Appl Note 201: DPC 2 & 2 Plus - Emergency Stop and Cycle Activation (J902)

Appl Note 201: DPC 2 & 2 Plus - Emergency Stop and Cycle Activation (J902)
DUKANE
-1-
Application Note
Intelligent Assembly Solutions
AN201
Emergency Stop and Cycle Activation Interface
For J902 of a DPC II and DPC II+ Welding Systems
DPC II and DPC II+ welding systems that are equipped with the optional pneumatic press feature, are also equipped with
the J902 Base Plate / Abort interface. This connector provides an interface that allows automation to control cycle
activation and cycle termination during an emergency stop condition. This document will provide guidelines that will help
you interface automation to a DPC welding system per Dukane Corporation’s requirements. Information within this
document is intended to supplement the information in the DPC II manual (Dukane part # 403-558) and DPC II+ manual
(Dukane part # 403-551).
Warning: Compliance with all related safety requirements of the safety regulatory agencies governing the geographic
location where the Dukane equipment will be operated is required before the Dukane equipment is operated.
Application Note Topics:
•
•
•
•
•
The J902 Pin assignments
The 200-1124 Interface Cable
The 200-1293 Emergency Stop Bypass Plug
System Input Signal Descriptions
System Input Interface Examples
Dukane Corporation
2900 Dukane Drive Saint Charles, IL 60174 USA
Phone (630) 797-4900 FAX (630) 797-4949
http://www.dukane.com/us
© Dukane Corporation 2004. All rights reserved.
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Application Note
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AN201
Intelligent Assembly Solutions
J902 Base Interface Connector
The J902 Base Interface connector is an optional feature on all DPC II and DPC II+ welding systems that are
equipped to control a Dukane pneumatic press. It provides automation with an interface to initiate and terminate the
DPC welding system cycle. All DPC II and DPC II+ welding systems equipped with J902 must utilize the Emergency
Stop feature of the J902 connector for proper operation of the DPC welding system.
Note: Pin numbers indicating an “ * “ are only available on DPC II+ welding systems.
Pin Number
1 *
2 *
3
4*
5
6
7
8
9
DPC Signal Name
DPC Signal Type
Manual Activation Switch 1
Manual Activation Switch 2
Emergency Stop
Emergency Stop Sense
Ground
No Connections
Ground
Automation Start
+22 VDC
Input
Input
Input
Input
DPC Supply Ground
N/C
Ground Pin for Input Signals
Input
Power Supply
Pin 5
Pin 1
Pin 9
Pin 6
J902
Dukane Corporation
2900 Dukane Drive Saint Charles, IL 60174 USA
Phone (630) 797-4900 FAX (630) 797-4949
http://www.dukane.com/us
© Dukane Corporation 2004. All rights reserved.
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Pin #
1
2
3
4
5
6
7
8
9
Conductor Color
WHT
GRN
BLU
ORN
RED / BLK
GRN / BLK
BLK
WHT / BLK
RED
Part Number
200-1124
200-1124-15
200-1124-20
200-1124-25
200-1124-30
Length
10 FT
15 FT
20 FT
25 FT
30 FT
The 200-1293 emergency stop bypass plug is designed to
bypass the emergency stop feature of the J902 connector.
Use of the 200-1293 shorting plug is restricted to DPC II and
DPC II+ welding systems that do not require the use of the
DPC Emergency Stop feature to comply with all applicable
safety requirements as directed by compliance agencies which
include but are not limited to CE, OSHA, CSA, and UL.
200-1293
Warning: The 200-1293 Emergency Stop bypass plug should
not be used on systems that either do not comply with
applicable safety regulations when the plug is in use or on
systems that can expose the operator to a safety hazard
related to the operation of Dukane equipment.
Dukane Corporation
2900 Dukane Drive Saint Charles, IL 60174 USA
Phone (630) 797-4900 FAX (630) 797-4949
http://www.dukane.com/us
© Dukane Corporation 2004. All rights reserved.
3383
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DUKANE
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Application Note
Intelligent Assembly Solutions
AN201
J902 System Input Signal Descriptions:
+22 VDC -
(J902 pin 3) This system power supply provides the voltage required for the Dukane pneumatic
press and other safety related features of the DPC welding system. It is connected to a set of
normally closed contacts within the emergency stop switch.
Emergency Stop –
(J902 pin 9) This system input receives the DPC +22VDC power supply signal that is returning
from a set of normally closed contacts of the emergency stop switch. This signal functions as a
power supply for the Dukane pneumatic press as well as other features related to safety of the
DPC welding system. Activation of the emergency stop switch will open the switch contacts and
remove the +22VDC power supply from this pin. This switch should be activated simultaneously
with the E-Stop Sense system input (E-Stop Sense system input is only required for DPC II+
welding systems).
E-Stop Sense -
(J902 pin 4) This system input is activated by a set of normally open contacts within the
emergency stop switch that closes during an emergency stop switch activation. This input
functions as an emergency stop status signal for the DPC II+ welding system. This switch should
be activated simultaneously with the Emergency Stop system input. (This feature is only available
on DPC II+ welding systems).
Ground -
(J902 pin 5 and pin 7) This DPC power supply ground connects to a normally open set of contacts
within the emergency stop switch. It is used for the activation of the E-Stop Sense, Safety Switch,
and Automation system inputs. (E-Stop Sense and Safety Switch system inputs are only available
on DPC II+ welding systems).
Safety Switch #1 -
(J902 pin 1) This system input is one of two system inputs that interface with palm activation
switches. It is activated by a dry contact switch closure from the palm switch when utilizing the
“Manual” initiate feature of the DPC II+ welding system. Activation of this input must occur within
100mS of the activation of Safety Switch #2 and must be maintained until the trigger switch of the
pneumatic press is activated. Please refer to the Initiate Mode section of the DPC II+ manual for
details on the activation and use of the “Manual” initiate mode. (This feature is only available on
DPC II+ welding systems).
Safety Switch #2 -
(J902 pin 2) This system input is one of two system inputs that interface with palm activation
switches. It is activated by a dry contact switch closure from the palm switch when utilizing the
manual activation feature of the DPC II+ welding system. Activation of this input must occur
within 100mS of the activation of Safety Switch #1 and must be maintained until the trigger switch
of the pneumatic press is activated. Please refer to the Initiate Mode section of the DPC II+
manual for details on the activation and use of the “Manual” initiate mode. (This feature is only
available on DPC II+ welding systems).
Automation Input -
(J902 pin 8) This system input signal activates a DPC welding cycle when an automated device is
being used to initiate the welding cycle. It is activated by an external dry contact closure to the
DPC ground on J902 pin 7.
DPC II+ welding systems – Requires the configuration of the initiate mode of the DPC II+ software
to the “Auto” mode. The minimum duration for the activation of this input is 100 mS. The
maximum duration of this input is determined by the duration of the weld cycle. This input should
be deactivated before the end of the weld cycle to avoid an error condition (Associated Error: #
E06 Auto Active at Cycle Start). Please refer to the Initiate Mode section of the DPC II+ manual
for details on the activation and use of the “Auto” initiate mode.
DPC II welding systems – Ultrasound will remain active for the duration of the contact closure.
Dukane Corporation
2900 Dukane Drive Saint Charles, IL 60174 USA
Phone (630) 797-4900 FAX (630) 797-4949
http://www.dukane.com/us
© Dukane Corporation 2004. All rights reserved.
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Application Note
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DPC II + System Activation Examples:
Warning:
The diagram below is a simplified example that demonstrates the basic requirements to interface with
a DPC II + welding system. Compliance with all related safety requirements of the safety regulatory
agencies governing the geographic location where the Dukane equipment will be operated is required
before the Dukane equipment is operated.
Note:
DPC II welding systems are not equipped with the Safety Switch feature on pins 1 and 2 of the J902
connector.
DPC II +
+5 VDC
Momentary Palm
Activation Switches
200-1124
Cable
1
Safety Switch 1
2 Safety Switch 2
7
J902
J902 Palm Activation Switch Interface Example
Dukane Corporation
2900 Dukane Drive Saint Charles, IL 60174 USA
Phone (630) 797-4900 FAX (630) 797-4949
http://www.dukane.com/us
© Dukane Corporation 2004. All rights reserved.
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Revision 01
DUKANE
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Application Note
AN201
Intelligent Assembly Solutions
DPC II and DPC II + System Activation Examples (Continued):
Warning:
The diagram below is a simplified example that demonstrates the basic requirements to interface with
a DPC II and DPC II + welding systems. Compliance with all related safety requirements of the safety
regulatory agencies governing the geographic location where the Dukane equipment will be operated is
required before the Dukane equipment is operated.
Note:
The System In connector of the DPC II and DPC II + welding system is also equipped with an automation
activation interface. Please refer to applicable DPC manual for further information on the use of the
System In connector.
+24 VDC
PLC
200-1124 Cable
8
Automation Input
7
J902
DPC II or
DPC II +
J902 Automation Activation Interface Example
Dukane Corporation
2900 Dukane Drive Saint Charles, IL 60174 USA
Phone (630) 797-4900 FAX (630) 797-4949
http://www.dukane.com/us
© Dukane Corporation 2004. All rights reserved.
6686
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Revision 01
DUKANE
-7-
Application Note
AN201
Intelligent Assembly Solutions
DPC II / DPC II + System Activation Examples (Continued):
Warning:
The diagram below is a simplified example that demonstrates the basic requirements to interface with
a DPC II and DPC II + welding systems. Compliance with all related safety requirements of the safety
regulatory agencies governing the geographic location where the Dukane equipment will be operated is
required before the Dukane equipment is operated.
Note:
The System In connector of the DPC II and DPC II + welding system is also equipped with an automation
activation interface. Please refer to applicable DPC manual for further information on the use of the
System In connector.
PLC
+24 VDC
+24 VDC
200-1124
Cable
8
Automation Input
7
Normally
Open
Relay
J902
DPC II or
DPC II +
J902 Automation Activation Interface Example
Dukane Corporation
2900 Dukane Drive Saint Charles, IL 60174 USA
Phone (630) 797-4900 FAX (630) 797-4949
http://www.dukane.com/us
© Dukane Corporation 2004. All rights reserved.
7787
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Revision 01
DUKANE
Application Note
-8-
AN201
Intelligent Assembly Solutions
. DPC II and DPC II + Emergency Stop Examples:
Warning:
The diagram below is a simplified example that demonstrates the basic requirements to interface with
a DPC II and DPC II + welding systems. Compliance with all related safety requirements of the safety
regulatory agencies governing the geographic location where the Dukane equipment will be operated is
required before the Dukane equipment is operated.
Note: DPC II welding systems are not equipped with the E-Stop Sense feature on pin 4 of the J902 connector.
Emergency Stop
Switch
+22 VDC
3
DPC II or
DPC II +
Emergency
Stop Features
9
E-Stop Switch
+24 VDC
To Dukane
pneumatic
press
7
4
200-1124
Cable
E-Stop Sense
J902
J902 Emergency Stop Interface Example
Dukane Corporation
2900 Dukane Drive Saint Charles, IL 60174 USA
Phone (630) 797-4900 FAX (630) 797-4949
http://www.dukane.com/us
© Dukane Corporation 2004. All rights reserved.
8888
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