Dukane DPC II Plus User`s manual

User’s Manual

Dukane Part No. 403–566-01

Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL +1–630–797–4900 • FAX +1–630–797–4949

ISO 9001:2000

Dukane products are manufactured in ISO registered facilities

www.dukcorp.com/us

DPC II Plus and EZ Welder System – User’s Manual

Copyright © 2003—2004 Dukane Corporation

Ultrasonics Division

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 is 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 damaged caused or alleged to be caused directly or indirectly by the instructions contained in this manual, or by the hardware and software products described herein.

Printed in the United States of America.

PRINTED ON RECYCLED PAPER

Dukane Part Number: 403–566–01

Dukane ultrasonic equipment is manufactured under one or more of the following

U.S. Patents:

3,780,926 3,825,481 4,131,505 4,277,710 5,798,599 and 5,880,580.

DPC™ is a trademark of Dukane Corporation

EZ Welder™ is a trademark of Dukane Corporation ii

Dukane Manual Part No. 403–566–01

Table of Contents

DPC II Plus & EZ Welder Manual Revision History

Revision Revision

Number History

–00 Add information for EZ–Series Generator to DPC II Plus Manual.

Added EZ Welder™ Key Features to Section 1.

Table 3—1 references new DPC II Plus/EZ Welder manual.

Figure 4–1B shows EZ Generator w/o Hot Key for P2.

Figure 4–8B added to show current software revision for

EZ Generator. Figure 4–8A shows DPC II Plus version.

Figure 5–1 notes Multi–Probe modules are for DPC II Plus only.

Added note that photo on page 49 does not apply to EZ system.

Added note to Figure 7–30 that P2 branch is for DPC II Plus

systems only. EZ Series are single pressure.

Updated Dukane’s telephone numbers on pages 143–144.

Added Table 15—II for EZ Generator Part Number.

–01 Modify Table 5—V on page 48 (Pin 9 is +22V DC)

Clarify AFTERBURST option bypass on page 73 and 80.

Emergency Stop Switch Interface Diagram on page 25

New consolidated warranty.

Date

2003–Sept–25

2004–Dec–07

Dukane Corporation •

Dukane Manual Part No. 403-566-01

• Ultrasonics Division iii


This page intentionally left blank iv


Table of Contents

T

ABLE OF

C

ONTENTS

Section 1 – Introduction........................................................... 1

Before Operating ................................................................................... 3

Read The Manual First ................................................................................... 3

Caution and Warnings ................................................................................... 3

Drawings Labels ............................................................................................. 3

Manual Organization............................................................................. 4

DPC–II Plus Overview.............................................................................. 6

EZ Welder Overview ............................................................................... 6

Key DPC–II Plus Features ........................................................................ 7

Key EZ Welder Features ......................................................................... 8

Section 2 – Safety Tips .............................................................. 9

Health & Safety Tips ............................................................................. 11

Plastics Health Notice .................................................................................. 12

Electrical Grounding Safety ........................................................................ 12

RFI Considerations ................................................................................ 13

Section 3 – Unpacking & Installation .................................... 15

Shipping Carton Contents ................................................................... 17

DPC Placement ..................................................................................... 17

Benchtop ...................................................................................................... 17

Rack Mounting ............................................................................................. 18

Rear Panel Overview ............................................................................ 19

Ground the System............................................................................... 19

Connect the Cables .............................................................................. 20

Hand Probe System ...................................................................................... 20

Automated Probe System ........................................................................... 20

Multiple Probe System ................................................................................ 22

Automated Thruster System ....................................................................... 23

Dukane Press System ................................................................................... 24

Emergency Stop Switch Interface ............................................................... 25

Rear Electrical Power Switch ....................................................................... 25

Section 4 – Controls & Displays .............................................. 27

Front Panel Layout ............................................................................... 29

AC Power .............................................................................................. 30

Generator Status Section ..................................................................... 30

Generator Control Keys ............................................................................... 30

System Status Display .................................................................................. 31

System Power Output Display ..................................................................... 32

Process Control ..................................................................................... 33

Process Control Keys .................................................................................... 33

Menu Display ............................................................................................... 35

Dukane Manual Part No. 403-566-01 v


Section 5 – Rear Connectors .................................................. 37

Rear Panel Layout ................................................................................ 39

System Input Connector....................................................................... 40

System Output Connector ................................................................... 42

Remote Amplitude Control ................................................................. 46

Power Output Module Option ............................................................ 47

Press Control Module Option .............................................................. 48

Multi–Probe Module Options .............................................................. 50

Jumper Block Options .......................................................................... 51

Card Slot and Jumper Block Locations ....................................................... 52

Jumper Block Details ................................................................................... 53

Section 6 – Menu Structure ................................................... 55

Process Setup ........................................................................................ 57

Process Control ..................................................................................... 58

Process Limits ........................................................................................ 60

Utilities .................................................................................................. 61

Section 7 – Process Setup Menu ............................................ 63

Hand Probe ........................................................................................... 65

Untimed Hand Probe ................................................................................... 66

Timed Hand Probe ....................................................................................... 66

Timed Hand Probe – Energy ........................................................................ 67

MPC Probe ............................................................................................ 68

Auto Stop Option ........................................................................................ 68

Untimed MPC Probe – Probe Delay ............................................................ 68

Weld Method – Time ................................................................................... 69

Weld Method – Energy ................................................................................ 70

Weld Method – Ground Detect .................................................................. 70

Auto Probe ........................................................................................... 71

Auto Stop Option ........................................................................................ 72

Untimed Auto Probe – Delay ...................................................................... 73

Timed Auto Probe – Weld Method ............................................................. 73

HoldTime ...................................................................................................... 73

Afterburst ..................................................................................................... 73

Press Mode ........................................................................................... 75

Initiate Mode ............................................................................................... 76

Auto Stop ..................................................................................................... 76

Head Up On Auto Stop ............................................................................... 76

Trigger Type.................................................................................................. 76

Single/Dual Pressure Mode ......................................................................... 76 vi


Table of Contents

Press Mode Example ............................................................................ 77

Hot Keys ................................................................................................ 81

Process Control Recap .......................................................................... 82

Section 8– Process Limits Menu ............................................. 87

Process Limits Menu ............................................................................. 89

Limit Definition .................................................................................... 90

Suspect and Bad Limits ........................................................................ 90

Process Limits ........................................................................................ 90

Single Pressure Mode .................................................................................. 91

Dual Pressure Mode ..................................................................................... 92

Section 9 – Utilities Menu ...................................................... 95

Setup Utilities ....................................................................................... 97

Select Setup .................................................................................................. 98

Copy A Setup ................................................................................................ 99

Erase Setups ................................................................................................. 99

Part Count ........................................................................................... 100

Reset Part Count ........................................................................................ 100

Count Suspect/Bad Parts ............................................................................ 100

Preset Part Count ....................................................................................... 101

Status Outputs .................................................................................... 101

Cycle Press Off Line ............................................................................ 101

Section 11 – Probes/Probe Stacks ........................................ 103

The Ultrasonic Probe .......................................................................... 105

Theory of Operation .................................................................................. 105

Probe Configuration .................................................................................. 105

Ultrasonic Horn .......................................................................................... 106

Booster ....................................................................................................... 106

Stack Assembly ................................................................................... 107

Installing Replaceable Tips ........................................................................ 107

Mounting Stud to Horn/Booster ............................................................... 108

Horn to Booster ......................................................................................... 109

Booster to Probe ........................................................................................ 109

Horn to Probe ............................................................................................ 109

Torque Unit Conversion Chart ........................................................... 110

Stack Disassembly ............................................................................... 111

Booster Notes ..................................................................................... 114

Stack Mounting .................................................................................. 115

Dukane Manual Part No. 403-566-01 vii


Section 11 – DPC Checkout .................................................. 117

Startup and Self–Test ......................................................................... 119

System Test ......................................................................................... 120

Probe Operation................................................................................. 121

Stopping the Weld Cycle ................................................................... 121

Manual Systems ......................................................................................... 121

Automated System .................................................................................... 121

End of Day .................................................................................................. 121

Section 12 – Troubleshooting .............................................. 123

No Ultrasonic Output ......................................................................... 125

Probe .......................................................................................................... 125

Cable ........................................................................................................... 125

Generator ................................................................................................... 126

Operate Input ............................................................................................ 126

Generator Faults................................................................................. 127

OVERLOAD Indicator ................................................................................. 127

OVERTEMP Indicator ................................................................................. 127

FAULT Indicator .......................................................................................... 127

Generator Errors................................................................................. 128

INPUT TEST Indicator ................................................................................. 128

TEST Control Key ........................................................................................ 128

Troubleshooting Flowchart ............................................................... 129

Error Messages ................................................................................... 131

Section 13 – Care & Maintenance ....................................... 133

Front Panel ......................................................................................... 135

Rear Panel ........................................................................................... 135

Chasis .................................................................................................. 135

Stack Surfaces ..................................................................................... 136

Stack Maintenance .................................................................................... 136

Stack Inspection ......................................................................................... 136

Even Contact .............................................................................................. 136

Uneven Contact ......................................................................................... 136

Crowning .................................................................................................... 137

Center Depression...................................................................................... 137

Corrosion .................................................................................................... 137

Probe Reconditioning ........................................................................ 138

Overview .................................................................................................... 138

Machining the Mating Surfaces ................................................................ 138

Manual Resurfacing ................................................................................... 138 viii


Table of Contents

Section 14 – Contacting Dukane ......................................... 141

Ultrasonics Division Main Office ....................................................... 143

Email Addresses .................................................................................. 144

Telephone Extensions ........................................................................ 144

Section 15 – Specifications ................................................... 145

Regulatory Compliance...................................................................... 147

Federal Communications Commission ...................................................... 147

CE Marking (Conformité Europeéne) ....................................................... 147

Dimensions ......................................................................................... 148

Operating Enviornment ..................................................................... 148

Power Requirements .......................................................................... 149

Interpreting The DPC Model Number ............................................... 150

Section 16 – Warranty .......................................................... 151

Domestic warranty ............................................................................. 153

International Warranty ...................................................................... 154

Appendix A - List of Figures ................................................ 155

Appendix B - List of Tables .................................................. 159

Appendix C - User Supplied Circuitry .................................. 161

Manual Switch Circuit ........................................................................ 163

Automation Switch Circuits ............................................................... 164

Isolated Automation Controls ........................................................... 165

Current Sink ............................................................................................... 166

Current Source ........................................................................................... 167

Index ..................................................................................... 169

Dukane Manual Part No. 403-566-01 ix


This page intentionally left blank x


Section 1 – Introduction

S

ECTION

1

Introduction

• General Information

• Manual Organization

• DPC–II Plus Overview

• Key DPC–II Plus Features

• Key EZ Welder Features

Before Operating ............................................ 3

Read The Manual First ............................................ 3

Caution and Warnings ........................................... 3

Drawings Labels ..................................................... 3

Manual Organization ...................................... 4

DPC–II Plus Overview ...................................... 6

EZ Welder™ Overview .................................... 6

Key DPC–II Plus Features ................................. 7

Key EZ Welder™ Features ............................... 8



• Ultrasonics Division

1

DPC ™ II Plus and EZ Welder System – User’s Manual

This page intentionally left blank

2



Important User Information

Read This Manual First

Before operating the DPC™ II Plus, 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 an ultrasonic system. The examples given are chosen for their simplicity to illustrate basic setup procedures.

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 CAU-

TION 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.

Drawings and Tables

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. The figures use arabic sequence numbers

(e.g. –1, –2, –3) while the tables use roman sequence numerals (e.g. –I, –II, –III). As an example, Figure 3–2 would be the second illustration in section three while Table 3—II would be the second table in section three.

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.

WARNING

WARNING statements point out conditions or practices that could result in personal injury or loss of life.

 Ꮨ

Condition or Practice

Electrical

Hazard

Hand

Hazard

3


4


Manual Organization

Section 1 – Introduction describes the manual organization and the key features of the Dukane DPC TM ( Dynamic Process Controller ) II Plus Generator.

Section 2 – Safety discusses OSHA regulations and safety considerations.

Section 3 – Unpacking and Installation explains the DPC II

Plus placement and setup. It also shows the cable connections for quick–start operation.

Section 4 – Controls describes the function of the front panel controls, menu keys and status display.

Section 5 – Connectors gives the function, pinout and signal description of the rear panel connectors on the DPC II Plus. Operation of the optional modules is described in detail. The internal jumper blocks to control process automation are also identified.

Section 6 – Process Setup describes the overall menu organization of the DPC–II Plus, the setup and operate modes and gives a brief summary of the three main menus.

Section 7 – Process Control Menu describes the Hand

Probe, Timed Auto, MPC and Press mode menus and the Weld Methods. It also covers the user interface configuration and parameter values.

Section 8 – Limit Definition Menu describes the Suspect

Limit and Bad Limit menus in detail.

Section 9 – Utilities Menu describes the Setup File Utilities,

Part Count and Status Output menus in detail.

Section 10 –Hand Probe and Stack Assembly describes the assembly and mounting of both hand probes and probe stack assemblies.

Section 11 –System Checkout describes basic system tests to ensure that the DPC II Plus is functioning properly.


Section 12 –Troubleshooting provides helpful tips on solving the most common problems.

Section 13 –Maintenance lists a schedule of suggested preventive maintenance items.

Section 14 –Contacting Dukane provides information on contacting or obtaining support from your Dukane Ultrasonics team.

Section 15 –Specifications lists the DPC–II Plus dimensions, power and space requirements. It also interprets the model number coding.

Section 16 –Warranty contains a copy of our equipment warranty and tooling warranty.

Appendices

A

B

C

– List of Figures.

– List of Tables.

– Sample Circuitry for user supplied automation.

Index



5


DPC II Plus Overview

The DPC™ II Plus is the newest model in Dukane’s Dynamic Process Controller product family. This system will accept a wide variety of optional modules and is designed for use with ultrasonic presses or applications that require the use of hand probes or thruster systems.

The DPC II Plus provides basic system control inputs and system monitor and status outputs. This makes the

DPC II Plus ideal for automated control systems. Signal conditioning and electrical isolation are also provided.

Like other DPC models, the II Plus includes the same internal ultrasonic generator circuitry and features. Optional modules are available to enhance the DPC’s ability to meet a wide variety of process requirements. The most common combination includes the Timer board and a Press control board. Other options include an

Remote Amplitude control, a Power Signal module for

Weld–by–Energy requirements and up to two Multi–

Probe controller modules (DPC II Plus only) for driving multiple probe systems. In most cases, DPC II Plus systems in the field can be upgraded on-site if they already have the standard Timer board.

All DPC II Plus generators (except the highest power models) and the EZ/EZ–X Model 1000 feature a universal power supply with dual line–voltage 1 input.

In addition, the equipment is designed and tested to comply with

FCC and CE regulations that apply to this product.

6

EZ Welder

™

Overview

The EZ Welder ™ system combines the best features of the DPC II Plus ultrasonic generator with a quality press in a matched, low–cost welding system. The generator and press are sold as a package and are not upgradable or interchangeable with other Dukane generators.

The EZ and EZX Welders are both single–pressure systems. The EZX model adds an energy mode and features additional limit switches for pretrigger and end– of–weld indication. The EZ Welder press has a maximumstroke of 5–inches.

1 See Tables 15—I and 15—II



DPC II Plus

™

Key Features

• Timer Board option provides weld and hold time control and stores up to eight setup files.

• Press Board option provides control for a

Dukane ultrasonic press and thruster.

• Multi–Point Control Module option permits one DPC to handle up to eight probes in an automation environment (DPC II Plus or DPC II).

• Plug and Weld system recognizes when modules are added or removed from the system

• Process Control Menu automatically reconfigures the user interface to conform to the modules or hand probes currently installed.

• 4–Line LCD Display gives the complete parameter setting to speedup the setup process.

• System Connections are provided for automation equipment to monitor and control the ultrasonic welding process.

• Modular Design simplif ies upgrades and increases flexibility as your application requirements change.

• Flow Through Cooling Tunnel is thermostatically controlled to reduce thermal gradients and increase component life. Fan runs only when required to minimize dust buildup.

• Pulse Width Modulation is Dukane’s patented circuitry that allows the DPC power supply to eff iciently control the voltage sent to the transducer in the acoustic stack.

• Linear Ramp Softstart circuitry is provided allowing the acoustic stack to be brought to operating amplitude smoothly, minimizing the startup shock stress.

• Auto-Trac Tuning automatically tracks the resonant frequency of the acoustic stack (horn, booster, transducer), and adjusts the generator output frequency to match it.

2

(continued on next page)


2 Within specified ranges

7


• Dual Line–Voltage 1 Universal Power Supply means that the DPC will operate worldwide.

Auto-Ranging means that adjustments by the operator related to power input are unnecessary.

• Line Voltage Regulation automatically maintains a constant output regardless of line voltage deviation. 2

• Load Regulation provides constant amplitude automatically up to the rated overload power level.

• Electronic Overload protection prevent component failure.

• CE Certification means that the DPC II Plus and

DPC EZ meets the required European standards to be sold and used in Europe.

• ISO 9001 Certification means that the DPC II

Plus and EZ are manufactured to very high quality standards and assures you of Dukane’s commitment to being a quality vendor and its goal of continuous improvement.

8

EZ Welder

™

Key Features

• DPC Based generator means a rugged, quality system for reliable operation.

• Narrow–Profile Press (4.5 inches) for close spacing in multihead and automation installations.

• Top–of–Stroke limit switch output for automation applications.

• Chrome plated press column and aluminum alloy–booster are standard.

• Cast Aluminum heavy–duty base for stability.

• Calibrated dynamic trigger system with LED indicator initiates the weld cycle at user selectable force.

• Pneumatic stroke speed adjustment on press controls horn travel velocity to workpiece.

• Hinged press transducer door for quick tooling changeover.

1

See Tables 15—I and 15—II

2 Within specified ranges



S

ECTION

2

Safety Tips

• Health & Safety

• RFI Considerations

Health & Safety Tips...................................... 11

Plastics Health Notice ........................................... 12

Electrical Grounding Safety .................................. 12

RFI Considerations ........................................ 13




9



10


Section 2 – Safety Tips

Health and Safety Tips

Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your equipment. In this manual, the term

system refers to a complete group of components associated with the welding of plastic or metal parts, also known as an ultrasonic assembly sys-

tem. A typical system consists of a generator and/ or ultrasonic process controller, start and stop switches, power controls, connecting cables, and the probe assembly which includes the transducer, booster, horn and replaceable horn tip.

Proper Installation – Operate system components only after they are properly installed and checked.

No Unauthorized Modifications – Do not modify your system in any way unless authorized to do so by Dukane Corporation. Unauthorized modifications may cause injury to the operator and/or equipment damage. In addition, unauthorized modifications will void the equipment warranty.

Keep the Cover On – Do not remove the equipment cover unless specifically directed to do so by

Dukane Corporation. The generator produces hazardous electrical voltages which could cause injury.

Grounded Electrical Power – Operate this equipment only with a properly grounded electrical connection. (See Electrical Safety Grounding Instructions on the next page.)

Comply with Regulations – You may be required to add accessories to bring the system into compliance with applicable OSHA regulations.

Ꮨ IMPORTANT

Never operate the DPC II

Plus with the cover off.

This is an unsafe practice and may cause injury.

CAUTION

Parts being joined ultrasonically sometimes vibrate at audible frequencies. Wear ear protection to reduce annoying or uncomfortable sounds. In addition, sound absorbing materials, enclosures or sound deflectors may be installed to reduce the noise level.

11



Plastics Health Notice

Before using any Dukane ultrasonic welding system, be sure you are familiar with OSHA regulations from the U.S. Department of Labor about the particular type of plastic(s) you are using.

When plastic materials are being processed, they may emit fumes and/or gases that could be hazardous.

Make sure there is proper ventilation whenever these plastics are processed.

Electrical Safety Grounding

Instructions

For safety, the power cords used on all Dukane products have a three-prong, grounding-type plug.

Ꮨ

CAUTION

If you must have a twoprong electrical receptacle, we strongly recommend that you replace it with a properly grounded three-prong type. Have a qualified electrician replace it following the National Electric Code and any local codes and ordinances that apply.

See Figures 2-1 and 2-2.

Approved 2 pole, 3 wire grounding receptacle BRYANT No. 5621 or equivalent to NEMA 5–15R or 5–20R

Figure 2-1 Example of 120 Volt, Grounded,

3-Prong Receptacle

Approved 2 pole, 3 wire grounding receptacle HUBBELL No. 5652 or equivalent to NEMA 6–15R or 6–20R

Figure 2-2 Example of 220 Volt, Grounded,

3-Prong Receptacle

12

Ꮨ

CAUTION

If there is any question about the grounding of your receptacle, have it checked by a qualified electrician. Do not cut off the power cord grounding prong, or alter the plug in any way.

If an extension cord is needed, use a threewire cord that is in good condition. The cord should have an adequate power rating to do the job safely. It must be plugged into a grounded receptacle.

Do not use a two-wire extension cord with this product.


Section 2 – Safety Tips

The power cable normally provided for international use is compatible with many power outlets

(refer to Figure 2-3.) However, if your application requires another type of cable, check with the local Dukane products representative, and follow local regulations concerning proper wiring and grounding.

Grounding Contacts

Typical Outlet

AC Power Cable (Provided)

Figure 2-3 International 220/240V Grounding

RFI Considerations

In addition to the safety considerations, proper grounding at the generator power cord is essential for the effective suppression of RFI (Radio

Frequency Interference). Every DPC contains a

RFI filter which blocks noise on the AC power line from entering the DPC control circuitry. This filter also prevents ultrasonic RFI from being fed back into the AC power line. In order for the RFI filter to operate properly, it is necessary to adequately ground the DPC. Run an additional grounding wire from the rear grounding connection (see Figure 2-4) to the nearest grounded metal pipe or equivalent earth ground by means of a ground clamp. Use at least an 14 AWG** wire for the connection to the DPC chassis. Stranded is more flexible and easier to work with than solid wire. However if you use stranded wire, crimp spade lugs on the end to ensure a good connection.

If you have a color choice, green is the commonly accepted color for an electrical ground connection.

If you have connected the DPC to a Press and/or

Thruster, use a star

†

connection from the earth ground to the DPC and Press as illustrated in

Figure 2–5.

** 14 AWG wire has a diameter of 1.63mm or 0.064"

†

Run seperate ground wires from each piece of equipment to the earth ground. See the appropriate schematic diagram in Figures 3–4 thru 3–8.


I

O

10 – 24 x 1 /

2

" threaded stud

14 AWG to Earth Ground

Figure 2-4 DPCGrounding Arrangement

To

Ground

Figure 2-5

14 A

WG Wire

Press Grounding Arrangement

13



14


Section 3 – Unpacking and Installation

S

ECTION

3

Unpacking & Installation

• Unpacking the DPC

• Placement of the DPC

• Rear Panel Overview

• Grounding the System

• Connecting the Cables

Shipping Carton Contents ............................ 17

DPC Placement ............................................. 17

Benchtop ............................................................. 17

Rack Mounting .................................................... 18

Rear Panel Overview ..................................... 19

Ground the System ....................................... 19

Connect the Cables ...................................... 20

Hand Probe System ..............................................20

Automated Probe System .....................................20

Multiple Probe System .......................................... 22

Automated Thruster System ................................. 23

Dukane Press System ............................................24

Rear Electrical Power Switch ................................. 25




15



16



Shipping Contents

Quantity

1

Item

DPC II Plus or EZ Generator

Part Number

**

1 DPC II Plus/EZ User's Manual 403–566–00

** DPC Part Number depends upon Frequency and Power Rating

AC power cord and cables as specified. See your Packing List.

Compare with Table 3—II on page 21.

Table 3— I Contents of DPC II Plus Shipping Container

Carefully open the shipping container, and make sure it contains the items shown in Table 3–I. Inspect the DPC for damage. Report any damage immediately to Dukane Ultrasonics Support/Service.

DPC Placement

Placement of the DPC depends on whether it is a benchtop or rack-mounted configuration

Benchtop

Place the DPC on a flat surface with its front panel easily accessible. Make certain the placement and cabling do not interfere with the assembly operation.

Allow 5 inches (13 cm) at the rear of the DPC for cable clearance. Allow 2 inches (5 cm) of space on either side of the DPC for air circulation. Refer to the illustration in Figure 3-1.

 CAUTION

Allow space for air ventilation around the DPC II

Plus chassis, the air intake and exhaust. The fan draws in fresh air to cool the internal components, reduce thermal gradients and increase component life.

When viewed from the front, the fresh air intake is on the right and the hot air exhaust is on the left side.

If excessive dust accumulates in the slots, wipe or vacuum them clean. Do not use compressed air as this may force the dust inside the chassis.

Allow 5 inches (13 cm) space for cables behind the DPC

Intake Vent for Thermostatically Controlled Fan

GEN

INFO.

+

MODE

ENTER

WELD

P1

WELD

P2

AMP.

ADJUST

– ENTER CANCEL

SYSTEM POWER OUTPUT

0 20 40 60

PERCENTAGE OF A

80 100

VAILABLE POWER

FAULT

ON LINE

INPUT TEST

OVERLOAD

OVERTEMP

OFF LINE

STATUS

ON

LINE

TEST

Exhaust Air from

Flow–Thru Cooling Tunnel

Figure 3-1 Installing a Benchtop DPC

Allow space for vent ilation,

2 inches (5 cm) on each side.

17



Rack Mounting

Figure 3-2 shows the use of a bracket kit in mounting a DPC to a 19-inch equipment rack.

(Contact Ultrasonic Sales at Dukane, and request

Part Number US-1155.) The DPC illustrated has the standard, angled front panel of impactresistant ABS plastic.

Allow 5 inches (13 cm) of space behind the DPC for cables

18

0

0

2

22002

GEN.

OINFO.

+

MODE

WELD

P1

WELD

P1

WELD

P1

AMP.

ADJUST

–

ENTER CANCEL

SYSTEM POWER OUTPUT

0 20 40 60 80 100

FAULT

ON LINE

INPUT TEST OVERLOAD

OVERTEMP OFF LINE

STATUS

ON

LINE TEST OFF

LINE

Approximate

17.35 inches (44 cm)

19 inches (48 cm)

Figure 3-2 Rack-mounted DPC Using Bracket Kit

Appro ximate

22.25 in

(57 cm)



CAUTION

Allow space for air ventilation around the DPC II

Plus chassis, air intake and exhaust. The fan draws in fresh air to cool the internal components, reduce thermal gradients and increase component life.

When viewed from the front, the fresh air intake is on the right and the hot air exhaust is on the left side.

If excessive dust accumulates in the slots, wipe or vacuum them clean. Do not use compressed air as this may force the dust inside the chassis.



Rear Panel Overview

Familiarize yourself with the connection points for power, ground, ultrasound output, system I/O and the optional modules on the rear of the DPC II

Plus shown below in Figure 3–3. The standard modules and connectors are labeled with the black boxes. The optional modules are labeled with italics. The EEPROM Serial Programming Port is used to upgrade the DPC™ firmware. The grounding lugs, serial number tags, etc. are located in the same position on all DPC II, EZ Welder, DPC II

Plus, DPC III and DPC IV generators.

Grounding

Lug Rear AC

Power Switch

NOTE

Not all of the modules illustrated below can be installed simultaneously. They are shown to represent the various configurations that can be assembled to meet specific requirements.

Slave Multi–Probe

Controller Module (DPC II Plus only)

Master Multi–Probe

Controller Module

(DPC II Plus only)

Press Control

Module

EEPROM Serial

Programming Port

Power Signal

Output Module

Remote Amplitude

Control Module

IEC

AC Power

Input

Model No. Tag

System

Output

Connector

System

Input

Connector

J1 Ultrasound

Output (BNC)

Figure 3-3 DPC II Plus and EZ Welder Rear Panel and Optional Modules

Ground the System

The DPC II Plus includes an internal RFI filter.

The standard building AC ground connection is normally not sufficient to completely suppress the RFI. Attach a ground cable from the DPC grounding lug (located next to the rear AC power switch) to an earth ground. If you are using a press or automated probe system, each piece of equipment must also be solidly grounded. Refer to Figure 2–5 and Figures 3–4 through 3–8 for the proper grounding arrangement.


Ꮨ

CAUTION

Before attaching the cables, make sure the

DPC II Plus is properly grounded. Refer to Figure

2–5 and the appropriate diagram (Figures 3–4 thru

3–8) for the correct grounding connections.

19

Serial

No.

Tag

20


Connect the Cables

The instructions here and the diagrams in Figures

3–4 through 3–7 are meant to serve as a quick– start guide. The connectors and their pinouts are discussed in greater detail in Section 5.

Manual Probe System

Step 1.

Ground the DPC II Plus chassis.

Step 2.

Attach the System In adapter cable (see

Figure 3–4) to the 14-pin AMP connector at the end of the probe cable.

Step 3.

Connect the other end of the adapter to the System In HD-15 connector on the rear of the DPC II Plus.

Step 4.

Attach the high voltage ultrasound coaxial cable to the rear-panel J1 connector.

Step 5.

Optional – If your system has a Press

Control Module, you will also need a jumper block (Part No. 200-1293) to replace the normally closed contact from the Emergency Stop safety switch.

Step 6.

Attach the power cord to the DPC II

Plus and plug the other end into an approved AC outlet.

Automated Probe System

Step 1.

Ground the DPC II Plus chassis and the probe support.

Step 2.

Attach the high voltage coax cable from the probe mount to the rear-panel

DPC connector J1 (see Figure 3–5).

Step 3.

Connect the automation control cable from the user–supplied automation equipment to the System Input rear panel HD-15 connector (Figure 3–5).

Ꮨ CAUTION

Make sure electrical power is OFF before connecting/ disconnecting cables or installing/removing modules from the DPC II Plus. Make sure BOTH the front and rear panel AC power breaker switches are in the OFF position.

Failure to turn off the power may result in damage to the DPC and/or the modules.

Ꮨ CAUTION

The power cord is equipped with a threeprong, grounded-type plug for your safety.

Whenever a two-slot receptacle is encountered, we strongly recommend that it be replaced with a properly grounded three-lead receptacle. Have a qualified electrician perform the installation in accordance with the National Electrical

Code and local codes and ordinances.

DO NOT cut off the AC power cord grounding prong or alter the plug in any way.



U. S . PAT E N T 4 , 2 7 7 , 7 1 0

Grounding Lug



– WARNING–

POWER LINE MUST BE

GROUNDED AT OUTLET

#14 Gauge

Wire

LINE VOLTAGE

200–240Vac 50/60Hz

15A 

Ꮨ



M O D E L N U M B E R

2 0 0 - 2 4 0 VAC, 5 0 - 6 0 H z , 1 5 A

Jumper Block

Part No. 200–1293

 Power Signal

Output Module

Power

Signal

Output

Zero

Adjust

Power Monitor

Jacks

+

–

SYSTEM OUT

SYSTEM IN

S E R I A L N U M B E R

U S 1 0 0 0 0

DUKANE CORP

ST. CHARLES, IL 60174

MADE IN USA

– WARNING! –

POWERLINE MUST BE GROUNDED

AT OUTLET

REMOVE ALL POWER BEFORE

REMOVING COVER OR CONNECTING

OR DISCONNECTING CABLES.

Ꮨ

J1

ULTRASOUND

OUTPUT





14–Pin AMP to

HD–15 Adapter

Part No. 200–1248 

Flexible + Coaxial Cable

20kHz Part No. 200–624

40kHz Part No. 200–759

(Included with probe)

Earth Ground

110 VAC or

220 VAC

Figure 3-4 DPC II Plus and EZ Welder Hand Probe Cable Connections

1

6

3

9

5

Pins 3 & 9

Connected

Step 4.

Optional – Attach the status output cable from the user–supplied automation equipment to the System

Output DB-25 connector. Not all automation systems will have this cable.

Step 5.



The 3–prong AC Line cords supplied are matched to the DPC II Plus power rating and the continent of specified use.

The part numbers are —

200–1109 North America 110V

200–1110 North America 220V

200–1111 Continental Europe

Table 3— II DPC II Plus AC Power Cord Part Numbers

U. S . PAT E N T 4 , 2 7 7 , 7 1 0

Grounding Lug



– WARNING–



#14 Gauge

Wire

LINE VOLTAGE

200–240Vac 50/60Hz



Ꮨ

15A




2 0 0 - 2 4 0 VAC, 5 0 - 6 0 H z , 1 5 A

110 VAC or

220 VAC

Power Signal

Output Module

Power

Signal

Output

Zero

Adjust

Power Monitor

Jacks

+

–

SYSTEM OUT

SYSTEM IN


U S 1 0 0 0 0

DUKANE CORP


MADE IN USA



AT OUTLET




Ꮨ

J1

ULTRASOUND

OUTPUT



 

Coaxial Cable

RG62B/U

Automation

Control

P/N 200–1203

Automation

Equipment

Status

Output

P/N 200–1302

P/N 200–479

Grounding Lug



#14 Gauge Wire

Earth Ground

Figure 3-5 DPC II Plus and EZ Welder Automated Probe Cable Connections


Ultrasound

Input



21


Multiple Probe System

Step 1.

Ground the DPC II Plus chassis and the probe support.

Step 2.

First attach a short coaxial cable from the rear-panel DPC generator U/S output J1 (see Figure 3–6) to the MPC

U/S input.

Step 3.

Attach another high voltage coax cable from the rear MPC channel 1 probe output to the first probe. Attach a separate cable from each output channel to each probe.

Step 4.

Connect the automation control cable from the user–supplied automation equipment to the System Input rear panel HD-15 connector.

Step 5.

Attach the status output cable from the user–supplied automation equipment to the System Output DB-25 connector.

Step 6.



Ꮨ

CAUTION

To ensure safe and trouble– free operation, ground the

DPC chassis and probe mount as shown in Figures

3–4 to 3–7.

Use a STAR configuration

(illustrated below). Do not

DAISY CHAIN the grounds.

DPC Chassis

Grounding

Lug

Thruster or

Probe Mount

Grounding Lug

#14 Gauge

Stranded or

Solid Wire

#14 Gauge

Stranded or

Solid Wire

Earth

Ground

NOTE

The automated system cabling schematics in Figures 3–5, 3–6 and 3–7 are intended to represent connections for a typical automation system. Your system cabling may vary slightly from the diagrams.

U. S . PAT E N T 4 , 2 7 7 , 7 1 0

Grounding Lug



– WARNING–



LINE VOLTAGE

200–240Vac 50/60Hz

15A 

Ꮨ




2 0 0 - 2 4 0 VAC, 5 0 - 6 0 H z , 1 5 A

#14 Gauge

Wire

5

6

7

8

Multi–Probe

Master Module

Ultrasonic Input

RG62B/U Coax



3

4

1

2

110 VAC or

220 VAC



Power Signal

Output Module

Power

Signal

Output

Zero

Adjust

Power Monitor

Jacks

+

–

SYSTEM OUT

Remote Ampltd

Control Mod.

Current Loop

Status

POS

NEG

SHLD


U S 1 0 0 0 0

DUKANE CORP


MADE IN USA



AT OUTLET




SYSTEM IN

Ꮨ

J1

ULTRASOUND

OUTPUT



 

Coaxial Cable(s)

RG62B/U

Automation

Control

P/N 200–1203

Automation

Equipment

Status Output

P/N 200–1302

#14 Gauge Wire

Earth Ground

Figure 3-6 DPC II Plus Multiple Probe Conntroller Cable Connections

22

P/N 200–479





Ultrasound

Input(s)



Grounding

Lug





Automated Thruster System

Step 1.

Ground the DPC II Plus and the

Thruster as shown in Figure 3–7.

Step 2.

Attach the high voltage RG62B/U coax cable from the rear-panel DPC II Plus connector J1 to the ultrasound input J1 on the thruster (see Figure 3–7).

Step 3.

Connect the Automation Control cable from the user–supplied automation equipment to the System Input rear panel HD-15 connector.

Step 4.

Attach the Status Output cable from the user–supplied automation equipment to the Status Output DB-25 connector.

Step 5.

Connect the Press Base Input cable from J35 on the Press Base to the DB-9 connector (J902) on the Press Control

Module. If the automation system does not have a connection to J902, you may need a jumper block (Part No. 200-1293) to replace the normally closed contact from the press base Emergency Stop safety switch.

Step 6.

Connect the Operational Control cable from the user–supplied automation equipment to the 36–contact Thruster control connector (J901) on the Press

Control Module.

Step 7.



U. S . PAT E N T 4 , 2 7 7 , 7 1 0

Grounding Lug



– WARNING–



LINE VOLTAGE

200–240Vac 50/60Hz



Ꮨ

15A




2 0 0 - 2 4 0 VAC, 5 0 - 6 0 H z , 1 5 A

#14 Gauge

Wire

J901 Operational Control

Part No. 200–1104



110 VAC or

220 VAC to J902



Power Signal

Output Module

Power

Signal

Output

Zero

Adjust

Power Monitor

Jacks

+

–

SYSTEM OUT

Remote Ampltd

Control Mod.

Current Loop

Status

POS

NEG

SHLD


U S 1 0 0 0 0

DUKANE CORP


MADE IN USA



AT OUTLET




J1

SYSTEM IN

Ꮨ

ULTRASOUND

OUTPUT

 

Automation

Control

Cable

P/N 200–1203



Coaxial Cable

RG62B/U

Status

Output

Cable

P/N 200–1302

Automation

Equipment

Base Cable

Part No. 200–1124

— or —

Jumper Block

Part No. 200–1293

1

6

3

9

5 Pins 3 & 9

Connected

#14 Gauge Wire

80–100 psi

Air Supply

P/N 438–528

Ultrasound

Input



J1

Top–Of–Stroke

(Optional)

J3

J40

Grounding Lug



Earth Ground

Figure 3-7 DPC II Plus Automated Thruster Cable Connections


23


Dukane Press System

Step 1.

Ground the DPC II Plus, the Thruster and the Base as shown in Figure 3–8.

Step 2.

Attach the high voltage coax cable from the press J1 connector to the DPC

Ultrasound Out connector (J1).

Step 3.

Connect the Press Base Input cable from J35 on the Press Base to the DB-

9 connector (J902) on the Press

Control Module.

Step 4.

Connect the Operational Control cable from J3 at the top of the press to the

36–contact Thruster control connector

(J901) on the Press Control Module.

Step 5.



CAUTION

Ꮨ Use the STAR configuration illustrated below and in

Figure 3–8 to ground the

DPC chassis, base and thruster. Do not DAISY

CHAIN the grounds.

DPC Chassis

Grounding

Lug

#14 Gauge

Stranded or

Solid Wire

Thruster

Grounding

Lug

Earth

Ground

#14 Gauge

Stranded or

Solid Wire

Base/Fixture

Grounding

Lug

Ultrasound Input





J1

J3

J40

80–100 psi

Air Supply



Grounding

Lug



U. S . PAT E N T 4 , 2 7 7 , 7 1 0

– WARNING–



LINE VOLTAGE

200–240Vac 50/60Hz

15A 

Ꮨ

#14 Gauge

Wire




2 0 0 - 2 4 0 VAC, 5 0 - 6 0 H z , 1 5 A

J901 to

Thruster



Power Signal

Output Module

Power

Signal

Output

Zero

Adjust

Power Monitor

Jacks

+

–

SYSTEM OUT

Remote Ampltd

Control Mod.

Current Loop

Status

POS

NEG

SHLD


U S 1 0 0 0 0

DUKANE CORP


MADE IN USA



AT OUTLET




J1

SYSTEM IN

Ꮨ

ULTRASOUND

OUTPUT



J902 to

Base/Abort

Operational Control



Coaxial Cable

RG62B/U

Part No. 200–1104

#14 Gauge Wire

110 VAC or

220 VAC

Earth Ground

#14 Gauge Wire

8–conductor cable

Part No. 200–1124



J35

Grounding Lug 

Figure 3-8 DPC II Plus and EZ Welder Press Cable Connections

24



Emergency Stop Switch

Figure 3–9 is a simplified example that demonstrates the basic requirements to interface with the

DPC II Plus on J902. This is excerpted from Application Note AN201 available on our website.

Note that the emergency stop inputs cannot just be tied together from multiple DPCs when used on a common welding process. Multiple DPCs require individual contacts for each unit.

Check with your local safety compliance office before altering the factory connections. The user is responsible for complying with all requirements of the safety regulatory agencies governing the geographic location where the Dukane equipment will be operated.

Emergency

Stop Switch

Cable No.

200–1124

3

9

7

4

J902

+22V DC

DPC II or

DPC II Plus

E–Stop Switch

+24V DC

Emergency

Stop Features

E–Stop Sense

To Dukane

Pneumatic

Press

Figure 3-9 J902 Emergency Stop Interface Example

Electrical Power Switch

The rear panel AC breaker switch (Figure 3–10) is wired in series with the front panel breaker switch (shown in Figure 4-2). When the rear breaker switch is off, it isolates the AC power feed in the chassis for safety considerations. Both the front panel and rear panel switches must be on to supply AC power to the DPC generator.

Grounding

Lug

Rear AC

Breaker/Power

IEC

AC Power

Input

Figure 3-10 Rear Panel AC Breaker Switch

25




26


Section 4 – Controls & Displays

S

ECTION

4

Controls & Displays

• Front Panel Layout

• AC Power

• Generator Status Panel

• Menu Function Keys

• Control Menu Display

Front Panel Layout ........................................ 29

AC Power ..................................................... 30

Generator Status Panel ................................. 30

Generator Control Keys ........................................ 30

System Status Display ........................................... 31

System Power Output Display ............................... 32

Process Control Panel .................................... 33

Menu Function Keys .............................................33

Control Menu Display .......................................... 35




27



28



Front Panel Layout

This section describes the DPC II Plus and DPC EZ front panel controls, status, power output and menu displays.

The DPC front panel is laid out in three sections as illustrated below in Figure 4-1A (DPC II Plus) and

Figure 4–1B (DPC EZ). The three sections are:

1.

AC Power switch and indicator



2.

Generator Status Panel which contains

• Three Generator Control keys



• System Status display



• System Power Output display



3.

Process Control Panel which contains

• Menu Function keys



• LCD menu display



 DPC II Plus v1.50

PRESS ENERGY

MORE INFO: www.dukcorp.com/us/

GEN.

INFO



AMP.

ADJUST

MODE

HOLD

WELD

P1

WELD

P2

ENTER CANCEL





FAULT

ON LINE

INPUT TEST

OVERTEMP

OVERLOAD

OFF LINE



Figure 4–1A DPC II Plus Front Panel Layout



 EZ Series v1.50

PRESS SYSTEM


GEN.

INFO



AMP.

ADJUST

MODE

HOLD

WELD

P1

ENTER

CANCEL





FAULT

ON LINE

INPUT TEST

OVERTEMP

OVERLOAD

OFF LINE



Figure 4–1B DPC EZ Front Panel Layout




29


1. AC Power Section

The front-panel AC power section has a switch and power indicator that is shown in Figure 4-2.

ON/OFF The AC power switch connects AC power to the generator. This breaker switch is wired in series with the rear panel power switch (Figure 3–9). It also serves as a circuit breaker that provides overload protection for the DPC. Both switches must be turned on to supply

AC power to the generator.

Green LED The green indicator above the switch lights when the DC bus is up, after the

AC power has been switched on. At this point the generator is capable of producing an ultrasonic output signal.

2. Generator Status Panel

The Generator Status Panel is subdivided into three sections which provide control and status displays.

1. Generator Control Keys

2. System Status Display

3. System Power Output Display

Generator Control Keys

The Generator Control Key section consists of three keys as shown in Figure 4-3.

ON LINE This places the generator in an operational state. It can produce an ultrasonic output signal when triggered.

TEST

OFF LINE

The TEST key momentary activates the generator to provide ultrasound output for test or setup purposes. TEST will only work in the ON LINE state.

This key places the generator in a standby mode. This prevents the generator from producing an ultrasonic output signal.

30

Green

Power

Indicator

Front

AC Power

Switch

Figure 4–2 Front Panel AC Power Section

ON LINE

Key

TEST

Key

Figure 4–3 Generator Control Keys

OFF LINE

Key

NOTE

If a Press module is installed, these keys are only active if the Emergency Stop is not engaged. If the Emergency Stop switch is depressed, the System Status Display will not be lit and the Control Keys inactive.



System Status Display

The System Status Display indicates one of the six system states. If that state is active, the corresponding label is lit in the display. Figure 4-4 shows the

System Status Display with the ON LINE state activated. The six status conditions are described here.

FAULT This indicator lights when out-of-tolerance voltage fluctuations occur that are related to one of the following conditions.

1. AC Line Voltage

2. Internal DC Power Supply (+5 VDC,

+12 VDC, -12V DC or +24V DC.)

INPUT TEST This indicator normally flashes red during a power-up test. If there is a problem, a steady red light appears. This means that either the input AC line voltage is out of tolerance, or an internal fault has occurred in the generator.

OVERLOAD This red indicator lights when either of the following conditions occur.

1.

An instantaneous overload caused by a mismatch between the ultrasonic signal and the resonant characteristics of the acoustic stack (transducer, booster and horn.)

2.

Excessive power beyond the generator’s rated output is being drawn.

ON LINE The generator is capable of operation.

OVERTEMP One of the power modules has overheated and the generator has shut down.

This may be caused by excessive dust in the cooling channel or a cooling fan failure. The generator will automatically reset when the module temperature drops below the trip point which is 75

°

C

(167

°

F).

OFF LINE The generator is in a standby mode. The ultrasound output cannot be activated.

FAULT INPUT TEST

ON LINE OVERTEMP

Figure 4–4 System Status Display

OVERLOAD

OFF LINE


31


System Power Output Display

The tricolor System Power Output Display indicates the percentage of ultrasonic power being drawn by the load.

Green Eight green vertical bars indicating

10% to 80% power output are displayed during normal operation. Figure 4-5 shows the display indicating

80% output power.

GREEN

Figure 4–5 Normal Operation

Yellow

Red

Two yellow bars for 90% and 100% power output warn that the generator is operating near its maximum rated output.

YELLOW

The last red bar indicates that the generator is in an overload condition delivering more than its rated output power. Figure 4-6 shows the red overload and two yellow warning indicators. The red warning indicator lights up just prior to an overload condition. The ultrasonic signal is shut down when an overload condition occurs.

Figure 4–6 Warning Indicators

RED

32

NOTE

The available output power is directly proportional to the Amplitude setting.

Example: A 2200 Watt rated DPC set to 80%

Amplitude will overload at 1760 Watts.

(2200W x 0.80 = 1760 Watts)



3. Process Control Panel

Menu Function Keys

The menu keys are shown in Figure 4–7. Their function is described going across each row starting at the upper left.

GEN.

INFO

HOLD

WELD

P1

Pressing the GEN. INFO key displays the DPC model, the firmware version and the installed modules. A readout for a DPC II Plus equipped with both a Press Control module and a Power

Signal Output Module is shown in

Figure 4–8A. The DPC EZ Series is shown in Figure 4–8B. Press CAN-

CEL to return to the previous menu.

The up arrow key increments the data value each time it is pushed. Holding the key in continuously increments the value. This key is also used to move the cursor up one line on a menu selection screen

Pressing the HOLD key immediately brings you to the Hold Time data entry menu. You can quickly check and/or change the setting using the four arrow keys. Pressing ENTER completes the process and returns you to your last menu screen.

Pressing the WELD P1 key displays the parameter(s) for the first pressure setting. The value(s) can be quickly checked and/or altered without going back through the menu sequence.

Pressing ENTER completes the process and returns you to your last menu screen.

Pressing the left arrow key selects the next digit to the left of a parameter setting. The key is used when entering values and moves the flashing bar under the selected digit. The selection wraps around to the right digit after the left most digit position is reached.


Increment

General

Information

Left

Arrow

Amplitude

Adjust

Decrement

GEN.

INFO

AMP.

ADJUST

Figure 4–7 Menu Keys

+

MODE

–

Mode

Hold

HOLD

WELD

P1

WELD

P2

ENTER CANCEL

Enter

Right

Arrow

Cancel

DPC II Plus v1.50

PRESS + ENERGY


Figure 4–8A DPC II Plus GEN INFO Display

EZ Series v1.50

PRESS SYSTEM

MORE INFO:

Weld

Pressure 1

Weld

Pressure 2

(DPC II Plus only)

www.dukcorp.com/us/

Figure 4–8B DPC EZ GEN INFO Display

NOTE

For three of the ‘hot’ keys (HOLD, WELD P1, and WELD P2), data can only be entered or modified after the programming setup is completed.

33


MODE

WELD

P2

AMP.

ADJUST

ENTER

CANCEL

Pressing the MODE key toggles between the Weld mode (displays values for last weld cycle) and the Setup mode (displays main Process Setup menu).

Pressing the right arrow key selects the next digit to the right of a parameter setting. The key is used when entering values and moves the flashing bar under the selected digit.

The selection wraps around to the left digit after the right most digit position is reached.

Pressing the WELD P2 (DPC II plus only) key displays the parameter(s) for the second pressure setting only if a dual pressure mode has been previously selected. The value(s) can be quickly checked and/or altered without going back through the menu sequence. Pressing EN-

TER completes the process and returns you to your last menu screen.

Pressing this key displays the current ultrasound amplitude setting. This can be adjusted from 40% to 100% using the up and down arrow keys marked + and - respectively. Press

ENTER to confirm the value.

The down arrow key decrements the data value each time it is pushed.

Holding the key in continuously decrements the value. This key is also used to move the cursor down one line on a menu selection screen

Pressing the ENTER key completes the menu operation and displays the next decision or navigation menu.

Pressing the CANCEL key discards any values you may have changed and returns you to the previous decision or navigation menu.

TIP

For any of the four ‘hot’ keys (HOLD, WELD P1,

WELD P2 or AMP. ADJUST), pressing the

CANCEL key instead of ENTER returns you to the last menu screen without altering the value.

NOTE

Reducing the amplitude with the AMP. ADJUST key reduces the maximum power available. If the amplitude is reduced to 40% (the lowest setting), the maximum available power will be limited to 40% of the rated output power.

34



Process Control Menu Display

The menu display is a backlit 4–line LCD with 20 characters per line. The top line of the display contains the menu title (with a few exceptions).

Selection Menus

The selection menus have a triangular cursor at the far right of the display. These menus may also be thought of as a decision menu. Move the cursor to the menu choice and press the ENTER key to select your choice. Pressing the CANCEL key returns to the previous selection menu. A typical selection menu is shown in Figure 4–9.

Data Entry Menu

The data entry screens have the parameter name on the first line and the parameter value on the third line. Use the left and right triangle keys to select the digit and the Increment (+) and Decrement (–) keys to change the value. Press the EN-

TER key to accept the value. A typical data entry screen is shown in Figure 4–11.

WELD TIME

0.750 SEC

PROCESS CONTROL

WELD MODE

HOLD TIME

AFTERBURST

Figure 4–9 Typical Selection menu

Confirmation Menus

A confirmation menu requests a Yes or No entry to continue the process. Select YES from the menu and press the ENTER key to proceed. A typical conformation menu is shown in Figure 4–10.

Figure 4–11 Typical Data Entry Screen

RESET PART COUNT

NO

YES

Figure 4–10 Typical Confirmation Screen

35




36



S

ECTION

5

Rear Connectors

• Rear Panel Layout

• System Input

• System Output

• Optional Modules

• Internal Jumper Blocks

Rear Panel Layout ......................................... 39

System Input Connector ............................... 40

System Output Connector ............................ 42

Remote Amplitude Control ........................... 46

Power Output Module Option....................... 47

Press Control Module Option ........................ 48

Multi–Probe Module Options ........................ 50

Jumper Block Options ................................... 51

Status Driver Normal Selection State ..................... 51

Status Driver Selection ..........................................51

Automation Cycle Stop or End Of Weld ...............51

Switch Debounce Filter Time Delay .......................51

Timer Board Enable/Bypass ...................................51

System Control Inputs ..........................................52

Card Slot and Jumper Block Locations ..................52




37



38


Section 5 – Rear Connectors

Rear Panel Layout

All of the connectors contained on the DPC II

Plus and the optional modules are shown below in Figure 5–1. No generator will have all the modules shown. Specifically the Multi–Probe Controller and the Press Control Modules are mutually exclusive. The modules are shown here to indicate their installed locations and connector types.

Grounding

Lug

Multi–Probe

Slave U/S

Outputs


Rear AC

Power Switch

Multi–Probe

Master U/S

Outputs


Press Base

Abort

EEPROM Serial

Programming Port

Power Signal

Output Monitor

Remote Amplitude

Control

IEC

AC Power

Input

Multi–Probe

Master U/S

Input


Thruster

Operational

Control

Figure 5–1 DPC II Plus and EZ Welder Rear Panel Connectors

System

Output

System

Input

Ultrasound

Output

39



System Input Connector

The System Input is a HD-15 (high-density, 15 contact) female connector. Pin assignments are shown in Figure 5–2. Table 5—I below lists the pinout and signal name for the System Input connector. A complete description of the input signals and their function is given on the next page. Users of custom automation will also find a list of wire color codes for the Dukane 200–1203 I/O cable assembly in Table 5—III. This cable is used to connect the DPC to custom automation equipment to control the welding process.

5 4 3 2 1

6

10

15 14 13 12 11

Figure 5–2 HD-15F System Input Connector

5

6

7

8

9

Pin Signal Name

3

4

1

2

+22VDC

Gnd

Iso Oper In

Iso Common

Signal Description

Current limited to 250 mA maximum

22VDC Return (DPC Chassis Ground)

Isolated Operate Input

Isolated Input Common (if jumper is selected – Figure 5–9/SH707)

Iso Press Cntrl Isolated Press Control

Not Used Spare Input Pin

Gnd 22VDC Return (DPC Chassis Ground)

Sw Oper Input Switch Closure Operate Input

Iso Auto Stop Isolated Automation Stop Input —OR—

Isolated Automation End–Of–Weld

(set by jumper SH704 see Figure 5–12)

10 Not Used

11 HPPI

Reserved for Future Use

Hand Probe Press Inhibit

12 Setup I.D. Bit 0 Remote Setup Selection Bit #0 (LSB)

13 Setup I.D. Bit 1 Remote Setup Selection Bit #1

14 Setup I.D. Bit 2 Remote Setup Selection Bit #2 (MSB)

15 F P Lock Front Panel Control Lock

Table 5— I System Input Connector Signals

40

Ꮨ

CAUTION

The System Input port uses the same type of connector as a standard computer video monitor port, but it is electrically very different. DO NOT connect any video monitor devices to this connector. Doing so may result in damage to both the video device and the DPC.

1 2 3 4 5

6

10

11 12 13 14 15

Figure 5–3 Cable end of SYSTEM IN connector.

NOTE

The connector pinout in Figure 5–2 is the female DPC panel connector. The male cable end is a mirror image and is shown in Figure 5–3.

Pin

14

Pin

13

Pin

12

Timer

Setup File

0 0 0 File 1

0 0 1 File 2

0

0

1

1

1

1

1

1

0

0

1

1

0

1

0

1

0

1

File 3

File 4

File 5

File 6

File 7

File 8

MPC Probe

Selected

Probe 1

Probe 2

Probe 3

Probe 4

Probe 5

Probe 6

Probe 7

Probe 8

Note: 1 = Pin Grounded (to DPC chassis)

0 = Pin Open (no connection)

Table 5— II Remote Setup File Selection



Input Signal Description

Pin 1 (+22V)

This pin can supply +22VDC at up to 250mA to power the user's automation controls.

Pin 2 (Gnd)

Pin 2 and 7 are the 22VDC and Operate returns and are tied to the chassis ground.

Pin 3 (Isolated Operate In)

This pin is used to initiate the operate sequence.

The factory default setting is a non-isolated sink requiring a dry contact closure to ground (pins 2 or 7). This input can be changed to a source or fully isolated input by jumper block SH707. See

Figures 5–11, 5–12 and Appendix C.

Pin 4 (Isolated Common)

This pin is used as the isolated return common if jumper block SH707 is configured as a fully isolated input (position JU726). See Figures 5–11,

5–12 and Figure C-5.

Pin 5 (Isolated Press Control)

This input is designed to be used in conjunction with the optional Press Control Board. The signal is used to activate the thruster up and down. The factory default setting is a non-isolated sink requiring a dry contact closure to ground (pins 2 or

7). This input can be changed to a source or fully isolated input by jumper block SH707. See Figures 5–11, 5–12 and Appendix C.

Pin 6 (Not Used)

Isolated input reserved for future use.

Pin 7 (Gnd)

Pin 2 and 7 are the 22VDC and Operate returns and are tied to the chassis ground.

Pin 8 (Operate)

A dry contact closure (no voltage) between pin 8 and ground (pins 2 or 7) will initiate the operate sequence and is functionally the same as pin 3.

Pin 9 (Isolated Auto Stop)

This signal stops the operation sequence. The factory default setting is a non-isolated sink requiring a dry contact closure to ground (pins 2 or 7).


Pin Color

1

2

Red

Black

Signal Desc

+22V

Gnd

Note

Red used by Belden may appear brown

Also connected to connector metal shell

3

4

5

6

7

8

9

White/Blk

White

Orange

10 Blue

11

12

13

14

Blue/Blk Iso Oper In

Green/Wht Iso Common

Blue/Wht Iso Auto Cntrl

Red/Blk

Orange/Blk

Red/Wht

Green/Blk

Black/Wht

Reserved


Gnd

Sw Oper Input

Iso Auto Stop

Reserved

Hand Probe

Press Inhibit

Remote Setup

Selection (LSB)

Remote Setup

Selection

Remote Setup

Selection (MSB)

Black may be faint –

Don't confuse with 9


15 Green F P Lock

Table 5— III System Input Cable Color Code (P/N 200–1203)

This input can be changed to a source or fully isolated input by jumper block SH707. See Figures

5–11, 5–12 and Appendix C.


Isolated input reserved for future use.

Pin 11 (Hand Probe Press Inhibit)

The adapter cable (P/N 200–1203) has pin 11 grounded to indicate a hand probe is connected.

Pins 12, 13, 14 (Remote Setup)

These pins are used to select one of eight setup files. When using the multi–probe controller module (MPC), these bits also select which probe is activated. A dry contact closure between pins 12,

13 or 14 and ground (pins 2 or 7) will activate one of the setup files. The pin combinations to select setup files 1 through 8 are given in Table 5—II.

Note that file 1 is the default selection.

Pin 15 (F P Lock)

A dry contact closure between pin 15 and ground

(pins 2 or 7) will lock out the front panel TEST key and prevent it from being activated. This also prevents any programming changes.

41


42

System Output Connector

The System Output panel connector is a DB-

25 Female type. Pin numbers are shown in Figure 5–4 and pin assignments are given in Table

5—IV. Dukane cable assembly P/N 200–1302 is used to connect the DPC to custom automation equipment to monitor the welding process.

A complete description of the signals and their function is given on the following pages.

13 12 11 10 9 8 7 6 5 4 3 2 1

25 24 23 22 21 20 19 18 17 16 15 14

Figure 5–4 DB-25 System Output Connector

Pin Signal Name Signal Description

1

2

+22VDC

Gnd

Current limited to 250 mA maximum

22VDC Return (DPC Chassis Ground)

5

6

3

4

7

Gnd

Stat Drv

Not Used

U/S Active

Sys Fault

8

9

O T Fault

O L Fault

10 On Line

11 Gnd

12 Loop Fault

Status Driver Output Ground (DPC Chassis Ground)

Status Driver Output

Spare Output Pin

Ultrasound Status Output

System Fault Output

Overtemperature Fault Output

Overload Fault Output

(1 amp maximum)

(Active Low)

(Active Low)

(Active Low)

(Active Low)

On Line Status Output (Active Low)

Status Outputs Ground (DPC Chassis Ground)

4–20 mA Current Loop Fault Output

1

13 Gnd

14 Freq Out

Monitor Outputs Ground

Frequency Monitor Output

(DPC Chassis Ground)

(31Vrms maximum)

15 Amp Out Amplitude Monitor Output

Power Signal Monitor Output

2

(10.0V = 100%)

16 Pwr Sig

17 Pwr Reg Stat Power Regulation Status Output

3

18 MPC Ready Multi–Probe Controller Ready

4

(1mV = 1 watt)

(Active Low) 19 Iso Pwr Fail Isolated Power Fail Signal

20 Iso BSP Isolated Bad/Suspect Part Output

5

21 Iso GP Isolated Good Part Output

5

22 Iso RDY

23 Iso ID

24 Iso Com

25 Not Used

Isolated Ready Signal

Isolated In–Dwell Signal

Isolated Outputs Common

Spare Output Pin

Table 5— IV System Output Connector Signals

(Active Low)

(Active Low)

(Isolated Gnd)

CAUTION

Ꮨ

The System Output port uses the same type of connecor as a standard RS-232,

DB-25 serial interface, but it is electrically very different. DO NOT connect any RS-232 devices to this connector. Doing so may result in damage to both the serial device and to the DPC internal circuitry.



Output Signal Description

Pin 1 (+22V)

This pin can supply +22VDC to supply power for user automation controls. It is limited to 250mA.

Pin 2 (Gnd)

Pin 2 is the 22VDC and Status Out return. It is tied to the chassis ground.

Pin 3 (Gnd)


Pin 4 (Status Driver)

An active low output on pin 4 indicates the condition set on Jumper Block SH702 has occurred (see Figures 4-7 and 4-8). The factory default is OVERLOAD.


Pin 5 is reserved for future use.

Pin 6 (U/S Active)

An active low output on pin 6 indicates the ultrasound is being delivered to the probe.

Pin 7 (System Fault)

An active low output on pin 7 indicates the generator has detected an out of tolerance voltage fluctuation.

The front panel status display will indicate FAULT.

Pin 8 (OVERTEMP)

An active low output on pin 8 indicates that one of the power modules in the generator has overheated and automatically shut down. The front panel status display will indicate OVERTEMP.

Pin 9 (OVERLOAD)

An active low output on pin 9 indicates that excessive power beyond the generators rated output is being drawn. The ultrasonic signal is shut down when an overload condition is detected. The front panel status display will indicate OVERLOAD. The overload signal resets when the operate input deactivates or the TEST switch is released.

NOTE

Active Low outputs are open collector

Darlington transistors that sink current to ground (either chassis ground or isolated common @20mA maximum).

Custom automation users must supply their own pullups. See Appendix C for sample circuits.


43


Pin 10 (ON LINE)

An active low output on pin 10 indicates the generator is on line and is capable of being triggered externally. The front panel status display will indicate ON LINE.

Pin 11 (Gnd)


Pin 12 (Current Loop Fault)

1

An active low output on pin 12 indicates the 4–20mA current loop output has a fault. This output is only available when a Remote Amplitude Control module is installed.

Pin 13 (Monitor Gnd)

Pin 13 provides a return path to the chassis ground for the monitor outputs on pins 14, 15 and 16.

Pin 14 (Freq Out)

The signal on pin 14 is the actual output frequency.

It is a sine wave with an amplitude of 31Vrms maximum.

Pin 15 (Amp Out)

The signal on pin 15 is proportional to the output signal amplitude. The scale is 10.0V = 100%. This allows automation equipment to monitor the DPC amplitude setting.

Pin 16 (Pwr Sig)

2

This output is only available when the optional Power

Signal Output module (part 438-826 ) is installed.

The signal on pin 16 is proportional to the true RMS ultrasonic output power being drawn from the DPC.

The scale is 1mV = 1Watt on the 20kHz, 30kHz and

40kHz models. The maximum full scale output is

4.095V (4,095 Watts). On the 50kHz and 70kHz models, the scale factor is 10mV = 1 Watt with a maximum scaled output of 409.5 Watts.

Pin 17 (Pwr Reg Status)

3

This option is not currently available.

44



Pin 18 (MPC Ready)

4

An active low output on pin 18 indicates the MPC module (Multi–Probe Controller) is ready and will accept probe selection changes on the Remote Setup inputs.

Pin 19 (Iso Power Fail)

An active low output indicates that AC power is within operating range. This output will turn off (high impedance state which no longer sinks current), if the

AC power fails or is switched off.

Pin 20 (Iso Bad/Suspect Part)

5

An active low output that indicates the weld cycle is outside the boundary limits set in the Bad Limits menu. This signal activates when the ultrasonic output is terminated at the end of the weld. The default setting is maintained which means the signal remains active until the beginning of the next cycle.

If the Utilities menu option is set to momentary, the signal is pulsed for 100 msec.

Pin 21 (Iso Good Part)

5

An active low output that indicates the weld cycle did not cross the boundary limits set in the Suspect or

Bad Limits menu. This signal activates when the ultrasonic output is terminated at the end of the weld.

The default setting is maintained which means the signal remains active until the beginning of the next cycle. If the Utilities menu option is set to momentary, the signal is pulsed for 100 msec.

Pin 22 (Iso Ready)

An active low output that occurs at the end of all portions of the weld cycle. The signal remains active until the beginning of the next cycle.

Pin 23 (Iso In–Dwell)

This output is active low while the ultrasonic output signal has been turned off during the HOLD time of the weld cycle.

Pin 24 (Iso Common)

5

Pin 24 provides the return path for the isolated output signals on pins 19, 20, 21, 22 and 23.


Pin 25 is reserved for future use.

FOOTNOTES

1 Requires a Remote Amplitude Control module.

2 Requires a Power Signal Output module.

3 Not presently available.

4 Requires a Multi–Probe Controller module.

5 Requires the standard DPC II Plus timer feature.


45


Remote Amplitude Control

Module

Part No. 438–799

This optional module enables remote control of output amplitude of the DPC II Plus. The control interface is a 4–20mA current loop. The current loop connector and fault indicator are shown in

Figure 5–5. The output can be adjusted from 36% to 100%. The scale factor is

∆

16mA =

∆

64% which is

∆

1mA =

∆

4%. The graph of output as a function of loop current is shown in Figure 5–6.

The input compliance is 10 volts minimum.

100%

80%

60%

40%

36%

20%

Failure to provide between 4mA and 20mA of loop current is detected as a fault and will not produce any output. The current loop fault indicator is a bi– color LED. It is green when the current is between 4 and 20mA and red when the current is below this value. The module contains an internal jumper block

(SH1) to select the current loop fault option. The default setting (jumper JU1) disables ultrasonic output if a loop fault occurs The setting can be reversed with JU2 to enable the minimum level output

(36%) if a loop fault occurs. This is used primarily for system testing when a current loop is unavailable.

Out% = (20% + 4 I

Loop

)% e.g. Determine %Output delivered

for an 8mA Loop Current

20 + 4 x 8 = 52%

I

Loop

=

Out% – 20 mA

4 e.g. Determine I

Loop

needed

for a 75% Output

75 – 20 = 13.75mA

4

JU2

Output

Enabled

Current

Loop

Fault

Region

0%

0mA

Output

Disabled

JU1

4mA

5mA 10mA 15mA

Figure 5–6 Current Loop Transfer Function Graph

NOTE

The equations for Out% and I

Loop

are only valid for normal operating conditions —

36% < Out% < 100% and

4mA < I

Loop

< 20mA

20mA

Current Loop

Fault Indicator

Remote Amplitude

Control Module

P/N 438–799

NOTE

If you have a Remote Amplitude

Control module installed, its setting will override any front panel setting.

The front panel menu will accept the value, but the output amplitude will be determined by the 4–20mA loop current.

Current Loop

Connector

Figure 5–5 Remote Amplitude Control Module

46



Power Signal Output Module

Part No. 438–826

This optional module enables the DPC II Plus to operate in the Weld–By–Energy mode. When installed, the DPC II Plus automatically detects the board and enables the energy options in the process control menu. The module also permits the user to monitor the True-RMS ultrasonic output power from the DPC II Plus. The module is shown in

Figure 5–7. The output signal can be monitored from three different connectors simultaneously. The scale factor is the same on all three outputs. On the

20kHz, 30kHz and 40kHz models, it is 1mV = 1 Watt and the maximum full scale output is 4,095 Watts.

On the 50kHz and 70kHz models, the scale factor is

10mV = 1 Watt with a maximum output of 409 Watts.

1.

A miniature phone jack is provided on the top of the rear panel.

2.

A pair of test jacks on the rear panel allow a hand-held multimeter to monitor the power.

3.

The power output signal can also be monitored by automation equipment using the System Output connector by measuring between pin 16 (Power Signal) and pin 13

(Monitor Ground Reference).

4.

This module also features an offset adjustment to set the output to zero. Only adjust the offset after the DPC system has been powered up for at least 15 minutes and with the ultrasound ouput deactivated.

1. Power Signal Output

(Phone Jack)

4. Output Zero

Adjustment

2. Power Signal

Output (Test Jacks)

Power Signal

Output Module

( aka Energy Module)

P/N 438–826

Ground (Pin 13)

3. Power Signal

Output (Pin 16)

Figure 5–7 Power Signal Output Module


47


Press Control Module

Part No. 110–3938

This optional module enables the DPC II Plus to control a Dukane Model 210, 220 or 410 press or custom automation. This module is also installed on a EZ Welder™ System. The module is illustrated in Figure 5–8. The cabling hookup to a

Dukane press system is shown in Figure 3–8.

J902 Press

Base Cable

Connector

Press Control

Module

P/N 110–3938

9

6

DB–9

5

1

36 18

19 1

Molex

36–Contact

Subminature D

Figure 5–9 Press

Connector Pin

Identification

Figure 5–8 Press Control Module

J901

Thruster Cable

Connection

Pin No.

Type Function

1

2

3

4

Input

Input

Input

Input

Signal Description

Activation Switch 1

Activation Switch 2

Normally Open (N.O.) dry contact closure to ground

Normally Open (N.O.) dry contact closure to ground

Hardware Abort Power In Normally Closed (N.C.) emergency switch contact

Software Abort Normally Open (N.O.) dry contact closure to ground

5

6

7

Ground Internal Ground



Internal Ground (Gnd)



8 Input Automation Input Normally Open (N.O.) dry contact closure to ground

9 +22V DC Hardware Abort Power Out Normally Closed (N.C.) emergency switch contact

Table 5— V J902 Press Base Connector Pinout

48



Table 5—V on the previous page lists the pinout and signal description for J902 which is the Press

Base connection. Note that there is an automation input on pin 8 which is electrically identical to pin 8 on the System Input connector. This permits you to use J902 to initiate operation without having to run a separate connection to pin 8 of the System

Input connector. Figure 5–9 on the previous page, identifies the pin numbers for both J902 and J901.

NOTE

J902 Press Base connector has multiple ground pins.

The DPC–2 Plus/EZ uses pins 5, 6 & 7 for Ground.

The DPC–3 uses pins 5 & 7 for Ground.

The DPC–4 uses pins 6 & 7 for Ground.

To keep your custom automation circuits compatible with DPC models, only use pin 7 for a ground connection to the Press Base connector.

It should be pointed out however, that the DPC–3 does have an Automation Input on pin 8.

Place switch in

WELD PRESSURE position before..

..connecting Dual

Pressure Press to the Press Control

Module. This only applies to the

DPC II Plus. The

EZ Welder System is a single pressure press.

Table 5—VI below gives the pinout and signal description for J901 which is the 36–pin Thruster connector. This connector is the same type as found on the DPC–III and DPC–IV. The cable specified is Part No. 200–1104 which is interchangeable with both DPC–III and DPC–IV generators.

Pin No.

1

2

3

5

13

Input/Output Function

Output

Output

Output

Output

Dual Pressure Valve

Trigger LED (–)

Up Valve

Down Valve

Input Dual Pressure Switch

14

15

16

Input

Input

Input

Ground Detect

Trigger Switch

End Of Weld Switch

Signal Type

Low side Mosfet driver to ground




Normally–Open dry contact switch closure to ground





Internal Power to Press

17 Input Pre–trigger Switch

4, 19, 20,

22, 24, 26

6, 8, 10, 12,

25, 27, 28, 29

30, 31, 32,34, 36

7, 9, 11, 18

21, 23, 33, 35

Power

Ground

Unused

+22V Press

+22V Return

Unused

Table 5— VI J901 Thruster Connector Pinout


Power and Signal Ground

Unused

49


Multi–Probe Master Module

Part No. 110–3954

This optional module enables the DPC II Plus to activate any one of four ultrasonic probes. Each probe can have its own setup file which is selected by the Setup ID# (pins 12, 13 & 14) of the HD–15

System Input connector. The functions are listed in Table 5–I and 5–II. Rear panel bicolor LED status indicators for each probe output illuminate green when the probe channel is selected and red when the U/S is active. Both a MPC Master and

Slave module are shown below in Figure 5–10.

Internal logic prevents more than one probe from being activated at a time or probe switching signals when the U/S is on. A ring-down circuit permits switching only when U/S output is zero. Internal fault logic senses any malfunction and deactivates the MPC Ready output.

The Multi–Probe Controller cannot be used with a press module. The master module has an extra wide back panel to prevent it’s accidental use with the press module.

MPC Slave

Module

P/N 110–3956

Multi–Probe Slave Module

Part No. 110–3956

This optional module adds four additional probe selection channels to the DPC II Plus. This gives a total of eight probe channels. The slave module cannot be used alone. It must be used with the master module. An internal connector supplies the ultrasound signal from the Master module. As with the Master module, each output channel has a bicolor LED status indicator that illuminates green when the probe channel is selected and red when the U/S is active.

MPC Master

Module

P/N 110–3954

NOTE

The Ultrasound input on the MPC Master must be connected to the DPC Ultrasound output connector (J1) with a RG62B/U coax.

This is indicated as Cable 2 in Figure 3–6.

Ultrasound

Input from J1

8 Ultrasound Outputs

(4 per Module)

Figure 5–10 Master and Slave Multi–Probe Controller (MPC) modules

50



Jumper Block Options

The DPC II Plus may be customized to your specific requirements by means of internal jumpers located on the main printed circuit board. Below is a list of the jumper blocks, their default factory settings and their alternate positions. Figures 5–11 and

5–12 on the following pages show the location of the jumper blocks in more detail. The factory default setting is indicated by a diamond

◊

next to the description in Figure 5–12.

Status Driver Normal State Selection

Jumper Block – SH701

(Pin 4 output on DB-25)

JU701 - Normally OFF (Factory Default)

JU702 - Normally ON

Status Driver Selection


(Pin 4 output on DB-25)

JU703 - Ultrasound Active Status

JU704 - Overload Fault (Factory Default)

JU705 - Over temperature Fault

JU706 - System Fault

JU707 - Any Fault

Automation Cycle Stop or End Of Weld Selection


JU713 - Normally OFF (Factory Default) – Use depends upon custom automation configuration

JU714 - Normally ON

JU715 - Automation Stop Fault – Move jumper to this position to use Auto Stop (Figure 7–13)

JU716 - Automation End of Weld (Factory Default)

Switch Debounce Filter Time Delay Selection


JU717 - No Time Delay (used for electronic switches)

JU718 - 1 msec

JU719 - 10 msec (Factory Default)

JU720 - 22 msec

Timer Board Enable/Bypass


JU723 - Timer Board Enable (normally selected for a DPC II Plus)

JU722 - Timer Board Bypass (Factory Default – used for standard DPC II)


51


System Control Inputs


JU724 - Non–Isolated Sink (Factory Default) – Dry contact between input and DPC ground.

JU725 - Non–Isolated Source – Dry contact between input and +22 VDC.

JU726 - Isolated Source – Input can be either sinking or sourcing. A signal of 5 to 24 VDC is required at the isolated inputs. The current is internally limited to 12.5mA.

C704

C707

C

Q702

C703

U721

1

J709

+

B

CR726

CR724

R725

STATUS RELAY

BOARD

1

E

R724

R726

R791

P704 P703 P707 P706

2

P705

40

P708

4

1 10

1 4

1 4

1

U709

U720

A1

A10

B1

B10

R798

J716

MULTI-PROBE

CONTROLLER BOARD

SLAVE

A1

A10

110-3606

DUKANE ULTRASONICS

MADE IN USA

B1

B10

U717

SW701

J715

MULTI-PROBE

CONTROLLER BOARD

MASTER

R732

R735

R782

R790

A1

A10

R768

CR729

C725

CR730

R766

R754

R767

B1

B10

J714

PRESS CONTROL

BOARD

CR737

R788

R787

R786

R794

R769

R758

R781

AMPLITUDE

MONITOR

OUTPUT

GAIN ADJ.

CR731

R783

C726

JU723

SH706

JU722

R752

TIMER BD. ENABLE

TIMER BD. BYPASS

39

JU710

JU711

JU712

OVERLOAD

OVERTEMP

SYS. FAULT

ANY FAULT

U719

STATUS RELAY

SELECTION BLOCK

SH703

R756

JU708

JU709

U/S ACTIVE

RP701

CR736

AUTOMATION SIGNALS

SELECTION BLOCK

JU713

SH704

NORMALLY OFF

JU714 NORMALLY ON

JU715

JU716

AUTO STOP FAULT

AUTO END OF WELD

C728

C713

CR723

C705

U715

R789

1

R745

C719

C706

SWITCH DEBOUNCE

FILTER TIME DELAY

SELECTION BLOCK

SH705

JU717

JU718

JU719

JU720

NO DELAY

1 mSEC

10 mSEC

22 mSEC

CR708

R753

C711

C712

U726

C714

C718

CR722

CR725

U701

R793

CR707

A O I

C702

C727

CR714

C701

CR701

+

R701

CR702

CR713

RP702

STATUS DRIVER

SELECTION BLOCK

JU703

SH702

U/S ACTIVE

JU704

JU705

JU706

JU707

OVERLOAD

OVERTEMP

SYS FAULT

ANY FAULT

CR710

U718 A

U705

O

I

VR707

CR706

U703

CR709

R723

A

O

I

U706

CR705

CR712

VR708 U704

R749

STATUS DRIVER

NORMAL STATE

SELECTION BLOCK

SH701

JU701

JU702

NORMALLY OFF

NORMALLY ON

J711

1

CR704

A

O

U707

I

R717

C729

U702

J712

1

CR703

R759

RP703

C717

CR727

C708 C709

CR720 CR721

VR709

R712 REMOTE

CONTROL

BOARD

R716

CR728

R765

1

R710

R711

U710

R713

R709

R721 R715

U722 U725

R708

R707

R720

Q701 VR705

R738

R785

R736

C721

J710

POWER SIGNAL

OUTPUT BOARD

E701

VR702

C720

C710

R780

C716

U727

U724

R739

R799

R737

R784

R792

U708

R770 1

C724

C723

R771

NON-ISO SINK

NON-ISO SOURCE

C722

R772

R778

R779

R744

R797

CR715

P713

ISOLATED

JU724

JU725

JU726

U723

13

J702

1

R775

5

J701

R776 SH707

1 CR717

R777

CR719

CR718

R795

+

SYSTEM OUT SYSTEM IN

Figure 5–11 Card Slot, Connector and Jumper Block Locations

52



JU723

JU722

SH706

TIMER BD. ENABLE

TIMER BD. BYPASS

SWITCH DEBOUNCE

FILTER TIME DELAY

SELECTION BLOCK

SH705

JU717

JU718

JU719

JU720

NO DELAY

1 mSEC

10 mSEC

22 mSEC

R753

C711

C712

STATUS RELAY

SELECTION BLOCK

SH703

JU708 U/S ACTIVE

RP701

AUTOMATION SIGNALS

SELECTION BLOCK

SH704

JU713 NORMALLY OFF

JU709

JU710

JU711

OVERLOAD

OVERTEMP

SYS. FAULT

JU714

JU715

JU716

NORMALLY ON

AUTO STOP FAULT

AUTO END OF WELD

JU712 ANY FAULT C728

CR723

CR736

C705

R789

CR708

RP702

CR710

VR707

STATUS DRIVER

SELECTION BLOCK

SH702

JU703

JU704

JU705

JU706

JU707

U/S ACTIVE

OVERLOAD

OVERTEMP

SYS FAULT

ANY FAULT

U718 A

U705

O

I

CR706

U703

R749

J711

STATUS DRIVER

NORMAL STATE

SELECTION BLOCK

SH701

JU701

JU702

NORMALLY OFF

NORMALLY ON

1

CR704

A

U707

I

O

R717

C729

R712

C714

CR705

U702

J712

1

REMOTE

CONTROL

BOARD

CR703

R716

1

R710 R711

R715

VR705

R707

J710

POWER SIGNAL

OUTPUT BOARD

Figure 5–12 Jumper Block Detail

R771

C723

R772

C722

NON-ISO SINK

NON-ISO SOURCE

ISOLATED

SH707

JU724

JU725

JU726


53



54



S

ECTION

6

Menu Structure

• Process Setup

• Process Control

• Process Limits

• Utilities

Process Setup ............................................... 57

Process Control ............................................. 58

Process Limits ............................................... 60

Utilities ......................................................... 61




55



56


Section 6 – Menu Structure

Process Setup Menu

This section deals with the overall menu structure.

Each setup menu is later discussed in detail in its own section. Each time the DPC II Plus is powered up, the processor scans the system to determine which modules are installed and if a hand probe is connected. It first displays which version of the

DPC firmware is installed as shown in Figure 6–1.

Then the screen then displays the operate page which contains the measured values from the last weld cycle as shown in Figure 6–3. If the Parts

Counter (covered in detail in Section 9 –Utilities) is active, the count is displayed in the upper left– hand corner in place of the dashes (– – – – –). The

# sign and the digit after the dashes indicate which setup file is active. There are eight setup files available. Setup files are covered in Select Setup of

Section 9 – Utilities Menu.

DUKANE DPC II+ v1.10

(c)2002 Dukane Corp.

All Rights Reserved

Figure 6–1 DPC II Plus Startup Menu

After a few seconds, the screen displays the welding mode and installed modules. Depending upon your configuration, your screen may display

HAND PROBE

DETECTED, AUTO PROBE DETECTED, MPC PROBE DE-

TECTED, ECONOMY PRESS DETECTED.

or

PRESS BOARD

DETECTED.

This is shown in Figure 6–2.

– – – – – #1 TIME ENERGY

P1 0.000 0

P2 0.000 0

TOTAL 0.000 0

Figure 6–3 DPC II Plus Weld Cycle Display

Press the MODE key once to switch from the

Operate mode to the Setup mode and display the

Process Setup menu shown below in Figure 6–4.

AUTO MODE

PRESS BOARD DETECTED

PROCESS SETUP

PROCESS CONTROL

PROCESS LIMITS

UTILITIES

Figure 6–2 DPC II Plus Configuration Menu

Figure 6–4 DPC II Plus Process Setup Menu

57



Part Count appears here

OPERATE

Mode

----- #1 TIME ENERGY

P1 0.000 0

P2 0.000 0

TOTAL 0.000 0

Setup File currently being used

MODE

From many levels down in the menu

MODE MODE

Only present if

Power Output Module is installed

CANCEL CANCEL

SETUP

Mode

PROCESS SETUP

PROCESS CONTROL

PROCESS LIMITS

UTILITIES

ENTER

Only present if

Press Control Module is installed

TRIGGER METHOD

PRESS

TIMED PROBE

UNTIMED PROBE

SECTION 7

LIMIT DEFINITION

SUSPECT LIMITS

BAD LIMITS

SECTION 8

SECTION 9

UTILITIES

SETUP UTILITIES

PART COUNT

STATUS OUTPUTS

Figure 6–5 Process Setup Main Menu Structure

The main structure of the Process Setup menu is shown in Figure 6–5. You can press the MODE key or the CANCEL key twice at any time to return to the

Process Setup menu. The MODE key toggles between the Weld Cycle data (Operate mode) and Process

Setup menu (Setup mode) each time it is pressed. Process Setup is the root menu to select all subsequent sub menus. The Press menu option is only present if a

Press Control Module is installed. The energy value is only displayed if a Power Output module is installed.

The Process Control menu sets the welding parameters. Limit Definition menu sets the bounds for suspect parts and bad parts. Utilities menu enables you to save, copy and erase setup files, count parts which are out of limit and configure status outputs.

Process Control Menu

By pressing the up–arrow and down–arrow keys you can navigate the triangle pointer to select the

58

Process Control, Limit Definition or Utilities menu. Press the ENTER key to activate the selected menu. The Process Control Menu selects the trigger method, the welding mode and sets the values for the welding parameters. This menu’s structure is the most complex of the three. However, since the DPC II Plus reconfigures the user interface to be consistent with the installed modules, only the relevant portion of the menu structure is displayed.

The flow chart for the Process Control menu is shown in Figure 6–6. The menu structure builds logically upon itself starting with the Hand Probe on the right side and progressing with more options towards the Press menu on the left. Process

Control is discussed in detail in Section 7.



PROCESS

CONTROL

PROCESS

SETUP

AUTO STOP

ENABLE DISABLE

PRESS

TRIGGER METHOD

AUTO

PROBE

TIMED PROBE

UNTIMED PROBE

MPC

PROBE

HAND

PROBE

TIMED UNTIMED TIMED UNTIMED TIMED UNTIMED

INITIATE

MODE

AUTO MANUAL

AUTO STOP

ENABLE or DISABLE

HEAD UP ON

AUTO STOP

ENABLE DISABLE

PROCESS CONTROL

WELD

MODE

HOLD

TIME

AFTER–

BURST

Step 1 Step 2

Step 3

SINGLE

PRESSURE

PRESS

WELD MODE

SINGLE

PRESSURE

DUAL

PRESSURE

WELD METHOD

TIME ENERGY

GND.

DETECT

DUAL

PRESSURE

PRESS

PRESSURE 1

TIME

1

ENERGY

1

DPC II

Plus

Models

Only—

Not

Available on

EZ Series

PRESSURE 2

TIME

2

ENERGY

2

TRIGGER TYPE

MOMENTARY MAINTAINED

RTW

UNTIMED

AUTO

PROBE

RTW

UNTIMED

MPC

PROBE

UNTIMED

HAND

PROBE

RTW = READY TO WELD

TIMED

AUTO

PROBE

PROCESS CONTROL

WELD

METHOD

Step 1

HOLD

TIME

Step 2

AFTER–

BURST

Step 3

WELD METHOD

TIME ENERGY

GND.

DETECT

TIMED

MPC

PROBE

WELD METHOD

TIME ENERGY

GND.

DETECT

TIMED

HAND

PROBE

WELD METHOD

TIME ENERGY


Figure 6–6 Process Control Menu Flowchart


RTW RTW RTW

59


Limit Definition Menu

The Limit Definition menu has two classes of settings. The first class is the suspect limits and the second class is for bad part limits. When applicable, choices for time, energy, total time and total energy are available. A simplified flow chart for the Limit Definition menu is shown in

Figure 6–7. Although not indicated in this drawing, both upper and lower bounds can be set for each limit. The Limit Definition menu is covered in greater detail in Section 8.

PROCESS

LIMITS

PROCESS

SETUP

LIMIT DEFINITION

SUSPECT

BAD

LIMITS

TOTAL

WELD TIME

TIME

ENERGY

TOTAL TIME

TOTAL ENERGY

TOTAL

WELD ENERGY

Total Limits

Available Only with

Press Controller in

Dual Pressure Mode

PROCESS

LIMITS

WELD

ENERGY P1

WELD

ENERGY P2

PROCESS

LIMITS

WELD

TIME P1

WELD

TIME P2

Figure 6–7 Limit Definition Menu Flowchart

60



Utilities Menu

The Utilities menu has four different sections. The first section handles setup file operations. The second section accesses the parts count functions. The third section configures the status output. The fourth section allows the operator to cycle the press off line. A simplified flow chart for the Utilities menu is shown in Figure 6–8 and is covered in greater detail in Section 9.

UTILITIES

PROCESS

SETUP

UTILITIES

SETUP UTILITIES

PART COUNT

STATUS OUTPUTS

CYCLE PRESS OFF LINE

STATUS

OUTPUTS

MAINTAINED PULSED

SELECT

SETUP

SETUP

UTILITIES

COPY

SETUP

ERASE

SETUPS

RESET

PART

COUNT

PART

COUNT

COUNT

BAD

PARTS

PRESET

PART

COUNT

SETUP

TYPE

LOCAL REMOTE

ERASE

SETUPS

ERASE

CURRENT

SETUP

ERASE

ALL

SETUPS

Figure 6–8 Utilities Menu Flowchart


61



62



S

ECTION

7


• Hand Probe

• MPC Probe

• Auto Probe

• Press Mode

• Hot Keys

Hand Probe .................................................. 65

Untimed Hand Probe ............................................66

Timed Hand Probe ...............................................66

Timed Hand Probe – Energy .................................67

MPC Probe ................................................... 68

Auto Stop Option ................................................. 68

Untimed MPC Probe – Probe Delay .......................68

Weld Method – Time ...........................................69

Weld Method – Energy ........................................70

Weld Method – Ground Detect ............................70

Auto Probe ................................................... 71

Auto Stop Option ................................................. 72

Untimed Auto Probe – Delay ................................73

Timed Auto Probe – Weld Method .......................73

HoldTime .............................................................73

Afterburst ............................................................73

Press Mode ................................................... 75

Initiate Mode .......................................................76

Auto Stop ............................................................76

Head Up On Auto Stop ........................................76

Trigger Type..........................................................76

Single/Dual Pressure Mode ...................................76

Press Mode Example ..................................... 77

Hot Keys ....................................................... 81

Process Control Recap................................... 82

Dukane Corporation • • Ultrasonics Division


63



64


Section 7 – Process Control Menu


The Process Control Menu has a dynamic structure. Its configuration is determined each time the

DPC II Plus is turned on. The processor scans for installed modules and connected probes and configures the user interface to match the installed hardware. This is another reason the AC power must be turned off before any modules or probes are installed or removed. If you are using a hand probe, make sure you have the latest version of the hand–probe adapter cable (P/N 200–1248).

This has pin 11 (Hand Probe Detect) of the male

HD–15 cable connector grounded.

Hand Probe

Make sure you have connected the hand probe as indicated in Figure 3–4. When the DPC II Plus is powered up, it displays the current version of the firmware and then indicates the current configuration. This is shown in Figures 7–1 and 7–2. The screen then displays the measured values from the last weld cycle as shown in Figure 7–3. If a Power

Output module is installed, the menu will also display the energy data as in Figure 7–4.

CAUTION Ꮨ

Make sure electrical power is OFF before connecting/ disconnecting cables or installing/removing modules from the DPC II Plus. Make sure BOTH the front and rear panel AC power breaker switches are in the OFF position.

Failure to turn off the power may result in damage to the DPC and/or the modules.

The DPC must also be properly grounded, as discussed in Section 3, to prevent any static discharge damage.

TIP

We highly recommend that you read this chapter completely. Even though some of the configurations may not be applicable to your process, the options and menu selections are covered in a sequential fashion. If you jump directly to the menu structure of interest, you will miss some of the preliminary topics.

DUKANE DPC II + v1.10

(c)2002 Dukane Corp.

All Rights Reserved

Figure 7–1 DPC II Plus Startup Menu

– – – – – #1 TIME

0.000

Figure 7–3 DPC II Plus Time Weld Cycle Display

AUTO MODE

HAND PROBE DETECTED


0.000 0

Figure 7–2 DPC II Plus Configuration Menu Figure 7–4 DPC II Plus Energy Weld Cycle Display

65



Press the MODE key to display the Process Setup menu. In Process Setup, the cursor should be pointing to Process Control as shown in Figure 7–5. If it is not, press the up–arrow and down–arrow key to navigate the triangle pointer to select Process

Control. Press the ENTER key to activate the selected menu.

TRIGGER METHOD

TIMED HAND PROBE

UNTIMED HAND PROBE

Figure 7–6

PROCESS SETUP

PROCESS CONTROL

PROCESS LIMITS

UTILITIES

Figure 7–5 Process Setup Menu

Since the DPC II Plus reconfigures the user interface to be consistent with the installed modules, only the portion of the menu structure relating to hand probe operation is displayed. The only option for the Process Control screen is the Trigger

Method which is shown in Figure 7–6.

TRIGGER METHOD

TIMED HAND PROBE

UNTIMED HAND PROBE

Hand

Probe

Trigger

Switch

ENTER

UNTIMED

HAND

PROBE

RTW

LEGEND

RTW = Ready To Weld

ENTER

= Front Panel ENTER Key

(Section 4.3 – Menu Keys)

= Parameter Value Entry

T = Time

E = Energy

ENTER

TIMED

HAND

PROBE

Figure 7–9

WELD METHOD

TIME ENERGY

Figure 7–6 Process Control Trigger Method Menu

The flow chart for the Process Control menu with a hand probe connected is shown in Figure 7–7. If you do not have a Power Output module installed, the Energy Weld Method will not be displayed.

Untimed Hand Probe

Untimed Hand Probe operation has no parameters to enter. The generator is triggered whenever the hand probe trigger is engaged and continues until the trigger is released. Press ENTER and you are ready to weld ( RTW ).

Timed Hand Probe

In Timed Hand Probe mode, the welding stops whenever the trigger is released or the specified weld time

66

Maximum E weld

Minimum E weld

= 12,000 Joules

= 1 Joule*

Figure 7–10

Maximum T max

Minimum T max

= 30.000 Seconds

= 0.001 Second*

Maximum T weld

Minimum T weld

= 29.999 Seconds

= 0.001 Second*

Figure 7–8

ENTER

Hand

Probe

Trigger

Switch

Figure 7–11

ENTER

ENTER

* These values can be set to zero, but will not produce any output. The values listed represent the resolution and are the smallest values that will produce any output signal.

RTW

Figure 7–7 Hand Probe Flow Chart



WELD METHOD

WELD BY TIME

WELD BY ENERGY

Figure 7–8 Hand Probe Weld Method is reached, whichever comes first. Press ENTER and the data entry screen appears as shown in Figure

7–9. If a Power Output module is installed, then a

Weld Method screen shown in Figure 7–8 is displayed first. Press the ENTER key to display the weld time data entry. If a Power Output module is not installed, there is only one choice and the Weld

Method screen is bypassed. Timed Hand Probe operation requires the weld time to be entered. Use the

Left and Right arrow keys to move to the desired digit position and the Up and Down arrow keys to increment or decrement the value. When the desired value is displayed, press ENTER for the next menu until all the required values have been entered.

NOTE

The flowchart beginning with powerup to the

Process Setup menu (Figure 7–5) and the Trigger

Method screen (Figure 7–6) is shown in Figure

6–5. A portion of the drawing is repeated here.


0.000 0

Figure 7–3 and 7–4

MODE MODE

MODE

Only present if

Power Output Module is installed

CANCEL CANCEL

PROCESS SETUP

PROCESS CONTROL

PROCESS LIMITS

UTILITIES

Figure 7–5

ENTER

Figure 7–6

TRIGGER METHOD

TIMED PROBE

UNTIMED PROBE

WELD TIME

0.500 SEC

Figure 7–9 Hand Probe Weld Time

Timed Hand Probe – Energy

If a Power Output module is installed, you can also choose the Weld By Energy method. From the

Weld Method screen shown in Figure 7–8, move the cursor down so it points to Weld By Energy and press the ENTER key.

To weld using the Energy Method, you first enter the desired welding energy, This data entry screen is shown in Figure 7–10. Enter the desired welding energy and press ENTER . Now enter the maximum weld time as shown in Figures 7–11. Press

ENTER to complete the process. You will return to the Process Setup menu (Figure 7–5).


WELD ENERGY

75 J

Figure 7–10 Hand Probe Weld Energy

MAX WELD TIME

1.000 SEC

Figure 7–11 Hand Probe Max Weld Time

67


MPC Probe

The cable connection diagram for connecting the

Multi–Probe Controller module is shown in Section 3 in Figure 3–6. The flow chart for the Process Control menu with a Multi–Probe Controller installed is shown in Figure 7–12. If you do not have a Power Output module installed, the Energy

Weld Method menu will not be displayed.

The Multi–Probe Controller (MPC) flow chart adds three options to the basic Hand Probe flow chart shown in Figure 7–7.

1. An

AUTO STOP

option is included which can be enabled or disabled.

2. A delay time value (T delay

) can be entered for untimed operation.

3. A weld method called

GROUND DETECT

is now available. This method requires values to be entered for the maximum weld time (T max

) and for a parameter called scrub time (T scrub

).

AUTO

*

STOP Option

This menu is shown in Figure 7–13. To use this option, move the SH704 jumper block to JU715

(see Figure 5–12). Use the down arrow key to select

ENABLE

and press ENTER to continue.

TRIGGER METHOD

TIMED MPC PROBE

UNTIMED MPC PROBE

Maximum T delay

= 30.000 Seconds

Minimum T delay

= 0.000 Second

UNTIMED

MPC

PROBE

AUTO STOP


ENTER

RTW

LEGEND


ENTER




T = Time

E = Energy

TIMED

MPC

PROBE

WELD METHOD

TIME ENERGY

GND.

DETECT

AUTO STOP

DISABLE

ENABLE



= 30.000 Seconds

= 0.001 Second*

ENTER



= 12,000 Joules

= 1 Joule*

ENTER

Figure 7–13 MPC Probe Auto Stop Mode Menu

When Auto Stop is enabled, a signal on pin 9 of the

HD–15 SYSTEM IN connector will be recognized.

This permits external automation equipment to stop the welding cycle. If Auto Stop is set to disable, then the signal will be ignored. If the SH704 jumper block is left in the End–Of–Weld factory default position

(JU716), only the welding is stopped. Any programmed Hold or Afterburst (discussed later) will still be executed regardless of the Auto Stop mode.

* AUTO refers to Automation not automatic

68

Maximum T max

Minimum T max

= 30.000 Seconds

= 0.001 Second*

Maximum T scrub

Minimum T scrub

= 0.150 Seconds

= 0.001 Second

ENTER

ENTER

ENTER


RTW

Figure 7–12 Multi–Probe Controller Flow Chart



Untimed MPC Probe – Probe Delay

The probe delay time value for untimed operation is shown in Figure 7–14. This parameter is typically used in a single auto probe configuration which is covered later in this section. For MPC untimed operation, the suggested value for the delay time is 0.000 second.

PROBE DELAY

0.000 SEC

CAUTION

 If the AUTO STOP option is set to ENABLE, you must supply the Isolated

Automation Stop input signal to pin 9 of the HD–

15 SYSTEM INPUT connector (see Table 5—I). The SH707 jumper block (see Figure 5–11) determines whether the the signal is isolated or non–isolated and sourcing or sinking.

Figure 7–14 MPC Probe Time Delay

Weld Method – Time

For the Time welding method, an ultrasonic signal is generated for a specific time once triggered.

After the

AUTO STOP

menu, the

WELD METHOD

menu is displayed. This is shown in Figure 7–15.

R771

C723

R772

C722

NON-ISO SINK

NON-ISO SOURCE

ISOLATED

SH707

JU724

JU725

JU726

WELD METHOD

WELD BY TIME

WELD BY ENERGY

GROUND DETECT

Figure 7–15 MPC Probe Weld Method Selection Menu

To weld by time, select

WELD BY TIME

using the

Up and Down arrow keys and press the ENTER key. The weld time data entry screen appears as shown in Figure 7–16.

Use the Left and Right arrow keys to move the cursor to the desired digit position and the Up and

Down arrow keys to increment or decrement the value. When the desired value is displayed, press

ENTER to return to the main

PROCESS SETUP

menu shown in Figure 7–5.

WELD TIME

0.450 SEC

Figure 7–16 MPC Probe Weld Time

NOTE

The RTW symbol (RTW = Ready To Weld) at the bottom of each logical branch in the flowchart,means the DPC II Plus is logically capable of being triggered to generate an ultrasonic output. This is indicated on the display screen by the presence of the

PROCESS SETUP

menu shown in Figure 7–5.

69



Weld Method – Energy

If a Power Output module is installed, you can choose the Energy Welding method. The decision menu for choosing the Weld Method was shown in Figure 7–15. Use the down arrow key to move the cursor next to

WELD BY ENERGY

selection and press the ENTER key. To setup the Energy weld method, you must first enter the desired welding energy (see Figure 7–17).

WELD ENERGY

125 J

DEFINITION

Power is defined as Energy per unit of Time

(i.e. how fast energy is produced or consumed).

Energy is defined as the capacity to do Work .

The release of energy does work, and in doing work on something, adds energy to it.

Work and energy are equivalent concepts. The

Weld–By–Energy mode measures energy in units of Joules . By definition, a Watt ( power ) is one Joule ( energy ) per Second ( time ). Therefore a Joule is equivalent to one Watt–Second .

Figure 7–17 MPC Probe Weld Energy

MAX WELD TIME

Press ENTER and the maximum weld time data entry screen is displayed as shown in Figure 7–

18. This is the time limit on the welding process if the specified energy has not been reached.

Enter a value which permits the desired weld energy to be reached.

Press the ENTER key to return home to the

Process Setup menu.

1.250 SEC

Figure 7–18 MPC Probe Maximum Weld Time

Weld Method –

Ground Detect

The

GROUND DETECT

welding method is available in both MPC

Probe and Auto Probe conf igurations. In ground detect mode, the ultrasonic signal is initiated when the operate input is triggered and terminated when the horn touches the metal fixture during the welding cycle. For the ground detect fea-

70

Connect a wire from the fixture to pin 14 of J901

Use plastic insulating washers between the bolts and fixture. Center the washers so the bolts do not touch the inside of the fixture mounting holes

Plastic

Washer

Ground

Detect

Wire

Figure 7–19 Ground Detect Fixture Isolation

Fixture

Base

Horn

The horn is grounded and acts as a switch closure when it contacts the fixture.

Install a plastic insulator between the fixture and the base.

Plastic

Insulating

Sheet


Section 7 – Process Control Menu ture to function properly, the fixture must be electrically isolated from the horn support and base as shown in Figure 7–19. The horn is grounded and acts as a switch closure when it contacts the fixture. The ground detection is a current limited +5V

DC signal on pin 14 of J901 which is the Thruster connector on the Press Control module. Ground detect is normally used with a press system.

The MPC module cannot be used simultaneously with a Press Control module. If the ground–detect function is needed with a MPC configuration, connect the ground detect wire from the isolated fixture to the Iso Auto Stop (pin 9) on the System

Input HD–15 connector. This is a current limited

+22V DC signal. Move the SH704 jumper block to JU715 and refer to the discussion of the Auto

Stop option under Figure 7–13, since pin 9 is used to stop the weld in both cases.

Max Weld Time

Maximum Weld Time is the value at which the welding process terminates regardless of whether the ground detect signal or scrub process has been activated. The data entry screen for maximum weld time looks the same as the screens shown in Figures 7–11 and 7–18. Set the maximum weld time to a value greater than the time required to complete the welding cycle including the scrub time.

Scrub Time

Scrub Time is an extension of the welding cycle which is generated when the ground detect signal would normally end the weld cycle. This is typically used in cutting operations. Often the horn cuts through the material at a single point. This activates the ground detect to end the weld cycle.

But the cut may not be complete, and the additional scrub time keeps the ultrasound signal on to complete the cut. The data entry screen for scrub time is shown in Figure 7–20. The maximum allowable time value is 0.150 seconds.

SCRUB TIME

0.075 SEC

Figure 7–20 Ground Detect Scrub Time Data Entry

NOTE

The word AUTO in the menu options is short for Automation not automatic. Any menu that contains the word AUTO means the DPC II Plus will require an external signal(s) from custom automation equipment for correct operation.

71



AUTO Probe

The cable connection diagram for connecting an automated probe or an automated thruster is shown in Section 3 in Figures 3–5 and 3–7. The flow chart for the Process Control menu using Auto Probe is shown in Figure 7–21. If you do not have a Power

Output module installed, the Energy Weld Method menu will not be displayed.

The Auto Probe Setup logic adds a Process Control menu before the Weld Method decision menu.

Compare the flowchart in Figure 7–21 to the previous MPC flowchart in Figure 7–12. The Process Control menu offers two additional settings to control the welding process. After the normal

Weld Method is programmed, Hold time and

Afterburst settings are available.

1. The HOLD TIME parameter (T hold

) determines the length of time the probe is held in contact with the parts after the welding cycle has stopped. Holding permits the material to solidify under pressure before the head retracts.

2. In some applications, the material being welded can stick to the horn as it retracts. A short burst of ultrasonic energy called

AFTERBURST prevents this. This operation is defined by two values. The delay after the start of the upstroke before the burst starts (T delay

) and the duration of the burst signal (T burst

).

The maximum value of both of these parameters is 0.999 second.

AUTO STOP Option

The Auto Stop option is shown in Figure 7–13. It is designed for use with automation equipment and is available in both the Timed and Untimed Auto Probe

Trigger Method. To use this option, move the SH704 jumper block to JU715 (see Figure 5–12). If Auto

Stop is enabled, then a stop signal on pin 9 of the

HD–15 SYSTEM IN connector will be recognized.

This permits external automation equipment to stop the welding cycle. If Auto Stop is set to disable, then a signal on pin 9 will be ignored.

72

TRIGGER METHOD

TIMED AUTO PROBE

UNTIMED AUTO PROBE

LEGEND


ENTER




T = Time

E = Energy

AUTO STOP



= 30.000 Seconds


= 0.000 Second

UNTIMED

AUTO

PROBE

ENTER

RTW

PROCESS CONTROL

WELD

METHOD

Step 1

HOLD

TIME

Step 2

AFTER–

BURST

Step 3

TIMED

AUTO

PROBE

Maximum T hold

= 30.000 Seconds

Minimum T hold

= 0.001 Second*

WELD METHOD

TIME ENERGY

GND.

DETECT

ENTER

E/D

Enable/

Disable

ENTER


= 30.000 Seconds


= 0.001 Second*



= 12,000 Joules

= 1 Joule*

ENTER

ENTER

ENTER

Maximum T max

= 30.000 Seconds

Minimum T max

= 0.001 Second*

ENTER

ENTER

ENTER

Maximum T scrub

= 0.150 Seconds

Minimum T scrub

= 0.001 Second*

ENTER



= 0.999 Second

= 0.000 Second

Maximum

Minimum

T burst

T burst

= 0.999 Second

= 0.001 Second*


Figure 7–21 Auto Probe Setup Flow Chart

RTW



Untimed Auto Probe – Delay

The generator is triggered by external automation equipment. The automation control provides the ultrasound start and stop signal. In certain operations, a delay may be required to allow the clamping head(s) to fully engage before starting the ultrasound. The probe delay time menu for untimed operation was shown previously in Figure 7–14. This parameter sets the post–trigger delay. The maximum value which can be entered is 30.000 seconds. The minimum value for the

Delay Time is 0.000 second which effectively disables any delay.

Process Control – Weld Method

In Timed Auto Probe mode, after choosing the Auto

Stop option and pressing ENTER , the next menu displayed is titled Process Control as shown in Figure 7–22. The Process Control Menu includes the

Weld Method and adds two more menu screens.

Refer back to the Hand Probe and MPC Probe sections for information on the Time, Energy and

Ground Detect Welding method menus.

The data entry screen for Hold Time is shown in

Figure 7–24. The maximum allowable holding time is 30.000 seconds.

HOLD TIME

1.200 SEC

Figure 7–24 Auto Probe Hold Time Data Entry Screen

Process Control – Afterburst

After the hold time value has been entered, press the ENTER key to return back to the Process Control menu. Afterburst is now automatically selected as shown in Figure 7–25.

PROCESS CONTROL

WELD METHOD

HOLD TIME

AFTERBURST

PROCESS CONTROL

WELD METHOD

HOLD TIME

AFTERBURST

Figure 7–22 Process Control Weld Method Menu

Process Control – Hold Time

After the Weld Method has been chosen and parameter values entered, the menu flow returns back to Process Control but with Hold Time automatically selected. This is shown below in Figure 7–23.

Figure 7–25 Auto Probe Process Control Afterburst Menu

Press the ENTER key to select the final set of welding parameters. To bypass the afterburst option, select

DISABLE

and press the ENTER key. You are then returned back to the Process Control menu (Figure 7–22). Press the CANCEL key once or the MODE key twice to return to the root Process Setup menu (Figure 7–29).

AFTERBURST

DISABLE

ENABLE PROCESS CONTROL

WELD METHOD

HOLD TIME

AFTERBURST

Figure 7–26 Auto Probe Afterburst Enable Menu

Figure 7–23 Auto Probe Process Control Hold Time Menu


73


To select an afterburst, move the cursor down next to

ENABLE

as shown in Figure 7–26 and press the ENTER key.

To setup the afterburst, the menu prompts you for two parameter values. The first is the afterburst delay. This is the delay after the start of the upstroke before the burst starts. This data entry screen is shown in Figure 7–27. Use the arrow keys to display the desired value and press the ENTER key.

NOTE

The RTW symbol in the flow chart is signified by the display of the

PROCESS CONTROL

menu.

From the

PROCESS CONTROL

menu, press the

MODE key twice or the CANCEL key once to return to the root

PROCESS SETUP

menu.


0.000 0

MODE

AFTERBURST DELAY

0.150 SEC

MODE MODE

PROCESS SETUP

PROCESS CONTROL

PROCESS LIMITS

UTILITIES

CANCEL

PROCESS CONTROL

WELD MODE

HOLD TIME

AFTERBURST

Figure 7–27 Auto Probe Afterburst Delay Data Entry

The menu now prompts you for the afterburst signal duration. This screen is shown in Figure 7–28.

Again enter the desired signal duration and press the ENTER key.

AFTERBURST DURATION

0.300 SEC

Figure 7–28 Auto Probe Afterburst Duration Data Entry

This returns you to the Process Control menu as shown in Figure 7–22. Press the CANCEL key once or the MODE key twice to return to the root Process Setup menu shown in Figure 7–29.

PROCESS SETUP

PROCESS CONTROL

PROCESS LIMITS

UTILITIES


74



PRESS Mode

The cable connection diagram for connecting a

DPC II Plus to a Dukane press is shown in Section 3 in Figures 3–8. The flow chart for the Process Control menu is shown in Figure 7–30. If a

Press Control module is not installed, this menu will not be displayed. If you do not have a Power

Output module installed, the Energy Weld Method menu options will not appear either.

The Press Setup logic features two areas of enhancement over the Auto Probe logic. The PRESS TRIG-

GER METHOD has three additional control options in the Auto Stop logical branch (the Auto Probe trigger methods are still available). The WELD

MODE menu is also expanded and offers a choice of SINGLE PRESSURE or DUAL PRESSURE mode.

Compare the flowchart in Figure 7–30 to the previous Auto Probe flowchart in Figure 7–21.

1. The

TRIGGER METHOD – PRESS

mode has an

INITIATE MODE

menu preceding Auto Stop.

The MANUAL mode is the recommended setting. This permits the dual palm switches on the press base to initiate the operate sequence.

2. If ENABLE was selected in the

AUTO STOP

menu, the

HEAD UP ON AUTO STOP

menu is displayed. Auto Stop has been covered previously under MPC Probe and AUTO Probe. The

HEAD UP

menu determines whether the press head remains at its last position or retracts when an external Auto Stop signal is detected.

NOTE

The symbol legend for the Press Mode flow chart is the same as the other flow charts. It is repeated here for your convenience.

LEGEND


ENTER




T = Time

E = Energy


TRIGGER METHOD

PRESS

TIMED AUTO PROBE

UNTIMED AUTO PROBE

ENTER

ENTER

ENTER

AUTO STOP

ENABLE DISABLE

ENTER

ENTER

INITIATE

MODE

AUTO MANUAL

ENTER

ENTER

AUTO STOP


ENTER

HEAD UP ON

AUTO STOP

ENABLE DISABLE

TRIGGER TYPE


ENTER

ENTER

ENTER

RTW

PROCESS CONTROL

WELD

MODE

HOLD

TIME

AFTER–

BURST

Step 1

Timed

Auto

Probe

Bypasses

Single/Dual

Pressure

Mode

ENTER

SINGLE

PRESSURE

PRESS

Press Trigger

Method Only

ENTER

WELD MODE

SINGLE

PRESSURE

DUAL

PRESSURE

ENTER ENTER

Step 2

ENTER

DUAL

PRESSURE

PRESS

Step 3

E/D

Enable/

Disable

ENTER

WELD METHOD

TIME ENERGY

GND.

DETECT

PRESSURE 1

TIME

1

ENERGY

1

ENTER

ENTER

ENTER

ENTER

DPC II Plus

Models

Only —

Not Available on

EZ Series

ENTER ENTER

ENTER

PRESSURE 2

TIME

2

ENERGY

2

ENTER

ENTER

ENTER ENTER

ENTER

ENTER

Figure 7–30 Press/Auto Probe Setup Flow Chart

RTW

75


3. If DISABLE was selected in the

AUTO STOP

menu, the

TRIGGER TYPE

menu is displayed next. This selects whether the trigger which initiates the weld cycle is momentary or must be maintained throughout the weld cycle.

4. The

SINGLE PRESSURE

mode follows the same programming sequence as Weld Method in the previous Timed Auto Probe. The

DUAL

PRESSURE

mode eliminates ground detect for obvious reasons and allows welding by Time or Energy at both pressure level settings.

Initiate Mode

When using a press, the usual choice is to select

MANUAL for the Initiate Mode. This permits the dual palm switches to initiate the operate sequence.

If AUTO mode is selected, then an external initiate signal must be supplied to either pins 3 and 4 (Iso

Oper In) or pin 8 (Sw Oper In) of the HD–15 System In connector. Refer back to Figure 5–2 and

Table 5—I for more information.

Auto Stop

The normal configuration when using a press is to set Auto Stop to DISABLE . This permits the standard emergency OFF switch on the front of the press base to halt the weld cycle. If Auto Stop is set to ENABLE , then an external signal must be supplied to pin 9 (Iso Auto Stop) of the HD–15

System In connector. Refer back to the discussion under Figure 7–13 and also to Table 5—I for more detailed information.

Head Up On Auto Stop

If DISABLE was selected in the

AUTO STOP

menu, the


menu is bypassed. If

ENABLE was selected in

AUTO STOP

, the

HEAD UP

menu is displayed. It offers two choices for head position. If ENABLE is selected for the Head Up option, the head retracts when an Auto Stop signal is detected. If the DISABLE option is selected, the press head remains stationary after an Auto Stop signal.

Note that this option and Auto Stop are only available when the Initiate Mode has been set to Auto.

76

NOTE

The word AUTO in the menu options is short for Automation not automatic. Any menu that contains the word AUTO means the DPC II Plus will require an external signal(s) from custom automation equipment for correct operation.

Trigger Type

If DISABLE was selected in the

AUTO STOP

menu, the

TRIGGER TYPE

menu is displayed next. Otherwise it follows the


menu.

If MOMENTARY is selected, the trigger switch is ignored after the first contact closure. The

DPC external bus scan time is 1 msec so the minimum signal duration is >1 msec. If the trigger switch opens after the weld cycle is initiated, the welding processes continues normally. Momentary is recommended for most welding processes except hand probes.

If MAINTAINED is selected, the trigger must be maintained during the entire portion of the weld cycle. If the trigger signal is momentarily lost while the ultrasonic signal is on, the weld cycle is terminated. This mode is recommended for special applications. It has an advantage over momentary trigger in that it will generate a

TRIGGER LOST

error message if you suddenly lose trigger force (see Error Messages in Section 12 – Troubleshooting). This may happen when welding soft plastic or small parts.

Single/Dual Pressure Mode

The

SINGLE PRESSURE

mode has the same programming sequence as Weld method in the previous Timed Auto Probe. The

DUAL PRESSURE

mode eliminates ground detect and allows Time or Energy target values to be used at both pressure trigger points. The modes can be mixed us-


Section 7 – Process Control Menu ing Energy for the first mode and Time for the second mode or vice versa. Each of the blocks labeled Pressure 1 and Pressure 2 are equivalent to the Single Pressure Weld Method branch without Ground Detect. Note that the Auto Probe Trigger Method bypasses the Single/Dual Pressure

Weld Mode and jumps directly to Weld Method.

The Dual Pressure mode is a feature exclusive to the DPC II Plus model and is not available on the

EZ Series.

PRESS Mode Example

We will now go through programming a typical press configuration with no automation and using dual pressure mode. We will assume that a

Power Output module is also installed. If your configuration does not have this module, you can still follow along and substitute Time anywhere we have selected Energy.

We will start from an initial DPC power up, so cycle the AC power switch off then back on. If you are using a dual–pressure press, make sure the pressure select switch is in the WELD position. The screen first displays the firmware revision and then the hardware configuration as shown in Figures

7–1 and 7–2. The screen then displays the previous weld cycle data on the Operate screen. This is shown in Figure 7–4 which is repeated here as Figure 7–31. If you do not have a Power Output module, your screen will look like Figure 7–3.

PROCESS SETUP

PROCESS CONTROL

PROCESS LIMITS

UTILITIES

Mode Key

GEN.

INFO

+

MODE

HOLD

WELD

P1

WELD

P2

AMP.

ADJUST

–

ENTER CANCEL

Enter Key

Figure 7–32 Mode and Enter Menu Keys


Process Control is selected by default. Press the

ENTER key to display the Trigger Method menu shown below in Figure 7–34.


0.000 0

TRIGGER METHOD

PRESS

TIMED AUTO PROBE

UNTIMED AUTO PROBE

Figure 7–34 Press Trigger Method Menu

Figure 7–31 Previous Welding Cycle Data

Press the MODE key once (see Figure 7–32) and the screen changes from the Operate screen to the

Process Setup menu as shown in Figure 7–33.

The

PRESS

option should be selected by default.

If it isn’t, use the increment key (up arrow) to position the cursor and then press ENTER .

77



The menu changes to display the Initiate mode as shown in Figure 7–35. We will assume a standard press configuration using the dual palm operate switches. Since we will manually trigger the press, move the cursor to

MANUAL

and press ENTER .

INITIATE MODE

MANUAL

AUTO

Auto Probe. The Press option reads Weld Mode whereas the Auto Probe menu reads Weld Method.

We leave

WELD MODE

selected and press ENTER .

The next menu (Figure 7–38) appears only in press mode. It is titled Weld Mode and offers a choice of welding modes. You must have a dual–pressure press to use the dual pressure mode. A single pressure press displays Weld Method (see Figure 7–15).

WELD MODE

SINGLE PRESSURE

DUAL PRESSURE

Figure 7–35 Press Initiate Mode Menu

You can see from the flow chart in Figure 7–30 that we bypass both the

AUTO STOP

and

HEAD UP

ON AUTO STOP

menus when we select manual mode. The next menu displayed is

TRIGGER TYPE

which is shown in Figure 7–36.

TRIGGER TYPE

MAINTAINED

MOMENTARY

Figure 7–38 Single or Dual Pressure Selection Menu

To demonstrate the complete set of options, we will select

DUAL PRESSURE

and push the ENTER key. We can select time or energy as the welding parameter during the P1 portion of the welding cycle. This corresponds to the block labeled PRES-

SURE 1 in Figure 7–58. Select

WELD BY TIME

and press the ENTER key.

Figure 7–36 Press Trigger Type

The trigger type used for most welding conditions should be

MOMENTARY

. Use the down arrow key to select Momentary and press ENTER . We are now at the central Process Control menu. It is shown below in Figure 7–37.

WELD METHOD P1

WELD BY TIME

WELD BY ENERGY

PROCESS CONTROL

WELD MODE

HOLD TIME

AFTERBURST

Figure 7–39 Pressure One Weld Method Selection Menu

A data entry screen appears requesting the value of the weld time for pressure one. On the flow chart (Figure 7–30) this is labeled T 1 weld

. The data entry screen is shown below in Figure 7–40.

Figure 7–37 First Pass Through Process Control Menu

The cursor is pointing to Weld Mode by default.

Note there is a small difference between the wording of the Process Control menu for Press and for

78

WELD TIME P1

0.500 SEC

Figure 7–40 Pressure One Weld Time Data Entry



Using the four arrow keys, enter the weld time. Press the ENTER key when you have completed the data entry. This displays the Weld Method selection screen for Pressure Two as shown in Figure 7–41.

WELD METHOD P2

WELD BY TIME

WELD BY ENERGY

Dual Pressure Weld Mode Menus w/o Power Output Module

WELD MODE

SINGLE PRESSURE

DUAL PRESSURE

Figure 7–41 Pressure Two Weld Method Selection Menu

This time select

WELD BY ENERGY

and press the

ENTER key. This brings up the data entry screen for pressure two as shown below in Figure 7–42.

If you do not have a Power Output module, the energy option will not appear. Figure 7–44 shows the logical flow for dual pressure mode without the energy option.

WELD ENERGY P2

75 J

WELD TIME P1

0.500 SEC

WELD TIME P2

0.250 SEC

Figure 7–42 Pressure Two Weld Energy Data Entry

Again use the arrow keys to enter the weld energy. This parameter is labeled E 2 weld

on the flow chart. Press the ENTER key when you have finished to bring up the data entry screen for P2

Maximum Weld Time as shown in Figure 7–43.

This value sets the time limit to reach the P2 weld energy. This time limit applies only to the P2 cycle.

Figure 7–44 Dual Pressure Time Only Menus

If we select energy for the P1 cycle, it will have its own maximum weld time limit. Press the

ENTER key to return to the Process Control menu as shown in Figure 7–45.

MAX WELD TIME P2

0.350 SEC

Figure 7–43 Pressure Two Max Weld Time Data Entry


PROCESS CONTROL

WELD MODE

HOLD TIME

AFTERBURST

Figure 7–45 Second Pass Through Process Control Menu

79


From here on, the menu follows the same logical sequence as Auto Probe. Hold Time is automatically selected for the second pass through Process Control. Press the ENTER key to display the Hold Time data entry menu as shown in Figure 7–46. Enter a value for the hold time and press the ENTER key.

The data entry screen for the afterburst delay appears as shown in Figure 7–49. Enter a value for the delay time and press the ENTER key.

AFTERBURST DELAY

0.150 SEC

HOLD TIME

0.500 SEC

Figure 7–46 Press Hold Time Data Entry

We return for a third time to the Process Control menu. This time the Afterburst option is automatically selected as shown in Figure 7–47.

Figure 7–49 Press Afterburst Delay Data Entry

The data entry screen for the afterburst duration appears as shown in Figure 7–50. Enter a value for the burst time and press the ENTER key.

AFTERBURST DURATION

0.250 SEC

PROCESS CONTROL

WELD MODE

HOLD TIME

AFTERBURST

Figure 7–50 Press Afterburst Duration Data Entry

The Process Control menu screen appears again with Weld Mode selected. This screen below in

Figure 7–51 looks just like Figure 7–37.

Figure 7–47 Third Pass Through Process Control Menu

Press the ENTER key to display the Afterburst menu. This permits you to enable or bypass the afterburst option. To bypass the afterburst option, select

DISABLE

and press the ENTER key. You then jump back to Process Control as shown in

Figure 7–51. To select an afterburst, move the cursor down to

ENABLE

as shown in Figure 7–48 and press the ENTER key.

PROCESS CONTROL

WELD MODE

HOLD TIME

AFTERBURST

Figure 7–51 Return To Process Control Menu

AFTERBURST

DISABLE

ENABLE

Figure 7–48 Press Afterburst Enable Menu

80



We have now defined the welding mode and set values for the necessary parameters. Press the

CANCEL key once to return to the root Process

Setup menu shown in Figure 7–52 (the same as

Figure 7–33).

Minimum &

Maximum

Values

Hold Time

P1 Weld

Target Value

P2 Weld

Target Value

(DPC II Plus only)

PROCESS SETUP

PROCESS CONTROL

PROCESS LIMITS

UTILITIES


GEN.

INFO

+

HOLD

WELD

P1

MODE

WELD

P2

AMP.

ADJUST

–

ENTER CANCEL

Press the MODE key to display the welding parameters menu. Notice it now has three values:

P1, P2 and Total. This is different from the operate screen in Figure 7–31 because we are now configured for a dual pressure mode instead of single pressure.


P1 0.000 0

P2 0.000 0

TOTAL 0.000 0

Amplitude Adjust

Figure 7–54 HOT Keys

Press the HOLD key and the menu displays the value entered for the hold time (see Figure 7–46).

Press the GEN. INFO key to display the minimum and maximum values for hold time. This is illustrated in Figure 7–55. Press the CANCEL key to return to the Hold Time menu and once more to return to the Process Setup menu.

Figure 7–53 Dual Pressure Welding Cycle Data

Press the MODE key again to return to the Process Setup menu.

HOLD TIME

MAXIMUM VALUE: 30.000

M I N I M U M VALUE: 0.000

Figure 7–55 Min and Max Values for Hold Time

HOT Keys

In Section Four – Controls and Displays, we explained the function of the menu keys including the four hot keys: HOLD, WELD P1, WELD P2 and

AMP. ADJUST . The hot keys are identified in Figure 7–54. Since we have now programmed values for these parameters, we can use the hot keys to check or alter their values.

To modify the Hold Time, use the arrow keys to change the value as shown in Figure 7–56. To ac-

HOLD TIME

0.750 SEC

Figure 7–56 Modified Hold Time

81


DPC ™ II Plus and EZ Welder System – User’s Manual cept the new value press the ENTER key. This will return you to the Process Setup menu shown in

Figure 7–52. To return to Process Setup without modifying the hold time, press the CANCEL key.

The WELD P1 and WELD P2 hot keys function in the same manner. If a single pressure mode is selected (Figure 7–38 = SINGLE PRESSURE ), then only the Weld P1 key will display information. Pressing the Weld P2 hot key flashes a brief message reading

THIS BUTTON IS ONLY AVAILABLE FOR

DUAL PRESSURE WELD MODE

.

The AMP. ADJUST hot key permits you to adjust the output amplitude from 40% to 100%. This is accomplished using the up and down arrow keys.

A modified output level menu is shown in Figure

7–57. Press the ENTER key to accept the value or

CANCEL to return to Process Setup.

AMPLITUDE

75 %

NOTE

If you have a dual–pressure press connected to the DPC II Plus, make sure the pressure select switch is in the WELD position before turning on the DPC AC power. The DPC scans for installed modules, connected press and probe, etc. at power-up. If the switch is in HOLD position, the

DPC II Plus may not correctly recognize the press.

Switch Must Be In

WELD PRESSURE

Position Before

Turning The

DPC Power On.

NOTE – This only applies to the DPC

II Plus. The EZ

Welder System is a single pres-sure press.

Figure 7–57 Amplitude Adjust

Process Control Recap

We have examined all four modes available in the

Process Control menu: Hand Probe, MPC Probe,

Auto Probe and Press. Figure 6–6 showed the Process Control flow chart. It did not however indicate the parameters and where their values were entered. We have added that information and the complete flowchart is shown in Figure 7–58. The symbol legend in the upper right hand corner of the flow chart explains the Figure number references and parameter data. The ENTER key symbols shown in Figures 7–7, 7–12, 7–21 and 7–30 are not shown here for readability.

NOTE

If you have a Remote Amplitude Control module installed, its gain setting will override the front panel menu. The front panel menu will accept the value, but the output amplitude will still be determined by the 4–20mA loop current. Refer back to Section 5 and Figure 5–6 for more detailed specifications.

82



PROCESS

CONTROL

7–5

7–29

7–33

7–52 PROCESS

SETUP

AUTO STOP

ENABLE DISABLE

HEAD UP ON

AUTO STOP

ENABLE DISABLE

7–34

PRESS

TRIGGER METHOD

TIMED PROBE

UNTIMED PROBE

AUTO

PROBE

MPC

PROBE

HAND

PROBE

7–6

TIMED UNTIMED TIMED UNTIMED TIMED UNTIMED

7–35

INITIATE

MODE

AUTO MANUAL

7–13

AUTO STOP

7–13


SYMBOL LEGEND

7–16

7–16

Menu and Logic

Path appear in this Figure No.

Menu in different logic path but looks the same as this Figure No.

Parameter Value

T = Time

E = Energy

7–36

TRIGGER TYPE


7–14 7–14

Hand

Probe

Trigger

Switch

UNTIMED

AUTO

PROBE

UNTIMED

MPC

PROBE

UNTIMED

HAND

PROBE 7–37

PROCESS CONTROL

WELD

MODE

HOLD

TIME

AFTER–

BURST

7–47 7–45

Step 1 Step 2

Step 3

7–38

7–46

SINGLE

PRESSURE

PRESS

TIME ENERGY

WELD MODE

SINGLE

PRESSURE

7–15

WELD METHOD

GND.

DETECT

DUAL

PRESSURE

Enable/

Disable E/D

7–48

DUAL

PRESSURE

PRESS

7–39

PRESSURE 1

TIME

1

ENERGY

1

7–49

RTW RTW

TIMED

AUTO

PROBE

7–22

PROCESS CONTROL

WELD

METHOD

Step 1

HOLD

TIME

AFTER–

BURST

7–23

Step 2

Step 3

7–25


7–40

7–41

PRESSURE 2

TIME

2

ENERGY

2

7–50

7–51

7–24

7–15

Enable/

Disable E/D

7–26

WELD METHOD

TIME ENERGY

GND.

DETECT

TIMED

MPC

PROBE

7–15

WELD METHOD

TIME ENERGY

GND.

DETECT

TIMED

HAND

PROBE

7–8

WELD METHOD

TIME ENERGY

7–16 7–17

7–18

7–42

7–27

7–16

Hand

Probe

Trigger

Switch

7–10

7–18 7–20

7–44

7–16 7–17

7–18

7–17 7–18

7–28

7–43

7–18 7–20

7–18 7–20 7–9

7–11

7–52

Figure 7–58 Process Control Menu Flowchart



RTW RTW RTW

83


Table 7—I below summarizes the various method and mode menus and references their Figure number. Table 7–II on the next page lists the data entry screens and references their Figure number. It also gives the minimum and maximum values for each of the parameters. The only variation between models is for weld energy. The high–frequency (50kHz and 70kHz) models have a lower power output, and the scale factor change enables

0.1 Joule resolution at these lower power levels.

Menu Name

STARTUP

CONFIGURATION

WELD CYCLE DATA

PROCESS SETUP

PROCESS CONTROL

Description

DPC II Plus Firmware Version and Date

Installed Modules

Previous Weld Cycle Data

Root Menu

TRIGGER METHOD

TRIGGER METHOD

WELD METHOD

Probe - Timed or Untimed

Press

Weld By Time or Energy

Weld By Time, Energy or Ground Detect WELD METHOD

AUTO STOP Enable or Disable

PROCESS CONTROL Weld Method

Weld Mode

Figure No.

Remarks

6–1, 7–1

6–2, 7–2

6–3, 7–3

7–4, 7–53

7–4, 7–29

7–33, 7–52

7–6

Press Board or Power Output

Modules

7–34

7–8

7–15

7–13

7–22 Probe Trigger Method

7–37, 7–51 Press Trigger Method Only

PROCESS CONTROL

PROCESS CONTROL Afterburst

AFTERBURST

INITIATE MODE

TRIGGER TYPE

WELD MODE

Hold Time

Enable or Disable

Manual or Auto

Momentary or Maintained

Single or Dual Pressure

7–23, 7–45

7–25, 7–47

7–26, 7–48

7–35

7–36

7–38

Press Trigger Method Only



WELD METHOD P1

WELD METHOD P2 Time or Energy

Table 7—I Process Control Menu Listing

84

Time or Energy 7–39

7–41

Dual Pressure Mode Only

Dual Pressure Mode Only



Parameter Menu Name

T delay

T burst

T 1 weld

T 2 weld

E 1 weld

T 1 max

E 2 weld

T 2 max

T delay

T weld

E weld

T max

T max

T scrub

T hold

Probe Delay

Weld Time

Weld Energy

Description

Post–Trigger Delay

Ultrasound Gate Time

Target Welding Energy Press & Any* Timed Probe Energy

Max Weld Time Welding Time Limit


Scrub Time

Hold Time

Scrub Gate Time

Post–Weld Hold Time

Afterburst Delay Burst Time Delay

Afterburst Time Burst Gate Time

Weld Time

Weld Time

Weld Energy



Untimed MPC/Auto Probe Untimed Probe Only

Press & Any* Timed Probe Time

Press & Any* Timed Probe Energy

Press, MPC & Auto Probe Ground Detect

Press, MPC & Auto Probe Ground Detect

Target Welding Energy Press – Dual Pressure


Weld Energy Target Welding Energy Press – Dual Pressure


Table 7—II Parameter Min–Max Values

Trigger Method

Press & Auto Probe

Press & Auto Probe

Press & Auto Probe

Press – Dual Pressure



Weld Method

Time & Energy

Time & Energy

Time & Energy

Time – Pressure 1

Time – Pressure 2

Energy – Pressure 1



Figure No.

Minimum Value Maximum Value

7–14

7–8, 7–16

7–10, 7–17

7–11, 7–18

7–11, 7–18

7–20

7–24, 7–46

7–27, 7–49

7–28, 7–50

7–40

7–44 similiar to

7–42 similiar to

7–43

7–42

0.000 Second

0.000 Second

0 Joules

0.000 Second

0.000 Second

0.000 Second

30.000 Seconds

30.000 Seconds

12000 Joules

†

30.000 Seconds

30.000 Seconds

0.000 Second 0.150 Seconds


0.999 Second

0.000 Second 0.999 Second



0 Joules 12000 Joules

†


0 Joules 12000 Joules

†

Press – Dual Pressure Energy – Pressure 2

* Any Timed Probe = Timed Hand Probe

Timed MPC Probe

Timed Auto Probe

7–43 0.000 Second 30.000 Seconds

12000 Joules

1200.0 Joules

†

†

= 20kHz, 30kHz and 40kHz DPC II Plus

= 50kHz and 70kHz DPC II Plus

(Requires Power Output Module)

NOTE

The 50kHz/150 Watt DPC II Plus and the 70kHz/

100 Watt DPC II Plus have a maximum weld energy setting (E weld

) of 1200.0 Joules. The reduced scaling permits the DPC to achieve better adjustment resolution at low power levels. All other models covered in this manual have a maximum weld energy of 12,000 Joules.


85



86



S

ECTION

8

Process Limits Menu

• Limit Definition

• Suspect and Bad Limits

• Process Limits

Process Limits Menu...................................... 89

Limit Definition ............................................. 90

Suspect and Bad Limits ................................. 90

Process Limits ............................................... 90

Single Pressure Mode ........................................... 91

Dual Pressure Mode .............................................92




87



88


Section 8 – Process Limits Menu

Process Limits Menu

The Process Limits Menu allows you to define upper and lower bounds for suspect parts or for bad parts. The limits are available in both units of time and units of energy depending upon the welding method chosen in Process Control setup.

In addition, if a dual–pressure welding method is selected, total time and/or total energy limits are also available for suspect or bad parts. The same memory location is used for suspect and bad part limits. The difference is that exceeding a bad part limit terminates the weld cycle. Exceeding a suspect limit allows the weld cycle to continue until it finishes normally or exceeds a

Total limit. There are 12 different limit settings which are broken down as follows:

1a. There are two possible

BAD PART UPPER TIME

LIMITS

(one for each pressure level).

1b. There are two possible

BAD PART UPPER ENERGY

LIMITS

(one for each pressure level).

1c. There is one

TOTAL BAD PART UPPER TIME LIMIT and one

TOTAL BAD PART UPPER ENERGY LIMIT

.

This makes a total of six

BAD PART UPPER

LIMITS

.

2. There are six

BAD PART LOWER LIMITS

.

During a dual–pressure mode welding cycle however, only six of the limits (eight in mixed mode) are applicable. In single pressure mode, this drops to two usable limits at any one time since the totals are available only in dual mode. For example, you can set both upper time and energy limits, but only the upper time limit is recognized in the weld by time mode.

Table 8—I summarizes the 8 limits recognized in a dual–pressure, mixed–mode welding cycle.

Table 8—II summarizes the 6 limits recognized in a dual–pressure, uniform–mode welding cycle.

Table 8—III lists the 2 limits recognized in a single– pressure welding cycle.

A Bad Parts Counter is also available in the Utilities menu which is covered in the next section.

DEFINITION

A mixed mode is a dual–pressure weld cycle in which one unit of measurement (e.g. time) is used for Pressure 1 and the other unit of measurement (e.g. energy) is used for Pressure 2.

A uniform mode is a dual–pressure weld cycle in which the same unit of measurement (e.g. time) is used for both Pressure 1 and Pressure 2.

Cycle State Parameter Limit Type

P1 T(E)

U

P2 E(T)

U

Total T

U

Total E

U

P1 T(E)

L

P2 E(T)

L

Total T

L

Total E

L

Table 8—I

P1 Upper T IME (E NERGY ) Limit

P2 Upper E NERGY (T IME ) Limit

Total Upper T IME Limit

Total Upper E NERGY Limit

P1 Lower T IME (E NERGY ) Limit

P2 Lower E NERGY (T IME ) Limit

Total Lower T IME Limit

Total Lower E NERGY Limit

Recognized Limits in a Dual–Pressure

Mixed–Mode Welding Cycle


P1 T(E)

U

P2 T(E)

U

Total T(E)

U

P1 T(E)

L

P2 T(E)

L

P1 Upper T

P2 Upper T

IME

IME

Total Upper T

P1 Lower T

P2 Lower T

IME

IME

(E

(E

NERGY

NERGY

IME

(E

(E

(E

) Limit

) Limit

NERGY

NERGY

NERGY

) Limit

) Limit

) Limit

Total T(E)

L

Table 8—II

Total Lower T IME (E NERGY ) Limit

Recognized Limits in a Dual–Pressure

Uniform–Mode Welding Cycle


P1 T(E)

U

P1 T(E)

L

Table 8—III

P1 Upper T IME (E NERGY ) Limit

P1 Lower T IME (E NERGY ) Limit

Recognized Limits in a Single–Pressure

Welding Cycle

89



Limit Definition

To access the Limit settings, start from the Process Setup menu shown in Figure 8–1.

PROCESS SETUP

PROCESS CONTROL

PROCESS LIMITS

UTILITIES

Figure 8–1 Process Setup Main Menu

Select

PROCESS LIMITS

with the cursor and then press ENTER . This displays the

LIMIT DEFINITION

menu as shown in Figure 8–2. These steps are indicated at the top of Figure 8–4 which is the flow chart for the Limit Definition. Both the suspect

Limits and Bad Limits share the same logical structure, so no distinction is made between them in this flow chart.

LIMIT SELECTION

You normally select the alternate unit of measurement for bad and suspect limits. If you are welding by time ( Seconds ), all the weld cycles have the same weld time. There should be no measurable deviation from the target time value.

There will however, be some variation in the power drawn by each part. Since the time is constant, the power and thus the energy will vary slightly between parts. The limit check therefore should be in units of energy ( Joules ). Too low an energy draw might result from a mechanical stop interfering with travel. Too much energy drawn may be caused by a misaligned part resulting in a large mating surface area.

If you are using dual–pressure mixed mode, a good limits check would set the companion limit for each pressure plus the total time and energy limits. In a dual–pressure uniform mode, only the alternate units for P1, P2 and TOTAL will be meaningful.

LIMIT DEFINITION

SUSPECT LIMITS

BAD LIMITS

Figure 8–2 Limit Definition Menu

Suspect & Bad Limits

You can select either a Suspect or Bad Part Limit.

A Suspect Limit allows the weld cycle to continue, but causes an error indication in the display ( > or

< for upper or lower limit). If a Bad Limit is exceeded, the weld cycle is terminated, and an error indication is displayed ( >> or << for upper or lower limit) until the next weld cycle is initiated. A bad limit and suspect limit value share the same memory location. To change a Suspect Limit value to a Bad Limit value, move the cursor to

BAD

90

LIMITS

in the Limit Definition menu and press

ENTER . The value is now associated with a Bad

Limit and will now terminate the weld cycle if the measured value fall outside the boundary limits.

Process Limits

Select either Suspect Limits or Bad Limits and press the ENTER key. The choice can be easily changed later. The Process Limits menu is then displayed.

This is shown in Figure 8–3 as it would appear for a single–pressure mode weld cycle.

PROCESS LIMITS

TIME

ENERGY

Figure 8–3 Single–Pressure Process Limits Menu



PROCESS

LIMITS

ENTER

Figure 8–1

PROCESS

SETUP


SUSPECT

BAD

LIMITS Figure 8–2

ENTER

Figure 8–3

TIME

ENERGY

TOTAL TIME

Figure 8–5

TOTAL ENERGY

ENTER ENTER

ENTER

TOTAL

WELD TIME

ENTER

ENTER

ENTER

PROCESS

LIMITS

WELD

ENERGY P1

WELD

ENERGY P2

TOTAL

WELD ENERGY

ENTER

ENTER

ENTER ENTER

Total Limits

Available Only in

Dual Pressure Mode

ENTER

Dual

Pressure

Mode?

2P?

NO

YES

ENTER

In Dual Pressure mode, the

Weld Methods can be mixed

Figure 8–4 Limit Definition Flow Chart

PROCESS

LIMITS

WELD

TIME P1

WELD

TIME P2

ENTER ENTER

ENTER

Dual

Pressure

Mode?

2P?

NO

YES

ENTER

For a dual–pressure mode, both the normal limits and the total limits are displayed as shown in Figure 8–5.

TIME

ENERGY

TOTAL TIME

TOTAL ENERGY

Figure 8–5 Dual–Pressure Process Limits Menu


In the flowchart, the single–pressure limits are on the right side and the dual–pressure total limits section are in the shaded area on the left side.

Single Pressure Mode

If a single–pressure mode has been programmed, the limits begin with the selection of Time or Energy in the Process Limits menu (Figure 8–3).

Pressing the ENTER key displays the limit parameter selection which is shown in Figure 8–6.

91


WELD ENERGY

MAXIMUM LIMIT

270 J

PROCESS LIMITS

WELD ENERGY P1

WELD ENERGY P2

Figure 8–6 Single Pressure Max Energy Data Entry

After the minimum and maximum limit values have been entered, the display returns to the Process Limit menu shown in Figure 8–3. Logical comparison ensures that the minimum value is less than the maximum value before permitting the value to be entered. The error screen shown in Figure 8–7 appears briefly and returns to the minimum limit value entry screen. Reduce the minimum value or press the CANCEL key to step back to the maximum limit value entry screen and increase its value until the logical condition is satisfied.

LOWER LIMIT MUST BE

LESS THAN UPPER

LIMIT !

Figure 8–8 Dual–Pressure Limits Selection Menu

To detect a suspect or bad weld cycle, the minimum and maximum values for each pressure limit must be set. In dual–pressure mode, a logical decision function (indicated on the flowchart by the diamond with 2P? inside), diverts the sequence after the P1 values have been entered and returns back to the limit selection menu for the P2 value.

You must however move the cursor to the P2 limit before pressing ENTER otherwise you will return back through the P1 section. Pressing the CAN-

CEL key will return you to the P1/P2 selection menu shown in Figure 8–8. The data entry screens for dual–pressure mode also identify the P1 or P2 pressure phase. The screen for entering the P1

Maximum Energy Limit is shown in Figure 8–9.

Figure 8–7 Minimum Value Error Message

After the minimum and maximum values have been entered, the display shows the Process Limits Menu (Figure 8–3). Press the CANCEL key to return to the Limit Definition Menu (Figure 8–2).

Press CANCEL again to return to the Process Setup

Menu (Figure 8–1).

Dual Pressure Mode

If a dual–pressure mode has been programmed, the limits selection also includes total values in the Process Limits menu (Figure 8–5). First choose one of the two top parameters by selecting either Time or Energy with the cursor. Pressing the ENTER key displays the limit parameter selection which is shown in Figure 8–8.

92

WELD ENERGY P1

MAXIMUM LIMIT

90 J

Figure 8–9 P1 Maximum Energy Data Entry

After the minimum and maximum limit values have been entered, the display returns to the Process Limit menu shown in Figure 8–5. Press the

CANCEL key to return to the Limit Definition

Menu (Figure 8–2). Press CANCEL again to return to the Process Setup Menu (Figure 8–1).

The return sequence flowchart for the CANCEL key is shown in Figure 8–10. Only the energy loops are labeled to avoid confusion, but the time loops have the same return sequence.



PROCESS

LIMITS

ENTER

CANCEL

Figure 8–1

PROCESS

SETUP

CANCEL


SUSPECT

BAD

LIMITS Figure 8–2

ENTER

ENTER

TOTAL

WELD TIME

ENTER

ENTER

Figure 8–3

TIME

ENERGY

Figure 8–5

TOTAL TIME

TOTAL ENERGY

ENTER

CANCEL

TOTAL

WELD ENERGY

CANCEL

ENTER

ENTER

ENTER ENTER

SINGLE

PRESS.

DUAL

PRESS.

PROCESS

LIMITS

WELD

ENERGY P1

WELD

ENERGY P2

CANCEL

CANCEL

PROCESS

LIMITS

WELD

TIME P1

WELD

TIME P2

ENTER ENTER

ENTER ENTER

CANCEL

ENTER

2P?

NO

YES

ENTER

ENTER

2P?

YES

NO

ENTER

Figure 8–10 CANCEL Key Return Path Flow Chart


93



94



S

ECTION

9

Utilities Menu

• Setup Utilities

• Part Count

• Status Outputs

• Cycle Press Off Line

Setup Utilities ............................................... 97

Select Setup .........................................................98

Copy A Setup ....................................................... 99

Erase Setups .........................................................99

Part Count .................................................. 100

Reset Part Count ................................................100

Count Suspect/Bad Parts ....................................100

Preset Part Count ...............................................101

Status Outputs ............................................ 101

Cycle Press Off Line ..................................... 101




95



96


Section 9 – Utilities Menu

Utilities Menu

The Utilities Menu is the third option from the main Process Setup menu. It is divided into four distinct menu groups:

1.

SETUP UTILITIES

PART COUNT

2.

3.

4.

STATUS OUTPUTS

CYCLE PRESS OFF LINE

The basic flowchart for the Utilities Menu was shown in Figure 6–7. A more detailed flowchart is shown below in Figure 9–1. Unlike the other two main menus, the four branches in the Utilities menu are unrelated and independent of each other.

They only share a common thread of performing utilitarian functions.

UTILITIES

PROCESS

SETUP

UTILITIES

SETUP UTILITIES

PART COUNT

STATUS OUTPUTS

CYCLE PRESS OFF LINE

ENTER

ENTER

ENTER

NO

Cycle

Press

Off Line?

C?

YES

ENTER

ENTER

ENTER

STATUS

OUTPUTS

MAINTAINED PULSED

ENTER ENTER

RESET

PART

COUNT

PART

COUNT

COUNT

BAD

PARTS

PRESET

PART

COUNT

NO

ENTER

Reset

Part

Count?

R?

YES

Count

Bad

Parts?

C?

NO

YES

ENTER

ENTER

ENTER ENTER

SELECT

SETUP

SETUP

UTILITIES

COPY

SETUP

ERASE

SETUPS

ENTER ENTER

SETUP

TYPE

LOCAL REMOTE

ERASE

SETUPS

ERASE

CURRENT

SETUP

ERASE

ALL

SETUPS

ENTER ENTER

ENTER ENTER ENTER

ENTER

OK to

Erase

NO

Setups? OK to

E?

Erase

Setups?

YES NO

E?

YES

ENTER

ENTER

ENTER

ENTER

Figure 9–1 Utilities Menu Flow Chart


97


Setup Utilities

To access the Utilities menu, start from the Process

Setup menu shown in Figure 9–2. Move the cursor down to select Utilities and press the ENTER key.

SETUP TYPES

LOCAL

REMOTE

PROCESS SETUP

PROCESS CONTROL

PROCESS LIMITS

UTILITIES

Figure 9–2 Process Setup Main Menu

The Utilities menu screen appears with four option listed. By default, the cursor is set to the top line which is Setup Utilities as shown in Figure 9–3.

Figure 9–5 Setup Types Selection Menu

Press the ENTER key to display the setup entry screen which is shown in Figure 9–6. You can enter eight different setups named 1# to 8#. Use the increment (up arrow) and decrement (down arrow) keys to change the setup number.

ENTER NEW SETUP

1 #

SETUP UTILITIES

PART COUNT

STATUS OUTPUTS


Figure 9–3 Setup Utilities Menu

Pressing the ENTER key moves to the next menu screen which is the Setup Utilities selection shown in Figure 9–4. Notice the first line is indented which means it is a menu title, not a selectable option. From this menu, we can choose to either select, copy or erase the setups.

Figure 9–6 Enter New Setup Menu

Pressing the ENTER key displays the Process Setup menu shown in here Figure 9–2 and earlier in Figures 7–5, 7–29 and 7–37. This enables you to begin modifying the setup information. If the setup has not been configured, a message briefly appears

(Figure 9–7) before displaying the Process Setup menu. The flow follows the logic paths described in Section 7 – Process Control Menu.

SETUP UTILITIES

SELECT SETUP

COPY A SETUP

ERASE SETUPS

THE CURRENT STEUP

IS EMPTY AND NEEDS

TO BE CONFIGURED

Figure 9–4 Setup Utilities Selection Menu

Select Setup

Pressing the ENTER key displays a decision menu from which you can enable either a local or remote setup control. This is shown in Figure 9–5.

98

Figure 9–7 New Setup Configuration Message

If Remote setup is chosen, the PLC controls Remote Setup Selection Bits which determine which setup file is selected. The file number is determined by the Setup ID defined in Table 5—II.



Copy A Setup

Starting from the Utilities menu in Figure 9–4, move the cursor down to Copy A Setup and press the ENTER key. The display first requests the source file number. This is shown in Figure 9–8.

Erase Setups

Again, starting from the Utilities menu in Figure

9–4, move the cursor down to Erase Setups and press the ENTER key. The menu gives us a choice to erase the current setup or to erase all setups.

This menu is shown in Figure 9–11.

COPY FROM

1 #

ERASE SETUPS

ERASE CURRENT SETUP

ERASE ALL SETUPS

Figure 9–8 Source File Location Entry

Use the increment and/or decrement key to select a source file and press the ENTER key. Next the display requests a destination for the file as shown in Figure 9–9. Again, use the increment and/or decrement key to select a destination and press the

ENTER key.

Figure 9–11 Erase Setups Selection Menu

The current setup is the one chosen from the Select Setup menu. Press the enter key, and the menu prompts you with a confirmation messages indicating the setup to be deleted. This is shown in

Figure 9–12.

COPY TO

2 #

ERASE SETUP #1

NO

YES

Figure 9–9 Destination File Location Entry

The display will ask for confirmation before proceeding. This screen is shown in Figure 9–10.

O K T O C O P Y S E T U P ?

NO

Y ES

Figure 9–12 Confirm Erase Selected Setup

To erase the indicated setup, move the cursor down to YES and press ENTER . The display will display the message that the setup is being erased (Figure

9–13) and return to the Process Setup menu (Figure 9–2). Leaving the cursor at NO and pressing

ENTER will still return you to the Process Setup menu (Figure 9–2).

Figure 9–10 Confirm Copy Files

To proceed, move the cursor down to YES and press the ENTER key. The file is copied and the display returns to the Setup Utilities selection menu shown in Figure 9–4.

ERASING SETUP

IN PROCESS...

Figure 9–13 Erase Setup In Process


99


To erase all the stored setups, move the cursor from

ERASE CURRENT SETUP (see Figure 9–11) to down to ERASE ALL SETUPS and press ENTER . A confirmation message is displayed. Move the cursor down to YES as shown in Figure 9–14. Press the ENTER key to delete the setup files.

Reset Part Count

This function resets the parts counter back to zero.

With the cursor at the reset function, press the

ENTER key. The confirmation screen shown in

Figure 9–17 is displayed next.

ERASE ALL SETUPS

NO

YES

RESET PART COUNT

NO

YES

Figure 9–14 Confirm Erase All Setups

A progress message (see Figure 9–15) appears for about 8 seconds. When the process is complete, the display returns to the Process Setup menu as shown in Figure 9–2

ERASING ALL SETUPS

IN PROCESS...

.

Figure 9–17 Confirm Reset Part Count

Use the decrement key to move the cursor down one line to YES and press the ENTER key. The counter will be reset and the menu returns to the part count selection menu shown in Figure 9–16.

Count Suspect/Bad Part

The second option controls the suspect/bad part counter. The counter can be set to count all parts or only the good parts. To configure the counter, move the cursor down to COUNT SUS/BAD PART (see

Figure 9–16) and press ENTER . A confirmation screen (shown in Figure 9–18) is then displayed.

Figure 9–15 Erasing All Setups In Process

Part Count

The parts count option (see Figure 9–3) offers three options. The three choices are to reset the counter, count suspect/bad parts and preset the counter as shown in Figure 9–16.

COUNT SUS/BAD PART

NO

YES

PART COUNT

RESET PART COUNT

COUNT SUS/BAD PART

PRESET PART COUNT

Figure 9–16 Part Count Selection Menu

The count replaces the - - - in the upper left of the operate screen (see Figures 7–3. 7–4, 7–31 and 7–53).

100

Figure 9–18 Confirm Counter Enabled

To count all parts, move the cursor to YES, press

ENTER and the menu returns to the part count selection screen shown in Figure 9–16. To exclude bad/suspect parts, move the cursor to NO and press

ENTER. The bad/suspect parts are ignored and only good parts are counted. The menu returns to the part count selection screen shown in Figure 9–16.



Preset Part Count

This option allows you to preset a value (maximum = 60,000) in the counter. Again from the part count selection menu, move the cursor to the bottom line next to PRESET PART COUNT and press

ENTER . A data entry screen for presetting the value is displayed. Use the left and right arrow keys to select the digit position, and the up and down arrow keys to increment or decrement the value.

PRESET PART COUNT

_0

The four outputs controlled by this menu are:

1. Isolated Bad Part on Pin 20

2. Isolated Good Part on Pin 21

3. Isolated Ready on Pin 22

4. Isolated In–Dwell on Pin 23

For a complete description of each signal, refer back to Table 5—IV.

Cycle Press Off Line

The last option in the Utilities Menu (Figure 9–3) is Cycle Press Off Line. To access this option move the cursor down to the last line and press ENTER .

This subsequent menu is shown in Figure 9–21.

Figure 9–19 Counter Preset Value

The underscore indicates the digit position which is initially under the right–most digit. To preset the counter, press ENTER and you are returned to the part count selection menu shown in Figure 9–16.

Status Outputs

The third option in the Utilities Menu (see Figure

9–3) is Status Outputs. Moving the cursor down to Status Outputs and pressing the ENTER key displays the Status Output Selection menu.

This menu option permits you to set the four Isolated Status Outputs as either maintained or pulsed.

The default setting is maintained. If the output is set to pulsed, the output pulse width is 100 msec.

The status output selection menu is shown in Figure 9–20. To change the mode, move the cursor to

PULSED and press ENTER .


YES

NO

Figure 9–21 Cycle Press Selection Menu

This option works only with the palm operate switches on the press base. When the DPC front panel status is set OFF LINE , it cannot be triggered to cycle the press. During testing or fixture setup, it may be necessary to cycle the press without producing an ultrasonic output signal. This menu option permits cycling the press with the DPC set to

OFF LINE. To enable this menu option, move the cursor key up one line to YES and press the ENTER key. The press can now be cycled by pressing both palm activation switches. without producing an ultrasonic output signal. An Automation Input signal

(pin 8 of J902) will not cycle the press with this menu option with the DPC set to OFF LINE .

STATUS OUTPUTS

MAINTAINED

PULSED

Figure 9–20 Status Output Mode Selection


101



102



S

ECTION

10

Probes & Probe Stacks

• Theory of Operation

• Probe Configuration

• Probe Stack Assembly

• Booster Notes

• Probe Stack Mounting

The Ultrasonic Probe ................................... 105

Theory of Operation ........................................... 105

Probe Configuration ........................................... 105

Ultrasonic Horn .................................................. 106

Booster .............................................................. 106

Stack Assembly ........................................... 107

Installing Replaceable Tips .................................. 107

Mounting Stud to Horn/Booster ......................... 108

Horn to Booster ................................................. 109

Booster to Probe ................................................109

Horn to Probe .................................................... 109

Torque Unit Conversion Chart ..................... 110

Stack Disassembly ....................................... 111

Booster Notes ............................................

114

Stack Mounting .......................................... 115




103



104


Section 10 – Probes and Probe Stracks

The Ultrasonic Probe

Theory of Operation

Plastic welding is the most common application of ultrasonic assembly. To perform ultrasonic plastic welding, the vibrating tip is brought into contact with one of the work pieces. Pressure is applied and ultrasonic energy travels through the material generating frictional heat at the contact point of the two parts. The frictional heat melts a molded ridge of plastic on one of the pieces and the molten material flows between the two surfaces.

When the vibration stops, the material solidifies forming a permanent bond.

Probe Configuration

A basic ultrasonic probe package consists of —

1. A probe which houses the transducer to convert the electrical energy supplied by the generator into mechanical vibrations.

2. A horn to transfer the mechanical vibrations from the probe to the parts to be welded.

Optional components include special replaceable tips which can be threaded on to the tip of the horn, and a booster to amplify the mechanical vibrations of the horn. A basic hand–held probe system is shown in Figure 10–1. The hand probe is easily identified by its trigger actuator and permanently attached cable. Normally a booster is not used with a hand probe as this increases the length and weight and reduces its versatility. The optional threaded titanium tip can be used when the application calls for a staking profile or a pointed spot weld. Replaceable tips are not commonly used in high–volume production environments.

Hand

Probe

Standard

Horn

A mounted probe lacks the trigger actuator and has a HV–BNC connector for attaching the high voltage coaxial cable. A mounted probe may also have a booster to change its output amplitude.

Tip

Figure 10–1 Hand Probe, Horn and Tip

Custom

Horn

105



Ultrasonic Horn

The horn transfers the ultrasonic mechanical vibrations (originating at the transducer in the probe housing) to the plastic parts through direct physical contact. The horn is precision machined and designed to vibrate at either 20kHz, 30kHz,

40kHz, 50kHz or 70kHz. The tuning is accomplished using electronic frequency measurement.

Inherent variations in material composition prevent tuning by dimensional machining alone.

There are many different horn profile styles depending upon the process requirements. Factors which affect the horn design are the materials to be welded and the method of assembly. Horns are usually constructed from aluminum, hardened steel or titanium. As the frequency increases, vibration amplitude typically decreases, but internal stress in the horn increases. Higher frequencies are used for delicate parts that cannot handle a lot of amplitude. Some factors to keep in mind for high–frequency (e.g. 40kHz) ultrasonic welding versus low–frequency (e.g.

20kHz) ultrasonic welding are listed here.

1. Stress in the horn is higher at high frequencies.

2. Wear on the horn is greater at high frequencies.

3. Clean and flat mating surfaces between the horn, booster and transducer are more critical at high frequencies.

Booster

The function of a booster is to alter the gain (i.e.

output amplitude) of the probe. A booster is amplifying if its gain is greater than one and reducing if its gain is less than one. A neutral or coupling booster is used to provide an additional clamping location for added probe stack stability. A probe designed to be mounted in a fixture along with a booster and horn is shown in Figure 10–2. This is commonly referred to as a stack. As indicated, the components are secured with threaded studs.

Probe

Housing

Booster

Horn

Figure 10–2 Probe, Booster and Horn

106



Stack Assembly

Attaching A Replaceable Tip

To A Horn

1. Inspect all horn and tip surfaces for stress cracks, chips, or gouges. Any of these irregularities will affect operation and could lead to further equipment damage. Contact the Dukane Ultrasonics Tooling Department concerning damaged horn components.

2. Apply an extremely thin layer of a high temperature, high pressure silicon grease to the back surface that mates with the horn. The grease will allow both surfaces to intimately mate and become acoustically transparent which improves the energy transfer. Do not apply any grease to the threads. We recommend

Dow–Corning #4 (or #111 as an alternate). A small packet of Dow–Corning #4 is supplied with the system. If you cannot use a silicon– based grease in your facility, a petroleum– based grease may be used. However, it is likely to leave carbonaceous deposits on the surface, and require more frequent joint maintenance.

Failure to follow these instructions, may result in the mating surfaces bonding and difficulty removing the tip from the horn.

3. Thread the tip into the horn and tighten to the torque specifications below using an open end wrench of the correct size to fit the wrench flats of the tip. This is illustrated in Figure 10–

3. If necessary, use a spanner wrench (on horns with spanner wrench holes) or an open end wrench (on horns with wrench flats) to keep the horn from turning in your hand. A canvas strap wrench is permissible if it does not gouge or scratch the horn.

• 70 inch-lbs for an 8mm threaded tip

• 100 inch-lbs for a 3/8" x 24 threaded tip

• 160 inch-lbs for a 1/2" x 20 threaded tip

NOTE

Do not apply any grease to the threads of the replaceable tip. This may cause the tip to loosen from the horn resulting in inconsistent operation.

 CAUTION

NEVER clamp the horn in a vise. The resulting scratches or gouges in the surface are stress risers which may result in cracks.

Tighten

Figure 10–3 Replaceable Tip Installation

NOTE

Dukane Part No for the 20kHz spanner wrenches is 721–68

Dukane Part No for the 40kHz spanner wrenches is 721–44

107



Attaching The Mounting

Stud To A Horn Or A Booster

1. Inspect the stud for cracks or damaged threads.

Replace the stud if it is cracked or otherwise damaged.

2. Remove any foreign matter from the threaded stud and the mating hole.

3. Thread the mounting stud into the input* end of the horn or the input* end of the booster and tighten to the following torque specifications using an allen wrench in the socket head of the mounting stud. Table 10—I lists the torque specifications in units for both English and Metric systems of measurements. Figure

10–5 is a handy conversion graph if you require intermediate values not listed in the tables.

DO NOT hold the booster by the mounting rings when tightening stud. The mounting rings have a shear pin which could snap under excessive torque. Use a spanner wrench (on horns with spanner wrench holes) or an open end wrench (on horns with wrench flats) to keep the horn or booster from turning in your hand.

• 70 inch-lbs for an 8mm threaded stud

• 100 inch-lbs for a 3/8" x 24 threaded stud

• 160 inch-lbs for a 1/2" x 20 threaded stud inch–lbs ft–lbs N–m

70 5.8 7.9

100 8.3 11.3

160 13.3 18.1

Table 10—I Stud Torque Unit Conversions

*

Always assemble the mounting studs that mate boosters, transducers and horns to the input end of the horn or the input end of the booster first. This is shown in Figures 10–6 and 10–7.

NEVER thread a stud into the transducer or the output end of the booster first. See Booster Notes in this section for correctly identifying the output end of a booster.

108

NOTE

Do not apply any grease to the stud threads or the tapped hole. This may cause the stud to loosen. If the stud wanders within the joint, it can vibrate, resulting in excessive heat. In some cases, this can melt the tooling material.

NOTE

To convert inch-lbs to ft-lbs, divide by 12

To convert inch-lbs to Nm, divide by 8.852

To convert ft-lbs to Nm, multiply by 1.356

To convert Nm to ft-lbs, multiply by 0.7376

Torque specifications have a tolerance of about

±

10%.

See Figure 10–4 for a handy conversion graph.



Attaching The Horn To A

Booster, Booster To A

Probe, Or Horn To A Probe

1. Inspect all surfaces to be joined for stress cracks, chips, or gouges. Any of these irregularities will affect operation and could lead to further equipment damage. Contact the Dukane Ultrasonic Tooling Department concerning a damaged booster.

2. Ensure that the mating surfaces of the two components are clean and smooth. These surfaces must make intimate contact for the mechanical energy to pass from one component to the next. Pitting or a buildup of old grease and dirt on a mating surface will interfere with the energy transfer and reduce the power delivered.

3. Make sure that the stud in the horn or booster is tight. See the preceding mounting stud assembly instructions for torque specifications.

4. Remove any foreign matter from the threaded stud and mating hole.

NOTE

Always remove a probe stack from the machine in which it is mounted before attaching or removing a horn.

CAUTION 

Never leave a horn or booster assembly hand tight. Torque it to the proper specifications before proceeding. If the assembly is installed without being properly torqued down, the assembly may vibrate severely, damaging the mating surfaces and causing the generator to overload.

5. Apply an extremely thin layer of a high temperature, high pressure silicon grease to the surface that mates with the horn. The grease will allow both surfaces to intimately mate and become acoustically transparent which improves the energy transfer. We recommend

Dow–Corning #4 (or #111 as an alternate). A small packet of Dow–Corning #4 is supplied with the system. If you cannot use a silicon– based grease in your facility, a petroleum– based grease may be used. However, it is likely to leave carbonaceous deposits on the surface, and require more frequent joint maintenance.

Grease may be omitted if mylar washers are preferred on systems that require frequent changes. Mylar is plastic and will creep under

Tighten compression, so mylar is not recommended for system that are not changed frequently. Failure to follow these instructions, may result in the mating surfaces bonding and difficulty re-

Figure 10–4 Stack Assembly Procedure

109


DPC ™ II Plus and EZ Welder System – User’s Manual moving the horn from the booster or the booster from the probe.

6. Thread the components together and tighten to the following torque specifications using only the correct size wrenches. Use spanner wrenches on components with spanner wrench holes or an open end wrench on components with wrench flats. See Figure 10–4 for the correct procedure. Refer to Table 10—II for torque units conversions. Be careful not overtighten.

• 40kHz Stacks - 130 inch-lbs

• 20kHz Stacks - 200 inch-lbs inch–lbs ft–lbs N–m

130 10.8 14.7

200 16.7 22.6

Table 10—II Horn/Booster Torque Unit

Conversions

NOTE

Horn and booster torque specifications are higher than stud torque specs. Be sure to tighten the horn or booster joints to the higher torque limits.

Do not tighten the studs to these higher ratings as it may induce unnecessary stress in the assembly.

20

15

10

1 /

2 x 20 Stud

40kHz Stack

3 /

8 x 24 Stud

8mm Stud

20kHz Stack

5

ft-lbs

0 5

N-m

Figure 10–5 Torque Value Conversion Graph

10 15 20 25

110


240

200

180

160

130

120

100

60

70

30

in-lbs


Stack Disassembly

Stack disassembly is required when changing the booster or horn, or for a thorough inspection of all stack components. In mounted systems, always remove the stack from its mounting to disassemble the stack components.

To establish a maintenance schedule, inspect the mating surfaces after the first 200–400 hours of operation. If they require cleaning (see Probe Maintenance in Section 13), halve the time between inspections. If the surfaces do not require reconditioning, then double the time between inspections.

Each system is different due to the large number of operational parameters and stress factors.



CAUTION

Never hold a probe by the housing when tightening or loosening an adjoining component. The probe housing has anti–rotation devices to keep the transducer aligned. These could shear under excessive torque.

A SSEMBLY

HAND

PROBE

HOUSING

Output End

Mounting Stud

(Insert Into Horn

First and Tighten

to Torque Specs)

Input End

HORN

Figure 10–6 Hand Probe Assembly and Disassembly


HAND

PROBE

HOUSING

Spanner

Wrench

Holes

HORN

HAND

PROBE

ASSEMBLY

D ISASSEMBLY

111


The assembly and disassembly procedures for a hand probe shown in Figure 10–6. The same procedure for a probe stack with booster is shown in

Figure 10–7. It makes no difference whether the horn is attached to the booster first, or the booster is attached to the probe first.



CAUTION

Never hold a probe by the housing or a booster by the mounting rings when tightening or loosening an adjoining component. The probe housing and booster rings have anti–rotation devices to keep the transducer and booster aligned and could shear under excessive torque.

A SSEMBLY

PROBE

HOUSING

Ultrasound

Coaxial

Connector

Mounting Stud

(Insert Into Booster Input

End First and Tighten

to Torque Specs)

Booster Input End

(Threads Shallower

Than Output End)

BOOSTER

Output End

(Threads Deeper

Than Input End)

Mounting Stud

(Insert Into Horn

First and Tighten

to Torque Specs)

Input End

HORN

Spanner

Wrench

Hole

(Typical)

Input End

Booster

Mounting

Ring

(Do not clamp)

(Cap Screws Face

Toward Input)

Spanner

Wrench

Hole

Output End

PROBE

STACK

ASSEMBLY

Booster

Mounting

Ring

(Do not clamp)

D ISASSEMBLY

Figure 10–7 Probe Stack with Booster Assembly and Disassembly

112



Separating The Horn From A

Booster, Booster From A

Probe Or Horn From A Probe

On all transducers and horns with spanner wrench holes (see Figures 10–8), use only the correct size spanner wrench that came with your system to provide sufficient torque to loosen a joint.

Loosen



CAUTION

NEVER clamp a horn or booster in a vise. The resulting scratches or gouges in the surface are stress risers which may result in cracks.

Dukane has a stainless steel tool vise (Part

No.UFTV20) for clamping 20kHz boosters and transducers to facilitate disassembly of stubborn components without damage. It accepts front slug and booster tooling diameters of 1.5 and

1.81 inches and has replaceable antirotation pins.

Figure 10–8 Seperating The Horn From The Booster

On boosters and horns with wrench flats, use only the correct size wrench to provide sufficient torque to loosen a joint when necessary.

Removing The Mounting Stud

From A Horn Or Booster

Only use an allen wrench of the correct size in the socket head of stud to remove the stud from the horn or booster.

Removing Replaceable Tips

From A Horn

Use an open end wrench of the correct size to fit the wrench flats of the detachable tip. Use a spanner wrench (on horns with spanner wrench holes) or an open wrench (on horns with wrench flats) to provide an opposite force and keep the horn from turning in your hand. Refer to Figure 10–9 for the correct tip removal procedure.


NOTE

Do not hold a booster by the mounting rings when removing the stud from the booster. Use a spanner or open–end wrench to provide opposite force and keep the horn or booster from turning in your hand when loosening the stud.

Use a spanner wrench on horns and boosters with spanner wrench holes. Use an open end wrench on horns and boosters with wrench flats.

113


Loosen

Figure 10–9 Removing A Replaceable Tip From The Horn

Booster Notes

How To Tell The Booster

Input End From The Output

1. The depth of the threaded hole on the output end is always deeper than the threaded hole on the input end.

2. On an amplifying booster (gain > 1.0), the larger diameter end is the input end. On a reducing booster (gain < 1.0) the larger diameter end is the output end. On a neutral acting booster the diameters are equal.

3. The cap screws on the booster mounting rings are always inserted from the output end toward the input end (see Figure 10–7).

How To Tell If The Booster Is

Amplifying Or Reducing

Boosters have a die-stamped number on their surface that indicates their gain or reduction. If the number is greater than 1.0 (e.g. 1.5), it is an amplifying booster. If the number is less than 1.0 (e.g. 0.6), it is a reducing or reverse booster. A neutral booster has no gain and has 1.0 stamped on it. A neutral or coupling booster is used to provide another probe stack clamping location for added stability.

114

 CAUTION

NEVER install a booster upside down to change an amplifying system to a reducing system. The boosters are dimensionally asymmetric. They are tuned from input to output to act like an acoustic lens. Reversing them will not give the expected results and may cause damage to the system.



Mounting The Stack

A probe-horn assembly or probe-booster-horn assembly (stack) can be mounted into a customerprovided machine to ensure stability and proper alignment during operation or for automated operation. A stack is secured in a machine by clamping the probe (and booster, when present) at designated locations. Clamping at these designated locations provides stability to the stack and at the same time does not interfere with the transmission of ultrasonic vibrations of the stack components. The following rules apply when mounting a probe system stack.

1.

A probe may be clamped anywhere along its body (except the 41S30). If it has a side mounted BNC, then it may require a thin mounting ring if it is to be clamped near the top. It may also be clamped below the BNC connector.

2.

Secure a probe-horn stack by clamping the probe in two places.

3.

Secure a probe-booster-horn stack by clamping the probe in one place and the booster in one place.

4.

Never clamp the horn.

NOTE

Never hold a probe by the housing or booster by the mounting rings when tightening or loosening from an adjoining component (see Figures

10–6 and 10–7 to identify these parts). Always use the proper spanner wrenches when tightening or loosening the horn or booster.

115




116



S

ECTION

11

DPC Checkout

• Startup & Self–Test

• System Test

• Probe Operation

• Stopping the Weld Cycle

Startup and Self–Test .................................. 119

System Test ................................................. 120

System Operation ....................................... 121

Stopping the Weld Cycle............................. 121

Manual Systems ................................................. 121

Automated System ............................................. 121

End of Day ......................................................... 121




117



118


Section 11 – DPC Checkout

Startup and Self–Test

1. Push the rear panel AC breaker switch to the

ON position (see Figure 3–3 or 3–9 for the switch location.)

2. Push the front panel AC power switch to the

ON position (marked I on the switch.) This is labled A in Figure 11–1.

NOTE

If either of the AC Breakers open, they will flip the switch to its Off position marked by the O.

SYSTEM POWER OUTPUT

0 20 40 60 80 100

FAULT

ON LINE

INPUT TEST OVERLOAD

OVERTEMP OFF LINE

STATUS

ON

LINE

TEST

OFF

LINE

    

Figure 11–1 Front Panel Startup Controls and Indicators

3. The INPUT TEST indicator in the Status Display (B) flashes red for 5 to 10 seconds. This indicates the power-up self test is running.

When the test has successfully completed, the

INPUT TEST indicator goes dark.

4. The green power indicator (C in Figure 11–1) should then light up. The yellow OFF LINE status indicator (D in Figure 11–1) should also be lit. After subsequent power cycles, the DPC will return to its last state ( ON LINE or OFF

LINE ) when the front panel AC power switch is turned ON again.

5. Press the ON LINE generator control key on the front panel (labeled E in Figure 11–1.) The green ON LINE indicator in the Status Display

(labeled F in Figure 11–2) should now be lit.

NOTE

If the INPUT TEST indicator does not flash, check the AC line input. Both the rear panel and front panel AC breaker switches must be in the ON position, and the DPC line cord must be properly connected to a live AC outlet.

If the INPUT TEST indicator flashes and then remains in a steady red state –

1. The AC line level may be out of specified operating range.

2. The DPC may have an inter nal fault preventing normal opertion.

NOTE

If a Press Control module is installed, and the ON LINE and OFF LINE indicators do not light, check the follwoing items.

1. A Press Base cable (P/N 200–1124) must be connected to J35 on the press and

J902 on the DPC (Cable 3 in Figure 3–8).

2. The Emergency Stop switch must be in its reset position (pulled out).

3. In place of a press cable, a jumper block

(Dukane P/N 200–1293) can be installed on J902 (see Figure 3–4).


119


DPC System Test

To test the DPC II Plus system’s ultrasound signal delivery, perform the following steps.

1. For the initial test, the generator must be ON

LINE . Refer to step 5 on the previous page.

2. Position the probe so that its horn is not in contact with anything. Do not hold the probe if you are not accustomed to ultrasonic welding. The initial ultrasonic sensation may surprise you and cause you to drop the probe. Momentarily press the generator control TEST key (G in Figure

11–2). The following conditions should occur.



SYSTEM POWER OUTPUT

5. When the TEST key is released, the ON LINE status indicator lights up again and the Power

Output display goes blank.

NOTE

Neither a press system, automation system, hand probe or TEST key can trigger the generator to produce an ultrasound output if the

DPC II Plus is OFF LINE.

The Front Panel Control Lock (Pin No. 15 on the HD–15 System Input connector) will disable the TEST key from producing an output.

Refer to Section 5, Table 5—I.

The F P Control Lock will also inhibit any programming changes. The menu navigation will function normally, but data entry is inhibited.

0 20 40 60 80 100

FAULT

ON LINE



STATUS

ON

LINE

TEST

OFF

LINE

 

Figure 11–2 System Test Controls and Indicators

3. One green segment of the System Power Output bar display will light up indicating normal operation (H in Figure 11–2.)

4. The ON LINE status indicator goes blank. This indicates the ultrasonic probe is activated. The probe should operate without any unusual noise. The probe will operate as long as the

TEST key is pressed.

120


Section 11 – DPC Checkout

System Operation

1. If the generator is not online, press the ON

LINE key. This is labeled E in Figure 11–1.

The green ON LINE status should light up (F in Figure 11–2).

2. Program the appropriate weld method and time or energy to achieve the desired welding results.

3. Apply the probe to the components to be ultrasonically joined, and press the probe’s activation switch, or press the palm switches on the press base. In automation systems, the customer supplies external controls to trigger the generator.

4. The Power Output display will light up to indicate the percentage of power being delivered to the probe while the trigger switch is engaged.

5. The Power Output display should never reach

100% during normal operation.

6. The Power Output display should go blank indicating zero output power, after the probe trigger is released.

CAUTION

Any unusually loud noise from the probe stack indicates that it has been improperly assembled.

Check the probe stack for proper assembly and correct torque readings.

End of Day

Push the OFF LINE generator control key on the front panel (I in Figure 11–3).

The yellow OFF LINE status indicator (J in Figure 11–3) should be illuminated.

Stopping the Weld Cycle

Hand Probe System

Release the trigger switch on the hand probe to stop the welding cycle.

Automated System

The customer-supplied external controls provide the means to stop the welding cycle for an automated system.

Press System

Push in the Emergency Stop button on the press base to stop the welding cycle.

SYSTEM POWER OUTPUT

0 20 40 60 80 100

FAULT

ON LINE



STATUS

ON

LINE

TEST

OFF

LINE

 

Figure 11–3 Stopping the Weld Cycle


121



122


Section 12 – Troubleshooting

S

ECTION

12

Troubleshooting

• No Ultrasonic Output

• Generator Faults

• INPUT TEST Indicatorr

• TEST Control Key

• Troubleshooting

Flowchart

• Error Messages

No Ultrasonic Output ..................................... 125

Probe .................................................................... 125

Cable .................................................................... 125

Generator ............................................................. 126

Operate Input ....................................................... 126

Generator Faults ............................................ 127

OVERLOAD Indicator ............................................. 127

OVERTEMP Indicator ............................................. 127

FAULT Indicator ..................................................... 127

Generator Errors ............................................ 128

INPUT TEST Indicator ............................................. 128

TEST Control Key .................................................. 128

Troubleshooting Flowchart ............................. 129

Error Messages .............................................. 131




123



124



No Ultrasonic Output

Probe

Make sure that the probe coaxial cable is connected to the generator Ultrasonic output connector J1 (see

Figure 12–1). Make sure the probe stack was assembled following the instructions in Section 10.


U S 1 0 0 0 0

DUKANE CORP


MADE IN USA



GROUNDED AT OUTLET.




J1

SYSTEM IN

ULTRASOUND

OUTPUT

Probe or

Automation

Control Input

Figure 12–1

Ultrasound Out

Rear Ultrasound and System-In Connectors

Cables

Make sure that both the U/S coaxial and Control

Input cables are connected. You must have a trigger input to the SYSTEM IN HD-15 connector either by the probe's control cable or custom automation. Refer to Figures 3–4 through 3–8 for details. Put the generator OFF LINE and turn off the

AC power switch. Check the coaxial cable for any signs of damage which may result in an open circuit preventing the cable from transmitting the signal from the generator to the probe. If you have a mounted probe, replace the coaxial cable with a known good cable. If you are using a hand probe, try a different known good probe to determine if the problem is related to the generator or external cables and probe.

Ꮨ

CAUTION

Always turn the AC power off and wait a few seconds, before disconnecting or connecting any cable to the DPC.

Failure to turn off the AC power may result in damage to the generator or probe.

125



Generator

The generator will not produce an output signal when triggered if it is OFF LINE. Make sure that the green power indicator [A] is lit. The status display should indicate ON LINE which is marked as [B] in Figure 12–2. If the generator is OFF

LINE, press the ON LINE control key [C].

SYSTEM POWER OUTPUT

0 20 40 60 80 100

FAULT

ON LINE



STATUS

ON

LINE

TEST

OFF

LINE

 

Figure 12–2 Generator ON LINE Key and Indicator

Operate Input

If you are using a hand probe, make sure the control cable is connected to the System Input connector. The trigger on the hand probe activates the

Ultrasonic output through the control cable.

If you have supplied custom automation signals, pin 8, or pins 3 & 4 of the Operate Input must be used to trigger the Ultrasonic output. The system control inputs are user configurable. Refer to Section 5, Jumper Block SH707 for a detailed description of the options. The factory default setting

(JU724) is a contact closure to ground. If you are using the isolated source jumper position (JU 726), then the input requires a minimum of 5V to trigger the generator.

NOTE

Figure 5–3 shows the male cable end of the

System Input connector and is repeated here.

The cable end connector is a mirror image of the female panel connector shown in Figure

5–2. Make sure you have correctly wired the connector if you are using custom automation signals.

1 2 3 4 5

6

10

11 12 13 14 15

126



Generator FAULTs

OVERLOAD

If the generator OVERLOAD light comes on, it indicates excessive power is being drawn. This could be caused by a mismatch between the ultrasonic signal and the resonant characteristics of the acoustic stack. Improperly assembled probes may draw excessive power if their components were not properly torqued to specifications. Make sure you have the correct probe and horn. A 40kHz probe and a 20kHz DPC may result in an instantaneous overload. The same is true for the reverse combination. Excessive power drawn by the load may result in damage to the probe and horn.

OVERTEMP

If the OVERTEMP indicator comes on, it indicates that one of the generator’s power modules has overheated. This may occur due to a cooling fan failure or excessive dust inside the cooling channel.

The module’s temperature sensor will automatically shut down the generator. The generator will automatically reset and turn off the OVERTEMP indicator when the module temperature drops below the 75

°

C (167

°

F) trip point.

FAULT

If the generator FAULT light comes on, it indicates an out–of–tolerance voltage condition. This could be related to one of two conditions.

1. AC line voltage out of tolerance. Refer to Table

15—I for the AC voltage specifications.

2. Internal DC power supply problems (+5VDC,

+12VDC, –12VDC or +24VDC).

If the AC line voltage is within tolerance, then the DPC has an internal fault. Contact your local Dukane representative.

NOTE

The OVERLOAD, OVERTEMP and FAULT indicators are triggered by independent sensors. It is possible to get more than one error indicator.

The ultrasonic output is disabled on any one of the errors.

127



Generator Errors

INPUT TEST Indicator

Steady Red

During power up, the INPUT TEST indicator should flash red for 5–10 seconds. This indicates the power-up test is running. When the test has successfully completed, the INPUT

TEST indicator goes out. If the INPUT TEST indicator flashes and then remains in a steady red state, there are two possible causes.

1. The AC line level may be out of the specified operating range. Check the AC power to determine if it is within the limits specified in

Section 15.

2. If the AC power is within specifications, the DPC has an internal circuit fault preventing normal operation. Contact your local Dukane representative.

Does Not Flash

If the INPUT TEST indicator does not flash during power up, check the AC line input. Both the rear panel and front panel AC breaker switches must be in the ON position, and the

DPC line cord must be properly connected to a live AC outlet. The generator will not turn on if the line voltage is below the rated minimum. The INPUT TEST indicator should light up even without a probe connected.

TEST Control Key

The TEST key should cause the first green bar on the power display to light even without a probe (see System Test in Section 11 and Figure 11–2). If the TEST control key will not trigger the INPUT TEST light, check that pin 15 of the System Input is not grounded. A contact closure between this pin and ground (pin

2 or 7) will lock out the front panel TEST key.

128



START (Plug in AC Powercord into outlet)

INPUT TEST indicator lights up

?

YES

NO

1. Both the front and rear AC breaker switches on

the DPC must be turned on (Figure 3–9 and 4–2).

2. Make sure the AC outlet has power.

INPUT TEST flashes for

5–10 sec

?

YES

NO

Verify that the AC voltage is within specifications.

INPUT TEST indicator goes out

?

YES

NO


Green

AC power light on

?

YES

NO

1. Defective power indicator lamp.

2. Internal fault – contact Dukane Service.

FAULT indicator off

?

YES

NO


A (Continued on next page)

Figure 12–3 Troubleshooting Flowchart – Part 1


129


A (Continued from previous page)

OVER

TEMP indicator off

?

YES

NO Allow module(s) to cool down. Check cooling fan and cooling channel for excessive dust build up.

OVER

LOAD indicator off

?

YES

NO

1. Make sure correct probe is connected to generator.

2. Check the ultrasonic coaxial cable for shorts.

3. Try changing the probe and/or cable.

4. Make sure probe stack is properly assembled.

ON LINE key works

?

YES

NO

1. If Press Module installed, check J902.

2. Check Emergency Stop is not pushed in.


OFF LINE key works

?

YES

NO 1. If Press Module installed, check J902.


TEST key works

?

YES

NO

Disconnect the probe cables from DPC. The TEST key should work even without a probe or SYSTEM I/O cable.

Make sure FP Control Lock is not enabled (Table 5—I).

END

Figure 12–4 Troubleshooting Flowchart – Part 2

130



Error Messages

TRIGGER LOST

This error message is displayed when the trigger type is set to MAINTAINED , and the trigger signal is interrupted or lost. The weld cycle is terminated.

END OF WELD SIGNAL DETECTED

At the start of the cycle, one or both of the

END OF WELD signals ( AUTOMATION END

OF WELD and PRESS END OF WELD ) becomes active. The weld cycle is terminated.

TIMER STOP SIGNAL DETECTED

During the weld cycle, the TIMER STOP signal becomes active. The weld cycle is terminated.

SYSTEM OVERLOAD SIGNAL DETECTED

During the weld cycle, the SYSTEM OVER-

LOAD signal becomes active. The weld cycle is terminated.

AUTOMATION FAULT SIGNAL DETECTED

During the weld cycle, the AUTOMATION

FAULT signal becomes active. The weld cycle is terminated.

RIGHT SAFETY SWITCH RELEASED TOO SOON

If the Initiate Mode is set to MANUAL , the right safety switch was released too soon at the start of the weld cycle. Both switches must be held until the trigger switch is activated. The weld cycle is terminated.

LEFT SAFETY SWITCH RELEASED TOO SOON

If the Initiate Mode is set to MANUAL , the left safety switch was released too soon at the start of the weld cycle. Both switches must be held until the trigger switch is activated. The weld cycle is terminated.

SYSTEM OFF LINE

The SYSTEM OFF LINE signal is active. The

DPC generator must be ON LINE in order to produce an ultrasonic output signal.

FRONT PANEL LOCKED

KEYPAD ENTRY NOT ALLOWED

If the F P LOCK signal is active, the menu navigation functions normally, but data entry or program modifications are inhibited. For more information, refer to

Section 5, Table 5—I and the Input Signal Description following the table.

131




132


Section 13 – Care & Maintenance

S

ECTION

13

Care & Maintenance

• Front Panel

• Rear Panel

• Chasis

• Probes

• Reconditioning

Front Panel ................................................. 135

Rear Panel .................................................. 135

Chasis ........................................................ 135

Stack Surfaces ............................................ 136

Stack Maintenance .............................................136

Stack Inspection ................................................. 136

Even Contact .....................................................136

Uneven Contact ................................................. 136

Crowning ........................................................... 137

Center Depression ..............................................137

Corrosion ........................................................... 137

Reconditioning ........................................... 138

Overview ............................................................138

Machining the Mating Surfaces ..........................138

Manual Resurfacing ...........................................138




133



134



Front Panel

Cleaning

Do not use any solvents or abrasive cleaners on the front panel. Do not spray cleaner directly onto the front panel. Apply a small amount of computer cleaner to a soft towel first. Clean the panel with the moistened towel. Do not spray or apply the cleaner directly to the DPC. Do not allow any liquid to collect around the AC power switch.

Display

Do not use a sharp object on the display.

Control Keys

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 to push the keys.

Rear Panel

Connectors

The rear panel System Input and Status Output each have a pair of 4-40 threaded nuts to secure the connectors. Do not overtighten them

AC Power Cord

The AC power cord should be kept in good condition and free from any cuts. The AC plug should be straight with no bent prongs.

Grounding Stud

The rear chassis earth ground connection (see Figures 2–5 and 3–3) is a 10–24 x 1/2" threaded stud.

Do not overtighten the nut.

Chassis

Side Ventilation Slots

Keep the two side ventilation slots free from obstructions. If excessive dust or dirt collects on the slots, wipe or vacuum them clean. Do not use compressed air to clean them as this may force the dirt inside the chassis. The right hand slot (when viewed from the front) is the air intake and the left hand side is the exhaust. Allow at least 2 inches

(5 cm) on either side for air circulation as shown in Figure 13–1.

Exhaust Air from

Flow–Thru Cooling Tunnel

Intake Vent for

Thermostatically Controlled Fan

GEN

INFO.

+ ENTER

WELD

P1

MODE

WELD

P2

AMP.

ADJUST

– ENTER CANCEL

SYSTEM POWER OUTPUT

0 20

40 60 80

100

VAILABLE POWER

PERCENTAGE OF A

FAULT

ON LINE



STATUS

ON

LINE

TEST

OFF

LINE

2"

2"

Allow space for vent ilation,

2 inches (5 cm) on ea ch side.

Figure 13–1 Location of DPC Air Cooling Vents


135


Top Cover

Keep the cover on at all times. The chassis is robust enough to hold considerable weight. However, avoid placing excessively heavy objects on top of the chassis which may bend or dent the top cover resulting in damage to internal components.

Replaceable Parts

The DPC is self contained and has no parts that are replaceable by the user. If a part needs replacement, contact your local Dukane representative.

See Section 14 for contact information.

Stack Surfaces

Stack Maintenance

It is essential that the mating surfaces of the acoustic stack components be flat and smooth. When the components are joined together and tightened, there must not be any air gap between the surfaces.

If there is any air gap , there will be a loss in power and efficiency. Air has much higher transmission losses than the metal horn. Whenever the wavefront encounters an air gap, the propagation velocity is significantly reduced and attenuated. This results in considerable loss. In some cases, the union between the mating surfaces could be so poor as to prevent the probe stack from operating. This could result in excessive power drawn from the generator and may damage the mating surfaces. Figure

13–2 shows the mating surfaces on a typical probe and booster assembly.

Mating Surfaces

Stack Inspection

Examine the mating surfaces of the horn and probe

(and booster if applicable). Look for a shiny, burnished area. This indicates where the surfaces have been in contact. It will indicate whether the surfaces are flat and making good contact, or if they are uneven and making poor contact.

Inspection Schedule

To establish a maintenance schedule, inspect the mating surfaces after the first 200–400 hours of operation. If they require cleaning, halve the next inspection time. If the surfaces do not require reconditioning, then double the next inspection time.

Surfaces with Even Contact

A flat surface will make even contact and its surface will be evenly burnished across the entire contact area. Fig-

Hole for

Mounting

Stud ure 13–3 shows a surface that has made even contact.

Burnished

Area

Figure 13–3 Flat Surface With Even Contact

Surfaces with Uneven Contact

A surface that is not completely flat will make uneven contact. Its surface will be burnished only in the area where it has made contact. Figure 13–4 shows what such a surface would look like. The inner and outer areas have no marks on it indicating there has been no contact in these areas.

Figure 13–2 Location of Stack Mating Surfaces

136

Burnished

Area

Figure 13–4 Flat Surface With Uneven Contact



Crowning

A surface which is burnished only in the inner ring area around the stud, indicates the surface is convex or crowned. An example of this is shown in figure 13–5. To get an idea of amount of deviation from a flat surface, place a straight edge along the stack element. Since its surface is higher at the center than at the edges, there will be a gap at the outer edge of the element.

Crown

Corrosion

Corrosion is a factor to consider when determining the overall system performance. Over time, corrosion can build up on the mating surfaces of the acoustic stack. This build up interferes with the efficient transfer of ultrasonic energy to the parts to be welded. It may contribute to a loss in performance. Evidence of corrosion build up includes discolored mating surfaces or surfaces encrusted with hard deposits. To extend equipment life and maintain performance levels, minimize the system's exposure to corrosive sources.

Gap

Straight

Edge

Figure 13–5 Crowned Surface

Center Depression

A surface which is burnished only in the outer ring area around the edge, indicates the surface is concave or depressed. An example of this is shown in figure 13–6. To get an idea of amount of deviation from a flat surface, place a straight edge along the stack element. Since its surface is higher at the edge than at the center, there will be a visible gap near the center indicating the depth of the depression.

Gap

Straight

Edge

Figure 13–6 Center Depression


137


Reconditioning

Overview

Stack components require reconditioning when the mating surfaces become uneven or corroded.

These conditions cause poor contact between the mating surfaces which wastes power. It also makes tuning the stack difficult, can cause heat damage to the transducer, and can contribute to a higher system noise level.

Machining the Mating Surfaces

Instructions on how to properly machine the stack components is beyond the scope of this manual.

Please call Dukane's Tooling Support Team for machining information. A list of Dukane contacts is provided in Section 14.

Manual Resurfacing

To manually resurface the stack component mating surfaces, follow the steps given here.

1. Disassemble the acoustic stack and wipe all the mating surfaces clean. Use a clean cloth or a paper towel.

2. Examine all the surfaces. If any are corroded, discolored or coated with hard deposits, they should be reconditioned.

3. If the surfaces appear to be in good condition, proceed to step 11.

4. Remove the mounting stud(s) if any are installed.

5. Tape a clean sheet of #400 grit (or finer) emery cloth grit side up to a clean, flat surface such as a piece of plate glass.

6. Hold the stack component with one hand near the bottom as shown in Figure 13–7. This view shows the thumb covering one of the three spanner wrench holes.

Without applying any downward pressure, carefully stroke the part in one direction across the emery cloth. The component's weight alone is enough pressure as the part is

138

NOTE

Before deciding to recondition the mating surfaces yourself, consider calling Dukane

Corporation's Tooling Support team to discuss the situation. This is especially important if the mating surfaces are uneven, because machining of the component(s) may be required.

Factory personnel can offer their skills and experience to help you determine the options for your particular needs.

See Section 14 for a list of Dukane contacts.



CAUTION

An improperly altered horn can cause destructive stress to the transducer, booster, generator and horn. The horn should only be modified by Dukane's

Horn Department.



 CAUTION

Use extreme care to keep the part level when moving it across the emery cloth. Be careful not to tilt the part.

An uneven mating surface could leave the mating surface inoperative.

Surface flatness is more important than surface finish.

Figure 13–7 Manual Resurfacing moved across the emery cloth. Complete a second stroke across the cloth just like the first.

7. Keep the element's surface flat against the emery cloth and turn it 120

°

(one–third of a complete rotation) so the thumb covers the next spanner wrench hole. Again move the part twice across the emery cloth as covered in the previous step.

8. Give the part a final one–third turn and repeat the two strokes described in Step 6.

9. Reexamine the mating surfaces. Repeat Steps

6 through 8 until the corrosion has been removed.

10. Clean any grit from the resurfaced element and the stud mounting threads using a clean cloth or paper towel.

11. If you had to remove the mounting studs, they need to be reinserted. Before they are reinserted, it is necessary to ensure proper thread engagement.

a. Inspect and clean the stud.

b. Clean the threaded hole with a clean cloth.

c. Thread the stud into the hole. Tighten the stud to the torque specifications given in

Table 10—II.

12. Reassemble the stack and install it using the procedure in Section 10 using Figures 10–6 and 10–7 as guides.

13. Complete the Operational Test in Section 11.



CAUTION

It is important to perform only two strokes each time the component is rotated. Performing more than two strokes affects whether the surface remains flat. It is important for the mating surface to maintain its perpendicularity in relationship to the component's centering axis. If this relation between the surface and the axis is altered, the welding system may become inoperative.

NOTE

If the studs are overtightened, the threads may deform. Removing a stud that has been overtightened could damage the threads in the horn/booster. If this should happen, retap the horn/booster threads and replace the stud with a new one.

139




140


Section 14 – Contacting Dukane

S

ECTION

14

Contacting Dukane

• Corporate Office

• Extensions & eMails

Ultrasonics Division Main Office .................. 143

Email Addresses .......................................... 144

Telephone Extensions .................................. 144




141



142


Section 14 – Contacting Dukane

Contacting Dukane

Identify Equipment

When contacting Dukane about a service–related problem, be prepared to give the following information:

• DPC model number, line voltage and serial number

• Any fault indicators from the DPC status display

• Description of the problem 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.

Local Support

Your local Dukane representative has received factory training and can answer all of your questions regarding Dukane equipment.

Ultrasonics Division

Mailing Address: Dukane Ultrasonics

2900 Dukane Drive

Main Phone:

St. Charles, IL 60174 USA

(630) 797–4900

Main Fax: (630) 797–4949

Service & Parts Fax: (630) 584–0796

Department Phone Numbers

You can reach each department by dialing directly

Application Support (630) 797–4930

For applications and/or process technology questions.

Engineering (630) 797–4950

For engineering of standard and customized systems.

Service & Parts (630) 762–4090

For equipment servicing or replacement parts.

Tooling (630) 797–4930

For information on tooling, fixtures and horns.

Department email Addresses

Applications: .......................

[email protected]

Engineering: ........................

[email protected]

Service & Parts: ..................

[email protected]

Tooling: ................................

[email protected]

Our Website

Dukane Ultrasonics is on the world wide web at:

http://www.dukcorp.com/us

and then go to your area of interest.


NOTE

See the next page for additional department phone numbers and email addresses.

143


Ultrasonics Division email Addresses

Applications: .............................

[email protected]

Engineering: ..............................

[email protected]

Food Processing: .......................

[email protected]

International Sales: ...................

[email protected]

Marketing: .................................

[email protected]

Sales: ..........................................

[email protected]

Support/Service & Parts: ...........

[email protected]

Technical Writing: .....................

[email protected]

Tooling: ......................................

[email protected]

Training: ....................................

[email protected]

Ultrasonics Division Phone Numbers

Application Support (630) 797–4930

For applications and/or process technology questions.

Engineering (630) 797–4950

For engineering of standard and customized systems.

Food Processing (630) 797–4920 or –4938

For information about using ultrasonics in food processing.

International (630) 797–4915

For questions about international locations, support, etc.

Marketing (630) 797–4906

For product literature, and trade show information.

Metal Welding (630) 797–4953

For information about any aspect of metal welding.

Sales (630) 797–4918

Your local Dukane representative is the main source of product and order information, however you may have a need to contact Sales.

Service & Parts (630) 762–4090

For equipment servicing or replacement parts.

Technical Writing (630) 797–4907

For information and comments about user’s manual content.

Tooling Support (630) 797–4930

For information about tooling, horns, and fixturing.

Training Hotline (630) 797–4904

We offer a curriculum of educational programs at our corporate headquarters in St. Charles, Illinois.

Please call the Dukane Ultrasonics Training Hotline for a free Education Catalog or with any questions you may have.

24-hour Emergency Service

Effective May 10, 2004

(630) 797–4987

144


Section 15 – Specifications

S

ECTION

15

Specifications

• Regulatory Compliance

• Dimensions

• Power Requirements and Model Ratings

Regulatory Compliance ............................... 147

Federal Communications Commission ................147

CE Marking (Conformité Europeéne) ..................147

Dimensions ................................................. 148

Operating Enviornment ............................... 148

Power Requirements ................................... 149

Interpreting The DPC Model Number .......... 150




145



146



Regulatory Agency Compliance

FCC

The DPC II Plus complies with the following Federal Communications Commission regulations.

• The limits for FCC measurement procedure

MP-5, “Methods of Measurement of Radio

Noise Emissions from ISM Equipment”, pursuant to FCC Title 47 Part 18 for Ultrasonic

Equipment.

CE Marking

This mark on your equipment certifies that it meets the requirements of the EU (European Union) concerning interference causing equipment regulations.

CE stands for Conformité Europeéne (European

Conformity). The DPC II Plus complies with the following CE requirements.

• The EMC Directive 89/336/EEC for heavy industry —

EN55011 and

EN50082 using

EN61000–4–2

EN61000–4–3

EN61000–4–4

EN61000–4–5

EN61000–4–6

EN61000–4–8

ENV50204

 CAUTION

DO NOT make any modifications to the

DPC or associated cables as the changes may result in violating one or more regulations under which this equipment is manufactured.

• The Low Voltage Directive 73/23/EEC.

• The Machine Directive 89/392/EEC using

EN60204–1:1993 Safety of Machinery –

Electrical Equipment of Machines. Part 1:

Specification for General Requirements.

147



Dimensions

Allow 2 in (5 cm) space for ventilation

Heated

Exhaust Air

23.78 in

604 mm

Allow 4 in (10 cm) space for cables

Allow 4 in (10 cm) space for cables

Cooling Fan

Allow 2 in (5 cm) space for ventilation

Cooling

Air Inlet

17.17 in

436 mm

U. S . PAT E N T 4 , 2 7 7 , 7 1 0

– WARNING–



LINE VOLTAGE

200–240Vac 50/60Hz

15A 

Ꮨ


2 0 0 - 2 4 0 VAC, 5 0 - 6 0 H z , 1 5 A

Multi–Probe Slave Module

Multi–Probe Master Module

–

SYSTEM OUT

Power Signal

Output Module

Power

Signal

Output

Zero

Adjust

Power Monitor

Jacks

+

SYSTEM IN


U S 1 0 0 0 0

DUKANE CORP


MADE IN USA



AT OUTLET




5.12 in

130 mm

5.47 in

139 mm

J1

Ꮨ

ULTRASOUND

OUTPUT

Power Signal Output

Press Control Board

Figure 15–1 Generator 3–View and Dimensions

Operating Environment

Operate the DPC II Plus within these guidelines:

Temperature: 40

°

F to 100

°

F (+5

°

C to +38

°

C)

Pressure: Ambient

Air Particulates: Keep the DPC dry.

Humidity:

Vibration:

Minimize exposure to moisture, dust, dirt,smoke and mold.

5% to 95% Non–condensing

@ 0

°

C to +30

°

C

1.0 G

148

Storage guidelines:

Temperature: -4

°

F to 158

°

F (-20

°

C to +70

°

C)

Humidity:

Vibration:

5% to 95% Non–condensing

@ 0

°

C to +30

°

C

2.5 G



Power Supply Requirements

The AC power requirements depend on the frequency and power rating of the generator. The tables below, list the nominal AC requirements (maximum current drawn before overload) and the service rating of the AC outlet each model of the DPC II Plus and DPC EZ is designed for.

Frequency

DPC–2 Plus

Generator Model

Peak Power

Rating (Watts) Nominal Input Power Requirements

AC Outlet

Current Rating

20 kHz

2050

2120

500

1200

95–130V 50/60 Hz @ 8 Amps

190–260V 50/60 Hz @ 4 Amps

95–130V 50/60 Hz @ 15 Amps

190–260V 50/60 Hz @ 8 Amps

30 kHz

40 kHz

2170

2220

3150

4035

4070

1700

2200

1500

350

700

190–260V 50/60 Hz @ 12 Amps

190–260V 50/60 Hz @ 15 Amps

190–260V 50/60 Hz @ 12 Amps

95–130V 50/60 Hz @ 6 Amps

190–260V 50/60 Hz @ 4 Amps

95–130V 50/60 Hz @ 12 Amps

190–260V 50/60 Hz @ 8 Amps

4100 1000

95–130V 50/60 Hz @ 15 Amps

190–260V 50/60 Hz @ 8 Amps

50 kHz 5015 150

95–130V 50/60 Hz @ 6 Amps

190–260V 50/60 Hz @ 4 Amps

95–130V 50/60 Hz @ 6 Amps

70 kHz 7010 100

190–260V 50/60 Hz @ 4 Amps

Table 15—I DPC II Plus Generator Model and Power Supply Requirements

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

Frequency

DPC EZ

Generator Model

Peak Power

Rating (Watts) Nominal Input Power Requirements

AC Outlet

Current Rating

95–130V 50/60 Hz @ 15 Amps

1000EZ 1000

190–260V 50/60 Hz @ 8 Amps

95–130V 50/60 Hz @ 15 Amps

20 kHz 1000EZX 1000

2000EZ 2000

190–260V 50/60 Hz @ 8 Amps

190–260V 50/60 Hz @ 15 Amps

2000EZX 2000 190–260V 50/60 Hz @ 15 Amps

Table 15—II DPC EZ Generator Model and Power Supply Requirements

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps

15 Amps


149


Interpreting the DPC II Plus Model Number

Generator Controller Level

2200-LN4-PE-L2

FREQUENCY

2 = 20 kHz

3 = 30 kHz

4 = 40 kHz

5 = 50 kHz

7 = 70 kHz

POWER RATING

010 = 1 0 0 w

015 = 150 w

035 = 350 w

050 = 500 w

070 = 700 w

100 = 1000 w

120 = 1200 w

170 = 1700 w

220 = 2200 w

INPUT POWER

MODULE

L = Low

power

module

H = High

power

module

N = Non-power

Factor

F = Power Factor

Corrected

TRANSDUCERS

2 = 2 ceramics

4 = 4 ceramics

L2 = level 2

T = Time Only

E = Time & Energy

P = Press Control Board

Figure 15–2 Interpeting the DPC II Plus Model Number

NOTE

Figure 15-2 is designed to help you determine which options your DPC II Plus has. It is not meant to suggest that all combinations of these options are possible.

150


Section 16 – Warranty

S

ECTION

16

Warranty

• Domestic Warranty

• International Warranty

Domestic warranty ...................................... 153

International Warranty ................................ 154




151



152


Section 16 – Warranty

DUKANE CORPORATION

NORTH AMERICAN WARRANTY POLICY

Subject to the terms, limitations and exclusions set forth below, Dukane Corporation IAS Division (Dukane) warrants to the original Purchaser, unless otherwise expressly agreed to in writing by Dukane, that all equipment and tooling designed and built by Dukane will be free from defects in material or workmanship. Normal wear items are not covered by this warranty. Warranty duration shall be defined as documented herein and in conjunction with any exceptions or exclusions in the accompanying Dukane quotation to the Purchaser.

Equipment Type

Custom Systems

Hot Plate Welder

Laser Welder

Spin Welder

Thermal Press

Ultrasonic Welder

Vibration Welder

All Production

Tooling

Prototype Tooling

Equipment Warranty Duration Other Comments

12 months on all Dukane designed and built content Dukane standard product included in custom systems

that is not part of our standard product.

are covered by the applicable product warranty.

24 months

For all laser sources, Original equipment

manufacturer (OEM) warranty is applicable.

none

All internal laser optics and external beam delivery optics are warranted for only 30 days.

24 months

24 months

36 months

24 months

12 months, one-time replacement. (6-month, one-time replacement for carbide tipped horns)

• All tooling made from Renshape 460 (Renwood)

are only warranted for 200 part-cycles.

• All other prototype tooling is warranted as

described in each specific proposal.

none none

See WARRANTY EXCLUSIONS OR EXCEPTIONS below.

none none

Prototype Renshape 460 (Renwood) tools employ reusable content, and therefore remain the property of Dukane.

All Dukane warranties commence on the date of the original shipment of the equipment or tooling, and duration is based upon a single shift per day, five day per week operation. The warranty period on rentals of new equipment that are converted to a purchase are deemed to have commenced on the initial date of rental.

These warranties are limited to equipment and tooling operated and maintained per Dukane’s written instructions, and used under normal operating conditions. These warranties do not include normal wear or normal wear items, and do not cover damage attributable to misuse, improper installation, faulty repair, unauthorized alteration or modification, neglect, or accident. Misuse includes operation of equipment with tooling that is not qualified for the equipment or properly installed on the equipment.

The warranty on all Dukane equipment and tooling purchased and installed in North America is a parts and labor warranty only. Equipment installed outside of North America, regardless of where it was purchased, is covered by Dukane’s International Warranty Policy. In all cases, when on-site service is required, Travel & Living (T&L) expenses will be billed at cost. Warranty service labor (including travel time) at the customer’s site is provided on a Monday through Friday (excluding holidays), 7 a.m. to 7 p.m. basis. Any warranty service requested outside of these hours is available on a charge basis equal to 150% of Dukane’s prevailing rate for technical service work.

Any equipment or tooling that proves to be defective in material or workmanship during the stated warranty period will be repaired or replaced at the sole discretion of Dukane Corporation when Dukane is promptly notified in writing. During the warranty period, defective equipment, components, or tooling that are returned properly packed with all transportation charges prepaid will be repaired or replaced and returned to the end-user without charge. Shipments of warranty parts will be via standard, non-expedited delivery service. Expedited shipment requests are subject to freight charges to the Purchaser.

Computers, PLCs, CRTs, LCDs, touch screens, and keyboards separate and/or incorporated as an integral part of a system will carry a one (1) year warranty from the date of shipment when used under normal operating conditions, and not subjected to misuse, abuse, or neglect. For all other equipment, components, or parts included in equipment or systems from Dukane, but not manufactured by Dukane or its affiliates, this warranty shall be limited in time and extent to the warranty given to Dukane by the OEM.

EQUIPMENT WARRANTY EXCLUSIONS OR EXCEPTIONS:

When specified in our quotation, a limited warranty may apply to certain components of the equipment, and/or for certain types of applications of the equipment, including those noted below.

❑ This warranty is void if the ultrasonic welder and/or tooling [i.e., horn(s) and fixture(s)] are used for applications requiring metalto-metal contact, when the ultrasonic exposure period (weld cycle) exceeds 250 milliseconds.

❑ Ultrasonic Equipment and tooling used in continuous duty cycle modes such as, but not limited to, continuous cut and seal, and food processing are warranted for 2000 hours or 12 months from shipment, whichever occurs first.

❑ Any ultrasonic horn or tool quoted and sold as “Experimental” is not warranted.

❑ This warranty does not cover failures of equipment and components attributable to improper cooling or overheating of the transducer.

❑ Ultrasonic Horn Analyzers have a 12-month warranty.

❑ Ultrasonic Transducers have a one-time replacement warranty.

❑ Normal wear items and consumables excluded from any warranty coverage include, but are not limited to, filters, fuses, light bulbs, lubricants, gaskets and seals, cast urethane fixture components, laser flashlamps, laser beam delivery optics, and lasing gases.

The forgoing warranty is the sole and exclusive warranty and is made in lieu of all other warranties, express, implied or statutory, including without limitation any warranties of merchantability, fitness for a particular purpose, description, quality, productiveness or any other warranty. The remedy set forth in this warranty policy is the sole and exclusive remedy of Purchaser and in no event shall Dukane be liable for any compensatory, consequential, special, punitive or contingent damages or for damages arising from any delay in performance by Dukane under this warranty.


153


DUKANE CORPORATION

INTERNATIONAL WARRANTY POLICY

Subject to the terms, limitations and exclusions set forth below, Dukane Corporation IAS Division (Dukane) warrants to the original Purchaser, unless otherwise expressly agreed to in writing by Dukane, that all equipment and tooling designed and built by Dukane will be free from defects in material or workmanship. Normal wear items are not covered by this warranty. Warranty duration shall be defined as documented herein and in conjunction with any exceptions or exclusions in the accompanying Dukane quotation to the Purchaser.

Equipment Type

Custom Systems

Hot Plate Welder

Laser Welder

Spin Welder

Thermal Press

Ultrasonic Welder

Vibration Welder

All Production

Tooling

Prototype Tooling

Equipment Warranty Duration Other Comments

12 months on all Dukane designed and built content Dukane standard product included in custom systems

that is not part of our standard product.

are covered by the applicable product warranty.

12 months none

For all laser sources, Original equipment

manufacturer (OEM) warranty is applicable.

12 months

12 months

12 months

12 months

12 months, one-time replacement. (6-month, one-time replacement for carbide tipped horns)

All internal laser optics and external beam delivery optics are warranted for only 30 days.

none none

See WARRANTY EXCLUSIONS OR EXCEPTIONS below.

none none

• All tooling made from Renshape 460 (Renwood)

are only warranted for 200 part-cycles.

• All other prototype tooling is warranted as

described in each specific proposal.

Prototype Renshape 460 (Renwood) tools employ reusable content, and therefore remain the property of Dukane.

All Dukane warranties commence on the date of the original shipment of the equipment or tooling, and duration is based upon a single shift per day, five day per week operation. The warranty period on rentals of new equipment that are converted to a purchase are deemed to have commenced on the initial date of rental.

These warranties are limited to equipment and tooling operated and maintained per Dukane’s written instructions, and used under normal operating conditions. These warranties do not include normal wear or normal wear items, and do not cover damage attributable to misuse, improper installation, faulty repair, unauthorized alteration or modification, neglect, or accident. Misuse includes operation of equipment with tooling that is not qualified for the equipment or properly installed on the equipment.

The warranty on all Dukane equipment and tooling purchased and installed in North America is a parts and labor warranty only. Equipment installed outside of North America, regardless of where it was purchased, is covered by Dukane’s International Warranty Policy. In all cases, when on-site service is required, Travel & Living (T&L) expenses will be billed at cost. Warranty service labor (including travel time) at the customer’s site is provided on a Monday through Friday (excluding holidays), 7 a.m. to 7 p.m. basis. Any warranty service requested outside of these hours is available on a charge basis equal to 150% of Dukane’s prevailing rate for technical service work.

Any equipment or tooling that proves to be defective in material or workmanship during the stated warranty period will be repaired or replaced at the sole discretion of Dukane Corporation when Dukane is promptly notified in writing. During the warranty period, defective equipment, components, or tooling that are returned properly packed with all transportation charges prepaid will be repaired or replaced and returned to the end-user without charge. Shipments of warranty parts will be via standard, non-expedited delivery service. Expedited shipment requests are subject to freight charges to the Purchaser.

Computers, PLCs, CRTs, LCDs, touch screens, and keyboards separate and/or incorporated as an integral part of a system will carry a one (1) year warranty from the date of shipment when used under normal operating conditions, and not subjected to misuse, abuse, or neglect. For all other equipment, components, or parts included in equipment or systems from Dukane, but not manufactured by Dukane or its affiliates, this warranty shall be limited in time and extent to the warranty given to Dukane by the OEM.

EQUIPMENT WARRANTY EXCLUSIONS OR EXCEPTIONS:

When specified in our quotation, a limited warranty may apply to certain components of the equipment, and/or for certain types of applications of the equipment, including those noted below.

❑ This warranty is void if the ultrasonic welder and/or tooling [i.e., horn(s) and fixture(s)] are used for applications requiring metalto-metal contact, when the ultrasonic exposure period (weld cycle) exceeds 250 milliseconds.

❑ Ultrasonic Equipment and tooling used in continuous duty cycle modes such as, but not limited to, continuous cut and seal, and food processing are warranted for 2000 hours or 12 months from shipment, whichever occurs first.

❑ Any ultrasonic horn or tool quoted and sold as “Experimental” is not warranted.

❑ This warranty does not cover failures of equipment and components attributable to improper cooling or overheating of the transducer.

❑ Ultrasonic Horn Analyzers have a 12-month warranty.

❑ Ultrasonic Transducers have a one-time replacement warranty.

❑ Normal wear items and consumables excluded from any warranty coverage include, but are not limited to, filters, fuses, light bulbs, lubricants, gaskets and seals, cast urethane fixture components, laser flashlamps, laser beam delivery optics, and lasing gases.

The forgoing warranty is the sole and exclusive warranty and is made in lieu of all other warranties, express, implied or statutory, including without limitation any warranties of merchantability, fitness for a particular purpose, description, quality, productiveness or any other warranty. The remedy set forth in this warranty policy is the sole and exclusive remedy of Purchaser and in no event shall Dukane be liable for any compensatory, consequential, special, punitive or contingent damages or for damages arising from any delay in performance by Dukane under this warranty.

154


Appendix A – List of Figures

A

PPENDIX

A

List of Figures

Figure 2–1 120Volt, Grounded, 3-Prong Receptacle ......................................... 12

Figure 2–2 220Volt, Grounded, 3-Prong Receptacle ......................................... 12

Figure 2–3 International 220/240V Grounding ................................................. 13

Figure 2–4 DPC Grounding Arrangement ........................................................ 13

Figure 2–5 Press Grounding Arrangement ....................................................... 13

Figure 3–1 Installing a Benchtop DPC .............................................................. 17

Figure 3–2 Rack-mounted DPC Using Bracket Kit ............................................. 18

Figure 3–3 DPC II Plus and EZ Rear Panel & Optional Modules ......................... 19

Figure 3–4 DPC II Plus and EZ Hand Probe Cabling Connections ...................... 21

Figure 3–5 DPC II Plus and EZ Automated Probe Cabling Connections ............. 21

Figure 3–6 DPC II Plus Multiple Probe Cabling Connections ............................. 22

Figure 3–7 DPC II Plus Automated Thruster Cabling Connections .................... 23

Figure 3–8 DPC II Plus and EZ Press Cabling Connections ................................ 24

Figure 3–9 Emergency Stop Switch Interface ................................................... 25

Figure 3–10 Rear Panel AC Breaker Switch ........................................................ 25

Figure 4–1A DPC II Plus Control Panel Layout ..................................................... 29

Figure 4–1B DPC EZ Control Panel Layout .......................................................... 29

Figure 4–2 Front Panel AC Power Section ........................................................ 30

Figure 4–3 Generator Control Keys .................................................................. 30

Figure 4–4 System Status Display ..................................................................... 31

Figure 4–5 Power Output Display Normal Operation ........................................ 32

Figure 4–6 Power Output Display Warning Indicators ...................................... 32

Figure 4–7 Menu Keys ..................................................................................... 33

Figure 4–8A DPC II Plus GEN. INFO Menu Display ............................................... 33

Figure 4–8B DPC EZ GEN. INFO Menu Display .................................................... 33

Figure 4–9 Menu Display – Typical Selection Menu .......................................... 35

Figure 4–10 Menu Display – Typical Confirmation Screen ................................... 35

Figure 4–11 Menu Display – Typical Data Entry Screen ....................................... 35

Figure 5–1 DPC II Plus and EZ Welder Rear Panel Connectors .......................... 39

Figure 5–2 HD–15 System Input Connector ..................................................... 40

Figure 5–3 Cable End of System Input Connector ............................................ 40

Figure 5–4 DB–25 System Output Connector ................................................... 42

Figure 5–5 Remote Amplitude Control Module ................................................ 46

Figure 5–6 Current Loop Transfer Function Graph............................................ 46

Figure 5–7 Power Signal Output Module ......................................................... 47

Figure 5–8 Press Control Module ..................................................................... 48

Figure 5–9 Press Connector Pin Identification .................................................. 48

Figure 5–10 Master and Slave Multi–Probe Controller Modules ......................... 50

Figure 5–11 Card Slot, Connector & Jumper Block Locations ............................. 52

Figure 5–12 Jumper Block Details ...................................................................... 53

• Ultrasonics Division Dukane Corporation •


155


Figure 6–1 DPC II Plus Startup Menu ............................................................... 57

Figure 6–2 DPC II Plus Configuration Menu ..................................................... 57

Figure 6–3 DPC II Plus Weld Cycle Display ........................................................ 57

Figure 6–4 DPC II Plus Process Setup Menu ...................................................... 57

Figure 6–5 Process Setup Main Menu Structure ............................................... 58

Figure 6–6 Process Control Menu Flowchart .................................................... 59

Figure 6–7 Limit Definition Menu Flowchart .................................................... 60

Figure 6–8 Utilities Menu Flowchart ................................................................. 61

Figure 7–1 DPC II Plus Startup Menu ............................................................... 65

Figure 7–2 DPC II Plus Configuration Menu ..................................................... 65

Figure 7–3 DPC II Plus Time Weld Cycle Display ............................................... 65

Figure 7–4 DPC II Plus Energy Weld Cycle Display ............................................ 65

Figure 7–5 Process Setup Menu ....................................................................... 66

Figure 7–6 Process Control Trigger Method Menu ........................................... 66

Figure 7–7 Hand Probe Flow Chart .................................................................. 66

Figure 7–8 Hand Probe Weld Method Menu .................................................... 67

Figure 7–9 Hand Probe Weld Time Menu ........................................................ 67

Figure 7–10 Hand Probe Weld Energy Menu ...................................................... 67

Figure 7–11 Hand Probe Maximum Weld Time Menu ........................................ 67

Figure 7–12 Multi–Probe Controller Flowchart ................................................... 68

Figure 7–13 Auto Stop Weld Menu ................................................................... 68

Figure 7–14 Probe Time Delay Menu ................................................................. 69

Figure 7–15 Weld Method Selection Menu ........................................................ 69

Figure 7–16 MPC Probe Weld Time Menu ......................................................... 69

Figure 7–17 MPC Probe Weld Energy Menu ...................................................... 70

Figure 7–18 MPC Probe Maximum Weld Time ................................................... 70

Figure 7–19 Ground Detect Fixture Isolation ...................................................... 70

Figure 7–20 Ground Detect Scrub Time Data Entry ............................................ 71

Figure 7–21 Auto Probe Setup Flowchart ........................................................... 72

Figure 7–22 Process Control Weld Method Selection ......................................... 73

Figure 7–23 Process Control Hold Time Selection ............................................... 73

Figure 7–24 Auto Probe Hold Time Data Entry Screen ........................................ 73

Figure 7–25 Auto Probe Afterburst Selection Menu ........................................... 73

Figure 7–26 Auto Probe Afterburst Enable Menu ............................................... 73

Figure 7–27 Auto Probe Afterburst Delay Data Entry ......................................... 74

Figure 7–28 Auto Probe Afterburst Duration Data Entry .................................... 74


Figure 7–30 Press/Auto Probe Setup Flowchart .................................................. 75

Figure 7–31 Startup Welding Cycle Data Screen ................................................ 77

Figure 7–32 Mode and Enter Menu Keys ........................................................... 77


Figure 7–34 Press Trigger Method Menu ............................................................ 77

Figure 7–35 Press Initiate Mode Menu ............................................................... 78

Figure 7–36 Press Trigger Type Menu ................................................................. 78

Figure 7–37 First Pass Through Process Control Menu ....................................... 78

Figure 7–38 Single or Dual Pressure Selection Menu .......................................... 78

Figure 7–39 Pressure One Weld Method Selection Menu ................................... 78

Figure 7–40 Pressure One Weld Time Data Entry ............................................... 78

Figure 7–41 Pressure Two Weld Method Selection Menu ................................... 79

156


Appendix A – List of Figures

Figure 7–42 Pressure Two Weld Energy Data Entry ............................................. 80

Figure 7–43 Pressure Two Max Weld Time Data Entry ........................................ 79

Figure 7–44 Dual Pressure Time Only Menus ..................................................... 79

Figure 7–45 Second Pass Through Process Control Menu .................................. 79

Figure 7–46 Press Hold Time Data Entry ............................................................. 80

Figure 7–47 Third Pass Through Process Control Menu ...................................... 80

Figure 7–48 Press Afterburst Enable Menu ........................................................ 80

Figure 7–49 Press Afterburst Delay Data Entry ................................................... 80

Figure 7–50 Press Afterburst Duration Data Entry .............................................. 80

Figure 7–51 Return to Process Control Menu ..................................................... 80


Figure 7–53 Dual Pressure Welding Cycle Data .................................................. 81

Figure 7–54 Hot Keys ........................................................................................ 81

Figure 7–55 Min and Max Values for Hold Time ................................................ 81

Figure 7–56 Modified Hold Time ....................................................................... 81

Figure 7–57 Amplitude Adjust ........................................................................... 82

Figure 7–58 Process Control Menu Flowchart .................................................... 83

Figure 8–1 Process Setup Main Menu .............................................................. 90

Figure 8–2 Limit Definition Menu .................................................................... 90

Figure 8–3 Single Pressure Process Limits Menu ............................................... 90

Figure 8–4 Limit Definition Flowchart .............................................................. 91

Figure 8–5 Dual Pressure Process Limits Menu ................................................. 91

Figure 8–6 Single Pressure Max Energy Data Entry ........................................... 92

Figure 8–7 Minimum Value Error Message ....................................................... 92

Figure 8–8 Dual Pressure Limits Selection Menu ............................................... 92

Figure 8–9 P1 Maximum Energy Data Entry ..................................................... 92

Figure 8–10 CANCEL Key Return Path Flow Chart ............................................. 92

Figure 9–1 Utilities Menu Flowchart ................................................................. 97

Figure 9–2 Process Setup Main Menu .............................................................. 98

Figure 9–3 Setup Utilities Menu ....................................................................... 98

Figure 9–4 Setup Utilities Selection Menu ........................................................ 98

Figure 9–5 Setup Types Selection Menu ........................................................... 98

Figure 9–6 Enter New Setup Menu .................................................................. 98

Figure 9–7 New Setup Configuration Message ................................................ 98

Figure 9–8 Source File Location Entry ............................................................... 99

Figure 9–9 Destination File Location Entry ........................................................ 99

Figure 9–10 Confirm Copy Files ......................................................................... 99

Figure 9–11 Erase Setups Selection Menu .......................................................... 99

Figure 9–12 Confirm Erase Selected Setup ......................................................... 99

Figure 9–13 Erase Setup in Progress ................................................................... 99

Figure 9–14 Confirm Erase All Setups .............................................................. 100

Figure 9–15 Erasing All Setups In Process ......................................................... 100

Figure 9–16 Part Count Selection Menu .......................................................... 100

Figure 9–17 Confirm Reset Part Count ............................................................ 100

Figure 9–18 Confirm Counter Enabled ............................................................ 100

Figure 9–19 Counter Preset Value .................................................................... 101

Figure 9–20 Status Output Mode Selection ...................................................... 101

Figure 9–21 Cycle Press Selection Menu .......................................................... 101


157


Figure 10–1 Hand Probe, Horn and Replaceable Tip ........................................ 105

Figure 10–2 Probe with Booster and Horn ....................................................... 106

Figure 10–3 Replaceable Tip Installation .......................................................... 107

Figure 10–4 Stack Assembly Procedure ............................................................ 109

Figure 10–5 Torque Value Conversion Graph ................................................... 110

Figure 10–6 Hand Probe Assembly and Disassembly ........................................ 111

Figure 10–7 Probe Stack With Booster Assembly and Disassembly ................... 112

Figure 10–8 Separating The Horn From The Booster ........................................ 113

Figure 10–9 Removing Replaceable Tip From Horn .......................................... 114

Figure 11–1 Front Panel Startup Controls and Indicators .................................. 119

Figure 11–2 System Test Controls and Indicators .............................................. 120

Figure 11–3 Stopping The Weld Cycle ............................................................. 121

Figure 12–1 Rear Ultrasound and System In Connectors .................................. 125

Figure 12–2 Generator ON LINE Key and Indicator ........................................... 126

Figure 12–3 Troubleshooting Flowchart – Part 1 .............................................. 127

Figure 12–4 Troubleshooting Flowchart – Part 2 .............................................. 128

Figure 13–1 Location of DPC Air Cooling Vents ............................................... 135

Figure 13–2 Location of Stack Mating Surfaces ................................................ 136

Figure 13–3 Flat Surface With Even Contact .................................................... 136

Figure 13–4 Surface With Uneven Contact ...................................................... 136

Figure 13–5 Crowned Surface ......................................................................... 135

Figure 13–6 Center Depression ........................................................................ 135

Figure 13–7 Manual Resurfacing ...................................................................... 139

Figure 15–1 Generator 3–View and Dimensions .............................................. 148

Figure 15–2 Interpreting the DPC II Plus Model Number .................................. 150

Figure C–1 Manual Control Switch ................................................................. 163

Figure C–2 Automation Control Switches ...................................................... 164

Figure C–3 Non–Isolated Current Sink Switch ................................................ 165

Figure C–4 Non–Isolated Current Source Switch ............................................ 166

Figure C–5 Isolated Current Source Circuit ..................................................... 167

158


Appendix B – List of Tables

A

PPENDIX

B

List of Tables

Table 3—I Contents of DPC II Plus Shipping Container ...................................... 17

Table 3—II DPC II Plus AC Power Cord Part Numbers ......................................... 21

Table 5—I System Input Connector Signals ....................................................... 40

Table 5—II Remote Setup File Selection ............................................................. 40

Table 5—III System Input Cable Color Code ........................................................ 41

Table 5—IV System Output Connector Signals .................................................... 42

Table 5—V J902 Press Base Connector Pinout .................................................... 48

Table 5— VI J901 Thruster Connector Pinout ....................................................... 49

Table 7—I Process Control Menu Listing ........................................................... 84

Table 7—II Parameter Min–Max Values .............................................................. 85

Table 8—I Recognized Limits in a Dual–Pressure Mixed–Mode Welding Cycle .............. 89

Table 8—II Recognized Limits in a Dual–Pressure Uniform–Mode Welding Cycle .......... 89

Table 8—III Recognized Limits in a Single–Pressure Welding Cycle .............................. 89

Table 10—I Stud Torque Unit Conversions ........................................................ 108

Table 10—II Horn/Booster Torque Unit Conversions ........................................... 110

Table 15—I DPC II Plus Generator Models and Power Supply requirements ............. 149

Table 15—II DPC EZ Generator Models and Power Supply requirements ................. 149




159



160


Appendix B – List of Tables

A

PPENDIX

C

User Supplied Circuitry

• Manual Control Switch

• Automation Control Switch

• Isolated Automation Control

Manual Switch Circuit ................................. 163

Automation Switch Circuits ......................... 164

Non–Isolated Switch Circuits ....................... 165

Current Sink ....................................................... 165

Current Source ................................................... 166

Isolated Switch Circuit................................. 167




161



162


Manual Switch Circuit

Figure C–1 is an example of a typical, user supplied manual control circuit connected to the DPC

Control Input conector. The switch contacts are connected to the Switch Closure Input at Pin #8 or

Pin #15 and DPC Ground at Pin #7 or Pin #2.

System Input Cable

User

Supplied

Switch

Manual

Control

Switch

DPC Switch Input

Pin #8 – Operate or

Pin #15 – F P Lockout

DPC II Plus

HD–15 System

Input Connector

DPC Ground

Pin #2 or #7

Figure C–1 Manual Control Switch

Appendix C – User Supplied Circuitry

NOTE

The drawings and circuits shown in this section are intended solely for purposes of example. Since there are many variables and requirements associated with any particular installation, Dukane does not assume responsibility or liability for actual use based upon the examples shown in this section.


163


Automation Switch Circuits

Figure C–2 shows examples of various types of user supplied automation control circuits connected to the DPC Input. These examples can be used in place of the low–side or high–side switches in Figure C–3 and Figure C–4.

User Supplied

Open-Collector

Darlington Driver

HD–15

System Input

Connector



DPC Isolated Input 2 (Figure C–3) or

DPC Power Source (Figure C-4)

To

Automation

Control

Signal

User Supplied

Transistor Driver

Circuit



HD–15

System Input

Connector



DPC Ground (Figure C–3) or

DPC Isolated Input 1 (Figure C–4)



To

Automation

Control

Signal





HD–15

System Input

Connector




DPC Power Source (Figure C-4) or

DPC Switch Input

To

Automation

Control

Signal

User Supplied

Relay

Normally

Open

Contact

User Supplied

Opto-Coupler





DPC Ground

HD–15

System Input

Connector





To

Automation

Control

Signal





Figure C–2

164

Automation Control Switches



Non–Isolated Switch Circuits

Current Sink Control Circuit

Figure C–3 illustrates an automation control circuit connected to the low side of one of the Isolated Automation Inputs. Even though the switch drives an Opto–Isolator, it is still connected to

DPC ground and not isolated. The SH707 jumper block is in the factory default postion (JU724).

Any of the examples in Figure C–2 can be used in place of the block labeled Low Side Switch

Sinks Current To Ground.

DPC Internal

Power Supply

+24V

+22V

Current

Limit Circuit

250mA max.

Internal

DPC II Plus

Circuitry



User

Supplied

Switch

Circuitry

Low-Side

Switch

Sinks Current to Ground

Isolated Input

Pin #3 – Operate

Pin #5 – Press Control

Pin #9 – Auto Stop

12.5 mA max

4 mA min Current

Limit Circuit

12.5 mA max.

Jumper Block SH707

Position JU724

(Refer to Figure 5–12)

Optical Isolation

Circuit



DPC Ground

Pin #2 or #7

Figure C–3 Current Sink Switch


165


Current Source Control Circuit

Figure C–4 illustrates an automation control circuit connected to the highside of one of the Isolated Automation Inputs. Even though the switch drives an Opto–Isolator, it is still connected to the DPC power source and not isolated. The

SH707 jumper block must be in the JU725 position (see Figure 5–12). Any of the examples in

Figure C–2 can be used in place of the block labeled High Side Switch Sources Current.

DPC Internal

Power Supply

+24V

+22V

Current

Limit Circuit

250mA max.

User

Supplied

Switch

Circuitry

High-Side

Switch

Sources

Current



Pin #1



Isolated Input

Pin #3 – Operate



DPC II Plus

+22V Power

12.5 mA max

4 mA min Current

Limit Circuit

12.5 mA max.

Internal

DPC II Plus

Circuitry


Position JU725


Optical Isolation

Circuit

No Connection

Pin #2 & Pin #7

DPC Ground

Figure C–4 Current Source Switch

166



Isolated Switch Circuit

Isolated Current Source Circuit

Figure C–5 illustrates a fully isolated circuit connected to the Isolated Automation Inputs. This requires an external power supply to drive the switch.

The SH707 jumper block needs to be placed in the JU726 position (refer to Figure 5–12).

+5 to +24V

Automation

Power Source

DPC Internal

Power Supply

+24V

+22V

Current

Limit Circuit

250mA max.

No Connection

Pin #1

Isolated Input

High–Side

Pin #3 – Operate



12.5 mA max

4 mA min Current

Limit Circuit

12.5 mA max.

Internal

DPC II Plus

Circuitry

Isolated

Current

Source

User

Supplied

Switch

Circuitry


Position JU726


Optical Isolation

Circuit

Isolated Input

Low–Side

Pin #4 – Iso Common

No Connection

Pin #2 & Pin #7

DPC Ground

Automation

Ground

Figure C–5 Isolated Current Source


167



168


Index

I

NDEX

A

AC Power Indicator ....................................................................................... 29

AC Power Switch/Breaker ........................................................... 19, 25, 30, 39

AC Requirements ........................................................................................ 149

Afterburst .................................................................................... 73–74, 80, 85

Air Circulation ....................................................................................... 17, 135

AMP. ADJUST Key .................................................................................... 34, 82

Amplitude Adjust .......................................................................................... 82

Amplitude Control Module, Remote ........................................................... 46

Amplitude Monitor Output ................................................................... 32, 44

Arrow Keys .............................................................................................. 33–34

Auto Probe Mode Flowchart ........................................................................ 72

Auto Probe, Afterburst ................................................................................. 73

“ “ , Auto Stop Menu ...................................................................... 72

“ “ , Data Entry .......................................................................... 73–74

“ “ , Hold Time ................................................................................. 73

“ “ , Maximum Weld Time ............................................................... 72

“ “ , Menu .................................................................................. 72–73

“ “ , Timed ........................................................................................ 73

“ “ , Untimed .................................................................................... 73

“ “ , Weld Method Menu ................................................................ 73

Auto Stop Enable .......................................................................................... 69

Auto Stop Menu................................................................................ 68, 72, 76

Automated Probe System ............................................................................. 20

Automated Thruster System ........................................................................ 23

Automation Circuits ............................................................................ 163, 164

Automation Control Inputs .................................................................... 40–41

Automation Equipment ............................................................................... 21

Auto–Trac Tuning ............................................................................................ 7

B

Bad Part Counter......................................................................................... 100

Bad Part Limit ................................................................................................ 90

Bad Part Status Output ................................................................................. 45

Base (Press) Input Cable .................................................................... 23–24, 48

Benchtop Placement ..................................................................................... 17

Booster ......................................................................................................... 106

Booster Gain ................................................................................................ 114

Booster Notes .............................................................................................. 114

Booster Output End Geometry .................................................................. 114

C

Cable Color Code .......................................................................................... 41

Cable Connections .......................................................... 20–24, 40, 42, 47–49

Cable Part Numbers ................................................................................ 21–24


169


Cable Schematics, System ....................................................................... 21–24

Cable Troubleshooting ............................................................................... 125

CANCEL Key ............................................................................................. 34, 74

CE Compliance (Conformité Européene) .......................................... 6, 8, 147

Center Depression ....................................................................................... 137

Chassis Maintenance ................................................................................... 135

Circuits, User Supplied ........................................................................ 161–166

Configuration Menu ............................................................................... 57, 65

Confirmation Screen ..................................................................................... 35

Connectors, Identified .................................................................... 19, 39, 125

Connector Pinouts............................................................... 40, 42, 48–49, 126

Controls, Front Panel .................................................................................... 29

Connectors, Rear Panel ................................................ 19,39, 40, 42, 125, 135

Control Inputs ............................................................................................... 41

Control Keys .................................................................. 30, 119–121, 128, 135

Cooling Air Vents .................................................................................. 17, 148

Copy Setup .................................................................................................... 99

Corrosion, Horn ........................................................................................... 137

Counter Preset ............................................................................................. 101

Counter Reset .............................................................................................. 100

Crowning, Horn ........................................................................................... 137

Current Loop Connector, 4–20 mA .............................................................. 46

Current Loop Fault ........................................................................................ 44

Current Loop Transfer Function ................................................................... 46

Current Sink Circuit ..................................................................................... 165

Current Source Circuit ................................................................................ 166

Cycle Press Off Line Menu .......................................................................... 101

D

Data Entry Menu ........................................................................................... 35

DB-25 Connector (System Output) ............................................................... 42

Dimensions .................................................................................................. 148

Decrement Key .............................................................................................. 34

Display, Care of ........................................................................................... 135

Display, Menu .......................................................................................... 29, 35

Display, Status ................................................................................. 31, 19–121

Dwell Time (In–Dwell) Status Output .......................................................... 45

Dual Pressure Mode ...................................................................................... 76

Dukane Press System .................................................................................... 24

Dukane Website .......................................................................................... 143

E

170

Email Addresses, Dukane ........................................................................... 144

Emergency Stop Switch .................................................................. 20, 25, 119

Energy, Welding By ....................................................................................... 70

Energy, Definition ......................................................................................... 70

Energy Limits ................................................................................................. 89

Energy, Min–Max Values .............................................................................. 85

Energy Module .......................................... see Power Signal Output Module


Index

ENTER Key ............................................................................................... 34, 77

Enter New Setup ........................................................................................... 98

Erase Setups ................................................................................................... 99

Error Messages ...................................................................................... 92, 131

Example Setup ......................................................................................... 77–81

EZ Generator ................................................. 8, 19–24, 29, 33, 39, 48–49, 149

F

FAULT Status Display ............................................................................. 31, 127

FCC Compliance ....................................................................................... 6, 147

Features of DPC II Plus .................................................................................... 7

Flowcharts .............................. 59, 60, 66, 68, 72, 75, 83, 91, 93, 97, 129, 130

40kHz Considerations ................................................................................. 106

Frequency Monitor Output .......................................................................... 44

Front Panel Controls ........................................................... 29–30, 32–34, 119

Front Panel Control Lock ...................................................................... 41, 120

Front Panel Displays ................................................................................ 31–32

Front panel Maintenance ........................................................................... 135

G

GEN. INFO. Key .............................................................................................. 33

Good Part Status Output .............................................................................. 45

Grounding ................................................................................. 19, 22, 24, 135

Ground–Detect Fixture ................................................................................. 70

Ground–Detect Weld Method...................................................................... 70

H

Hand Probe ............................................................................................ 65, 105

Hand Probe Mode Flow Chart ..................................................................... 66

Hand Probe, Data Entry ................................................................................ 67

“ “ , Timed ....................................................................................... 66

“ “ , Trigger Method ....................................................................... 66

“ “ , Untimed ................................................................................... 66

“ “ , Weld Energy ............................................................................ 67

“ “ , Weld Method .......................................................................... 67

“ “ , Weld Time ............................................................................... 67

“ “ , Weld Time, Maximum ............................................................ 67

HD–15 Connector (System Input) ................................................................. 40

Head Up On Auto Stop ................................................................................. 76

Health and Safety Tips .................................................................................. 11

HOLD Key ................................................................................................ 33, 81

Hold Time .......................................................................................... 73, 80, 85

Horn ............................................................................................................. 106

Horn Assembly ............................................................................................ 112

Horn Contact Surfaces ................................................................................ 136

Horn Corrosion ............................................................................................ 137

Horn Disassembly ........................................................................................ 111

Horn Resurfacing ........................................................................................ 138

Hot Keys ................................................................................................... 34, 81


171


I

Increment Key ............................................................................................... 33

In-Dwell Status Output ................................................................................. 45

Indicator, AC Power ................................................................................ 19, 30

Initiate Mode ........................................................................................... 76, 78

Input Connector, System In ...................................................... 19, 39, 40, 125

Input, Isolated ......................................................................................... 41, 69

INPUT TEST Display ....................................................................... 31, 119, 128

INPUT TEST Status Display ............................................................................ 31

Internet Site ................................................................................................. 143

Isolated Inputs ................................................................... 41, 69, Appendix C

Isolated Outputs.............................................................................. 42, 45, 101

ISO 9001 Certification ......................................................8, Inside Rear Cover

J

Joules, Definition .......................................................................................... 70

Jumper Blocks, Internal .................................................................... 51–53, 69

Jumper Block, Press Control Module ................................................... 20, 119

J901 Thruster Connector .............................................................................. 48

J902 Press Base Connector ...................................................................... 48–49

K

Key Features of DPC II Plus ............................................................................. 7

Keys, Control ................................................................. 30, 119–121, 128, 135

Keys, Hot .................................................................................................. 34, 81

Keys, Menu .................................................................................. 29, 33–34, 77

L

LCD Display ...................................................................................... 29, 35, 135

Left Arrow Key .............................................................................................. 33

Line Voltage Regulation ................................................................................. 7

Limit Definition Flowchart ............................................................... 60, 91, 93

Limits, Bad ..................................................................................................... 90

“ , Data Entry ......................................................................................... 92

“ , Dual Pressure Mode .......................................................................... 92

“ , Menu .................................................................................................. 90

“ , Min–Max Values ................................................................................ 89

“ , Selection Criteria ............................................................................... 90

“ , Single Pressure Mode ....................................................................... 91

“ , Suspect ............................................................................................... 90

Load Regulation .............................................................................................. 8

M

Maintenance, Scheduled .................................................................... 111, 137

Master MPC Module ..................................................................................... 50

Mating Surfaces (Horn) .............................................................................. 136

Maximum Parameter Values ........................................................................ 85

Maximum Weld Energy .......................................................................... 72, 75

172


Index

Maximum Weld Time .................................................................. 67, 70, 71, 79

Menu, Confirmation ..................................................................................... 35

Menu, Data Entry .......................................................................................... 35

Menu, Selection ............................................................................................ 35

Menu Flowchart .................................................................... 59, 66, 68, 72, 75

Menu Keys ................................................................................... 29, 33–34, 77

Model Number Coding ............................................................................... 150

Mounted Probes.......................................................................................... 111

MODE Key ......................................................................................... 34, 74, 77

Mode Menu ............................................................................................. 75, 79

Model Number Tag Location ....................................................................... 19

MPC Module .................................................................................................. 50

MPC Probe, Auto Stop Menu ....................................................................... 68

“ “ , Data Entry ........................................................................... 69–71

“ “ , Maximum Weld Time ................................................................ 70

“ “ , Weld Energy Menu ................................................................... 70

“ “ , Weld Method Menu ................................................................. 69

“ “ , Weld Time Menu ....................................................................... 69

Multi–Probe Control Module ....................................................................... 50

Multi–Probe Mode Flow Chart ..................................................................... 68

Multiple Probe System Cabling .................................................................... 22

N

Navigation Keys (Menu Keys) .................................................... 29, 33–34, 77

O

OFF LINE Status Display ........................................................................ 31, 120

OFF LINE Key ................................................................................................. 30

ON LINE Status Display ......................................................................... 31, 119

ON LINE Key .......................................................................................... 30, 119

Operational Checkout ........................................................................ 119–120

Operating Conditions ................................................................................. 148

Operational Control (Thruster) Cable.............................................. 23–24, 49

OSHA Compliance ......................................................................................... 12

Output Connector, System Status .................................................... 19, 39, 42

Output, Isolated ...................................................................................... 42, 45

OVERLOAD Status Display .............................................................. 31–32. 127

OVERLOAD Status Output ............................................................................ 43

OVERTEMP Status Display .................................................................... 31, 127

OVERTEMP Status Output ............................................................................ 43

P

Parameter Values, Min–Max ........................................................................ 85

Part Count, Count Sus/Bad Part ................................................................. 100

“ “ , Menu ........................................................................................ 100

“ “ , Preset ........................................................................................ 101

Part Count, Reset ........................................................................................ 100

Placement of DPC .......................................................................................... 17


173


Plug–and–Weld ............................................................................................... 7

Power, Definition .......................................................................................... 70

Power Indicator, AC ................................................................................ 29, 30

Power Output Display ............................................................................ 29, 32

Power Output Module ................................................................................. 47

Power Signal Output Monitor ..................................................................... 44

Power Switch, AC .................................................................................... 25, 30

Power Requirements, AC ............................................................................ 149

Press Base Cable Connector ...................................................... 23–24, 48, 119

Press Control Module ........................................................................... 48, 119

Press Emergency Stop Switch ............................................................. 101, 119

Press Mode Flowchart ................................................................................... 75

Press Mode, Afterburst ................................................................................. 80

“ “ , Auto Stop Menu ....................................................................... 76

“ “ , Data Entry ........................................................................... 78–80

“ “ , Head Up On auto Stop ............................................................. 76

“ “ , Hold Time .................................................................................. 80

“ “ , Initiate Mode ...................................................................... 76, 78

“ “ , Maximum Weld Time ................................................................ 79

“ “ , Trigger Method ......................................................................... 77

“ “ , Trigger Type ........................................................................ 76, 78

“ “ , Weld Method ...................................................................... 78, 79

“ “ , Weld Mode .................................................................... 76, 78, 79

Press Operate Palm Switches ...................................................................... 101

Press Setup, Example Program ............................................................... 77–81

Press System Cabling ..................................................................................... 24

Probe, Auto Menu ........................................................................................ 65

“ , Hand Menu ....................................................................................... 72

“ , ID Selection Bits ................................................................................ 40

“ , Maintenance ................................................................................... 136

“ , MPC Menu ......................................................................................... 68

“ , Operation ........................................................................................ 121

“ , Stacks ....................................................................................... 107–112

“ , Stack Mounting ............................................................................... 115

“ , Time Delay Menu .............................................................................. 69

“ , Troubleshooting .............................................................................. 125

Process Control Flowchart ............................................................................ 59

“ “ Menu .......................................................... 58–59, 65–66, 84

“ “ Trigger Method Menu ........................................................ 66

Process Limits Menu ................................................................................ 60, 90

Process Setup Flowchart ......................................................................... 58, 74

Process Setup Menu .......................................................................... 57, 66, 77

Programming Port, Serial ............................................................................. 19

Pulse Width Modulation ................................................................................ 7

R

Rack Mounting DPC ...................................................................................... 18

Ready Status Output ..................................................................................... 45

Rear Panel Connectors .................................................................... 19, 39, 125

174


Index

Rear Panel Layout ................................................................................... 19, 39

Remote Amplitude Control Module ............................................................ 46

Replaceable Tips .................................................................................. 107, 113

Resurfacing, Horn ............................................................................... 138–139

RFI Considerations ........................................................................................ 13

Right Arrow Key............................................................................................ 34

RS-232 Serial Port .......................................................................................... 19

S

Safety Tips ..................................................................................................... 11

Save Setups .................................................................................................... 98

Scheduled Maintenance ..................................................................... 111, 137

Scrub Time ............................................................................................... 71, 85

Select Setup ................................................................................................... 98

Selection Menu ............................................................................................. 35

Self Test ........................................................................................................ 119

Setup Files, Remote Selection ...................................................................... 40

Setup Utilities Menu ..................................................................................... 98

Setup, Copy ................................................................................................... 99

“ , Erase.................................................................................................... 99

“ , Select................................................................................................... 98

“ , Types (Remote) ................................................................................... 98

Serial Number Location ................................................................................ 19

Serial Programming Port .............................................................................. 19

Slave MPC Module ........................................................................................ 50

Single Pressure Mode ................................................................................... 76

Software Version ........................................................................................... 33

Specifications....................................................................................... 148–149

Stack Assembly ............................................................................................ 109

Stack Inspection .......................................................................................... 136

Stack Maintenance ..................................................................................... 136

Startup Screen ......................................................................................... 57, 65

Status Display .......................................................................................... 29, 31

Status Driver Selection Jumper .................................................................... 51

Status Output Signals ............................................................................. 42–45

Status Output Menu ................................................................................... 101

Status Output, Maintained/Pulsed ............................................................. 101

Status Panel ................................................................................................... 30

Stopping The Weld Cycle ............................................................................ 121

Storage Conditions ..................................................................................... 148

Studs, Horn & Booster ................................................................................ 108

Suspect Part Count ...................................................................................... 100

Suspect Part Limit ......................................................................................... 90

Switch Circuits, User Supplied ............................................................ 161–166

System Cabling ................................................................................ 21–24, 119

“ Control Input Jumper ...................................................................... 52

“ Input Connector ...........................................................19, 39, 40, 125

“ Input Signal Descriptions ................................................................ 41

“ Fault Status Output ......................................................................... 43


175


System Output Connector ................................................................ 19, 39, 42

“ Power Output Display ..................................................................... 32

“ Test .................................................................................................. 120

T

Theory of Operation ................................................................................... 105

Telephone Numbers, Dukane ..................................................................... 144

Test, Self ....................................................................................................... 119

Test, System ................................................................................................. 120

TEST Key ........................................................................................ 30, 120, 128

TEST, F P Lock ........................................................................................ 41, 120

Thruster Cable Connector .......................................................... 23–24, 48–49

Time Delay Menu, Probe .............................................................................. 69

Time, Maximum Weld ................................................................. 67, 70, 71, 79

Time, Welding By .................................................................................... 67, 69

Timed Probe ............................................................................................ 66, 73

Tips, Replaceable ................................................................................. 107, 113

Titanium ....................................................................................................... 106

Top of Stroke ................................................................................................. 23

Torque Specifications .................................................................. 107–108, 110

Torque Units Conversion ............................................................................ 110

Trigger Method Menu ...................................................................... 66, 75, 77

Trigger Type Menu .................................................................................. 76, 78

Troubleshooting .................................................................................. 125–131

U

Ultrasonic Output Connector ......................................................... 19, 39, 125

Ultrasonic Welding, Theory of ................................................................... 105

Universal Power Supply .................................................................................. 8

Untimed Probe ........................................................................................ 66, 73

Utilities Menu .......................................................................................... 61, 98

Utilities Flowchart ................................................................................... 61, 97

V

Values, Parameter Min–Max ........................................................................ 85

Vents, Cooling Air ...................................................................17, 31, 135, 148

Vise, Booster Clamping ............................................................................... 113

Version of DPC Firmware .............................................................................. 57

W

Warranty, Domestic .................................................................................... 153

Warranty, International .............................................................................. 154

Warranty, Tooling ....................................................................................... 154

Website, Dukane ......................................................................................... 143

Weld By Energy ............................................................................................. 70

Weld By Time ........................................................................................... 67, 69

176


Weld Cycle Data ................................................................................ 57, 65, 81

Weld Energy ...................................................................................... 67, 70, 79

Weld Method .................................................................................... 67, 69, 78

Weld Mode .............................................................................................. 75, 79

WELD P1 Key ........................................................................................... 33, 82

WELD P2 Key ........................................................................................... 34, 82

Weld Time .......................................................................................... 67, 69, 78

Weld Time Min–Max Values ......................................................................... 85

Weld Time Limits ........................................................................................... 89

Wrench, Horn & Booster ............................................................................ 107

Index


177



178


Dukane ISO

ISO CERTIFICATION

Dukane chose to become ISO 9001:2000 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 9001:2000 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 9001:2000 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 9001:2000

C E R T I F I E D

Dukane products are manufactured in ISO registered facilities

DUKANE CORPORATION

WHO ARE WE?

We are plastic welding technoligists. We are scientists.

We are employees and businessmen. We are instructors.

We are engineers. We are specialists in electronics and experts in plastic assembly. We are salesmen. We do basic research and we manufacture machines.

We are problem solvers and we are technical advisors

We Are Your Partners.

5

햲

REGIONAL OFFICES

Northeast Region

Rocco Telese

14 Delmar Drive – Suite 6B

Brookfield, CT 06084

(203) 740–0089

햳

Central Region

Jason Barton

4424 Aicholtz Road – Suite G

Cincinnati, OH 45245

(513) 752–8803

햴

Automotive Region

Raymond LaFlamme

11235 Stark Road

Livonia, MI 48150

(734) 513–4038

햵

Midwest Region

Vasko Naumovski

2900 Dukane Drive

St. Charles, IL 60174

(630) 797–4921

햶

Western Region & Alaska

James Jackstein

162 East Manilla Drive

Draper, UT 84020

(801) 523–6191

햷

Mexico, Canada & Caribbean

Nelson Romero

2900 Dukane Drive

St. Charles, IL 60174

(630) 797–4915

5

§

Tooling Lab

Western Serv.Cntr.

Mexico

Sales &

Serv.Cntr.

6

§

Mexico Serv. Cntr.

Alejandro (Alex) Juarez

Santa Gertrudis No. 1223

Col. La Purisima

Guadalupe NL CP 67129 Mexico

011–52–81–8298–3276

6

Engineering Lab

4

§

Main Serv.Cntr.

3

2

Automotive

Appl. Lab

1

Film & Fabric

Appl. Lab

Tooling Lab

§

Corporate Office and Training Center

Regional Office

Application Laboratory

Service Center

6

User's Manual – DPC II Plus and EZ Welder System

Part No. 403–566–01

40356601

$100.00

www.dukcorp.com/us

Printed in the United States of America

Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL +1–630–797-4900 • FAX +1–630–797–4949

Dukane DPC II Plus User`s manual 190 Pages

Dukane DPC II Plus User`s manual

User’s Manual

ISO 9001:2000

www.dukcorp.com/us

DPC II Plus & EZ Welder Manual Revision History

Revision Revision

Number History

Date

Introduction

Important User Information

Read This Manual First

Notes and Tips

Cautions and Warnings

Drawings and Tables

Manual Organization

DPC II Plus Overview

EZ Welder

™

Overview

DPC II Plus

™

Key Features

EZ Welder

™

Key Features

Safety Tips

Health and Safety Tips

Plastics Health Notice

Electrical Safety Grounding

Instructions

RFI Considerations

Unpacking & Installation

Shipping Contents

DPC Placement

Benchtop

Rack Mounting

Rear Panel Overview

Ground the System

Connect the Cables

Manual Probe System

Automated Probe System

Multiple Probe System

Automated Thruster System

Dukane Press System

Emergency Stop Switch

Emergency

Stop Switch

Electrical Power Switch

Controls & Displays

Front Panel Layout

1. AC Power Section

2. Generator Status Panel

Generator Control Keys

System Status Display

System Power Output Display

3. Process Control Panel

Menu Function Keys

DPC II Plus v1.50

PRESS + ENERGY

MORE INFO: www.dukcorp.com/us/

EZ Series v1.50

PRESS SYSTEM

MORE INFO:

www.dukcorp.com/us/

Process Control Menu Display

Selection Menus

Data Entry Menu

WELD TIME

0.750 SEC

PROCESS CONTROL

WELD MODE

HOLD TIME

AFTERBURST

Confirmation Menus

RESET PART COUNT

NO

YES

Rear Connectors

Rear Panel Layout