)
π = 3.14
D = average diameter of the joint (inch)
N = angular velocity (rev/sec)
but N = RPM/60 so we can write…
π D RPM
v=
60
The initial target for v is in the 360 to 600 inch/sec
range. This corresponds to the common quoted values of 30 to 50 ft/sec. Surface velocities as low as
800
M
RP
0
100 6.7
1
N=
400
RPM
500
.3
N=8
200
v
0
1
D
2
3
4
6
8
10
12
Average Weld Diameter (inch)
Figure 5–2 Dependence of the Surface Velocity on the Weld Diameter at various RPMs
Dukane Manual Part Number 403-547-03
Page 31
Spin Welder User’s Manual
120 inch/sec (3 m/sec) have been used for parts with
thin wall sections. Figure 5–2 is a plot of surface
velocity (v) as a function of weld joint diameter (D)
for five different RPM settings (N). You can use this
graph to estimate the surface velocity (vertical axis),
that various RPM settings will yield for a given part
diameter (horizontal axis).
Note that we have converted all units to inches/second for consistency. Some graphs mix part diameter
in inches with a surface velocity in feet/second. Be
careful to compare graphs in the same units. Solving
the previous expression for RPM gives us:
60 v
RPM = π D
Rotational Velocity (rev/min)
A plot of this expression is shown in Figure 5–3.
Now we have RPM plotted as a function of weld
joint diameter (D) for eight different values of v
ranging from 120 to 960 inch/sec.
4000
120 in/sec = 10 ft/sec — 3 m/sec
240 in/sec = 20 ft/sec — 6 m/sec
360 in/sec = 30 ft/sec — 9 m/sec
480 in/sec = 40 ft/sec — 12 m/sec
600 in/sec = 50 ft/sec — 15 m/sec
720 in/sec = 60 ft/sec — 18 m/sec
840 in/sec = 70 ft/sec — 21 m/sec
960 in/sec = 80 ft/sec — 24 m/sec
3000
2000
v=
1000
RPM
v=
0
1
D
2
v=
240
v=
360
480
v=
v=7
600
20
v = 84 v = 960 in
/sec
0
120
3
4
6
8
10
12
Average Weld Diameter (inch)
Figure 5–3 Dependence of Motor RPM on the Weld Diameter for Selected Surface Speeds
Page 32
Dukane Manual Part Number 403-547-03
Section 5 – Theory of Operation
The generalization of RPM being a noncritical
parameter applies only to motor drives. An inertial
drive utilizes a flywheel’s kinetic energy which is
a function of the square of its rotational velocity.
Inertial drive units adjust the energy delivered by
adjusting the flywheel’s speed and are therefore
more sensitive to a change in rotational velocity.
Weld Time
Weld times are very application dependent but typically less than a second. Filler content may reduce
the coefficient of friction. Softer plastics (except
fluropolymers) generally have higher coefficients of
friction. This influences the weld initiation time. If
you require a short weld time, it may be necessary
to allocate part of the weld time to the deceleration
time in order to achieve the desired weld penetration.
Once the polymers reach Phase III, an increase in
welding time does not significantly yield an increase
in weld strength. Excessively long weld times may
draw out reinforcing filler and realign the interchain
bonds in the weld plane resulting in a weak axial
weld joint. It may also lead to part distortion in
extreme cases.
Hold Time
The hold time typically ranges from 1.0 to 3.0 seconds. Amorphous plastics will normally take longer
to solidify than semicrystalline plastics. It is during
the hold time that the axial pressure forces the parts
together until the plastic solidifies. For large parts,
it may be upwards of 5 seconds.
Part Size
For larger diameter weld joints, the 5 HP model is
recommended. This model will accommodate tooling up to 12 inches in diameter and has sufficient
torque to handle large pieces. For smaller size parts,
the 3 HP model is preferred due to its higher RPM
capability. The 3 HP model has a maximum speed
Dukane Manual Part Number 403-547-03
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Spin Welder User’s Manual
rating of 3500 RPM, while the 5 HP model has a
maximum speed of 1750 RPM. The joint diameter
range given in Table 5–1 is a very general guide. The
overlap between the two models is large enough,
and the variability in applications diverse so that
only very general recommendations can be made.
Please contact the Dukane Applications Laboratory
(see Section 10) for a recommendation concerning
your specific application.
Model
Minimum Diameter Maximum Diameter
3 HP
1.25” (32 mm)
5” (125mm)
5 HP
4” (100 mm)
12” (305mm)
Table 5–1 Weld Joint Diameters for 3 HP and 5 HP Models
Page 34
Dukane Manual Part Number 403-547-03
Section 5 – Theory of Operation
Section 6
Control Functions
• AC Power Switch
• Operate & Emergency Off
• Pneumatic Controls
• Process Controller
• Motor Speed Control
• Height Adjustment
• Bottom Stop Switch
AC Power.......................................................37
AC Switch....................................................... 37
AC Fuses......................................................... 37
Operate Controls............................................38
Palm Switches................................................. 38
Emergency OFF............................................... 39
Status Display................................................. 39
Pneumatic Controls.........................................40
Regulator........................................................ 40
Down Speed Control...................................... 41
Counterbalance.............................................. 41
Controller Interface.........................................41
Keypad........................................................... 41
Display............................................................ 41
Motor Speed Control......................................43
Height Adjustment..........................................43
Bottom Stop...................................................44
Dukane Corporation •
Dukane Manual Part Number 403-547-03
• Ultrasonics Division
Page 35
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Page 36
Dukane Manual Part Number 403-547-03
Section 6 – Control Functions
AC Power
AC Switch
The main power switch turns the AC power off and
on. The power switch enclosure also contains three
fuses. The enclosure cover can be locked but still
permit operation of the power switch. The power
switch handle can also be locked out which effectively locks the enclosure lid. Figure 6–1 shows the
outside of the AC power switch enclosure and the
AC power switch in both the OFF (lower) and ON
(upper) position.

WARNING
Always turn the AC power OFF before opening
the AC switch enclosure.
Disconnect the AC power cord and lockout the
switch handle before
performing any tests or
maintenance on the fuses. The AC voltage inside
the enclosure is potentially lethal.
ON
OFF
Figure 6–1
AC Power Enclosure Showing the Switch
OFF and ON positions
AC Fuses
Inside the AC power switch enclosure are three 250
Volt, 20 Amp SLO-BLO Fuses. Figure 6–2 shows
the interior of the switch box and the location of the
fuses. Turn off both the AC power and compressed
air before opening the cover to inspect the fuses.
Disconnect the AC power before testing or servicing
the fuses. If a fuse has blown, determine the cause of
the fault and correct the condition before replacing
the fuse(s) and applying power.
Dukane Manual Part Number 403-547-03
Page 37
Spin Welder User’s Manual
20 Amp
Fuses (3)
Figure 6–2 AC Power Enclosure Showing the Three Fuses
Operate Controls
Palm Switches
The dual operate palm switches are located at either
side of the base near the front. These safety switches
comply with OSHA safety regulations and require
simultaneous activation to start the spin welder. The
switches must be held until the Start–Of–Weld optical switch is triggered (see Start–Of–Weld in Section
7). The palm switches are shown in Figure 6–3.
Left
Hand
Palm
Switch
ight
and
alm
witch
Figure 6–3 Base with the Dual Palm Switches
Page 38
Dukane Manual Part Number 403-547-03
Section 6 – Control Functions
Emergency OFF
The Abort/Emergency OFF switch is located at the
front of the base (see Figure 6–3). When the red
palm switch is pushed in, it will stop the spin welder
regardless of where it is in the cycle. When the
Emergency OFF switch is pushed in, the following
conditions are present:
• The motor and press are disengaged.
• The activation palm buttons are deactivated.
• The air is allowed to bleed out of the downstroke
air cylinder.
• The press may lower if the pneumatic
counterbalance is set too low.
To reset the spin welder, twist the Emergency OFF
switch clockwise and out as shown in Figure 6–4.
POWER
LE
IN CYC
ABORT
Figure 6–4 Base Status Display and Emergency OFF Switch
Status Display
Directly to the left of the Emergency OFF switch is
the status display. The display is blank when the AC
power is OFF. When AC power is on and the Emergency OFF switch is pushed in, the display indicates
ABORT in red. When the Emergency switch is out,
the display indicates POWER in green. When the
Dukane Manual Part Number 403-547-03
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Spin Welder User’s Manual
palm switches activate the spin welder, the display
also indicates IN CYCLE in green. These indicators
are shown in Figure 6–4.
Pneumatic Controls
Air Pressure Regulator
The air pressure regulator is located on the front
panel of the Spin Welder and is shown in Figure 6–5.
The pressure regulator knob is a ten–turn control.
About five turns are required to change the setting
from 0 to 100 psi (6.9 bar). Turning the knob clockwise increases the pressure.
Pressure
Gauge
Pressure
Regulator
Lock
Ring
Downspeed
Adjustment
Figure 6–5 Front Panel Controls, Display and Gauge
Regulator Gauge
The applied air pressure is indicated on the regulator
gauge located directly above the regulator control
knob. The gauge has a 1.5” diameter dial with a
range of 0 to 100 psi (0 to 7 kg/cm2) and is shown
in Figure 6–5.
Page 40
Dukane Manual Part Number 403-547-03
Section 6 – Control Functions
Down Speed Control
This control determines the downward velocity of
the Spin Welder tool hub when the palm switches are
activated. The Down speed control is located below
the regulator adjustment knob and is also shown
in Figure 6–5. It is a ten–turn valve that adjusts
the flow of the air exhausted from the air cylinder
during the downstroke. Clockwise rotation reduces
the flow which decreases the down speed. This is
indicated by a minus sign engraved on the front of
the knob. The speed is adjustable from about 0.5
second to 10 seconds for a complete 7” stroke. The
red ring behind the knob locks it in position when
pushed back. Pull the ring forward 1/16” to unlock
the knob.
Counterbalance Regulator
The 3” air cylinder also serves to counterbalance the
motor and slide assembly which weighs about 125
lbs. (57kg). The knob which regulates the amount
of counterbalance force applied is located on the
rear of the spin welder below the AC power cable
grommet. It is identical to the front panel pressure
regulator and is shown in Figure 6–6. Turning the
knob clockwise increases the counterbalance force
and raises the motor and slide. The application of the
counterbalance is controlled by an internal solenoid
and is applied when the Emergency OFF switch
is pushed in and during a welding cycle. Between
welding cycles, the motor and slide assembly is
controlled by the front panel air regulator.
Compressed
Air Input
Top
Of
Stroke
J8
Base
Interface
Air
Exhaust
Diffuser
Increase
Counterbalance
Regulator
Figure 6–6 Counterbalance Regulator
Controller Interface
Display
The display is a two–line by sixteen character high–
contrast LCD display with LED backlighting.
Keypad
The keypad is separated into three groups. The keys
are color coded to easily identify key functions.
Dukane Manual Part Number 403-547-03
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Spin Welder User’s Manual
The keypad uses a sealed membrane with a tactile
feedback. The keypad and the display are both illustrated in Figure 6–5.
Number Keys
The ten number keys are white with black letters.
They are arranged telephone style and located on
the right side of the keypad.
Function Keys
The two function keys are blue with white letters.
They are located in the upper left side of the keypad
and are labeled F1 and F2. They are used to display
any application screen assigned to the key.
Display/Format Keys
The remaining eight gray keys with white letters
are for display navigation or data formatting. The
function of each key is listed here.
MENU
Returns to the main menu of the application.
MODE
Accesses special features and configurations of operating parameters.
PREV
Steps back through a sequence of linked
screens.
NEXT
Steps forward through a sequence of
linked screens.
CE
Clears an entire value during data entry.
+ / –
Toggles a data value between positive
and negative.
•
Decimal point.
Page 42
Enter key – Sends data to the controller.
Data can either be default values or data
entered at the keypad.
Dukane Manual Part Number 403-547-03
Section 6 – Control Functions
Motor Speed Control
The motor speed is controlled by the digital switch
shown in Figure 6–5. This switch has three decades
of control and is used to set the motor RPM as a
percentage of the full rated motor speed. The rated
motor speed is nominally 3500 RPM for the 3 HP
model and 1750 RPM for the 5 HP model.
Mechanical Controls
NOTE
The maximum motor speed setting is
999 which corresponds to 99.9% ( 3HP
= 3496 RPM and 5HP = 1748 RPM).
The lowest practical setting for spin welding is about 100 which corresponds to
10.0% (3HP = 350 RPM and 5HP = 175
RPM).
A conversion chart is shown in Figure
7-7.
Height Adjustment
This hand crank (shown in Figure 6–7) sets the press
assembly rest height. Counterclockwise rotation
Figure 6–7 Dovetail Locks and Height Adjustment
Dukane Manual Part Number 403-547-03
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Spin Welder User’s Manual
raises the press. Clockwise rotation of the crank
lowers the press. The dovetail locking levers must
be loosened before the press height is adjusted.
Dovetail Locks
The dovetail locking levers lock the height adjustment in place. They must be loosened (counterclockwise) before the press height is adjusted, and tightened (clockwise) once the desired height is reached.
The dovetail locks are also shown in Figure 6–7.
Bottom Stop
The bottom stop adjustment knob shown in Figure
6–8 raises and lowers the bottom stop. This in turn
Indicator
Flag
7"
7" Scale in
0.1 inch
Increments
Bottom Stop
Adjustment
0"
Lengthen
Stroke
Bottom
Stop Lock
Figure 6–8 Bottom Stop Adjustment and Lock
Page 44
Dukane Manual Part Number 403-547-03
Section 6 – Control Functions
determines the vertical stroke. The vertical scale has
ten divisions per inch and a range of seven inches.
The scale is positioned the same way you would
place a ruler against the scale with 0.0” at the bottom
and 7.0” at the top. One rotation of the knob moves
the flag 0.0556” (1.41mm). Counterclockwise rotation raises the flag to the top of the scale which
lengthens the stroke. Clockwise rotation lowers
the flag to the bottom of the scale and reduces the
stroke. The figure shows a setting of about 4 inches
(measured from the bottom of the scale) which is
the same as the downstroke.
Bottom Stop Lock
This knob locks the bottom stop adjustment in place
to prevent any accidental change in the setting once
the optimum setting has been reached. Clockwise
rotation locks the bottom stop in place. The lock is
illustrated in Figure 6–8.
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Section
Section 76 –– Operational
Control Functions
Setup
Section 7
Operational Setup
• Terminology
• Tooling Capacity
• Setup Checklist
• Bottom Stop Adjustment
• Pneumatic Adjustments
• Motor Speed Control
• Operating Menus
Terminology....................................................49
Tooling Capacity.............................................50
Setup Checklist...............................................51
Press Height Adjustment.................................52
Bottom Stop Adjustment................................53
Pneumatic Adjustments..................................54
Regulator........................................................ 54
Counterbalance.............................................. 55
Down Speed................................................... 56
Motor Speed Control......................................56
User Interface.................................................57
Dukane Corporation •
Dukane Manual Part Number 403-547-03
Power Up Sequence........................................ 57
Operating Menus............................................ 58
Input Parameters............................................. 62
• Ultrasonics Division
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Spin Welder User’s Manual
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Page 48
Dukane Manual Part Number 403-547-03
Section 7 – Operational Setup
Terminology
Pre–Spin
There are two possible methods of starting the spin
welding process. The first is to spin the motor up
to the desired RPM, then bring the upper part into
contact with the lower part in the fixture and apply
pressure. This is called pre–spin and is the most
common spin welding process.
NOTE
Refer back to Section 5 – Theory of
Operation for further discussion of the
terms listed here.
Pre–Load
The second method is to first bring the two parts
into contact by applying pressure. This also seats the
parts prior to welding. The motor is then brought up
to speed. This method is called pre–load.
Weld Time
The time during which the upper part is being rotated to heat the thermoplastic interfaces and form
the weld joint is called the weld time. The minimum
programmable weld time is 0.01 seconds. The maximum programmable weld time is 9.99 seconds. A
typical value might be 0.5 second.
Hold Time
After the weld time is completed, the parts must
be held together under pressure to allow the weld
joint to solidify. This is called the hold time. The
minimum and maximum programmable hold time is
0.01 and 9.99 seconds respectively. A typical values
range from 1.0 to 3.0 seconds.
Weld by Time
The weld cycle is determined only by the time
programmed into the controller. The timer starts
0.50 inches above the trigger point and stops the
motor when the timer reaches the programmed
time limit.
Dukane Manual Part Number 403-547-03
Page 49
Spin Welder User’s Manual
Weld by Distance
The weld cycle is determined by the bottom stop
setting. The End–Of–Weld optical switch stops the
process 0.005” above the actual setting to compensate for the system momentum.
Tooling Capacity
Upper Hub
The upper hub can safely accommodate a maximum
tool nest diameter of 12 inches (305mm) which allows for a clearance of 0.22 inches (5.6mm) in the
back. This is shown in Figure 7–1.
Lower Fixture
The platen surface is 410mm wide (16.14”) by
347mm deep (13.66”). The fixture mounting holes
are shown in detail in Figure 11–3, and consist of
eight M10 x 1.5 2B tapped holes on three bolt circles
ranging from 7.00” to 12.00” diameter. Depending
upon the geometry of the fixture, there is between
7.63” and 8.50” available behind the hub center line.
See Figure 7–1 for the relevant dimensions.
** 26.94
(684)
CONFIGURATION
6.38
(162)
20.94**
MAX
(532)
HEIGHT
ADJUSTMENT
RANGE WITH
HAND CRANK
9.19
(233.4)
(99)
6.25
(158)
7.63
(194)
13.66
(347)
Fixture Height
The following measurements are taken with a
0.5” thick tooling hub, the AC power ON and the
counterbalance regulator adjusted so that the motor
and hub are fully retracted upward. The adjustment
range is achieved by unlocking the dovetail locks
and rotating the hand crank. The normal maximum
height between the platen and upper hub available
is 20.94” (see Figure 7–1). This can be adjusted
at the factory during assembly to a larger capacity
of 26.94” to accommodate unusually high fixture
requirements. The lowest adjustment height (with
the motor and hub retracted) between the platen and
the upper tool hub is 9.19” (15.19” with the extra
height modification). The total stroke available during welding is determined by the air cylinder and
Page 50
inches
(millimeters)
8.50
(216)
Figure 7–1 Tooling Capacity Range Adjustment
Dukane Manual Part Number 403-547-03
Section 7 – Operational Setup
the bottom stop adjustment. The maximum stroke
is 7” (178mm). This gives the lowest achievable
height above the platen of 2.19” (55.6mm). The
stroke range you set determines the space you have
to load and unload the parts.
Air
Lockout
100 psi Air
J8
Optional
Pre–Filter
Setup Checklist
1. Attach Tooling
Make sure the upper tool nest is securely fastened
to the tooling hub. Also attach the lower tooling
fixture at this time.
2. Disable System
Before applying power, push the red Emergency
OFF switch in. This prevents any electrical or
pneumatic energy from being applied to the spin
welder.
Base Interface Cable
3. Base Interface Cable
The Base Interface cable should be connected between the base connector and the press connector as
shown in Figure 7–2 . These are identified as (4) and
(18) on the major components view Figure 2–3.
Tooling
(Typical)
J35
10
240 VAC 3Ø/60Hz
Figure 7–2 Location of Setup Checklist Items
4. Connect AC Power
Make sure the AC switch enclosure is securely
closed. Plug in the AC power cord to a 240 VAC
60Hz 3-phase outlet. This safely grounds the spin
welder. Leave the AC power switch OFF.
5. Connect Compressed Air
Turn the front air pressure regulator  all the way
counterclockwise. Turn the rear panel counterbalance regulator  all the way counterclockwise.
The compressed air can now be connected. The air
connection is shown in detail in both Figures 4–3
and 6–6. The compressed air supply should be clean
and dry. If your compressed air quality is marginal,
install a prefilter to avoid contaminating the internal
regulators, solenoids and air cylinder in the spin
Dukane Manual Part Number 403-547-03
Page 51
Spin Welder User’s Manual
welder. You may also be required to install an air
lockout as mentioned in Section 3 under Pneumatic
Safety. If you have an air lockout, flip it to the ON
position at this time.
6. Turn Power ON
Flip the AC power switch handle up to the ON position. The status display should now indicate ABORT
in red as shown in Figure 7–3.
7. Front Panel Regulator
ABORT
Figure 7–3 Base Status Display Indicates ABORT
Adjust the front air pressure regulator by turning the
regulator knob clockwise until the pressure gauge
reads about 40 psi.
8. Down Speed Adjustment
Pull the red ring forward to unlock the knob. Turn
the knob clockwise all the way in. Now turn the
knob out two turns . This is a good starting point
and will also enable the counterbalance to function
properly.
9. Counterbalance Regulator
Adjust the rear counterbalance regulator by first
turning the knob clockwise (CW) until the motor
and tool hub fully retract upward into the press
housing. Turn the knob counterclockwise until the
motor and hub gently drop down against the mechanical stop. Now slowly turn the knob CW back,
until the motor and hub fully retract again. There is
about a three-quarter turn difference between the up
and down adjustments. The counterbalance is now
correctly adjusted.
10. Enable System
POWER
Twist the red Emergency OFF button clockwise and
out. The motor and hub should now retract upwards.
The status display should now indicate POWER in
green as shown in Figure 7–4.
Height Adjustment
Figure 7–4 Base Status Display Indicates POWER
The hand crank (see Figure 6–7) is used to adjust
the height of the tooling hub above the base platen.
Page 52
Dukane Manual Part Number 403-547-03
Section 7 – Operational Setup
Turning the crank clockwise lowers the tooling hub.
Place the parts to be welded in the upper tool nest
and in the lower fixture. Adjust the hand crank to
raise or lower the tool hub to allow sufficient room
for safely loading and unloading the parts.
Stroke Adjustment

CAUTION
The bottom stop should
turn without too much effort. If the knob is difficult
to turn, check that the bottom stop lock on the side is
loosened (CCW).
Stop Lock
The bottom stop lock (shown in Figure 6–8 and
Figure 7–5) should be turned counterclockwise
to loosen the bottom stop adjustment knob. Once
the final optimum adjustment has been reached for
production, the stop lock should be tightened to
maintain consistency.
Bottom Stop Adjustment
The bottom stop setting determines the stroke. Figure 7–5 shows the bottom stop adjusted for a stroke
of four inches. Turning the knob counterclockwise
will cause the flag to rise on the scale which will
increase the stroke. Clockwise rotation lowers the
flag which results in a shorter stroke.
Adjust the bottom stop to slightly less than the desired stroke. Press the Emergency OFF button. The
hub should lower until it reaches the bottom stop
setting. Make any final adjustments in the lower
fixture centering to align it with the upper tool nest.
Measure the remaining stroke needed to bring the
upper tool to the correct finished weld height.
Reset the Emergency OFF switch so the upper hub
rises. Turn the bottom stop adjustment counterclockwise the appropriate amount to achieve the correct
finished weld height. The threaded rod attached to
the flag has 18 turns per inch, so one turn is 0.0556”
(1.41mm). Typical weld depths for spin welding are
about 0.030” (0.75mm). If you have a welded part,
or if the tooling fixtures make contact, adjust the
bottom stop an extra turn to achieve more than the
desired stroke.
Dukane Manual Part Number 403-547-03
Figure 7–5 Setting the Stroke Distance With the
Bottom Stop Adjustment
Page 53
Spin Welder User’s Manual
Press the Emergency OFF button again. If you adjusted the bottom stop for more stroke than needed,
turn the bottom stop knob clockwise to reduce the
stroke (lower the flag) until it backs up against the
mechanical limit. Repeat this process until you
have achieved the desired stroke and bottom stop
settings.
Start–Of–Weld
The Start–Of–Weld trigger occurs 0.50” (12.7mm)
above the bottom stop setting. After this point, the
Spin Welder process is in cycle and the digital timer
starts. Prior to this point, if the palm activation
switches are released, the tool hub will retract, and
the process will reset. After this point, the process
will complete automatically.
End–Of–Weld
The End–Of–Weld optical switch triggers 0.005”
(0.127mm) above the bottom stop setting to allow
for system momentum. If you are in a weld by distance mode, this marks the end of the weld cycle, and
terminates the process. The End–Of–Weld switch
has no effect on a weld by time operation.
Pneumatic Adjustments
Front Regulator
The front panel regulator (see Figure 6–5) controls
the amount of air pressure applied to the 3” air cylinder which in turn determines the force applied to the
weld joint. The boost factor of the air cylinder is calculated by the ratio of cylinder area to the area used
for standard atmospheric pressure measurements. A
3” diameter cylinder has an area of 7.07 sq. inches so
its boost is simply 7x the applied pressure in pounds
per sq. inch. A setting of 40 psi gives a downward
force of 280 lbs. If the joint contact area is 0.5 sq.
inch then the parts will have an applied pressure of
560 psi (280 lbs per 0.5 sq inch). A schematic of the
pneumatic system is shown in Figure 7–6.
Page 54
Dukane Manual Part Number 403-547-03
Section 7 – Operational Setup
Exhaust
Diffuser
Compressed
Air In
Pressure
Gauge
3–inch Air
Cylinder
Main
Valve
Quick
Exhaust
Valve
Front Panel
Regulator
Counterbalance
Regulator
Pilot
Valve
Air
Downspeed
Adjustment
Figure 7–6 Pneumatic System Schematic
Counterbalance Regulator
The counterbalance regulator on the rear of the
press (see Figure 6–6) adjusts the amount of upward pressure applied to the air cylinder between
weld cycles. To properly set the counterbalance,
push the Emergency OFF switch in. Then turn the
rear counterbalance regulator knob clockwise so
the motor and hub just retract upwards into the
press housing. This is the same procedure performed in Step 9 on page 52. Proper adjustment
of the counterbalance will enable you to achieve
better control of the down speed adjustment.
If the counterbalance is set too high, it will adversely
affect the down speed adjustment or the press may
not descend at all. If the counterbalance is set too
low, it will allow the air to escape from the air cylinder when the Emergency OFF switch is pushed
in. This in turn will allow the motor and tool hub
to descend until it reaches the bottom stop setting.
The motor and slide assembly weigh about 125 lbs.
(57kg), so it is important to keep your hands and
parts out from under the tool hub unless the counterbalance is properly adjusted.
Dukane Manual Part Number 403-547-03

CAUTION
If counterbalance regulator is set too high, the press
will not descend. Follow the
instructions for properly adjusting the counterbalance
regulator.
Page 55
Spin Welder User’s Manual
Down Speed Adjustment
The down speed adjustment on the front of the press
(see Figure 6–5) adjusts the flow of air leaving the
air cylinder during the downward stroke only. The
restoring pressure during the upward stroke is not
affected. The knob has numeric graduations ranging
from 0 to 9 and controls a ten–turn flow valve with a
one–way bypass. There are also two small windows
to view a color–coded internal shaft. The shaft has
eight colored bands. Reading from back to front they
are Green, Yellow, Blue, White, Red, Blue, Gray and
Brown. Pull the red ring forward to unlock the knob
before adjusting it. Once the final speed setting has
been determined, the red ring should be pushed back
to lock the setting in place.

CAUTION
Make sure the red lock
ring on the down speed
knob is pulled forward
to its unlocked position
before adjusting it. The
down speed knob should
turn freely.
The down speed setting is a flow control device, so
the amount of air released from the air cylinder during down stroke is dependent upon the pressure set
by the front panel regulator. Higher pressure gives
a faster down speed. The initial setting should be
approximately 1-1/2 to 2-1/4 turns open at a pressure regulator setting of 40 psi. Excessively high
counterbalance forces may adversely affect the
adjustment range of the down speed control.
Motor Speed Control
The motor speed is controlled by the digital switch
shown in Figure 6–5. This switch has three decades
of control and is used to set the motor RPM as a
percentage of the full rated motor speed. The motor
is an AC motor and its drive frequency is adjusted
as different speeds are selected. The rated motor
speed is nominally 3500 RPM for the 3 HP model
and 1750 RPM for the 5 HP model. The nomograph
shown in Figure 7–7 can be used to set the digital
speed control for the desired motor RPM. Select the
desired RPM from the outer left column (5 HP) or
inner left (3 HP) and read horizontally across to the
right column to obtain the speed setting to enter on
the digital switch. The speed settings are not criti-
Page 56
Dukane Manual Part Number 403-547-03
Section 7 – Operational Setup
cal, so the chart is more than adequate for setting
the speed control.
For example, a setting of 500 (50.0%) results in a
motor speed of 875 RPM for the 5 HP and 1750
RPM for the 3 HP motor. The maximum setting is
999 (99.9%). At less than maximum speed, the variable frequency drive maintains a fairly constant HP
output from the motor. This means that the torque
increases as RPM decreases. At low motor speeds,
the rotor–stator structure behaves like a transformer
which does not work well at low frequencies, The
lowest practical usable setting is about 100 (10%)
which is 350 RPM for the 3 HP Below this, the
motor may fail to reach the selected RPM within
the controller’s acceleration time window.
5 HP
Model
(RPM)
1750
3 HP
Model
(RPM)
3500
Speed
Setting
(0—999)
999
1700
1600
1500
900
3000
800
1400
1300
2500
1200
700
1100
User Interface
Power Up Sequence
1. When the Spin Welder is initially powered up,
the LCD display will light and remain blank for
approximately one second.
2. The processor then tests the display for one
second by turning on every pixel.
3. The display is again cleared and the processor
verifies the system memory.
4. If all test pass, the processor displays the boot
code powerup screen for one second.
MicroView
Core: 1.01(c)1995
600
1000
2000
900
500
800
1500
700
400
600
500
1000
300
400
200
300
500
200
100
100
5. Then two operating system screens are briefly
displayed.
MicroView
FRN: 1.01(c)1995
000
Figure 7–7 Motor RPM Conversion Chart
MicroView
MicroLogix DF1
Dukane Manual Part Number 403-547-03
Page 57
Spin Welder User’s Manual
6. The next screen displayed gives three options for
a menu selection. You can return to this screen
at any time by pressing the MENU key.
1=RUN
2=SETUP
3=MODIFY
Operating Menus
SETUP
Press the numeric 2 key to switch the processor to its
setup mode. The display then instructs you to push
the Emergency OFF button to begin setup. Push the
Emergency OFF button in.
PUSH ESTOP
TO BEGIN SETUP
The display now instructs you to set the bottom stop.
If you wish to bypass this step press 1 then press the
enter key in the lower right–hand corner.
SET BOTTOM STOP
1=BYPASS
To set the bottom stop, turn the counterbalance
regulator CCW to allow the motor and hub to drop
down to the limit stop (see Step 9 on page 52). Once
the stop has been set, the display will indicate it has
recognized the setting.
STOP SET
Now, turn the counterbalance regulator CW to allow
the motor and hub to rise back up. The display now
prompts you to select either a pre–load or pre–spin
mode. The most common mode is pre–spin.
1=PRELOAD
2=PRESPIN
The entire flowchart for the SETUP menu is displayed in Figure 7–8. For the spin welding process,
Page 58
Dukane Manual Part Number 403-547-03
Section 7 – Operational Setup
SETUP
Menu
MENU
1=RUN
2=SETUP
3=MODIFY
2
PUSH ESTOP
TO BEGIN SETUP
Push Emergency OFF
Button In
SET BOTTOM STOP
1=BYPASS
1
Turn Counterbalance Regulator
CCW To Allow Motor To Drop
Down To Limit Stop
STOP SET
1=PRELOAD
2=PRESPIN
NOTE
A flashing black box
(on the second line
to the right of the
current data) in the
display prompts you
to enter the data for
the specified parameter. When you have
entered the desired
data using the number and decimal point
keys, press the Enter
key as shown. If you
wish to use the current data, just press
the Enter key. The
Enter key needs to
be used for all data
except for the initial
Menu selection.
1
Turn Counterbalance Regulator
CW To Allow Motor To Rise
Back Up Into Press
2
PART PICKUP?
1=YES 2=NO
Enter Desired Value
Then Press ENTER
SET PRELOAD
TIME .25
1
SET PICKUP TIME
1.00
1=WELD BY DIST.
2=WELD BY TIME
2
2
1
SET MAX. TIME
LIMIT 1.50
SET WELD TIME
.75
SET HOLD TIME
.50
SET HOLD TIME
.50
Figure 7–8 SETUP Menu Flowchart
Dukane Manual Part Number 403-547-03
1=RUN
2=SETUP
3=MODIFY
Page 59
Spin Welder User’s Manual
it is preferable to begin with the Weld by Time mode.
After you have some experience with your parts and
the correct parameters, you may wish to experiment
with the Weld by Distance mode.
RUN Menu
Once the necessary parameters have been entered,
twist the Emergency OFF button clockwise and out.
Select the RUN menu by pressing 1. Now simultaneously press both palm switches to start operation.
The RUN menu flowchart is shown in Figure 7–9.
RUN
Menu
MENU
1=RUN
2=SETUP
3=MODIFY
Start of New
Weld Cycle
1
MACHINE READY
PART COUNT=
0
Counter Incremented
After End of Weld Cycle
Counter Can Be
Reset in MODIFY Menu
*WORKING*
Both Palm Switches
Simultaneously Pressed
Down Stroke
WELD TIME
Spin Cycle Ends
HOLD TIME
Display Indicates
Which Mode the
Spin Welder is
Currently Operating
Upstroke
*WORKING*
End of Weld Cycle
End of Current
Weld Cycle
MACHINE READY
PART COUNT=
1
Counter Incremented
MACHINE READY
PART COUNT=9999
Maximum Part Count
Figure 7–9 RUN Menu Flowchart
Page 60
Dukane Manual Part Number 403-547-03
Section 7 – Operational Setup
MODIFY Menu
To modify the parameter values, press the MENU
key, then 3 to enter the MODIFY menu. The flowchart for MODIFY is shown in Figure 7–10.
MODIFY
Menu
MENU
1=RUN
2=SETUP
3=MODIFY
3
RESET COUNTER?
1=YES
2=NO
1
2
Counter is reset to zero
Counter is not reset
Checks Which Mode Was
Selected in the SETUP Menu
PRE–LOAD Was Selected in SETUP Menu
PRE–SPIN Was Selected in SETUP Menu
Check If PART PICKUP Was
Selected in SETUP Menu
Part Pickup = YES
SET PRELOAD
TIME .25
Part Pickup = NO
SET PICKUP TIME
1.00
1=WELD BY DIST.
2=WELD BY TIME
1
2
SET MAX. TIME
LIMIT 1.50
SET WELD TIME
.75
SET HOLD TIME
.50
SET HOLD TIME
.50
1=RUN
2=SETUP
3=MODIFY
Figure 7–10 MODIFY Menu Flowchart
Dukane Manual Part Number 403-547-03
Page 61
Spin Welder User’s Manual
Input Parameters
PART PICKUP
An option available for the Pre-Spin mode only. If
selected, the tool hub lowers to pick up the upper
portion of the part from the fixture, then rises to the
top. The lower portion of the part remains in the
fixture. The tool hub then begins spinning as it is
lowers to begin the weld cycle.
PICKUP TIME
This is the amount of time that the tool hub spends
in the lowered position to pick up the part. This is
only available if the Part Pickup option was selected.
The minimum and maximum pickup times are 0.01
and 9.99 seconds respectively. A typical value might
be 1.0 second.
PRE–LOAD TIME
This is the amount of time that the tool hub spends
in the lowered position applying a preloading pressure to the upper and lower parts to be welded. This
setting is only available if the Pre–Load mode was
selected. The minimum and maximum values are
0.01 and 9.99 seconds respectively. A typical value
might be 0.25 second.
MAX. TIME LIMIT
This setting is only available in the Weld–By–Distance menu. This is the time limit that will terminate
the weld cycle if the End–Of–Weld trigger is not
reached. This time should be larger than the sum
of the estimated weld time and the hold time. The
minimum and maximum values are 0.01 and 9.99
seconds respectively. A typical value might be 3 to
4 seconds.
Page 62
Dukane Manual Part Number 403-547-03
Section 7 – Operational Setup
PREV and NEXT Keys
PREV Key
PREV
In the Setup menu, the Previous key recalls the data
value entered previous to the current one displayed.
This key does not work in Modify menu.
NEXT Key
NEXT
The Next key skips the currently displayed value
and steps to the next input parameter in either the
Setup or Modify menu.
Dukane Manual Part Number 403-547-03
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Spin Welder User’s Manual
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Page 64
Dukane Manual Part Number 403-547-03
Section
Section
7 – Operational
8 – Maintenance
Setup
Section 8
Maintenance
• User Interface Panel
• AC Power Cord & Plug
• Weekly Maintenance
• Monthly Maintenance
• Annual Maintenance
User Interface Panel........................................67
Cleaning......................................................... 67
Display............................................................ 67
Keypad........................................................... 67
AC Power Cord...............................................67
Weekly Maintenance......................................68
Pre–Filter......................................................... 68
Exhaust Diffuser.............................................. 68.
Visual Inspection............................................. 68
Monthly Maintenance.....................................68
Slides and Motor Shaft.................................... 68
Rear Counterbalance...................................... 68
Annual Maintenance.......................................69
Dukane Corporation •
Dukane Manual Part Number 403-547-03
Gas Spring...................................................... 69
Lubricate Slides............................................... 70
• Ultrasonics Division
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Spin Welder User’s Manual
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Page 66
Dukane Manual Part Number 403-547-03
Section 8 – Maintenance
User Interface Panel
Cleaning
Do not use any solvents or abrasive cleaners on the
display window. Using a soft cloth or clean sponge,
clean the display with a mild soap or detergent.
Dry the display with a chamois or moist cellulose
sponge to avoid water spots. Do not spray or apply
a cleaner directly to the interface panel.
Remove grease or fresh paint splashes before they
dry by rubbing lightly with isopropyl alcohol.
Afterward, provide a final cleaning using a mild
detergent and rinse with clean water.

CAUTION
Use of abrasive cleaners or
solvents may damage the
display window. Do not
scrub or use brushes. Some
types of paper towels may
scratch the window. Use only
a soft sponge or cloth.
Display
Do not use any sharp objects on the display. It
should not be touched unnecessarily. It is lit by a
long–life LED backlight and should not require any
maintenance other than occasional cleaning.
Keypad
Use your finger to press the control keys. Do not
use sharp objects on the keys. If your hands are
greasy or contaminated with dirt, use a soft object
like a pencil eraser.
AC Power Cord
The AC power cord should be kept in good condition and free from any cuts and abrasions. The AC
plug should be straight with no bent prongs.
Dukane Manual Part Number 403-547-03
WARNING
Never alter the AC plug
prongs to fit into the AC
outlet. The geometry
of the 240VAC 20A 3Ø
plug is different from a
120/240VAC 20A 1Ø (NEMA L14–
20P) configuration and also from
a 480VAC 20A 3Ø (NEMA L16–20P)
configuration. All three geometries
are incompatible with each other to
prevent accidental overloads.

Page 67
Spin Welder User’s Manual
Weekly Maintenance
Pre–Filter
If you have installed a pre–filter in the compressed
air line, check the filter once a week and clean if
necessary.
Exhaust
Diffuser
Exhaust Diffuser
The exhaust diffuser is porous, sintered metal filter.
It acts similar to a metallic sponge, and is designed
to trap solid particles in gas streams. Its location is
shown in Figure 8–1. A darkened diffuser indicates
contaminated compressed air is being exhausted
from the system. This implies that the incoming
compressed air is not clean. Install a pre–filter on
the compressed air line. The diffuser can be cleaned
by an ultrasonic bath or reverse flow flushing.
Visual Inspection
Figure 8–1 Location of Exhaust Diffuser
Visually inspect the cables and air lines once a week.
Replace or repair any damaged cables or air lines.
Monthly Maintenance
Slides & Motor Shaft
Once a month, clean the exposed vertical slides and
rack teeth of any accumulated debris and dirt. Clean
the lower motor shaft area to allow an unobstructed
flow of cooling air. These areas are identified in
Figure 8–2.
Rear Counterbalance
Check the counterbalance regulator for proper operation and setting. Push the Emergency OFF switch
in. The motor and hub should not descend. Turn the
rear counterbalance regulator knob CCW so that the
motor and slide descend. Then turn the counterbalance regulator knob CW so the motor and hub just
retract upward into the press housing.
Page 68
Motor
Shaft
Area
Vertical
Slides
Rack
Teeth
Figure 8–2 Slides, Gear Teeth & Motor Shaft Area
Dukane Manual Part Number 403-547-03
Section 8 – Maintenance
Annual Maintenance
Gas Spring
Check the external gas spring (see Figure 8–3) for
sufficient counterbalance force by turning the hand
crank to move the head all the way up and down.
Make sure to first unlock the two dovetail locking
levers. The gas spring counterbalances the entire
upper motor and press assembly up to the maximum
height, which is adjusted by the hand crank. The
rear counterbalance regulator adjusts the pressure
on the internal air cylinder to counterbalance just
the motor. These two items function separately and
should not be confused with each other. If the gas
cylinder has lost pressure, it will not provide sufficient restoring force at its maximum extension,
and should be replaced. The gas spring cannot be
recharged. Contact your local Dukane representative for the correct part number or you can try and
obtain one directly from Fairchild Fasteners at (818)
998–1412. The upper attachment nut is behind the
name plate as indicated in Figure 8–4 on the next
page. The gas spring may be installed with either the
main cylinder at the bottom or the top. It functions
properly in either orientation.
Upper
Bracket
Lower
Lubrication
Fitting
Gas
Spring
Figure 8–3 Gas Spring Location
Dukane Manual Part Number 403-547-03
Page 69
Spin Welder User’s Manual
Lubricate Slides
Lubricate the dovetail slides with Mobil Vactra #2
or equivalent. Do not use grease. There are four
fittings, two on each side. Three are clearly visible
and one is hidden behind the Dukane name plate
of the upper gas spring support bracket. Cut out an
access hole to gain access to this grease fitting (see
Figure 8–4). The lower fitting is shown in Figure
8–3. The two fittings on the opposite side are visible in Figure 6–7. They are adjacent to the dovetail
locking levers. Each fitting is accompanied by a
small red label advising against the use of grease
for lubricating the slides.
Attachment
Figure 8–4 Gas Spring Upper Support Bracket

Page 70
CAUTION
Do not use grease to lubricate the slide. Use Mobil
Vactra #2 or equivalent.
Dukane Manual Part Number 403-547-03
Section
Section
9 –8Troubleshooting
– Maintenance
Section 9
Troubleshooting
• Welding Process
• Welder Troubleshooting
• User Interface
Welding Process..............................................73
Material Choice.............................................. 73
Parameter Effects............................................ 73
Welder Troubleshooting..................................74
Pneumatics..................................................... 74
Mechanical..................................................... 74
Electrical Power............................................... 74
Base Interface Cable....................................... 74
AC Motor Controller....................................... 76
User Interface................................................. 76
Dukane Corporation •
Dukane Manual Part Number 403-547-03
• Ultrasonics Division
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Dukane Manual Part Number 403-547-03
Section 9 – Troubleshooting
Welding Process
Material Choices
A family of thermoplastics is usually compatible
with its own type and sometimes with other types.
Characteristics to consider are the melting point and
coefficient of linear expansion. Even members of
the same family may cause problems due to differences in the manufacturing process. For example,
an extruded Polyethylene (PE) piece may not weld
as well to an injection molded PE piece as it would
to another extruded PE piece.
Parameter Effects
Surface Velocity
Insufficient surface velocity may not allow the
plastic to reach its melting temperature. Instead,
it may simply erode away part of the material and
stick by a clawing effect. The surface velocity is
determined by both the weld joint diameter and the
motor speed.
Axial Pressure
In conjunction with surface velocity, axial pressure
determines whether the plastic reaches the melting
temperature. Both speed and pressure are needed
to produce sufficient frictional heating. Excessive
pressure may cause one part to scrape away part of
the surface and produce a lot of flash but insufficient
melt volume.
Weld Time
Insufficient welding time may not allow the melt
to propagate far enough into the plastic to achieve
the necessary melt volume and the required weld
strength.
Hold Time
Insufficient holding time may not allow the plastic
enough time to solidify and form a strong permanent bond.
Dukane Manual Part Number 403-547-03
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Spin Welder User’s Manual
Welder Troubleshooting
Pneumatics
The air cylinder requires a clean, dry supply of
compressed air at 100 psi (6.9 bar). If you have an
air lockout device, make sure it is turned on. If you
have a pre–filter, make sure it is clean and functioning properly.
Mechanical
The part fixture should be securely mounted perpendicular to, and centered under the spin axis.
Electrical Power
WARNING
Always turn the AC power OFF before opening
the AC switch enclosure.
Disconnect the AC power cord and lockout the
switch handle before performing
any tests or maintenance on the
fuses. The voltage inside the enclosure is dangerous.

Always lockout the compressed air
before performing any electrical
maintenance or service.
Make sure the AC power cord is plugged in to a 240
VAC, 3–phase electrical outlet with a 20 Ampere
capacity. Check that the circuit is live. Check that the
three 20 Amp fuses in the AC enclosure are electrically intact (see Figure 6–2). Also refer to Electrical
Safety in Section 3.
Base Interface Cable
The cable must be plugged in to the base and the
back of the press. If the cable is not plugged in, or
has a fault, the palm switches will not initiate any
action. Also the ABORT and POWER indicators on
the base status display will not function. Table 9–1
lists the internal connector pinout and wire color.
Pin
Color
Description
4
White
Common
5
Yellow
Safety switch 1
6
Red
Common
7
Green
Abort
8
Black
Safety Switch 2
13
Brown
+24 VDC Input
14
Blue
+24 VDC Output
Table 9–1 Base Interface Connector Pinout
Page 74
Dukane Manual Part Number 403-547-03
Section 9 – Troubleshooting
A complete block diagram of the electrical components is shown in Figure 9–1. The base interface
cable supplies power to the status display and passes
the operate and abort signals to the Micrologic
Controller. A more detailed schematic is shown in
Appendix B.
Main AC
Disconnect
& Fuses
240 VAC
3 Phase
Line Input
Master
Control
Relay
7 6 5 4
8
14 13
Safety Switch
Base Interface
Connector
A–B
Micrologic
PLC Controller
1
3
A-B
Motor
Controller
Top–Of–Stroke
Connector
Main
Pneumatic
Solenoid
Valves
Start–Of–Weld
End–Of–Weld
Optical Switches
Speed
Control
+24 VDC
Power
Supply
AC
Motor
CW
Figure 9–1 Block Diagram of Electrical Components
Dukane Manual Part Number 403-547-03
Page 75
Spin Welder User’s Manual
AC Motor Controller
The motor controller is located behind the removable front panel on the right hand side. The front of
the controller contains two indicator LEDs to aid in
troubleshooting. The controller is shown in Figure
9–2. The lower green READY indicator LED illuminates when the DC bus is charged and the drive
is ready to run. The upper red FAULT indicator LED
illuminates when a drive fault condition exists.
User Interface
To perform the diagnostic test on the user interface,
you must first access the test functions from the
Mode menu. The flowchart shown in Figure 9–3
shows how to access the Display Test (A) function
and other diagnostic functions. There are a total of
eight tests which can be performed along with the
reset function which exits the diagnostic test menu.
The Core ROM (B), System RAM (C), System
ROM (D), Program ROM (E) and Watchdog Timer
(H) tests all either pass or fail. The correct message
is that the test passed, then press any key to continue.
The Keyboard Test (F) is self explanatory and tests
the response of every key in sequence on the key
pad. Do not try to run the Comm Port (G) test as
this requires an external DC supply and a special
loopback connector. The test will fail if it is run.
All other tests should pass. If any of the ROM tests
(B, D or E) fail, it may indicate a possible defective
ROM or a corrupted operating system. If the System
RAM (C) test fails, the program may be corrupted.
If any of these four memory tests fail, execute the
Reset (I) function and recheck. If the test still fails,
contact the Dukane Service Department at 1-800231-8084. To exit the User Interface Diagnostic
tests, navigate to the Reset (I) function using the
NEXT or PREV keys and then press the Enter key
(see bottom of Figure 9–3).
Page 76
Figure 9–2 Motor Controller LEDs
Dukane Manual Part Number 403-547-03
Section 9 – Troubleshooting
TEST FUNCTIONS
Menu
MODE
*LIMITED ACCESS*
CODE:
Any Code Works Until
Access Code is Set
1
Valid Code
Access Permitted
1 Reset
2 Comm
3 Spec
4 Other
5
Eight Tests plus Reset
Press Enter Key to Initiate Test
Press NEXT or PREV Key to Select Test
Select Reset to Exit TEST Menu
4
1Code
2Scal
3Sim 5Ex
4Test
4
Diagnostic Tests
Display
PREV
A
Diagnostic Tests
Reset
Diagnostic Tests
Display
PREV
All Pixels Are
Turned On
Diagnostic Tests
Core ROM
PREV
Diagnostic Tests
System RAM
First One Checkerboard
Pattern Is Displayed
PREV
Diagnostic Tests
System ROM
Display Then Alternates
in Checkerboard Pattern
PREV
Diagnostic Tests
Program ROM
PREV
Any Key
Display Test is Terminated
Next Test is Queued
Diagnostic Tests B
Core ROM
Diagnostic Tests
Keyboard
PREV
Diagnostic Tests
Comm Port
PREV
Diagnostic Tests
Watchdog
Diagnostic Tests I
Reset
MicroView
Core: 1.01(c)1995
PREV
Diagnostic Tests
Reset
MicroView
FRN: 1.01(c)1995
I
A
B
NEXT
C
NEXT
D
NEXT
E
NEXT
F
NEXT
G
NEXT
H
NEXT
I
NEXT
NEXT
MicroView
MicroLogix DF1
1=RUN
2=SETUP
3=MODIFY
Figure 9–3 TEST Functions Flowchart
Dukane Manual Part Number 403-547-03
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Dukane Manual Part Number 403-547-03
Section
Section
10 –9Contacting
– Troubleshooting
Dukane
Section 10
Contacting Dukane
• Dukane Support
• Website
• FAX
• Telephone Numbers
Identify Equipment..........................................81
Our Website...................................................81
Mailing Address..............................................81
Phone Number................................................81
Dukane Corporation •
Dukane Manual Part Number 403-547-03
• Ultrasonics Division
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Page 80
Dukane Manual Part Number 403-547-03
Section 10 – Contacting Dukane
Contacting Dukane
Identify Equipment
When contacting Dukane about a service–related problem,
be prepared to give the following information:
• Model number, line voltage and serial number.
• Alarm messages from the touch screen display.
• Problem description and steps taken to resolve it.
Many problems can be solved over the telephone, so it is best
to call from a telephone located near the equipment.
Intelligent Assembly Solutions
Mailing Address: Dukane Ultrasonics
2900 Dukane Drive
St. Charles, IL 60174 USA
Phone: (630) 797–4900
Fax:
Main
(630) 797–4949
Service & Parts (630) 584–0796
E-mail:ussales@dukane.com
Website
www.dukane.com/us
The website has information about our products, processes, solutions, and technical data. Downloads are available for many
kinds of literature.
You can locate your local representative at:
www.dukane.com/us/sales/intsales.htm
Dukane Manual Part Number 403-547-03
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Dukane Manual Part Number 403-547-03
Section
Section
10 – Contacting
11 – Specifications
Dukane
Section 11
Specifications
• Energy Requirements
• Operating Environment
• Dimensions
• Model & Serial Numbers
Energy Requirements......................................85
Pneumatic....................................................... 85
AC Power....................................................... 85
Operating Enviornment...................................85
Dimensions.....................................................86
Identification Numbers....................................87
Base Model and Serial Number.......................88
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• Ultrasonics Division
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Dukane Manual Part Number 403-547-03
Section 11 – Specifications
Energy Requirements
Pneumatic
The compressed air supply must be clean and dry.
The acceptable pressure range is 80 psi to 110 psi
(5.5 bar to 7.6 bar).
If the air line contains moisture or oil, install a
pre–filter before the Spin Welder air inlet.
AC Power
The electrical power requirements are 200 to 240
VAC, 3–phase, 60 Hz at 20 AMPS.
3–phase Input Current
3 HP: 12 Amps (2.2kW)
5 HP: 18 Amps (3.7kW)
The spin welder uses three identical AC fuses. One
of the fuses is shown in Figure 11–1. They are each
SLO–BLO type FLNR 20 fuses rated at 250 VAC.
Figure 11–1 FLNR 250V/20Amp SLO–BLO Fuse
Operating Environment
Operate and store the Spin Welder within these
guidelines.
Oparating:
Temperature:
Humidity:
Altitude:
Vibration:
Particulates:
32° F to 122° F (0° C to 50° C)
5% to 95% Non–condensing
@ 0° C to 30° C
1,000 m (3,300 ft) without derating
1.0 G
Minimize exposure to dust, dirt,
smoke and mold.
Storage:
Temperature:
Humidity:
Vibration:
-4° F to 158° F (-20° C to 70° C)
5% to 95% Non–condensing
@ 0° C to 30° C
2.5 G
Dukane Manual Part Number 403-547-03
Page 85
Spin Welder User’s Manual
Dimensions
12.25
(311)
13.94
(354)
55.88
(1419)
inches
(millimeters)
6.38
(162)
20.94**
(532) MAX
16.50
(419)
21.50
(546)
** 26.94
(684)
WITH SPECIAL
FACTORY
CONFIGURATION
7.63
(194)
inches
(millimeters)
3.90
18.58
(472)
Figure 11–2 Front View and Dimensions
Page 86
6.25
(158)
13.66
(347)
8.50
(216)
27.75
(705)
Figure 11–3 Side View and Dimensions
Dukane Manual Part Number 403-547-03
Section 11 – Specifications
0.50
(12.7) DIA. HOLES
18.58
(472)
0.50 RADIUS
2 PLACES
16.50
(419)
inches
(millimeters)
8.25
(209.6)
(336.6)
M10 X 1.5 2B TAP THRU
EQUALLY SPACED AND
LOCATED AT TRUE
POSITION WITHIN .015 DIA
ON (2) TWO BOLT CIRCLES
8 PLACES
14.00
(355.6)
7.61
(193.3)
7.00 inch BOLT CIRCLE
125.0 mm BOLT CIRCLE
12.38
12.00 inch BOLT CIRCLE
24.84
(631
1.52/(38.6)
1.50/(38.1)
2.00/(50.8)
2.25
TYP.
M12 X 1.75 6H TAP THRU
5 PLACES
2.63 TYP.
(66.8)
Figure 11–4 Top View of Base and Dimensions
Identification Numbers
Welder Model & Serial
Number
The serial number and model number tags for the Spin
Welder are located on the rear of the upper housing,
just below the compressed air exhaust diffuser.
Figure 11–5 Spin Welder Serial & Model Number Location
Dukane Manual Part Number 403-547-03
Page 87
Spin Welder User’s Manual
Base Model and Serial Number
The base is Dukane model number 438–749. The serial
number tag is located on the rear of the base above the
Base Interface connector as shown in Figure 11–6.
Figure 11–6 Base Serial Number Location
Page 88
Dukane Manual Part Number 403-547-03
Section 11 – Specifications
Appendix A
List of Figures
List of Tables
Dukane Corporation •
Dukane Manual Part Number 403-547-03
• Ultrasonics Division
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Dukane Manual Part Number 403-547-03
Appendix A - List of Figures and Tables
List of Figures
Figure 2-1
Figure 2-2
Figure 2-3
Figure 2-4
240VAC L15-20 Plug......................................................................... 10
240VAC L15-20 Receptacle............................................................... 10
Major Components Rear View with Callouts...................................... 11
Major Components Front View with Callouts.................................... 12
Figure 3-1
AC Power Enclosure, Switch and Lockouts........................................ 16
Figure 4-1
Figure 4-2
Figure 4-3
Figure 4-4
Figure 4-5
Figure 4-6
Base Mounting Hole Locations.......................................................... 21
Tool Mounting Hub Dimensions......................................................... 21
Compressed Air Connection.............................................................. 22
Base Interface to Press Connection.................................................... 23
Top–Of–Stroke Cable......................................................................... 23
240VAC 3–Phase Receptacle Wiring.................................................. 24
Figure 5-1
Figure 5-2
Figure 5-3
Graph of Weld Penetration Velocity................................................... 27
Graph of Surface Velocity as a Function of Weld Diameter................. 31
Graph of Motor RPM as a Function of Weld Diameter....................... 32
Figure 6-1
Figure 6-2
Figure 6-3
Figure 6-4
Figure 6-5
Figure 6-6
Figure 6-7
Figure 6-8
AC Power Switch in OFF and ON Positions......................................... 37
AC Power Enclosure and Fuses.......................................................... 38
Base With Dual Palm Switches........................................................... 38
Base Status Display and Emergency OFF Switch................................. 39
Front Panel Controls, Display and Gauge........................................... 40
Counterbalance Regulator................................................................. 41
Dovetail Locks and Height Adjustment.............................................. 43
Bottomstop Adjustment and Lock..................................................... 44
Figure 7-1
Figure 7-2
Figure 7-3
Figure 7-4
Figure 7-5
Figure 7-6
Figure 7-7
Figure 7-8
Figure 7-9
Figure 7-10
Tooling Capacity Range Adjustment.................................................. 50
Location of Setup Checklist Items...................................................... 51
Base Status Display Indicates ABORT.................................................. 52
Base Status Display Indicates POWER................................................. 52
Setting Stroke Distance With Bottomstop.......................................... 53
Pneumatic System Schematic............................................................. 55
Motor RPM Conversion Chart............................................................ 57
SETUP Menu Flowchart..................................................................... 59
RUN Menu Flowchart........................................................................ 60
MODIFY Menu Flowchart.................................................................. 61
Figure 8-1
Figure 8-2
Figure 8-3
Figure 8-4
Location of Exhaust Diffuser.............................................................. 68
Slides, Gear Teeth & Motor Shaft Area............................................... 68
Gas Spring Location.......................................................................... 69
Gas Spring Upper Support Bracket.................................................... 70
Dukane Manual Part Number 403-547-03
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Spin Welder User’s Manual
Figure 9-1
Figure 9-2
Figure 9-3
Block Diagram of Electrical Components........................................... 75
Motor Controller LEDs....................................................................... 76
TEST Function Flowchart.................................................................... 77
Figure 11-1
Figure 11-2
Figure 11-3
Figure 11-4
Figure 11-5
Figure 11-6
FLNR 250V/20AMP SLO–BLO Fuse..................................................... 85
Front View and Dimensions............................................................... 86
Side View and Dimensions................................................................ 86
Top View of Base and Dimensions..................................................... 87
Spin Welder Serial & Model Number Location.................................... 87
Base Serial Number Location............................................................. 88
Figure B-1 Spin Welder Electrical Schematic....................................................... 95
List of Tables
Table 2-1
Table 5-1
Table 9-1
Page 92
Spin Welder Shipping Contents........................................................... 9
Recommended Weld Joint Diameters................................................ 34
Base Interface Connector Pinout........................................................ 74
Dukane Manual Part Number 403-547-03
Appendix
Appendix
A - List
B -ofElectrical
Figures and
Schematic
Tables
Appendix B
Electrical Schematic
Dukane Corporation •
Dukane Manual Part Number 403-547-03
• Ultrasonics Division
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Dukane Manual Part Number 403-547-03
Dukane Manual Part Number 403-547-03
N.O
SW1
END WELD
E-W
+12V
P-T
+24V
GND
8
BRN
14 13 12
YEL
BLK
ORN
BLU
RED/WHT
BLU
BLK
WHT
INPUT FROM
SAFETY SWITCH
GRN
GRAY
+24VDC
+12VDC
RED
0VDC
BLU/WHT
0
ABORT
O/0
2
SS2
BLK
O/1
1
SS1
YEL
OUTPUTS
COM
GRN
COM
4
BLK
ORN
GRN/ORN
RED
BLU
GRAY
0/2
3
O/3
4
TOS
1
ALLEN BRADLEY
MICROLOGIC
1000
3
AT
FREQ
ORN
BLU/WHT
6
END
WELD
7
ORN
G
L2
L1
8
DOWN
SV1
VDC
O/5
UP
SV2
EXTEND RETRACT
5
BLU
BLK
TOP OF STROKE
OUTPUT
2
BLU
BLK
OPTICAL SWITCHES
SW2
24V RETURN
14
PRETRIGGER
24V IN
ABORT
7
13
COMMON
6
SAFETY SW 2
SAFETY SW 1
5
8
COMMON
4
20 AMP
20 AMP
20 AMP
TOP OF STROKE
SWITCH
3
2
1
ORN
ORN
+24V
5
3
24 VDC
240
VAC
4
0VDC
0VDC
BLK
GRAY
+24VDC IN
BLU
T2
L2
L1
MCR
L2
T1
L1
L3
T3
L3
SPEED
CONTROL
BLK
RED
T1
T2
T3
A-B
1600 SERIES
MOTOR CONTROLLER
A2
A1
BLK
WHT
RED
GRN
Figure B–1 Spin Welder Electrical Schematic
N.C
N.O
N.O
DESC
PIN
240
VAC
AC POWER IN
MAIN
DISCONNECT
MOTOR
Appendix B - Electrical Schematic
+12VDC
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Dukane Manual Part Number 403-547-03
Index
Index
A
ABORT Status.................................................................................................. 39
AC Fuses...............................................................................................37-38, 87
AC Lockout...................................................................................................... 16
AC Power Cord............................................................................................... 67
AC Power Indicator........................................................................................ 39
AC Power Requirements.................................................................... 10, 24, 87
AC Power Switch...................................................................................... 37, 52
AC Receptacle........................................................................................... 10, 24
AC Safety................................................................................................... 16, 37
Air Cylinder................................................................................... 18, 30, 41, 54
Axial Pressure...................................................................................... 28, 30, 73
B
Base Interface Cable................................................................................. 23, 74
Base Interface Connector......................................................................... 23, 75
Base Platen................................................................................................ 50, 89
Bottom Stop Adjustment......................................................................... 44, 53
Bottom Stop Indicator Flag............................................................................ 44
Bottom Stop Lock........................................................................................... 45
C
Cable Color Code...................................................................................... 23, 74
Cable Connections.............................................................................23, 75, B-3
Cable Part Number......................................................................................... 23
Cable Pinout................................................................................................... 23
Compressed Air Lockout................................................................................ 51
Compressed Air Prefilter.......................................................................... 51, 68
Compressed Air Requirements.......................................................... 10, 22, 87
Compressed Air Safety..............................................................................17-18
Connector Pinout............................................................................... 23, 74, 97
Control Cable............................................................................................ 23, 75
Counterbalance Regulator........................................................... 41, 52, 55, 68
D
Diagnostic Tests.............................................................................................. 77
Dimensions...........................................................................................50, 88-89
Display/Format Keys....................................................................................... 42
Display, Cleaning............................................................................................ 67
Display, Status........................................................................................... 39, 52
Display, User Interface....................................................................40-41, 57-61
Down Speed Control.......................................................................... 41, 52, 56
Dovetail Locks............................................................................................43-44
Drawing, Part Identification.....................................................................11-12
Dukane Contacts............................................................................................ 81
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Spin Welder User’s Manual
E
Electrical Block Diagram................................................................................ 75
Electrical Schematic........................................................................................ 95
Emergency OFF Switch............................................................................. 38, 52
eMail Address................................................................................................. 81
End–Of–Weld.................................................................................................. 54
ENTER Key....................................................................................................... 42
Exhaust Diffuser....................................................................................... 22, 68
F
FAX Number.................................................................................................... 81
Fixture Height................................................................................................. 50
Frictional Heating Phase................................................................................ 27
Front Panel Cleaning...................................................................................... 67
Function Keys.................................................................................................. 42
Fuses, AC..............................................................................................37-38, 85
G
Gas Spring....................................................................................................... 69
Gauge, Pressure Regulator............................................................................ 40
Grounding....................................................................................................... 17
H
Health and Safety . ...................................................................................15-18
Height Adjustment................................................................................... 43, 52
Hold Phase...................................................................................................... 27
Hold Time...................................................................................... 30, 33, 49, 73
Hygroscopic Thermoplastics........................................................................... 28
I
IN–CYCLE Status.............................................................................................. 39
Initial Settings............................................................................................30-33
Installation.................................................................................................19-24
Internet Site.................................................................................................... 81
ISO 9001 Certification...................................................................................... 5
K
Keypad.......................................................................................................40-41
Key Functionality.................................................................................41-42, 63
L
Locking Ring, Down Speed Control.........................................................40-41
Lockout, AC..................................................................................................... 16
Lockout, Pneumatic.................................................................................. 17, 51
Lubrication, Slide............................................................................................ 70
Page 98
Dukane Manual Part Number 403-547-03
Index
M
Maintenance Schedule..............................................................................67-70
Maximum Time Limit Setting......................................................................... 62
Mechanical Safety.......................................................................................... 17
Melting Transition Phase............................................................................... 27
Menu Hierarchy.........................................................................................58-61
Model Numbers................................................................................................ 9
Model Number Tag...................................................................................87-88
MODIFY Menu Flowchart.............................................................................. 61
Motor Controller............................................................................................ 76
Motor Speed Control............................................................................... 43, 56
Motor Speed Effects....................................................................................... 73
Mounting Holes.............................................................................................. 21
N
NEXT Key......................................................................................................... 63
Number Keys................................................................................................... 42
O
Operate Controls...........................................................38 (see Palm Switches)
Operating Menus......................................................................................58-61
OSHA Safety Requirements............................................................... 15, 17, 38
P
Packing List....................................................................................................... 9
Palm Switches................................................................................................. 38
Part Identification Drawing..................................................................... 11, 12
Part Pickup Mode........................................................................................... 62
Part Size Considerations............................................................................33-34
Penetration Velocity....................................................................................... 27
Phases of Spin Welding Process..................................................................... 27
Pickup Time Setting........................................................................................ 62
Placement Considerations........................................................................ 10, 21
Plastics Health Notice..................................................................................... 15
Pneumatic Diagram........................................................................................ 55
Pneumatic Lockout......................................................................................... 51
Pneumatic Safety.......................................................................................17-18
Power Requirements................................................................................ 10, 87
POWER Status................................................................................................. 39
Power Up Sequence..................................................................................57-58
Pre–Filter, Compressed Air....................................................................... 51, 68
Pre–Load Mode............................................................................................... 49
Pre–Load Time Setting................................................................................... 62
Pre–Spin Mode................................................................................................ 49
Pressure Regulator Gauge....................................................................... 40, 54
Pressure Regulator Adjustment......................................................... 40, 52, 54
PREV Key......................................................................................................... 63
PVC Safety....................................................................................................... 15
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R
Regulator, Counterbalance.......................................................... 41, 52, 55, 68
Regulator, Pressure................................................................................... 40, 52
RPM Conversion Chart.................................................................................. 57
RUN Menu Flowchart..................................................................................... 60
S
Safety.........................................................................................................15-18
Serial Number Tags....................................................................................87-88
Service, Emergency......................................................................................... 82
Setup Checklist..........................................................................................51-52
SETUP Menu Flowchart.............................................................................58-59
Shipping Contents............................................................................................ 9
Slide Lubrication............................................................................................. 70
Solenoid............................................................................... 41, 55 (Figure 7–6)
Specifications.............................................................................................85-88
Start–Of–Weld................................................................................................ 54
STATUS Display............................................................................................... 39
Steady State Phase......................................................................................... 27
Stroke Adjustment......................................................................................... 53
Surface Velocity........................................................................................ 27, 73
Switch, AC Power..................................................................................... 37, 52
T
TEST Functions Menu..................................................................................... 77
Thermoplastic Considerations................................................................. 28, 73
Theory of Operation.................................................................................27-34
Timer............................................................................................................... 49
Tooling Capacity............................................................................................. 50
Tooling Hub.................................................................................................... 21
Top–Of–Stroke Connector........................................................................ 23, 75
Troubleshooting........................................................................................74-77
U
Unpacking......................................................................................................... 9
User Interface Display...............................................................................40-41
W
Wear Particle Phase........................................................................................ 27
Website........................................................................................................... 81
Weld–By–Distance.......................................................................................... 50
Weld–By–Time................................................................................................ 49
Weld Joint Diameter.................................................................................33-34
Weld Time..................................................................................... 29, 33, 49, 73
Work Bench Capacity..................................................................................... 21
Page 100
Dukane Manual Part Number 403-547-03
Dukane ISO
ISO CERTIFICATION
Dukane chose to become ISO 9001:2008
certified in order to demonstrate to our
customers our continuing commitment to
being a quality vendor. By passing its audit,
Dukane can assure you that we have in place
a well-defined and systematic approach to
quality design, manufacturing, delivery and
service. This certificate reinforces Dukane's
status as a quality vendor of technology and
products.
To achieve ISO 9001:2008 certification, you
must prove to one of the quality system
registrar groups that you meet three requirements:
1.Leadership
2.Involvement
3. Quality in Line Organizations and Quality
System Infrastructure.
The ISO 9001:2008 standard establishes a
minimum requirement for these requirements
and starts transitioning the company from a
traditional inspection-oriented quality system
to one based on partnership for continuous
improvement. This concept is key in that
Dukane no longer focuses on inspection, but
on individual processes.
Dukane's quality management system is
based on the following three objectives:
1. Customer oriented quality. The aim is to
improve customer satisfaction.
2. Quality is determined by people. The aim
is to improve the internal organization and
cooperation between staff members.
3. Quality is a continuous improvement.
The aim is to continuously improve the
internal organization and the competitive
position.
ISO 9001:2008
CERTIFIED
Dukane products are manufactured in ISO registered
facilities.
Please refer to our website at:
www.dukane.com/us/sales/intsales.htm
to locate your local representative.
Spin Welder User's Manual
Part No. 403 - 547 - 03
www.dukane.com/us
Printed in the United States of America
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 - 4900 • FAX (630) 797 - 4949