User Guide

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

Dukane Part No. 403–566-01

www.dukcorp.com/us

User’s Manual

ISO 9001:2000

Dukane products are manufactured

in ISO registered facilities

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Summary of content (190 pages)

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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.
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Table of Contents DPC II Plus & EZ Welder Manual Revision History Revision Number Revision History Date –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.
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Table of Contents TABLE OF CONTENTS Section 1 – Introduction........................................................... 1 Before Operating ................................................................................... 3 Read The Manual First ................................................................................... 3 Caution and Warnings ................................................................................... 3 Drawings Labels ....................................................
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DPC II Plus and EZ Welder System – User’s Manual Section 5 – Rear Connectors .................................................. 37 Rear Panel Layout ................................................................................ 39 System Input Connector....................................................................... 40 System Output Connector ................................................................... 42 Remote Amplitude Control .............................................................
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Table of Contents Press Mode Example ............................................................................ 77 Hot Keys ................................................................................................ 81 Process Control Recap .......................................................................... 82 Section 8– Process Limits Menu ............................................. 87 Process Limits Menu .............................................................................
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DPC II Plus and EZ Welder System – User’s Manual Section 11 – DPC Checkout .................................................. 117 Startup and Self–Test ......................................................................... 119 System Test ......................................................................................... 120 Probe Operation................................................................................. 121 Stopping the Weld Cycle ..................................................
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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................
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Section 1 – Introduction SECTION 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 ......................................
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Section 1 – Introduction 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.
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DPC™ II Plus and EZ Welder System – User’s Manual Manual Organization Section 1 – Introduction describes the manual organization and the key features of the Dukane DPCTM (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.
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Section 1 – Introduction 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 1 – Introduction 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).
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DPC™ II Plus and EZ Welder System – User’s Manual • 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.
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Section 1 – Introduction SECTION 2 Safety Tips • Health & Safety • RFI Considerations Health & Safety Tips...................................... 11 Plastics Health Notice ........................................... 12 Electrical Grounding Safety .................................. 12 RFI Considerations ........................................ 13 Dukane Corporation • Dukane Manual Part No.
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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 system.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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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.
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Section 3 – Unpacking and Installation SECTION 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 .....................................
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Section 3 – Unpacking and Installation Shipping Contents Quantity Item Part Number 1 DPC II Plus or EZ Generator 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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 GEN. OINFO. + WELD P1 WELD P1 SYSTEM POWER OUTPUT 0 WELD P1 MODE 20 2200 ON LINE AMP.
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Section 3 – Unpacking and Installation Rear Panel Overview NOTE 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 3 – Unpacking and Installation Jumper Block Part No. 200–1293 Grounding Lug SERIAL NUMBER  – WARNING– LINE VOLTAGE 200–240Vac 50/60Hz 15A  Ꮨ 5 9 Pins 3 & 9 Connected DUKANE CORP ST. CHARLES, IL 60174 MADE IN USA Power Signal Output Zero Adjust – WARNING! – Power Monitor Jacks J901 TO THRUSTER POWER LINE MUST BE GROUNDED AT OUTLET 3 6 US 10000 Power Signal Output Module J902 BASE/ ABORT  1 U. S .
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 3 – Unpacking and Installation 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. connector (J902) on the Press Control Module.
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DPC™ II Plus and EZ Welder System – User’s Manual Dukane Press System Step 1. CAUTION Ground the DPC II Plus, the Thruster and the Base as shown in Figure 3–8. Attach the high voltage coax cable from the press J1 connector to the DPC Ultrasound Out connector (J1). Connect the Press Base Input cable from J35 on the Press Base to the DB9 connector (J902) on the Press Control Module.
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Section 3 – Unpacking and Installation Emergency Stop Switch on a common welding process. Multiple DPCs require individual contacts for each unit. 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.
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Section 4 – Controls & Displays SECTION 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 ...........................................
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Section 4 – Controls & Displays 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 4 – Controls & Displays 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 FAULT INPUT TEST OVERLOAD ON LINE OVERTEMP OFF LINE This indicator lights when out-of-tolerance voltage fluctuations occur that are related to one of the following conditions. 1.
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DPC™ II Plus and EZ Welder System – User’s Manual System Power Output Display The tricolor System Power Output Display indicates the percentage of ultrasonic power being drawn by the load. Green 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.
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Section 4 – Controls & Displays 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. Pressing the GEN. INFO key displays the DPC model, the firmware version GEN. INFO 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.
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DPC™ II Plus and EZ Welder System – User’s Manual MODE WELD P2 AMP. ADJUST ENTER CANCEL 34 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.
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Section 4 – Controls & Displays Process Control Menu Display Data Entry Menu 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). 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 ENTER key to accept the value.
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Section 4 – Controls & Displays SECTION 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 ........................
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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.
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DPC™ II Plus and EZ Welder System – User’s Manual System Input Connector The System Input is a HD-15 (high-density, 15 contact) female connector. Pin assignments are 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.
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Section 5 – Rear Connectors Input Signal Description Pin Color Signal Desc Note Pin 1 (+22V) 1 Red +22V Red used by Belden may appear brown This pin can supply +22VDC at up to 250mA to power the user's automation controls. 2 Black Gnd Also connected to connector metal shell Pin 2 (Gnd) 3 Blue/Blk Iso Oper In 4 Green/Wht Iso Common 5 Blue/Wht Iso Auto Cntrl 6 Red/Blk Reserved Pin 2 and 7 are the 22VDC and Operate returns and are tied to the chassis ground.
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DPC™ II Plus and EZ Welder System – User’s Manual System Output Connector The System Output panel connector is a DB25 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.
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Section 5 – Rear Connectors 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 3 is the 22VDC and Status Out return. It is tied to the chassis ground. 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).
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DPC™ II Plus and EZ Welder System – User’s Manual 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 11 is the 22VDC and Status Out return. It is tied to the chassis ground. Pin 12 (Current Loop Fault)1 An active low output on pin 12 indicates the 4–20mA current loop output has a fault.
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Section 5 – Rear Connectors Pin 18 (MPC Ready)4 Pin 24 (Iso Common)5 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 24 provides the return path for the isolated output signals on pins 19, 20, 21, 22 and 23. Pin 25 (Not Used) Pin 25 is reserved for future use. Pin 19 (Iso Power Fail) An active low output indicates that AC power is within operating range.
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DPC™ II Plus and EZ Welder System – User’s Manual Remote Amplitude Control Module Part No. 438–799 100% Out% = (20% + 4 ILoop )% e.g. Determine %Output delivered for an 8mA Loop Current 20 + 4 x 8 = 52% 80% 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%.
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Section 5 – Rear Connectors 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 5 – Rear Connectors 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.
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DPC™ II Plus and EZ Welder System – User’s Manual Multi–Probe Master Module Multi–Probe Slave Module Part No. 110–3954 Part No. 110–3956 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.
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Section 5 – Rear Connectors 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.
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DPC™ II Plus and EZ Welder System – User’s Manual System Control Inputs Jumper Block – SH707 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.
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Section 5 – Rear Connectors C714 + SH706 JU723 JU722 TIMER BD. ENABLE TIMER BD. BYPASS AUTOMATION SIGNALS SELECTION BLOCK SH704 STATUS RELAY SELECTION BLOCK SH703 + + R753 SWITCH DEBOUNCE FILTER TIME DELAY SELECTION BLOCK C711 SH705 JU717 NO DELAY C712 JU718 1 mSEC JU719 10 mSEC JU720 22 mSEC RP701 JU708 U/S ACTIVE JU713 NORMALLY OFF JU709 JU714 NORMALLY ON JU710 OVERLOAD OVERTEMP JU715 AUTO STOP FAULT JU711 SYS.
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Section 5 – Rear Connectors SECTION 6 Menu Structure • Process Setup • Process Control • Process Limits • Utilities Process Setup ............................................... 57 Process Control ............................................. 58 Process Limits ............................................... 60 Utilities ......................................................... 61 Dukane Corporation • Dukane Manual Part No.
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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. DUKANE DPC II+ v1.10 (c)2002 Dukane Corp.
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DPC™ II Plus and EZ Welder System – User’s Manual Part Count appears here OPERATE Mode ----- #1 P1 P2 TOTAL MODE SETUP Mode Setup File currently being used TIME ENERGY 0.000 0 0.000 0 0.
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Section 6 – Menu Structure TRIGGER METHOD PROCESS CONTROL TIMED PROBE UNTIMED PROBE PRESS PROCESS SETUP AUTO PROBE TIMED AUTO STOP UNTIMED INITIATE MODE ENABLE DISABLE AUTO HEAD UP ON AUTO STOP MPC PROBE TIMED UNTIMED HAND PROBE TIMED UNTIMED AUTO STOP ENABLE or DISABLE MANUAL TRIGGER TYPE ENABLE DISABLE MOMENTARY MAINTAINED UNTIMED MPC PROBE UNTIMED AUTO PROBE UNTIMED HAND PROBE PROCESS CONTROL WELD MODE HOLD AFTER– TIME BURST Step 1 Step 2 RTW RTW RTW = READY TO WELD Step 3 T
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 6 – Menu Structure 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.
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Section 6 – Menu Structure SECTION 7 Process Control Menu • 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 ................................................
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Section 7 – Process Control Menu 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 7 – Process Control Menu NOTE 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 7 – Process Control Menu 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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).
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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.
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DPC™ II Plus and EZ Welder System – User’s Manual AUTO Probe = Front Panel ENTER Key (Section 4.3 – Menu Keys) = Parameter Value Entry T = Time E = Energy Maximum Tdelay = 30.000 Seconds Minimum Tdelay = 0.000 Second ENTER UNTIMED AUTO PROBE TIMED AUTO PROBE RTW PROCESS CONTROL HOLD AFTER– WELD METHOD TIME BURST Step 1 Step 2 Step 3 Thold Maximum Thold = 30.000 Seconds Minimum Thold = 0.001 Second* ENTER WELD METHOD GND. TIME ENERGY DETECT ENTER ENTER ENTER Maximum Tscrub = 0.
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Section 7 – Process Control Menu 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 7 – Process Control Menu PRESS Mode PRESS TIMED AUTO PROBE UNTIMED AUTO PROBE ENTER ENTER AUTO STOP AUTO MANUAL ENABLE DISABLE ENTER ENABLE or DISABLE HEAD UP ON AUTO STOP TRIGGER TYPE MOMENTARY MAINTAINED ENTER ENTER ENTER ENABLE DISABLE RTW ENTER PROCESS CONTROL ENTER Step 2 ENTER WELD MODE Timed Auto Probe Bypasses Single/Dual Pressure Mode SINGLE PRESSURE PRESS ENTER SINGLE DUAL PRESSURE PRESSURE ENTER ENTER DUAL PRESSURE PRESS TIME1 ENERGY1 ENTER T1max Eweld Tmax E
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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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. Mode Key GEN. INFO The Dual Pressure mode is a feature exclusive to the DPC II Plus model and is not available on the EZ Series.
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DPC™ II Plus and EZ Welder System – User’s Manual 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 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.
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Section 7 – Process Control Menu 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 Figure 7–41 Dual Pressure Weld Mode Menus w/o Power Output Module WELD MODE SINGLE PRESSURE DUAL PRESSURE Pressure Two Weld Method Selection Menu This time select WELD BY ENERGY and press the ENTER key.
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DPC™ II Plus and EZ Welder System – User’s Manual 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. HOLD TIME 0.500 SEC Figure 7–46 Press Hold Time Data Entry We return for a third time to the Process Control menu.
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Section 7 – Process Control Menu 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). P2 Weld Target Value (DPC II Plus only) GEN. INFO PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Figure 7–52 + HOLD WELD P2 MODE AMP. ADJUST – WELD P1 ENTER CANCEL Process Setup Menu Press the MODE key to display the welding parameters menu.
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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.
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Section 7 – Process Control Menu TRIGGER METHOD PROCESS CONTROL 7–34 7–5 TIMED PROBE UNTIMED PROBE 7–29 PRESS 7–33 7–52 PROCESS SETUP AUTO PROBE TIMED MPC PROBE UNTIMED TIMED HAND PROBE UNTIMED TIMED 7–6 UNTIMED SYMBOL LEGEND 7–16 Menu and Logic Path appear in this Figure No. 7–16 Menu in different logic path but looks the same as this Figure No.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 7 – Process Control Menu Menu Name Description Trigger Method Tdelay Probe Delay Post–Trigger Delay Untimed MPC/Auto Probe Untimed Probe Only Tweld Weld Time Ultrasound Gate Time Press & Any* Timed Probe Time Eweld Weld Energy Tmax Max Weld Time Tmax Parameter Weld Method Figure No. Minimum Value Maximum Value 7–14 0.000 Second 30.000 Seconds 7–8, 7–16 0.000 Second 30.
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Section 7 – Process Control Menu SECTION 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 .............................................
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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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 8 – Process Limits Menu PROCESS LIMITS LIMIT DEFINITION ENTER Figure 8–1 PROCESS SETUP SUSPECT LIMITS BAD Figure 8–2 ENTER TIME ENERGY TOTAL TIME ENTER TOTAL ENERGY ENTER Emin ENTER ENTER E2max ENTER E2min Emax ENTER Total Limits Available Only in Dual Pressure Mode ENTER E1min Tmax TOTAL WELD ENERGY Tmin TOTAL WELD TIME E1max WELD WELD ENERGY P1 ENERGY P2 ENTER ENTER YES Dual Pressure 2P? Mode? NO PROCESS LIMITS WELD WELD TIME P1 TIME P2 T2max PROCESS LIMITS ENTER
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DPC™ II Plus and EZ Welder System – User’s Manual WELD ENERGY MAXIMUM LIMIT 270 J 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.
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Section 8 – Process Limits Menu PROCESS LIMITS PROCESS SETUP ENTER LIMIT DEFINITION CANCEL Figure 8–1 SUSPECT LIMITS BAD Figure 8–2 CANCEL ENTER TIME ENERGY TOTAL TIME ENTER Figure 8–10 Emin Tmin CANCEL ENTER ENTER ENTER CANCEL T2max ENTER CANCEL ENTER ENTER T2min E2max CANCEL ENTER 2P? ENTER WELD WELD TIME P1 TIME P2 WELD WELD ENERGY P1 ENERGY P2 E2min Emax TOTAL WELD ENERGY PROCESS LIMITS PROCESS LIMITS T1max DUAL PRESS. ENTER ENTER SINGLE PRESS.
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Section 8 – Process Limits Menu SECTION 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 .............
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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 2. PART COUNT 3. STATUS OUTPUTS 4. 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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. 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.
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Section 9 – Utilities Menu Copy A Setup Erase Setups 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. 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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. 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.
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Section 9 – Utilities Menu 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.
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Section 9 – Utilities Menu SECTION 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 ..............................................................
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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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 10 – Probes and Probe Stracks 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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. 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. 2.
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Section 10 – Probes and Probe Stracks 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.
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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.
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Section 10 – Probes and Probe Stracks 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 10 – Probes and Probe Stracks 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 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 10 – Probes and Probe Stracks 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.
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Section 10 – Probes and Probe Stracks SECTION 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 ......................................
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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.) NOTE If either of the AC Breakers open, they will flip the switch to its Off position marked by the O. 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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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). 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. 2. Program the appropriate weld method and time or energy to achieve the desired welding results. 3.
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Section 12 – Troubleshooting SECTION 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 .............
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Section 12 – Troubleshooting 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. SERIAL NUMBER US 10000 DUKANE CORP ST. CHARLES, IL 60174 MADE IN USA – WARNING! – POWER LINE MUST BE GROUNDED AT OUTLET. REMOVE ALL POWER BEFORE REMOVING COVER OR CONNECTING OR DISCONNECTING CABLES.
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DPC™ II Plus and EZ Welder System – User’s Manual 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].
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Section 12 – Troubleshooting 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 12 – Troubleshooting START (Plug in AC Powercord into outlet) INPUT TEST indicator lights up ? 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. YES INPUT TEST flashes for 5–10 sec ? NO Verify that the AC voltage is within specifications. YES INPUT TEST indicator goes out ? NO Verify that the AC voltage is within specifications. YES Green AC power light on ? NO 1. Defective power indicator lamp.
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DPC™ II Plus and EZ Welder System – User’s Manual A (Continued from previous page) OVER TEMP indicator off ? YES OVER LOAD indicator off ? NO NO Allow module(s) to cool down. Check cooling fan and cooling channel for excessive dust build up. 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. YES ON LINE key works ? NO 1.
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Section 12 – Troubleshooting 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.
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Section 13 – Care & Maintenance SECTION 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 ......................................
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Section 13 – Care & Maintenance Front Panel AC Power Cord Cleaning 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. 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.
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DPC™ II Plus and EZ Welder System – User’s Manual Top Cover Stack Inspection 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. 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.
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Section 13 – Care & Maintenance Crowning Corrosion 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Section 13 – Care & Maintenance  Figure 13–7 Surface flatness is more important than surface finish. 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.
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Section 14 – Contacting Dukane SECTION 14 Contacting Dukane • Corporate Office • Extensions & eMails Ultrasonics Division Main Office .................. 143 Email Addresses .......................................... 144 Telephone Extensions .................................. 144 Dukane Corporation • Dukane Manual Part No.
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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.
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DPC™ II Plus and EZ Welder System – User’s Manual Ultrasonics Division email Addresses Applications: ............................. usapps@dukane.com Engineering: .............................. useng@dukane.com Food Processing: ....................... usfoodproc@dukane.com International Sales: ................... usintl@dukane.com Marketing: ................................. usmktg@dukane.com Sales: .......................................... ussales@dukane.com Support/Service & Parts: ...........
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Section 15 – Specifications SECTION 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 ...................................
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Section 15 – Specifications 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.
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DPC™ II Plus and EZ Welder System – User’s Manual Dimensions 23.78 in 604 mm Heated Allow 2 in (5 cm) space for ventilation Exhaust Air 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 SERIAL NUMBER US 10000 Power Signal Output Module DUKANE CORP ST.
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Section 15 – Specifications 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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 L2 = level 2 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 T = Time Only E = Time & Energy P = Press Control Board INPUT POWER MODULE L = Low power module H = High power module TRANSDUCERS 2 = 2 ceramics 4 = 4 ceramics N
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Section 16 – Warranty SECTION 16 Warranty • Domestic Warranty • International Warranty Domestic warranty ...................................... 153 International Warranty ................................ 154 Dukane Corporation • Dukane Manual Part No.
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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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Appendix A – List of Figures APPENDIX A List of Figures Figure 2–1 Figure 2–2 Figure 2–3 Figure 2–4 Figure 2–5 120Volt, Grounded, 3-Prong Receptacle ......................................... 12 220Volt, Grounded, 3-Prong Receptacle ......................................... 12 International 220/240V Grounding ................................................. 13 DPC Grounding Arrangement ........................................................ 13 Press Grounding Arrangement .................................
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DPC™ II Plus and EZ Welder System – User’s Manual Figure 6–1 Figure 6–2 Figure 6–3 Figure 6–4 Figure 6–5 Figure 6–6 Figure 6–7 Figure 6–8 DPC II Plus Startup Menu ............................................................... 57 DPC II Plus Configuration Menu ..................................................... 57 DPC II Plus Weld Cycle Display ........................................................ 57 DPC II Plus Process Setup Menu ......................................................
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Appendix A – List of Figures Figure 7–42 Figure 7–43 Figure 7–44 Figure 7–45 Figure 7–46 Figure 7–47 Figure 7–48 Figure 7–49 Figure 7–50 Figure 7–51 Figure 7–52 Figure 7–53 Figure 7–54 Figure 7–55 Figure 7–56 Figure 7–57 Figure 7–58 Pressure Two Weld Energy Data Entry ............................................. 80 Pressure Two Max Weld Time Data Entry ........................................ 79 Dual Pressure Time Only Menus .....................................................
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DPC™ II Plus and EZ Welder System – User’s Manual Figure 10–1 Figure 10–2 Figure 10–3 Figure 10–4 Figure 10–5 Figure 10–6 Figure 10–7 Figure 10–8 Figure 10–9 Hand Probe, Horn and Replaceable Tip ........................................ 105 Probe with Booster and Horn ....................................................... 106 Replaceable Tip Installation .......................................................... 107 Stack Assembly Procedure ............................................................
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Appendix B – List of Tables APPENDIX B List of Tables Table 3—I Table 3—II Contents of DPC II Plus Shipping Container ...................................... 17 DPC II Plus AC Power Cord Part Numbers ......................................... 21 Table 5—I Table 5—II Table 5—III Table 5—IV Table 5—V Table 5—VI System Input Connector Signals ....................................................... 40 Remote Setup File Selection .............................................................
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Appendix B – List of Tables APPENDIX 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.......................
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Appendix C – User Supplied Circuitry 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Appendix C – User Supplied Circuitry 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.
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DPC™ II Plus and EZ Welder System – User’s Manual 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.
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Appendix C – User Supplied Circuitry 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). DPC Internal Power Supply +5 to +24V Automation Power Source +24V Internal DPC II Plus Circuitry +22V Current Limit Circuit 250mA max.
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Index INDEX A AC Power Indicator ....................................................................................... 29 AC Power Switch/Breaker ........................................................... 19, 25, 30, 39 AC Requirements ........................................................................................ 149 Afterburst .................................................................................... 73–74, 80, 85 Air Circulation .....................................................
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DPC™ II Plus and EZ Welder System – User’s Manual Cable Schematics, System ....................................................................... 21–24 Cable Troubleshooting ............................................................................... 125 CANCEL Key ............................................................................................. 34, 74 CE Compliance (Conformité Européene) .......................................... 6, 8, 147 Center Depression ................................
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Index ENTER Key ............................................................................................... 34, 77 Enter New Setup ........................................................................................... 98 Erase Setups................................................................................................... 99 Error Messages ...................................................................................... 92, 131 Example Setup...........................................
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DPC™ II Plus and EZ Welder System – User’s Manual I Increment Key ............................................................................................... 33 In-Dwell Status Output ................................................................................. 45 Indicator, AC Power ................................................................................ 19, 30 Initiate Mode ...........................................................................................
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Index Maximum Weld Time .................................................................. 67, 70, 71, 79 Menu, Confirmation ..................................................................................... 35 Menu, Data Entry .......................................................................................... 35 Menu, Selection ............................................................................................ 35 Menu Flowchart ...........................................................
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DPC™ II Plus and EZ Welder System – User’s Manual Plug–and–Weld ............................................................................................... 7 Power, Definition .......................................................................................... 70 Power Indicator, AC ................................................................................ 29, 30 Power Output Display ............................................................................ 29, 32 Power Output Module ....
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Index Rear Panel Layout ................................................................................... 19, 39 Remote Amplitude Control Module ............................................................ 46 Replaceable Tips .................................................................................. 107, 113 Resurfacing, Horn ............................................................................... 138–139 RFI Considerations ..................................................................
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DPC™ II Plus and EZ Welder System – User’s Manual System Output Connector ................................................................ 19, 39, 42 “ Power Output Display ..................................................................... 32 “ Test .................................................................................................. 120 T Theory of Operation ................................................................................... 105 Telephone Numbers, Dukane ..................
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Index Weld Cycle Data ................................................................................ 57, 65, 81 Weld Energy ...................................................................................... 67, 70, 79 Weld Method .................................................................................... 67, 69, 78 Weld Mode .............................................................................................. 75, 79 WELD P1 Key .......................................................
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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.
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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.