Manuale d’uso / di manutenzione del prodotto 9001:2000 del fabbricante Dukane
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Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL +1–630–797–4900 • F AX +1–630–797–4949 Dukane Part No.
Cop yright © 2003—2004 Dukane Cor poration Ultrasonics Division 2900 Dukane Dri ve St. Charles, IL 60174 USA Notice of Rights: All rights reser ved.
T able of Contents Dukane Manual Part No. 403-566-01 iii –00 Add information for EZ–Series Generator to DPC II Plus Manual. 2003–Sept–25 Added EZ Welder™ Key Featur es to Section 1. T able 3—1 references new DPC II Plus/EZ W elder manual. Figure 4–1B shows EZ Generator w/o Hot Key for P2 .
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T able of Contents Dukane Manual Part No. 403-566-01 v T ABLE OF C ONTENTS Section 1 – Introduction ........................................................... 1 Before Operating ......................................................................
vi Dukane Manual Part No. 403-556-01 DPC II Plus and EZ Welder System – User’ s Manual Section 5 – Rear Connectors .................................................. 37 Rear Panel Layout ..........................................................
T able of Contents Dukane Manual Part No. 403-566-01 vii Press Mode Example ............................................................................ 77 Hot Keys ......................................................................................
viii Dukane Manual Part No. 403-556-01 DPC II Plus and EZ Welder System – User’ s Manual Section 11 – DPC Checkout .................................................. 117 Startup and Self–T est ..................................................
T able of Contents Dukane Manual Part No. 403-566-01 ix Section 14 – Contacting Dukane ......................................... 141 Ultrasonics Division Main Office ....................................................... 143 Email Addresses .......
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1 Dukane Manual Part No. 403–566–01 Section 1 – Introduction Befor e Operating ............................................ 3 Read The Manual First ............................................ 3 Caution and W arnings ............................
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3 Dukane Manual Part No. 403 – 566 – 01 Section 1 – Introduction Important User Information Read This Manual First Before operating the DPC™ II Plus, read this User’ s Manual to become f amiliar with the sys- tem. This will ensure cor rect and safe operation.
4 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Section 1 – Intr oduction describes the manual or ganization and the ke y features of the Dukane DPC TM ( Dy- namic Process Controller ) II Plus Generator .
5 Dukane Manual Part No. 403 – 566 – 01 Section 1 – Introduction Section 12 – T roub leshooting pro vides helpful tips on solv- ing the most common problems. Section 13 – Maintenance lists a schedule of suggested pre- venti ve maintenance items.
6 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual DPC II Plus Overview The DPC ™ II Plus is the ne w est model in Dukane ’ s Dy- namic Process Controller product famil y .
7 Dukane Manual Part No. 403 – 566 – 01 Section 1 – Introduction DPC II Plus ™ Key Features • Timer Boar d option pro vides w eld and hold time control and stores up to eight setup f iles. • Pr ess Board option pro vides control for a Dukane ultrasonic press and thruster .
8 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual • Dual Line–V oltage 1 Univ ersal P o w er Supply means that the DPC will operate w orldwide. Auto-Ranging means that adjustments b y the operator related to po w er input are unnecessar y .
9 Dukane Manual Part No. 403 – 566 – 01 Section 1 – Introduction Safety Tips • Health & Safety • RFI Considerations Dukane Corporation •• Ultrasonics Division S ECTION 2 Health & Safety Tips ......................................
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11 Dukane Manual Part No. 403 – 566 – 01 Section 2 – Safety T ips Health and Safety Tips Please observe these health and safety recommen- dations for safe, ef f icient, and injury-free opera- tion of y our equipment.
12 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Plastics Health Notice Before using an y Dukane ultrasonic welding sys- tem, be sure y ou are f amiliar with OSHA regula- tions from the U .S. Depar tment of Labor about the par ticular type of plastic(s) y ou are using.
13 Dukane Manual Part No. 403 – 566 – 01 Section 2 – Safety T ips The po w er cable normally pro vided for inter na- tional use is compatib le with many po wer outlets (refer to Figure 2-3.
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15 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Unpacking & Installation Dukane Corporation •• Ultrasonics Division S ECTION 3 Shipping Carton Contents ............................ 17 DPC Placement .......
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17 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Shipping Contents Carefull y open the shipping container, and mak e sure it contains the items sho wn in T ab le 3 – I. In- spect the DPC for damage. Report any damage immediately to Dukane Ultrasonics Support/Ser - vice.
18 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual F igure 3-2 sho ws the use of a bracket kit in mounting a DPC to a 19-inch equipment rack. (Contact Ultrasonic Sales at Dukane, and request P ar t Number US-1155.
19 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Rear AC Power Switch Slave Multi–Probe Controller Module Master Multi–Probe Controller Module Press Control Module Power Signal Output Module Remote Amplitude Control Module EEPROM Serial Programming Port Grounding Lug Model No.
20 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Connect the Cables The instr uctions here and the diag rams in Figures 3 – 4 through 3 – 7 are meant to serve as a quick – start guide. The connectors and their pinouts are discussed in g reater detail in Section 5.
21 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Ꮨ Ꮨ DUKANE CORP ST. CHARLES, IL 60174 MADE IN USA SERIAL NUMBER US 10000 – W ARNING! – POWERLINE MUST BE GROUNDED AT OUTLET REMOVE ALL POWER BEFORE REMOVING COVER OR CONNECTING OR DISCONNECTING CABLES.
22 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Ꮨ Ꮨ DUKANE CORP ST. CHARLES, IL 60174 MADE IN USA SERIAL NUMBER US 10000 – W ARNING! – POWERLINE MUST BE GROUNDED AT OUTLET REMOVE ALL POWER BEFORE REMOVING COVER OR CONNECTING OR DISCONNECTING CABLES.
23 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Figur e 3-7 DPC II Plus Automated Thruster Cable Connections Automated Thruster System Step 1. Ground the DPC II Plus and the Thruster as sho wn in Figure 3 – 7. Step 2.
24 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Ꮨ Ꮨ DUKANE CORP ST. CHARLES, IL 60174 MADE IN USA SERIAL NUMBER US 10000 – W ARNING! – POWERLINE MUST BE GROUNDED AT OUTLET REMOVE ALL POWER BEFORE REMOVING COVER OR CONNECTING OR DISCONNECTING CABLES.
25 Dukane Manual Part No. 403 – 566 – 01 Section 3 – Unpacking and Installation Figur e 3-10 Rear Panel AC Breaker Switch Emergency Stop Switch Figure 3 – 9 is a simplif ied example that demon- strates the basic requirements to interface with the DPC II Plus on J902.
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27 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays Contr ols & Displays Dukane Corporation •• Ultrasonics Division S ECTION 4 Fr ont Panel Layout ........................................ 29 AC Power ...........
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29 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays Fr ont Panel Layout This section describes the DPC II Plus and DPC EZ front panel controls, status, po w er output and menu displa ys. The DPC front panel is laid out in three sections as illustrated belo w in Figure 4-1A (DPC II Plus) and Figure 4 – 1B (DPC EZ).
30 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual 1. AC Power Section The front-panel A C po w er section has a s witch and po w er indicator that is sho wn in Figure 4-2. ON/OFF The A C po wer s witch connects AC po w er to the generator .
31 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays System Status Display The System Status Displa y indicates one of the six system states. If that state is acti ve, the correspond- ing label is lit in the displa y . Figure 4-4 sho ws the System Status Displa y with the ON LINE state acti- vated.
32 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual System Power Output Display The tricolor System P o w er Output Displa y indi- cates the percentage of ultrasonic po w er being dra wn b y the load.
33 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays 3. Pr ocess Contr ol Panel Menu Function Keys The menu ke ys are sho wn in Figure 4 – 7. Their function is described going across each ro w start- ing at the upper left.
34 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Pressing the MODE ke y to ggles be- tw een the W eld mode (displays v al- ues for last w eld c ycle) and the Setup mode (displa ys main Process Setup menu).
35 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays Pr ocess Control Menu Display The menu display is a backlit 4 – line LCD with 20 characters per line. The top line of the displa y con- tains the menu title (with a fe w exceptions).
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37 Dukane Manual Part No. 403 – 566 – 01 Section 4 – Contr ols & Displays Rear Connectors Dukane Corporation •• Ultrasonics Division S ECTION 5 Rear Panel Layout ......................................... 39 System Input Connector .......
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39 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Rear Panel Layout All of the connectors contained on the DPC II Plus and the optional modules are sho wn belo w in Figure 5 – 1. No generator will ha ve all the mod- ules sho wn.
40 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual System Input Connector The System Input is a HD-15 (high-density , 15 contact) female connector . Pin assignments are sho wn in Figure 5 – 2. T able 5 — I below lists the pinout and signal name for the System Input con- nector .
41 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Input Signal Description Pin 1 (+22V) This pin can suppl y +22VDC at up to 250mA to po w er the user's automation controls. Pin 2 (Gnd) Pin 2 and 7 are the 22VDC and Operate retur ns and are tied to the chassis ground.
42 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual System Output Connector The System Output panel connector is a DB- 25 F emale type. Pin numbers are sho wn in F ig- ure 5 – 4 and pin assignments are gi ven in T able 5 — IV .
43 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Output Signal Description Pin 1 (+22V) This pin can suppl y +22VDC to supply po w er for user automation controls. It is limited to 250mA. Pin 2 (Gnd) Pin 2 is the 22VDC and Status Out return.
44 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Pin 10 (ON LINE) An acti ve lo w output on pin 10 indicates the gen- erator is on line and is capab le of being triggered externall y . The front panel status display will indi- cate O N LINE .
45 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Pin 18 (MPC Ready) 4 An acti ve lo w output on pin 18 indicates the MPC module (Multi – Probe Controller) is ready and will accept probe selection changes on the Remote Setup inputs.
46 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Remote Amplitude Contr ol Module Part No. 438 – 799 This optional module enab les remote control of output amplitude of the DPC II Plus. The control interface is a 4 – 20mA cur rent loop.
47 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Power Signal Output Module Part No. 438 – 826 This optional module enab les the DPC II Plus to operate in the W eld – By – Energy mode. When installed , the DPC II Plus automatically detects the board and enables the ener gy options in the process control menu.
48 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Pr ess Control Module Part No. 110 – 3938 This optional module enab les the DPC II Plus to control a Dukane Model 210, 220 or 410 press or custom automation.
49 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors T able 5 — V on the previous page lists the pinout and signal description for J902 w hich is the Press Base connection. Note that there is an automation input on pin 8 w hich is electrically identical to pin 8 on the System Input connector .
50 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Multi – Pr obe Master Module Part No. 110 – 3954 This optional module enab les the DPC II Plus to acti vate an y one of four ultrasonic probes.
51 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Jumper Block Options The DPC II Plus ma y be customized to y our spe- cif ic requirements by means of internal jumpers lo- cated on the main printed circuit board. Belo w is a list of the jumper blocks, their default factory set- tings and their alternate positions.
52 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual System Contr ol Inputs Jumper Block – SH707 JU724 - Non – Isolated Sink (F actor y Def ault) – Dry contact betw een input and DPC g round. JU725 - Non – Isolated Source – Dry contact be- tw een input and +22 VDC.
53 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors JU723 JU722 JU703 JU704 TIMER BD. ENABLE TIMER BD. BYPASS STATUS DRIVER NORMAL STATE NORMALLY OFF NORMALLY ON JU701 JU702 NON.
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55 Dukane Manual Part No. 403 – 566 – 01 Section 5 – Rear Connectors Menu Structur e Dukane Corporation •• Ultrasonics Division S ECTION 6 Pr ocess Setup ............................................... 57 Pr ocess Control ...................
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57 Dukane Manual Part No. 403 – 566 – 01 Section 6 – Menu Structur e Pr ocess Setup Menu This section deals with the o v erall menu str ucture. Each setup menu is later discussed in detail in its o wn section.
58 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Process Control, Limit Def inition or Utilities menu. Press the ENTER ke y to activ ate the selected menu. The Process Control Menu selects the trig- ger method , the w elding mode and sets the values for the w elding parameters.
59 Dukane Manual Part No. 403 – 566 – 01 Section 6 – Menu Structur e TRIGGER METHOD PROCESS CONTROL PROCESS SETUP PRESS TIMED PROBE MANUAL INITIA TE MODE AUTO MOMENT AR Y MAINT AINED TRIGGER TYP.
60 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Limit Definition Menu The Limit Def inition menu has tw o classes of settings. The f irst class is the suspect limits and the second class is for bad part limits.
61 Dukane Manual Part No. 403 – 566 – 01 Section 6 – Menu Structur e Utilities Menu The Utilities menu has four dif ferent sections. The f irst section handles setup f ile operations. The sec- ond section accesses the par ts count functions. The third section conf igures the status output.
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63 Dukane Manual Part No. 403 – 566 – 01 Section 6 – Menu Structur e Pr ocess Contr ol Menu Dukane Corporation •• Ultrasonics Division S ECTION 7 Hand Pr obe .................................................. 65 Untimed Hand Probe ..........
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65 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Pr ocess Contr ol Menu The Process Control Menu has a dynamic struc- ture.
66 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Press the MODE k ey to displa y the Process Setup menu. In Process Setup, the cursor should be point- ing to Process Control as sho wn in Figure 7 – 5.
67 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu is reached , whiche ver comes f irst. Press ENTER and the data entry screen appears as sho wn in Figure 7 – 9. If a P ow er Output module is installed , then a W eld Method screen sho wn in Figure 7 – 8 is dis- pla yed f irst.
68 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual MPC Pr obe The cable connection diagram for connecting the Multi – Probe Controller module is sho wn in Sec- tion 3 in F igure 3 – 6.
69 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Untimed MPC Probe – Pr obe Delay The probe dela y time value for untimed operation is sho wn in Figure 7 – 14. This parameter is typi- call y used in a single auto probe conf iguration w hich is co vered later in this section.
70 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual W eld Method – Energy If a P o w er Output module is installed , y ou can choose the Energy W elding method. The decision menu for choosing the W eld Method was sho wn in F igure 7 – 15.
71 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu ture to function properl y , the f ixture must be elec- tricall y isolated from the horn suppor t and base as sho wn in F igure 7 – 19. The hor n is grounded and acts as a s witch closure when it contacts the f ix- ture.
72 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual AUTO Pr obe The cable connection diagram for connecting an automated probe or an automated thruster is sho wn in Section 3 in F igures 3 – 5 and 3 – 7.
73 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Untimed Auto Pr obe – Delay The generator is triggered b y e xter nal automa- tion equipment.
74 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual T o select an afterburst, mo v e the cursor down ne xt to ENABLE as sho wn in Figure 7 – 26 and press the ENTER key . T o setup the afterburst, the menu prompts y ou for tw o parameter v alues.
75 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu PRESS Mode The cab le connection diag ram for connecting a DPC II Plus to a Dukane press is sho wn in Sec- tion 3 in F igures 3 – 8. The flo w char t for the Pro- cess Control menu is sho wn in F igure 7 – 30.
76 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual 3. If D ISABLE was selected in the AUTO STOP menu, t h e TRIGGER TYPE menu is displa yed next. This s elects whether the trigger which initiates the w eld cycle is momentary or must be maintained throughout the w eld cycle.
77 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu ing Energy for the f irst mode and T ime for the second mode or vice versa. Each of the b locks labeled Pressure 1 and Pressure 2 are equi valent to the Single Pressure W eld Method branch with- out Ground Detect.
78 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual The menu changes to displa y the Initiate mode as sho wn in Figure 7 – 35. W e will assume a standard press conf iguration using the dual palm operate s witches.
79 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Using the four ar ro w keys, enter the w eld time. Press the ENTER ke y when y ou hav e completed the data entry . This displa ys the W eld Method selection screen for Pressure T w o as sho wn in Figure 7 – 41.
80 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual HOLD TIME 0.500 SEC PROCESS CONTROL WELD MODE HOLD TIME AFTERBURST AFTERBURST DISABLE ENABLE AFTERBURST DELAY 0.150 SEC AFTERBURST DURATION 0.250 SEC From here on, the menu follo ws the same logical sequence as Auto Probe.
81 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu W e ha ve no w def ined the w elding mode and set v alues for the necessar y parameters. Press the CANCEL key once to return to the root Process Setup menu sho wn in Figure 7 – 52 (the same as Figure 7 – 33).
82 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual cept the ne w value press the ENTER key . This will return you to the Process Setup menu sho wn in Figure 7 – 52. T o retur n to Process Setup without modifying the hold time, press the CANCEL key .
83 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu TRIGGER METHOD PRESS TIMED PROBE MANUAL INITIA TE MODE AUTO MOMENT AR Y MAINT AINED TRIGGER TYPE ENABLE or DISABLE AUTO .
84 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual T able 7 — I belo w summarizes the v arious method and mode menus and references their F igure num- ber . T able 7 – II on the next page lists the data en- tr y screens and references their F igure number .
85 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Parameter Description Figure No. Weld Method Minimum Value Weld T ime Ultrasound Gate T ime 0.
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87 Dukane Manual Part No. 403 – 566 – 01 Section 7 – Process Control Menu Pr ocess Limits Menu Dukane Corporation •• Ultrasonics Division S ECTION 8 Pr ocess Limits Menu ...................................... 89 Limit Definition ............
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89 Dukane Manual Part No. 403 – 566 – 01 Section 8 – Process Limits Menu Pr ocess Limits Menu The Process Limits Menu allo ws y ou to def ine upper and lo w er bounds for suspect par ts or for bad parts. The limits are a vailab le in both units of time and units of energy depending upon the w elding method chosen in Process Control setup.
90 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Limit Definition T o access the Limit settings, star t from the Pro- cess Setup menu sho wn in Figure 8 – 1. Select PROCESS LIMITS with the cursor and then press ENTER .
91 Dukane Manual Part No. 403 – 566 – 01 Section 8 – Process Limits Menu F or a dual – pressure mode, both the nor mal limits and the total limits are displa yed as sho wn in Figure 8 – 5.
92 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual WELD ENERGY P1 MAXIMUM LIMIT 90 J PROCESS LIMITS WELD ENERGY P1 WELD ENERGY P2 After the minimum and maximum limit v alues ha ve been entered , the display returns to the Process Limit menu sho wn in F igure 8 – 3.
93 Dukane Manual Part No. 403 – 566 – 01 Section 8 – Process Limits Menu TIME ENERGY TOT AL TIME TOT AL ENERGY PROCESS LIMITS WELD TIME P2 WELD TIME P1 PROCESS LIMITS WELD ENERGY P2 WELD ENERGY .
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95 Dukane Manual Part No. 403 – 566 – 01 Section 8 – Process Limits Menu Utilities Menu Dukane Corporation •• Ultrasonics Division S ECTION 9 Setup Utilities ............................................... 97 Select Setup ...................
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97 Dukane Manual Part No. 403 – 566 – 01 Section 9 – Utilities Menu Utilities Menu The Utilities Menu is the third option from the main Process Setup menu. It is di vided into four distinct menu g roups: 1. SETUP UTILITIES 2. PART COUNT 3. STATUS OUTPUTS 4.
98 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Setup Utilities T o access the Utilities menu, start from the Process Setup menu sho wn in F igure 9 – 2. Mo ve the cursor do wn to select Utilities and press the ENTER key .
99 Dukane Manual Part No. 403 – 566 – 01 Section 9 – Utilities Menu Copy A Setup Starting from the Utilities menu in Figure 9 – 4, mo ve the cursor do wn to Copy A Setup and press the ENTER key . The displa y f irst requests the source f ile number .
100 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual T o erase all the stored setups, mo ve the cursor from ERASE CURRENT SETUP (see F igure 9 – 11) to do wn to ERASE ALL SETUPS and press ENTER . A conf irmation message is display ed.
101 Dukane Manual Part No. 403 – 566 – 01 Section 9 – Utilities Menu Preset Par t Count This option allo ws you to preset a v alue (maxi- mum = 60,000) in the counter . Again from the part count selection menu, mo v e the cursor to the bot- tom line next to PRESET PART COUNT and press ENTER .
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103 Dukane Manual Part No. 403 – 566 – 01 Section 9 – Utilities Menu Pr obes & Pr obe Stacks Dukane Corporation •• Ultrasonics Division S ECTION 10 The Ultrasonic Pr obe ................................... 105 Theory of Operation .......
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105 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks The Ultrasonic Probe Theory of Operation Plastic w elding is the most common application of ultrasonic assembl y . T o perfor m ultrasonic plas- tic w elding, the vibrating tip is brought into con- tact with one of the w ork pieces.
106 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Ultrasonic Hor n The horn transfers the ultrasonic mechanical vi- brations (originating at the transducer in the probe housing) to the plastic par ts through direct ph ysi- cal contact.
107 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks Stack Assembly Attaching A Replaceable Tip T o A Horn 1. Inspect all horn and tip surf aces for stress cracks, chips, or gouges. Any of these irregu- larities will af fect operation and could lead to further equipment damage.
108 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Attaching The Mounting Stud T o A Hor n Or A Booster 1. Inspect the stud for cracks or damaged threads. Replace the stud if it is cracked or otherwise damaged.
109 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks Attaching The Horn T o A Booster , Booster T o A Pr obe, Or Hor n T o A Probe 1. Inspect all surfaces to be joined for stress cracks, chips, or gouges. An y of these ir regu- larities will af fect operation and could lead to further equipment damage.
110 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual mo ving the hor n from the booster or the booster from the probe. 6. Thread the components to gether and tighten to the follo wing torque specif ications using only the correct size wrenches.
111 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks HORN HORN HAND PROBE ASSEMBLY HAND PROBE HOUSING HAND PROBE HOUSING A SSEMBLY D ISASSEMBLY Output End Input End S.
112 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual The assemb ly and disassemb ly procedures for a hand probe sho wn in Figure 10 – 6. The same pro- cedure for a probe stack with booster is sho wn in Figure 10 – 7.
113 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks Separating Th e Hor n Fr om A Booster , Booster From A Pr obe Or Hor n Fr om A Probe On all transducers and horns.
114 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Booster Notes How T o T ell The Booster Input End Fr om The Output 1. The depth of the threaded hole on the output end is al wa ys deeper than the threaded hole on the input end.
115 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks Mounting The Stack A probe-horn assembl y or probe-booster-horn as- semb ly (stack) can be mounted into a customer - pro vided machine to ensure stability and proper alignment during operation or for automated op- eration.
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117 Dukane Manual Part No. 403 – 566 – 01 Section 10 – Pr obes and Probe Stracks DPC Checkout Dukane Corporation •• Ultrasonics Division S ECTION 11 Startup and Self – T est .................................. 119 System T est .............
118 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pa ge intentionally left b lank.
119 Dukane Manual Part No. 403 – 566 – 01 Section 11 – DPC Checkout Startup and Self – T est 1. Push the rear panel A C breaker s witch to the ON position (see F igure 3 – 3 or 3 – 9 for the switch location.) 2. Push the front panel A C po wer s witch to the ON position (marked I on the s witch.
120 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual DPC System T est T o test the DPC II Plus system ’ s ultrasound signal deliv er y , perform the follo wing steps. 1. F or the initial test, the generator must be ON LINE .
121 Dukane Manual Part No. 403 – 566 – 01 Section 11 – DPC Checkout System Operation 1. If the generator is not online, press the ON LINE ke y . This is labeled E in Figure 11 – 1. The g reen ON LINE status should light up (F in F igure 11 – 2).
122 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pa ge intentionally left b lank.
123 Dukane Manual Part No. 403 – 566 – 01 Section 12 – T roubleshooting No Ultrasonic Output ..................................... 125 Pr obe .................................................................... 125 Cable ........................
124 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pa ge intentionally left b lank.
125 Dukane Manual Part No. 403 – 566 – 01 Section 12 – T roubleshooting No Ultrasonic Output Pr obe Make sure that the probe coaxial cab le is connected to the generator Ultrasonic output connector J1 (see F igure 12 – 1). Make sure the probe stack w as as- semb led following the instructions in Section 10.
126 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Generator The generator will not produce an output signal w hen triggered if it is OFF LINE. Make sure that the g reen po w er indicator [A] is lit.
127 Dukane Manual Part No. 403 – 566 – 01 Section 12 – T roubleshooting Generator F AUL T s OVERLOAD If the generator OVERLOAD light comes on, it in- dicates e xcessiv e po w er is being drawn. This could be caused b y a mismatch between the ultrasonic signal and the resonant characteristics of the acous- tic stack.
128 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Generator Err ors INPUT TEST Indicator Steady Red During po w er up, the INPUT TEST indicator should flash red for 5 – 10 seconds. This indi- cates the po w er-up test is running.
129 Dukane Manual Part No. 403 – 566 – 01 Section 12 – T roubleshooting INPUT TEST indicator lights up ? INPUT TEST flashes for 5 – 10 sec ? 1. Both the front and rear AC breaker switches on the DPC must be turned on (Figure 3 – 9 and 4 – 2).
130 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual 1. Make sure correct probe is connected to generator . 2. Check the ultrasonic coaxial cable for shorts. 3. T ry changing the probe and/or cable. 4.
131 Dukane Manual Part No. 403 – 566 – 01 Section 12 – T roubleshooting Err or Messages TRIGGER LOST This er ror message is displa yed w hen the trigger type is set to MAINT AINED , and the trigger signal is inter r upted or lost. The w eld cycle is terminated.
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133 Dukane Manual Part No. 403 – 566 – 01 Section 13 – Care & Maintenance Fr ont Panel ................................................. 135 Rear Panel .................................................. 135 Chasis ...........................
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135 Dukane Manual Part No. 403 – 566 – 01 Section 13 – Care & Maintenance Fr ont Panel Cleaning Do not use an y solvents or abrasi ve cleaners on the front panel. Do not spra y cleaner directl y onto the front panel. Apply a small amount of com- puter cleaner to a soft to w el f irst.
136 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual T op Cover K eep the cov er on at all times. The chassis is ro- bust enough to hold considerable w eight.
137 Dukane Manual Part No. 403 – 566 – 01 Section 13 – Care & Maintenance Cr owning A surface which is burnished only in the inner ring area around the stud , indicates the surface is con- ve x or cro wned. An example of this is sho wn in f igure 13 – 5.
138 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Reconditioning Overview Stack components require reconditioning when the mating surfaces become unev en or cor roded. These conditions cause poor contact betw een the mating surfaces which w astes po w er .
139 Dukane Manual Part No. 403 – 566 – 01 Section 13 – Care & Maintenance CAUTION Use extreme care to keep the part level when moving it across the emery cloth. Be careful not to tilt the part. An uneven mating surface could leave the mating sur - face inoperative.
140 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual This pa ge intentionally left b lank.
141 Dukane Manual Part No. 403 – 566 – 01 Section 14 – Contacting Dukane Ultrasonics Division Main Office .................. 143 Email Addresses .......................................... 144 T elephone Extensions ...............................
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143 Dukane Manual Part No. 403 – 566 – 01 Section 14 – Contacting Dukane Department Phone Numbers Y ou can reach each department by dialing directl y A pplication Suppor t (630) 797 – 4930 F or applications and/or process technology questions.
144 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Applications: ............................. usapps@dukane.com Engineering: .............................. useng@dukane.com Food Processing: ......
145 Dukane Manual Part No. 403 – 566 – 01 Section 15 – Specifications Regulatory Compliance ............................... 147 Federal Communications Commission ................ 147 CE Marking (Conformit é Eur ope é ne) .................. 147 Dimensions .
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147 Dukane Manual Part No. 403 – 566 – 01 Section 15 – Specifications FCC The DPC II Plus complies with the follo wing F ed- eral Communications Commission regulations.
148 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Dimensions Operating Envir onment Operate the DPC II Plus within these guidelines: T emperatur e: 40 ° F to 100 ° F (+5 ° C to +38 ° C) Pressure: Ambient Air Particulates: Keep the DPC dr y .
149 Dukane Manual Part No. 403 – 566 – 01 Section 15 – Specifications Power Supply Requir ements The A C po w er requirements depend on the frequency and po wer rating of the generator .
150 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Interpr eting the DPC II Plus Model Number 2 2 0 0-LN 4-PE-L2 Generator Controller Le vel FREQU.
151 Dukane Manual Part No. 403 – 566 – 01 Section 16 – W arranty Domestic warranty ...................................... 153 Inter national W arranty .
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153 Dukane Manual Part No. 403 – 566 – 01 Section 16 – W arranty Subject to the terms, limitations and exclusions set forth below , Dukane Corporation IAS Division (Dukane) warrants to the orig .
154 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Subject to the terms, limitations and exclusions set forth below , Dukane Corporation IAS Divis.
155 Dukane Manual Part No. 403 – 566 – 01 Appendix A – List of Figures A PPENDIX A Dukane Corporation •• Ultrasonics Division List of Figur es Figure 2 – 1 120V olt, Gr ounded, 3-Prong Receptacle ......................................... 12 Figure 2 – 2 220V olt, Gr ounded, 3-Prong Receptacle .
156 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Figure 6 – 1 DPC II Plus Startup Menu ............................................................... 57 Figure 6 – 2 DPC II Plus Configuration Menu .
157 Dukane Manual Part No. 403 – 566 – 01 Appendix A – List of Figures Figure 7 – 42 Pr essure T wo Weld Energy Data Entr y ............................................. 80 Figure 7 – 43 Pr essure T wo Max W eld T ime Data Entry ............
158 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Figure 10 – 1 Hand Probe, Horn and Replaceable T ip ........................................ 105 Figure 10 – 2 Probe with Booster and Horn ...
159 Dukane Manual Part No. 403 – 566 – 01 Appendix B – List of T ables Dukane Corporation •• Ultrasonics Division List of T ables T able 3 — I Contents of DPC II Plus Shipping Container ...................................... 17 T able 3 — II DPC II Plus AC Power Cord Part Numbers .
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161 Dukane Manual Part No. 403 – 566 – 01 Appendix B – List of T ables Manual Switch Circuit ................................. 163 Automation Switch Cir cuits ......................... 164 Non – Isolated Switch Cir cuits ......................
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163 Dukane Manual Part No. 403 – 566 – 01 Appendix C – User Supplied Circuitry DPC Switch Input DPC Ground System Input Cable Manual Control Switch User Supplied Switch Pin #8 – Operate or Pin.
164 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual User Supplied Relay User Supplied Transistor Driver Circuit HD – 15 System Input Connector HD.
165 Dukane Manual Part No. 403 – 566 – 01 Appendix C – User Supplied Circuitry +22V DPC Internal Power Supply Current Limit Circuit 250mA max. Jumper Block SH707 Position JU724 (Refer to Figure 5 – 12) +24V Internal DPC II Plus Circuitry Optical Isolation Circuit Current Limit Circuit 12.
166 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual DPC II Plus +22V Power High-Side Switch Sources Current DPC Ground +22V DPC Internal Power Supply Current Limit Circuit 250mA max.
167 Dukane Manual Part No. 403 – 566 – 01 Appendix C – User Supplied Circuitry Isolated Switch Cir cuit Isolated Current Sour ce Circuit Figure C – 5 illustrates a full y isolated circuit con- nected to the Isolated Automation Inputs. This re- quires an external po w er supply to dri ve the s witch.
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169 Dukane Manual Part No. 403 – 566 – 01 Index I NDEX A AC Power Indicator ....................................................................................... 29 AC Power Switch/Breaker ........................................................
170 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Cable Schematics, System ....................................................................... 21 – 24 Cable T roubleshooting ................
171 Dukane Manual Part No. 403 – 566 – 01 Index ENTER Key ............................................................................................... 34, 77 Enter New Setup ......................................................................
172 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual I Increment Key ............................................................................................... 33 In-Dwell Status Output ........
173 Dukane Manual Part No. 403 – 566 – 01 Index Maximum W eld Time .................................................................. 67, 70, 71, 79 Menu, Confirmation ...............................................................................
174 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual Plug – and – W eld ............................................................................................... 7 Power , Definition ......
175 Dukane Manual Part No. 403 – 566 – 01 Index Rear Panel Layout ................................................................................... 19, 39 Remote Amplitude Control Module ..........................................................
176 Dukane Manual Part No. 403 – 566 – 01 DPC ™ II Plus and EZ Welder System – User ’ s Manual System Output Connector ................................................................ 19, 39, 42 “ Power Output Display .....................
177 Dukane Manual Part No. 403 – 566 – 01 Index Weld Cycle Data ................................................................................ 57, 65, 81 Weld Ener gy ..............................................................................
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Dukane ISO ISO CER TIFICA TION Dukane chose to become ISO 9001:2000 cer - tified in order to demonstrate to our customers our continuing commitment to being a quality vendor . By passing its audit, Dukane can as- sure you that we have in place a well–defined and systematic approach to quality design, manufacturing, delivery and ser vice.
40356601 Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL +1–630–797-4900 • F AX +1–630–797–4949 Part No. 403–566–01 Printed in the United States of America $100.00 User's Manual – DPC II Plus and EZ W elder System www .
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Dukane 9001:2000 è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Dukane 9001:2000 - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Dukane 9001:2000 imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Dukane 9001:2000 ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Dukane 9001:2000, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Dukane 9001:2000.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Dukane 9001:2000. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Dukane 9001:2000 insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
