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1. 5 CRSA 8917 E Roe 4 C908 R929 R 9 RASONICS 1 USA R920 2 loss a903 904 C903 9997 R924 G R923 CR907 4 m to Figure 5 10 Press Board SH901 Cycle Activation Jumper Cycle Activation Jumper Options Internal jumper SH901 on the Press Control Board offers options for activating a cycle Timer Control DPC
2. Figure 5 12 Card Slot Connector and Jumper Block Locations Dukane Manual Part 403 551 03 53 Dynamic Process Controller DPC II Plus User s Manual STATUS RELAY SELECTION BLOCK Figure 5 13 Jumper Block Detail SH705 00717 NO DELAY C712 JU718 mSEC JU 15 10 nsEC 40720 22 mSEC f EC C714 JU 23 TIMER BD ENABLE 41728 TIMER BD BYPASS SUITCH DEBOUNCE FILTER TIME DELAY SELECTION BLOCK R753 C711 AUTOMATION SIGNALS SELECTION BLOCK o R712 SH703 RP701 SH704 JU708 U S ACTIVE JU 713 NORMALLY OFF JU 0 OVERLOAD JU 1u NORMALLY ON Ju710 OVERTEMP JU 15 AUTO STOP FAULT JU 11 SYS FAULT JU 1b AUTO END OF WELD 40728 ume ANY FAULT 1 dL CR736 6705 EL CR708 702 ALD Tr STATUS DRIVER 710 SELECTION BLOCK I SsH D2 9718 JU703 U S ACTIVE JU70u OVERLOAD 1 du OVERTEMP DE E ur 705 1 SYS FAULT J CR704 08 E STATUS DRIVER 1 I NORMAL STATE vet Jn 4 SELECTION BLOCK SH 01 n E 0702 79 gt JU701 NORMALLY OFF4 JU702 NORMALLY ON 1 R714 R715 4710 POUER SIGNAL 1 OUTPUT BOARD R771 C723 NON ISO SINK C722 w R772 NON ISO SOURCE ISOLATED 707
3. 100 Remote Amplitude Control UR ORI UR Module 438 799 Bong 20 4 8 342 This optional module enables remote control of Troop mA output amplitude of the DPC II Plus The control eg Determine Iro needed interface is 4 20mA current loop The current 2 loop connector and fault indicator are shown Figure 5 5 The output can be adjusted from 36 to 10096 The scale factor is Al6 mA 464 40 v which is AlmA 44 The graph of output asa 35 Output function of loop current is shown in Figure 5 6 E The input compliance is 10 volts minimum 20 Failure to provide between 4mA and 20mA of loop Region current is detected as a fault and will not produce Output any output The current loop fault indicator is a bi gy 5201 color LED Itis green when the current is between 4 IMA 10mA 15mA 20mA and 20mA and red when the current is below this Figure 5 6 Current Loop Transfer Function Graph value The module contains an internal jumper block to select the current loop fault option The NOTE default setting jumper JU1 disables ultrasonic The equations for Out and ILoop are only valid output if a loop fault occurs The setting can be for normal operating conditions reversed with JU2 to enable the minimum level output 36 lt Out lt 100 and 36 if a loop fault occurs This is used
4. 99 I LU 98 AP Eu mU 98 Serial Number todo dose dias 19 Serial Programming Port 19 slave MPC MOQUE 51 Single Pressure MOGOB DR so Ox Sa Era 76 a ey 33 148 149 Stack ASSEMDIY PT 109 diac oar ici WE ES 136 Stack Maihitenahece a ELA RE RR Ea ERAI dA 136 a 57 65 Status Display cree aes 29 31 Status Driver Selection JUITIDBE Goku ron Goto grae petes totu ta 51 Status dra 42 45 Status Q tp t Men P m 101 Status Output Mamitsined Pulsedl 101 SECIS Panel TU TP 30 Stopping The Weld Cycle ak 121 Storage 148 Studs Horn amp Booster 1 11 1 1 4 1 4 esr innen nass nana 108 Suspect Part eoo xdi nda QU ANSA UR ANM das MEE 100 S spect Part Eri MR 90 Switch Circuits User Supplied diari ette 161 166 System usi ui addidi 21 24 119 Control Input J
5. 42 eet eee 148 brreculudsc 34 Display Care Of Mem tH c 135 Display D E E MM MEE 29 35 bie b KM T 31 19 121 Dwell Time In Dwell Status 45 Dual Pressure Mode 76 Dukane Press SSEGFII pda dd Lata kai gra adi s ck aa MR 24 Dukane WebSite 111 rennen enne nnns nnn nnn 143 E Email Addresses Dukane nennen nennen nnne 144 Emergency Stop Switch Mc 20 25 119 Energy Welding OS 70 Energy 70 Energy Eg i et sa a eect esi eh lh el aces ac dell ed tec PPS 89 Energy Values slate euet equus uda dead 85 Energy Module iot donnait Redi see Power Signal Output Module 170 Dukane Manual Part No 403 551 03 Index ENTER P 34 77 Enter New T 98 Erase adi den id 99 Error IMessag68s coe e Pone re eia iras 92 131 Example 77 81 FAULT Status DIS ay 31 127
6. 60 90 Process Setup FIGUWECDBD 58 74 Process SETUP dasha 57 66 77 Programming Porc Serial 19 Pulse Width Modulation esses ennemis 7 Rack Mounting RR den 18 Ready Status M 45 Rear Panel nennen nennen enn nennen nen 19 39 125 174 Dukane Manual Part No 403 551 03 Index Panel m 19 39 Remote Amplitude Control Module esses 46 Replaceable Tips andi iei 107 113 Resurfacing HON 138 139 RFI Considerati hS M TNR TP 13 RIONE Arrow ROY eH 34 Feo Fi POTU 19 Satety TIPS oe 11 Save M 98 Scheduled Maintenance 111 137 Ser b TIME EET D 71 85 Select Setup aui docebat boda aai ipta nU ad REOR 98 Selection MENU MX 35 119 Setup Files Remote Selection 40 Setup Utilities M n uiui uius aa aea 98 Setup CORY MN 99
7. MIMIN 101 Part Count 100 Placement of RN TTC 17 Dukane Manual Part 403 551 03 173 Dynamic Process Controller DPC II Plus User s Manual PET Em 7 Power Definition nennen ener 70 Power Indicator 2 0 1 4 71 44 29 30 Power Output Display 29 32 Power OQuiput MOSS iis aa nasi ca inei ep exa rna a aie Ra a axe da 47 Power Signal Output MODIEGO uas ai madida 44 Power Switch 0 2 166 25 30 Power Requirements 149 Press Base Cable 23 24 48 119 Press Control Module 22 4 4444 4 4 48 119 Press Emergency Stop Switch e aei emanare tta eda teta teda 101 119 Press Mode 75 Press Mode 0 44 00 80 5 AUTO SLOP 76 ENUY 78 80 d Mead Up auto ua 76 TINE 80 lt
8. Flexible Coaxial Cable 20kHz Part No 200 624 40kHz Part No 200 759 Included with probe Earth Ground Figure 3 4 DPC II Plus Hand Probe Cable Connections Step 4 Optional Attach the status output cable from the user supplied automation equipment to the System Output DB 25 connector Not all The 3 prong AC Line cords supplied are matched to the DPC II Plus power rating and the continent of specified use The part numbers are automation systems will have this cable 200 1109 North America 110V Step 5 Attach the power cord to the DPC II 200 1110 North America 220V Plus and plug the other end into an 200 1111 Continental Europe approved AC outlet Table 3 DPC Il Plus AC Power Cord Part Numbers Grounding ST CHARLES IL P N 200 479 MADE IN USA Ultrasound Input Grounding Lug 01 14 Coaxial Cable Wire RG62B U Automation P N 200 1203 Automation Equipment Status Output P N 200 1302 14 Gauge Wire Earth Ground Figure 3 5 DPC II Plus Automated Probe Cable Connections Dukane Manual Part 403 551 03 21 Dynamic Process Controller DPC Plus User s Manual Multiple Probe System Step 1 Ground the DPC II Plus chassis and the probe support Step 2 F
9. 136 Flat Surface With Even 136 Surface With Uneven Contact 136 m 135 audis HOI m 135 HE St TE EE S 139 Generator 3 View and Dimensions 148 Interpreting the DPC Plus Model Number 150 Control SWIEC aie oon a need uno 163 Automation Control Switches 164 Non Isolated Current Sink Switch 165 Non Isolated Current Source 5 22 2 2 2 7 7 2772 166 Isolated Current Source 2 167 158 Dukane Manual Part No 403 551 03 Table 3 I Table 3 II Table 5 I Table 5 II Table 5 III Table 5 IV Table 5 V Table 5 VI Table 7 I Table 7 II Table 8 1 Table 8 II Table 8 III Table 10 I Table 10 II Table 15 I APPENDIX B List of Tables Contents of DPC Plus Shipping 17 DPC Il Plus AC Power Cord Part Numbers 21 System Input Connector Signals nicer erar rms 40 Remote Setup File ott ttt 40 System Input Cable Color drerit de iius 41 System Output Connector Signals iiir nra ttt tnra cote snc 42
10. 6 147 Features of DPC Il Plus 7 Flowcharts 59 60 66 68 72 75 83 91 93 97 129 130 40kHz Considerations 2 00 106 Frequency Monitor Output 44 Front Panel Controls esee 29 30 32 34 119 Front Panel Control 41 120 Front Pan l auccm quuni qoid 31 32 Front panel Maintenance 135 G GEN INFO 2t PTT 33 Part Status UG 45 19 22 24 135 Ground Detect Fixture 70 Ground Detect Weld a ua queue 70 H Probe EE ETE TED 65 105 Hand Probe Mode Flow Chart 66 Hand Probe Data EV dU NEAR EUR 67 T MENS S RUNE 66 moger METTE 66 d Uhtimed eterne tete reper n ue Doe n ux Rupe DEDE px EE Ee EXER 66 E WERL EINIGE 67 i Method 67 5 TIME 67 d Weld Time Maximum 1 nnne nnn 67 HD 15 Connector System
11. 125 125 CR aeter 126 Operate TT T 126 Generator 127 OVERLOAD Indicator 127 OVERT TEMP Indicator uccide ea 127 FAULT India 127 Generator need 128 INPUT TEST Indicator esee 128 TEST Control 128 Troubleshooting Flowchart 129 Error ce P 131 Dukane Corporation oU IS Ultrasonics Division Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 124 Dukane Manual Part No 403 551 03 Section 12 Troubleshooting No Ultrasonic Output Probe Make sure that the probe coaxial cable is connected tothe generator Ultrasonic output connector J1 see Figure 12 1 Make sure the probe stack was as sembled following the instructions in Section 10 SERIAL NUMBER DUKANE CORP ST CHARLES IL 60174 MADE IN USA WARNING POWER LINE MUST GROUNDED AT OUTLET REMOVE ALL POWER BEFORE REMOVING COVER OR CONNECTING OR DISCONNECTING CABLES SYSTEM AL ULTRASOUND OUTPUT Probe or Automation Control Input Ultrasound Out Figure 12 1 Rear Ultrasound and System In Connectors Cables Make sure that both the U S coaxial and Control Input cables are connected You must have a trig
12. 69 s Time 69 Multi Probe Control Module 51 Multi Probe Mode Flow 11 2 68 Multiple Probe System Cabling sicco 22 N Navigation Keys Menu Keys 29 33 34 77 O OFFLINE Status Display 31 120 E wO O 30 ON LINE Status Display nau da Rug ln san 31 119 ON LINE rr c 30 119 Operational Checkout uicina cai dudit ax 119 120 Operating Ree ome 148 Operational Control Thruster 23 24 49 OSHA nde apa aka pasas am dd nai 12 Output Connector System Status 19 39 42 ISOLATE Me CC Ea 42 45 OVERLOAD aval bara Rae dua i rund 31 32 127 OVERLOAD Status OU 43 DOVERTEMP Status 31 127 OVER TEMP Stat Uk OUTPUT 43 P Parameter Values 85 Part Count Count Sus Bad Part 100 E gt 100 PES OU
13. 14 Gauge Wire Automation RG62B U Control Cable P N 200 1203 Automation P N 200 1302 Equipment Base Cable Part No 200 1124 Jumper Block Part No 200 1293 5 um Pins 3 amp 9 to J902 ES Connected 14 Gauge Wire Earth Ground Figure 3 7 DPC II Plus Automated Thruster Cable Connections Dukane Manual Part No 403 551 03 23 Dynamic Process Controller DPC II Plus User s Manual Dukane Press System Step 1 Ground the DPC II Plus the Thruster and the Base as shown in Figure 3 8 Step 2 Attach the high voltage coax cable from the press 71 connector to the DPC Ultrasound Out connector J1 Connect the Press Base Input cable from J35 on the Press Base to the DB 9 connector 1902 on the Press Control Module Connect the Operational Control cable from J3 at the top of the press to the 36 contact Thruster control connector 7901 on the Press Control Module Attach the power cord to the DPC II Plus and plug the other end into an approved AC outlet Step 3 Step 4 Step 5 us 100 DUKANE Ct je J902 to Base Abort J901 to Thruster 14 Gauge Wire Ultrasound Input T 00 ORP ST CHARLES IL 60174 MADE IN USA WARNING Part No 200 479 Coaxial Cable
14. 52 Status Driver 2 22 2 2 4 52 Automation Cycle Stop or End Of Weld 52 Switch Debounce Filter Time Delay 52 Timer Board Enable Bypass 52 System Control Inputs 53 Card Slot and Jumper Block Locations 53 Dukane Corporation 0 Ultrasonics Division Dynamic Process Controller DPC Plus User s Manual This page intentionally left blank 38 Dukane Manual Part No 403 551 03 Section 5 Rear Connectors Rear Panel Layout 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 mod ules shown Specifically the Multi Probe Control ler and the Press Control Modules are mutually exclusive The modules are shown here to indi cate their installed locations and connector types Multi Probe Slave U S Outputs Grounding PATENT 4 277 710 WARNING POWER LINE MUST BE GROUNDED AT OUTLET LINE VOLTAGE 200 240Vac 50 60Hz gt 15 Figure 5 1 Rear AC Power Switch MODEL 3150 HN4 L2 200 240 50 50 Hz 15A Multi Probe Master U S Input DPC II Plus Rear Panel Connectors Multi Probe Master U S Outputs Press Base EEPROM Serial Programming Port Power Signal Output Monitor Remote Amplitude Control Thruster Op
15. 21 TUNMO 7 Bad tied Desa c Ud ve EU gu Ewa 100 Bad Part 90 Bad Part Status Pics MM 45 Base Press Input Cable 1 eerie rennen nuns unn haa nan inna din 23 24 48 aaa a ai 17 BOOS Gi oder DIS em 106 Booster Galli eee te 114 Booster NOUS cade oda OR cub uude REND 114 Booster Output End Geometry 114 C Cable Color 41 Cable Connections 0 12 20 24 40 42 47 49 Cable Part Numbers 22 1 1 emen nnn nenne 21 24 Dukane Manual Part No 403 551 03 169 Dynamic Process Controller DPC II Plus User s Manual Cable Schematics System uos 21 24 125 EY c 34 74 CE Compliance Conformit Europ ene 6 8 147 Center DepressiOfis uus nacidos an RR RV 137 Chassis Maintenance 1 1 1 n rss nnns
16. BD BYPASS MONITOR e R781 ADJ SWITCH DEBOUNCE R753 CR73 FILTER TIME DELAY SELECTION AES cni 16728 705 E E DELAY JU718 1 MSEC d 30719 10 mSEC 07197 Ju720 88 mSEC 1 1 STATUS RELAY AUTOMATION SIGNALS SELECTION BLOCK SELECTION BLOCK d OUTPUT SH 03 RP701 SH704 R783 JU 08 U S ACTIVE NORMALLY OFF 41709 OVERLOAD NORMALLY ON JU 10 OVERTEMP AUTO STOP FAULT JU7 11 SYS FAULT AUTO END OF UELD CR725 C702 40712 ANY FAULT 90728 4 CR728 1 CR707 C727 CR736 5 0715 R789 CR708 1 J 1b 4715 MULTI PROBE MULTI PROBE CONTROLLER BOARD CONTROLLER BOARD q 4 4 E STATU CR7 0 SELEC
17. 147 Federal Communications Commission 147 CE Marking Conformit Europe ne 147 CE ERN RT 148 Operating 148 Power Requirements 149 Interpreting The DPC Model Number 150 Dukane Corporation OUAIS e Ultrasonics Division Dynamic Process Controller DPC Plus User s Manual This page intentionally left blank 146 Dukane Manual Part No 403 551 03 Section 15 Specifications Regulatory Agency Compliance rcc FE The DPC II Plus complies with the following Fed eral Communications Commission regulations The limits for FCC measurement procedure MP 5 Methods of Measurement of Radio Noise Emissions from ISM Equipment pur suant to FCC Title 47 Part 18 for Ultrasonic Equipment CE Marking C This mark on your equipment certifies that it meets the requirements of the EU European Union con cerning interference causing equipment regulations CE stands for Conformit Europe ne European Conformity The DPC II Plus complies with the following CE requirements The EMC Directive 89 336 EEC for heavy in dustry EN55011 and EN50082 using EN61000 4 2 EN61000 4 3 61000 4 4 N61000 4 5 N61000 4 6 N61000 4 8 ENV50204 The Low Voltage Directive 73 23 EEC The Machine Directive 89 392 EEC usi
18. 107 Mounting Stud to Horn Booster 108 Horn to BOOSEBEI Laus cut epica tre 109 BOOSIE TO Probe t 109 Horno Proben 109 Torque Unit Conversion Chart 110 Stack 0 111 Booster NOteS 114 Stack 115 Dukane Corporation DU A e Ultrasonics Division Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 104 Dukane Manual Part No 403 551 03 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 plas tic welding the vibrating tip is brought into con tact with one of the work pieces Pressure is ap plied and ultrasonic energy travels through the material generating frictional heat at the contact point of the two parts The frictional heat melts a molded ridge of plastic on one of the pieces and the molten material flows between the two surfaces When the vibration stops the material solidifies forming a permanent bond Probe Configuration A basic ultrasonic probe package consists of 1 A probe which houses the transducer to con vert the electrical energy supplied by the gen erator into mechanical vibrations 2 A horn to transfer t
19. other prototype tooling is warranted as of Dukane described in each specific proposal All Dukane warranties commence the date of the original shipment of the equipment or tooling and duration is based upon a single shift per day five day per week operation The warranty period on rentals of new equipment that are converted to a purchase are deemed to have commenced on the initial date of rental These warranties are limited to equipment and tooling operated and maintained per Dukane s written instructions and used under normal operating conditions These warranties do not include normal wear or normal wear items and do not cover damage attributable to misuse improper installation faulty repair unauthorized alteration or modification neglect or accident Misuse includes operation of equipment with tooling that is not qualified for the equipment or properly installed on the equipment The warranty on all Dukane equipment and tooling purchased and installed in North America is a parts and labor warranty only Equipment installed outside of North America regardless of where it was purchased is covered by Dukane s International Warranty Policy In all cases when on site service is required Travel amp Living T amp L expenses will be billed at cost Warranty service labor including travel time at the customer s site is provided on a Monday through Friday excluding holidays 7 a m to 7 p m basis Any warranty service reque
20. 110 Trigger Method Menu eneen 66 75 77 Trigger Type 76 78 Troubleshooting senton naana 125 131 U Ultrasonic Output CONNECTION 19 39 125 Ultrasonic Welding Theory OT nasa strana rad ras 105 Universal Power pa quas condi a 8 Untimed Probe 66 73 Utilities T 61 98 Utilities Flowchart 61 97 V Values Parameter eseee 10 rennen enne 85 Vents Cooling Alr eR ST IRIURE 17 31 135 148 Vise Booster Clamping 113 Version Of DPC 57 W DOMESTIC 153 Warranty International siasio 154 Warranty er mr EN 154 Website 2 1 nanen nanne na 143 Weld 70 Weld By EE 67 69 176 Dukane Manual Part 403 551 03 Index Weld Cycle Data 57 65 81 Weld 67 70 79 Weld Method 67 69 78 Weld NY Lo
21. 143 Email Addresses es 144 Telephone 144 Dukane Corporation DUKA Ultrasonics Division Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 142 Dukane Manual Part No 403 551 03 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 15 best to call from a telephone located near the equipment Local Support Your local Dukane representative has received factory training and can answer all of your questions regarding Dukane equipment Ultrasonics Division Mailing Address Dukane Ultrasonics 2900 Dukane Drive St Charles IL 60174 USA Main Phone 630 797 4000 Main Fax 630 797 4949 Service amp Parts Fax 630 584 0796 Department Phone Numbers You can reach each department by dialing directly Application Support 630 797 4930 For applications and or process technology questions Engineering 630 797 4950 For engineering of standard and customized systems Service amp Parts 630 762 4090 For equipment servicing or replacement parts Tool
22. JU 24 JU 25 JU 2b 54 Dukane Manual Part No 403 551 03 SECTION 6 Menu Structure e Process Setup Process Control e Process Limits e Utilities 57 Process Control 58 60 61 Dukane Corporation Ultrasonics Division Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 56 Dukane Manual Part No 403 551 03 Section 6 Menu Structure Process Setup Menu This section deals with the overall menu structure Each setup menu 15 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 DUKRHE 11 1 10 c 2002 Dukane Corp Rights Reserved Figure 6 1 DPC II Plus Startup Menu After a few seconds the screen displays the welding mode and installed modules Depending upon your configuration your screen may display HAND PROBE DETECTED AUTO PROBE DETECTED MPC PROBE DE TECTED ECONOMY PRESS DETECTED or PRESS BOARD DETECTED This is shown in Figure 6 2 AUTO MODE PRESS BOARD DETECTED Figure 6 2 DPC II Plus Configuration Menu Then the screen then displays the operate page which contains the measured values from the last
23. 2 pair of test jacks on the rear panel allow a hand held multimeter to monitor the power 1 Power Signal Output Phone Jack 4 Output Zero Adjustment 2 Power Signal Output Test Jacks _ Ground Pin 13 3 Power Signal Output Pin 16 Figure 5 7 Power Signal Output Module The power output signal can also be monitored by automation equipment using the System Output connector by measuring between pin 16 Power Signal and pin 13 Monitor Ground Reference This module also features an offset adjustment to set the output to zero Only adjust the offset after the DPC system has been powered up for at least 15 minutes and with the ultrasound ouput deactivated Power Signal Output Module aka Energy Module P N 438 826 WARNING POWER LINE MUST GROUNDED OUTLET E REMOVE ALL POWER BEFORE REMOVING COVER OR CONNECTING DISCONNECTING CABLES Dukane Manual Part No 403 551 03 47 Dynamic Process Controller DPC II Plus User s Manual Press Control Module NOTE Part No 110 3938 The Press Module This optional module enables the DPC II Plus to i it control Dukane Model 210 220 or 410 press Multi Probe Master custom automation The module is illustrated in Module Figure 5 8 The cabling hookup to a Dukane press system is shown in Figure 3 8
24. 3 Read The Manual EISE dps 3 Caution and Warnings aesti pat 3 Drawings Labels isis rr initiate 3 Manual Organization cest tne Dress 4 DPC II Plus 6 Key DPC II Plus Features 7 Dukane Corporation DU Ultrasonics Division Dynamic Process Controller DPC Plus User s Manual This page intentionally left blank 2 Dukane Manual Part No 403 551 03 Section 1 Introduction Important User Information Read This Manual First Before operating the DPCTM Plus read this User s Manual to become familiar with the sys tem This will ensure correct and safe operation The manual is organized to allow you to learn how to safely operate an ultrasonic system The ex amples given are chosen for their simplicity to 1 lustrate basic setup procedures Notes and Tips Throughout this manual we use NOTES to provide information that is important for the successful ap plication and understanding of the product A NOTE block is shown to the right Cautions and Warnings In addition we use special notices to make you aware of safety considerations These are the CAU TION and WARNING blocks as shown here They represent increasing levels of important informa tion These statements help you to identify and avoid hazards and recognize the consequences One of three different symbols
25. 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 irregu larities will affect operation and could lead to further equipment damage Contact the Du kane Ultrasonic Tooling Department concern ing a damaged booster 2 Ensure that the mating surfaces of the two components are clean and smooth These sur faces must make intimate contact for the me chanical energy to pass from one component to the next Pitting or a buildup of old grease and dirt on a mating surface will interfere with the energy transfer and reduce the power de livered 3 Make sure that the stud in the horn or booster is tight See the preceding mounting stud as sembly instructions for torque specifications 4 Remove any foreign matter from the threaded stud and mating hole 5 Apply an extremely thin layer of a high tem perature high pressure silicon grease to the surface that mates with the horn The grease will allow both surfaces to intimately mate and become acoustically transparent which im proves the energy transfer We recommend Dow Corning 74 or 111 as an alternate A small packet of Dow Corning 4 is supplied with the system If you cannot use a silicon based grease in your facility a petroleum based grease may be used However it is likely to leave carbonaceous deposits on the surface and require more frequent joint mainte
26. Dukane Manual Part No 403 551 03 153 Dynamic Process Controller DPC Plus 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 Warranty duration shall be defined as documented herein and in conjunction with any exceptions or exclusions in the accompanying Dukane quotation to the Purchaser Equipment Type Equipment Warranty Duration Other Comments Custom Systems 12 months on all Dukane designed and built content Dukane standard product included in custom systems that is not part of our standard product are covered by the applicable product warranty manufacturer OEM warranty is applicable optics are warranted for only 30 days Ultrasonic Welder 12 months See WARRANTY EXCLUSIONS OR EXCEPTIONS below Vibration Welder 12 months Production 12 months one time replacement 6 month none Tooling one time replacement for carbide tipped horns Prototype Tooling All tooling made from Renshape 460 Renwood Prototype Renshape 460 Renwood tools employ are only warranted for 200 part cycles reusable content and therefore remain the property
27. This page intentionally left blank 64 Dukane Manual Part No 403 551 03 Section 7 Process Control Menu Process Control Menu The Process Control Menu has a dynamic struc ture Its configuration is determined each time the DPC II Plus is turned on The processor scans for installed modules and connected probes and con figures the user interface to match the installed hardware This is another reason the AC power must be turned off before any modules or probes are installed or removed If you are using a hand probe make sure you have the latest version of the hand probe adapter cable P N 200 1248 This has pin 11 Hand Probe Detect of the male HD 15 cable connector grounded Hand Probe Make sure you have connected the hand probe as indicated in Figure 3 4 When the II Plus is powered up it displays the current version of the firmware and then indicates the current configu ration This is shown in Figures 7 1 and 7 2 The screen then displays the measured values from the last weld cycle as shown in Figure 7 3 If a Power Output module is installed the menu will also display the energy data as in Figure 7 4 DUKRNE II v1 10 c 2002 Dukane Corp All Rig 5 ved Figure 7 1 DPC II Plus Startup Menu AUTO MODE PROBE DETECTED Figure 7 2 DPC II Plus Configuration Menu CAUTION Make sure electrical power is OFF before connecting disconnecting cables
28. ate schematic diagram in Figures 3 4 thru 3 8 Grounding Contacts Figure 2 3 Figure 2 4 To Gro Figure 2 5 Typical Outlet AC Power Cable Provided International 220 240V Grounding 10 24 x 1 threaded stud DPCGrounding Arrangement Press Grounding Arrangement Dukane Manual Part No 403 551 03 13 Dynamic Process Controller DPC Plus User s Manual This page intentionally left blank 14 Dukane Manual Part No 403 551 03 SECTION 3 Unpacking amp Installation e Unpacking the DPC e Placement of the DPC e Rear Panel Overview e Grounding the System e Connecting the Cables Shipping Carton Contents 17 DPC 17 Du etd 17 Rack MOUNTING 18 Rear Panel Overview 19 Ground the System PEE 19 Connect the Cables 20 Hand Probe System sedi eec oet nad eH 20 Automated Probe System 20 Multiple Probe 22 Automated Thruster System 23 Dukane Press E err el pu 24 Emergency Stop Switch Interface 25 Rear Electrical Power 5 25 Dukane Corporation Ultrasonics Division Dynamic Process Controller
29. ences and parameter data The ENTER key sym bols shown in Figures 7 7 7 12 7 21 and 7 30 are not shown here for readability 82 Dukane Manual Part No 403 551 03 Section 7 Process Control Menu PROCESS TRIGGER METHOD CONTROL TIMED PROBE 2 UNTIMED PROBE 7 52 PROCESS TIMED UNTIMED TIMED TIMED UNTIMED timed rmen nmen SymBoL LEGEND Menu and Logic EN Path appear in MODE wing fer MODE AUTO STOP 7 16 Menu in different ENABLE DISABLE logic path but AUTO MANUAL ENABLE or DISABLE looks the same as this Figure No Parameter Value T Time E Energy Hand HEAD UP ON Probe 5 Trierer TRIGGER TYPE 7 37 PROCESS CONTROL RTW READY TO WELD WELD MODE SINGLE DUAL Enable PRESSURE PRESSURE Disable gt PROCESS CONTROL PRESSURE WELD HOLD AFTER PRESS METHOD TIME BURST 7 25 2 15 WELD METHOD 7 23 Step 1 Step 2 Sp Enable So Disable 17 15 WELD METHOD WELD METHOD WELD METHOD GND GND TIME ENERGY TIME ENERGY TIME ENERGY Hand 4 O Probe S Cm 7 9 Figure 7 58 Process Control Menu Flowchart RTW READY WELD Dukane Manual Part No 403 551 03 83 Dynamic Process Controller DPC Plus User s Manual Table 7 1 below summarizes the various method and mode menus and references the
30. 25 Female type Pin numbers are shown in Fig ure 5 4 and pin assignments are given in Table 5 V Dukane cable assembly P N 200 1302 13 12 11109876 55432 1 is used to connect the DPC to custom automa 0000000000000 tion equipment to monitor the welding process A complete description of the signals and their 25 24 23 22 21 20 19 18 17 16 15 14 function is given on the following pages Figure 5 4 25 System Output Connector Pin Signal Name Signal Description 1 Current limited to 250 mA maximum 22VDC Return DPC Chassis Ground Status Driver Output Ground Chassis Ground Status Driver Output Spare Output Pin Ultrasound Status Output Active Low System Fault Output Active Low Overtemperature Fault Output Active Low Overload Fault Output Active Low On Line Status Output Active Low Status Outputs Ground DPC Chassis Ground 4 20 mA Current Loop Fault Output Active Low Monitor Outputs Ground DPC Chassis Ground Frequency Monitor Output 31Vrms maximum Amplitude Monitor Output 10 0V 10090 Power Signal Monitor Output 1mV 1 watt Pwr Reg Stat Power Regulation Status Output Active Low MPC Ready Multi Probe Controller Ready 4 Active Low Iso Pwr Fail Isolated Power Fail Signal Active Low Iso BSP Isolated Bad Suspect Part Output Active Low Isolated Good Part Output Active Low Isolated Ready Signal Active Low Isolated In Dwell Signal
31. Dukane Manual Part No 403 551 03 Section 10 Probes and Probe Stracks Stack Assembly NOTE Do not apply any grease to the threads of the Attaching A Replaceable Tip replaceable tip This may cause the tip to loosen To A Horn from the horn resulting in inconsistent operation 1 Inspect all horn and tip surfaces for stress cracks chips or gouges Any of these irregu larities will affect operation and could lead to further equipment damage Contact the Du kane Ultrasonics Tooling Department concern ing damaged horn components 2 Apply an extremely thin layer of a high tem perature high pressure silicon grease to the back surface that mates with the horn The grease will allow both surfaces to intimately mate and become acoustically transparent which improves the energy transfer Do not apply any grease to the threads We recommend Dow Corning 4 or 111 as an alternate A small packet of Dow Corning 74 is supplied with the system If you cannot use a silicon based grease in your facility a petroleum based grease may be used However it is likely to leave carbonaceous deposits on the surface and require more frequent joint maintenance Failure to follow these instructions may re sult in the mating surfaces bonding and diffi culty removing the tip from the horn 3 Thread the tip into the horn and tighten to the Figure 10 3 Replaceable Tip Installation torque specifications below
32. Maximum T ax 30 000 Seconds Minimum Tmax 0 001 Second Maximum 0 150 Seconds Minimum 0 001 Second These values can be set to zero but will not produce any output The values listed represent the resolution and are the smallest values that will produce any output signal Figure 7 12 Multi Probe Controller Flow Chart Dukane Manual Part 403 551 03 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 typi cally 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 Figure 7 14 MPC Probe Time Delay Weld Method Time For the Time welding method an ultrasonic sig nal is generated for a specific time once triggered After the AUTO STOP menu the WELO METHOD menu is displayed This is shown in Figure 7 15 WELO WELD BY TIME WELO BY ENERGY GROUND DETECT Figure 7 15 Probe Weld Method Selection Menu To weld by time select WELD BY TIME using the Up and Down arrow keys and press the ENTER key The weld time data entry screen appears as shown in Figure 7 16 WELO TIME 0 450 SEC Figure 7 16 MPC Probe Weld Time CAUTION If the AUTO STOP option is set to ENABLE you must supply the Isolat
33. SLAVE MASTER n SH 02 9718 D JU 03 U S ACTIVE 0705 41704 OVERLOAD 1 1 Ju 05 OVERTEMP SYS FAULT JU 0 FAULT CR706 749 zi J71 CR704 0707 4 STATUS DRIVER 1 J lu PRESS CONTROL 110 3606 BOARD DUKANE ULTRASONICS TS ne A MADE IN USA Juzna NoRMALLY NORMAL STATE SELECTION BLOCK 1 29 CR720 721 C708 C709 721 4710 POWER SIGNAL OUTPUT BOARD STATUS RELAY BOARD U708 al R771 JON IS0 SINK e JON IS0 SOURCE ISOLATED
34. ger input to the SYSTEM IN HD 15 connector ei ther by the probe s control cable or custom auto mation Refer to Figures 3 4 through 3 8 for de tails Put the generator OFF LINE and turn off the AC power switch Check the coaxial cable for any signs of damage which may result in an open cir cuit preventing the cable from transmitting the sig nal from the generator to the probe If you have a mounted probe replace the coaxial cable with a known good cable If you are using a hand probe try a different known good probe to determine if the problem is related to the generator or external cables and probe Dukane Manual Part No 403 551 03 125 Dynamic Process Controller DPC II Plus 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 dis play should indicate ON LINE which is marked as B in Figure 12 2 If the generator is OFF LINE press the ON LINE control key C SYSTEM POWER OUTPUT 0 20 40 60 80 100 PERCENTAGE OF AVAILABLE POWER Figure 12 2 Generator ON LINE Key and Indicator Operate Input If you are using a hand probe make sure the con trol cable is connected to the System Input con nector The trigger on the hand probe activates the Ultrasonic output through the control cable If you have supplied custom automation signals pin 8 or pins 3 amp 4 of the Operate
35. the resolution and are the smallest values that will produce any output signal Figure 7 7 Probe Flow Chart Dukane Manual Part No 403 551 03 Section 7 Process Control Menu METHOD WELD BY TIME WELO EY 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 Ifa Power Output module is installed then a Weld Method screen shown in Figure 7 8 is dis played first Press the ENTER key to display the weld time data entry If a Power Output module is not installed there is only one choice and the Weld Method screen is bypassed Timed Hand Probe op eration requires the weld time to be entered Use the Left and Right arrow keys to move to the desired digit position and the Up and Down arrow keys to increment or decrement the value When the desired value is displayed press ENTER for the next menu until all the required values have been entered WELO TIME 0 500 SEC Hand Probe Weld Time Figure 7 9 Timed Hand Probe Energy Ifa Power Output module is installed you can also choose the Weld By Energy method From the Weld Method screen shown in Figure 7 8 move the cursor down so it points to Weld By Energy and press the ENTER key To weld using the Energy Method you first enter the desired welding energy This data entry screen is shown in Figure 7 10 Enter the desired weld ing energy an
36. weld cycle as shown in Figure 6 3 If the Parts Counter covered in detail in Section 9 Utilities is active the count 1 displayed in the upper left hand corner in place of the dashes The sign and the digit after the dashes indicate which setup file is active There are eight setup files avail able Setup files are covered in Select Setup of Section 9 Utilities Menu ENERGY LI 0 000 0 000 Figure 6 3 DPC II Plus Weld Cycle Display Press the MODE key once to switch from the Operate mode to the Setup mode and display the Process Setup menu shown below in Figure 6 4 rss PROCESS CONTROL LIMITS PROCESS UTILITIES Figure 6 4 DPC II Plus Process Setup Menu Dukane Manual Part No 403 551 03 57 Dynamic Process Controller DPC II Plus User s Manual 4 Part Count appears here OPERATE TOTAL Only present if Setup File currently being used From many levels down in the menu Power Output Module is installed SETUP PROCESS SETUP 5 CONTROL 4 PROCESS LIMITS UTILITIES UTILITIES SETUP UTILITIES PART COUNT Process Setup Main Menu Structure Figure 6 5 The main structure of the Process Setup menu is shown in Figure 6 5 You can press the MODE key or the CANCEL key twice at any time to return to the Process Setup menu The MODE key toggles between the Weld Cycle data Operate mode and Process Setup menu
37. 13 7 Figure 15 1 Figure 15 2 Figure C 1 Figure C 2 Figure 3 Figure C 4 Figure C 5 Hand Probe Horn and Replaceable Tip 105 Probe with Booster and sa 106 Replaceable Tip Installation 2th retta 107 Stack Assembly potet aetate resa rostra rra 109 Torque Value Conversion Graph 110 Hand Probe Assembly and Disassembly 111 Probe Stack With Booster Assembly and Disassembly 112 Separating The Horn From The Booster 113 Removing Replaceable Tip From Horn 114 Front Panel Startup Controls and Indicators 2 1 21 119 System Test Controls and 120 Stopping The Weld eiii re 121 Rear Ultrasound and System In Connectors 125 Generator ON LINE Key and 126 Troubleshooting Flowchart Part 1 127 Troubleshooting Flowchart Part 2 128 Location or DPC Air Cooling 5 eet teta renes 135 Location of Stack Mating
38. 135 Circuits 161 166 Configuration coded D codd pua d idu uU Edu 57 65 Confirmation Screen 4 0 140 nennren nenas ennt net nanan anna 35 Connectors Identified 19 39 125 Connector 6 ener nenne nenne 40 42 48 49 126 Controls Front Panel eere ror ree 29 Connectors Rear 19 39 40 42 125 135 RM 41 S 30 119 121 128 135 Alt VENTS bena a a 17 148 CODY SETUP 99 137 Counter Presse eredi 101 Counter o teuer aus estu pulv det is Cetus es eve dds Golders te dus 100 TETTE DOE 137 Current Loop Connector 4 20 mA eee cte ctr 46 Current Loop asst a ct ci a ha ua a 44 Current Loop Transfer PUPICDIGDEL 46 Current 5 ue vean daga 165 Current Source Circuit 1120022 166 Cycle Press 101 D Data MCN ee 35 DB 25 Connector System
39. 2 Leaving the cursor at NO and pressing ENTER will still return you to the Process Setup menu Figure 9 2 ERASING IN sedat ase Figure 9 13 Erase Setup In Process Dukane Manual Part No 403 551 03 99 Dynamic Process Controller DPC Plus 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 cur sor down to YES as shown in Figure 9 14 Press the ENTER key to delete the setup files 1 1 YES Figure 9 14 Confirm Erase All Setups A progress message see Figure 9 15 appears for about 8 seconds When the process is complete the display returns to the Process Setup menu as shown in Figure 9 2 TERASING ALL SETUFS JOR RGIEE SS Figure 9 15 Erasing All Setups In Process Part Count The parts count option see Figure 9 3 offers three options The three choices are to reset the counter count suspect bad parts and preset the counter as shown in Figure 9 16 COUNT RESET PART COUNT COUNT SUS BAD PART PRESET PART COUNT a Figure 9 16 Count Selection Menu The count replaces the in the upper left of the operate screen see Figures 7 3 7 4 7 31 and 7 53 Reset Part Count This function resets the parts counter back to zero With the cursor at the reset
40. 5 145 Regulatory nennt ennnen eneen 147 Federal Communications COMMISSION epe 147 CE Marking Conformit 147 DIMENSIONS 148 Operating oe etu Renee numo ede rd REDE 148 Power Regui remens discus aei 149 Interpreting The Model Number eese 150 Section 16 Warranty 151 Domestic warranty 153 International Warranty 154 Appendix List of Figures 155 Appendix B List of 159 Appendix C User Supplied Circuitry 161 Manual Switch Circuit e E 163 Automation Switch Circuits 164 Isolated Automation 165 166 C rrent SOURCE 167 169 Dukane Manual Part 403 551 03 ix DPC II Plus User s Manual This page intentionally left blank x Dukane Manual Part No 403 551 03 SECTION 1 Introduction General Information Manual Organization DPC II Plus Overview Key DPC II Plus Features Before Operating
41. 7 Power Signal Output Module 47 Figure 5 8 Press 48 Figure 5 9 Press Connector Pin Identification 1 48 Figure 5 10 Press Board SH901 Cycle Activation Jumper 50 Figure 5 11 Master and Slave Multi Probe Controller Modules 21 Figure 5 12 Slot Connector Jumper Block Locations 53 Figure 5 13 Jumper Block Details 54 Dukane Corporation DUI NIS Ultrasonics Division Dynamic Process Controller DPC II Plus 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 Figure 7 1 Figure 7 2 Figure 7 3 Figure 7 4 Figure 7 5 Figure 7 6 Figure 7 7 Figure 7 8 Figure 7 9 Figure 7 10 Figure 7 11 Figure 7 12 Figure 7 13 Figure 7 14 Figure 7 15 Figure 7 16 Figure 7 17 Figure 7 18 Figure 7 19 Figure 7 20 Figure 7 21 Figure 7 22 Figure 7 23 Figure 7 24 Figure 7 25 Figure 7 26 Figure 7 27 Figure 7 28 Figure 7 29 Figure 7 30 Figure 7 31 Figure 7 32 Figure 7 33 Figure 7 34 Figure 7 35 Figure 7 36 Figure 7 37 Figure 7 38 Figure 7 39 Figure 7 40 DPC Startup Menu 57 Plus Configuration Menu 57 DPC Plus Weld Cycle Display
42. Active Low Isolated Outputs Common Isolated Gnd Spare Output Pin Table 5 IV System Output Connector Signals 1 amp maximum 1 1 1 1 1 1 1 8 2 2 2 2 2 1 2 3 4 5 6 7 0 1 2 3 4 5 2 42 Dukane Manual Part No 403 551 03 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 Fig ures 4 7 and 4 8 The factory default is OVERLOAD Pin 5 Not Used Pin 5 is reserved for future use Pin 6 U S Active An active low output on pin 6 indicates the ultra sound is being delivered to the probe Pin 7 System Fault An active low output on pin 7 indicates the generator has detected an out of tolerance voltage fluctuation The front panel status display will indicate FAULT Pin 8 OVERTEMP An active low output on pin 8 indicates that one of the power modules in the generator has overheated and automatically shut down The front panel status display will indicate OVERTEMP Pin 9 OVERLOAD An active low output on pin 9 indicates that ex
43. After the hold time value has been entered press the ENTER key to return back to the Process Con trol menu Afterburst is now automatically selected as shown in Figure 7 25 55 CONTROL WELD METHOD HULD TIME 5 Figure 7 25 Auto Probe Process Control Afterburst Menu Press the ENTER key to select the final set of welding parameters decision screen appears to either enable or bypass the afterburst setting To bypass the afterburst option select DISABLE and press the ENTER key You are then returned back to the Process Control menu Figure 7 22 Press the CANCEL key once or the MODE key twice to return to the root Process Setup menu Figure 7 29 RFTERBURST DISABLE ENABLE Figure 7 26 Auto Probe Afterburst Enable Menu Dukane Manual Part No 403 551 03 73 Dynamic Process Controller DPC Plus User s Manual To select an afterburst move the cursor down next to EMHBLE 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 dis play the desired value and press the ENTER key AFTERBURST DELAY 0 150 SEC Figure 7 27 Auto Probe Afterburst Delay Data Entry The menu now prompts you for the afterburst sig nal du
44. Although not indicated in this draw ing both upper and lower bounds can be set for each limit The Limit Definition menu is cov ered in greater detail in Section 8 PROCESS LIMIT DEFINITION LIMITS LIMIT DEFINITION lt gt SUSPECT nits PROCESS BAD SETUP TIME ENERGY TOTAL TIME PROCESS m LIMITS WELD WELD WELD WELD TOTAL TOTAL WELD TIME WELD ENERGY Total Limits Available Only with Press Controller Dual Pressure Mode Figure 6 7 Limit Definition Menu Flowchart 60 Dukane Manual Part No 403 551 03 Section 6 Menu Structure Utilities The Utilities menu has four different sections The first section handles setup file operations The sec ond section accesses the parts count functions The third section configures the status output The fourth section allows the operator to cycle the press off line A simplified flow chart for the Utilities menu is shown in Figure 6 8 and is covered in greater detail in Section 9 UTILITIES 2 PROCESS SETUP SETUP UTILITIES SELECT COPY ERASE STATUS PART OUTPUTS COUNT ERASE MAINTAINED PULSED RESET EUNT PRESET SETUPS COUNT PARTS COUNT LOCAL REMOTE ERASE ERASE CURRENT ALL SETUP sETUPS Figure 6 8 Utilities Menu Flowchart Dukane Manual Part No 403 551 03 61 Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 62 Dukane Manual
45. Control is discussed in detail in Section 7 58 Dukane Manual Part No 403 551 03 Section 6 Menu Structure PROCESS TRIGGER METHOD CONTROL TIMED PROBE z UNTIMED PROBE PROCESS AUTO MPC HAND SETUP PROBE PROBE PROBE TIMED UNTIMED TIMED UNTIMED TIMED MODE AUTO STOP AUTO MANUAL ENABLE or DISABLE HEAD UP ON AUTO STOP TRIGGER TYPE UNTIMED UNTIMED UNTIMED MPC HAND PROBE PROBE PROCESS CONTROL WELD HOLD AFTER MODE TIME BURST Step 1 V V RTW RTW READY TO WELD Step 2 Step 3 TIMED AUTO WELD MODE PROBE SINGLE DUAL PROCESS CONTROL SINGLE DUAL PRESSURE PRESSURE WELD AFTER PRESS PRESS METHOD TIME BURST WELD METHOD GND TIME ENERGY TIME 4 ENERGY TIMED HAND PROBE WELD METHOD WELD METHOD WELD METHOD GND GND TIME ENERGY DETECT TIME ENERGY DETECT TIME ENERGY mee oe omen il RTW READY TO WELD Step 1 Step 2 Step 3 Figure 6 6 Process Control Menu Flowchart Dukane Manual Part No 403 551 03 59 Dynamic Process Controller DPC II Plus 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
46. Conversions 1 5 x 20 Stud A0kHz Stack Xx Figure 10 5 Torque Value Conversion Graph 110 Dukane Manual Part No 403 551 03 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 Main tenance in Section 13 halve the time between in spections If the surfaces do not require recondi tioning then double the time between inspections Each system is different due to the large number of operational parameters and stress factors ASSEMBLY Output End 1 1 I lt Mounting Stud Insert Into Horn First and Tighten to Torque Specs i Input End Figure 10 6 Probe Assembly and Disassembly PROBE ASSEMBLY DISASSEMBLY Dukane Manual Part No 403 551 03 111 Dynamic Process Controller DPC Plus User s Manual The assembly and disassembly procedures for a hand probe shown in Figure 10 6 The same pro cedure for a probe stack with booster 15 shown in Figure 10 7 It makes no difference whether the horn is att
47. DPC front panel is laid out in three sections as illustrated below in Figure 4 1 The three sections are 1 AC Power switch and indicator 2 Generator Status Panel which contains e Three Generator Control keys e System Status display 9 e System Power Output display 0 3 Process Control Panel which contains e Twelve Menu Function keys LCD menu display SYSTEM POWER OUTPUT BAB 1 PERCENT OF AVAILABLE POWER WELD 2 CANCEL Dynamic Process Controller Figure 4 1 DPC II Plus Front Panel Layout Dukane Manual Part No 403 551 03 29 Dynamic Process Controller DPC Plus 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 Green LED The green indicator above the switch lights when the DC bus is up after the AC power has been switched on At this point the generator is capable of producing an ultrasonic output signal 2 Generator Status Panel The Generator Status Panel is subdivided into three sections which provide control and status displays 1 Generator Control Keys 2 System Status Dis
48. Input dies 40 Up On Auto p 76 Healthy and 11 HOLD KEY np ES 33 81 Hold 73 80 85 HOr 106 H rn PSS ita baud itin dead me 112 Horn Contact 136 HOP COFFOSIOD 137 Horn 111 H rn Res rfaciNg 138 HOLUKGyS tente e tec daa aa obra va flu 34 81 Dukane Manual Part No 403 551 03 171 Dynamic Process Controller DPC II Plus User s Manual KEY eas 33 In Dwell Status d ud a dl ndn 45 Indicator POW GM rate uode a cue De cute cue Ue dcc a date Ta do Te du de ud deux 19 30 Initiate 76 78 Input Connector System 19 39 40 125 Input Isolated cites RD 41 69 INPUT TEST Display Lm 31 119 128 INPUT TEST Status DISplay d 31 Internet Sites 143 Isolated tiis uas 41 69 Appendix Isolated OU IES HT 42 45 101 ISO 9001 Certification 4 400222 8
49. J902 Press Base Cable Press Control Connector Module P N 110 3938 ABORT 227 4 a e 36 Contact Subminature D Figure 5 9 Press Connector Pin Identification Thruster Cable Connection Figure 5 8 Press Control Module Fane Type rmn tese rs NENNT ope o ar on nro oroat meris merae aoc aae tr meramente Table 5 V J902 Press Base Connector Pinout 48 Dukane Manual Part 403 551 03 Section 5 Rear Connectors Table 5 V on the previous page lists the pinout NOTE and signal DE Tune Press J902 Press Base connector has multiple ground pins Base connection Note that there is an automation The DPC 2 Plus uses pins 5 6 amp 7 for Ground input on pin 8 which is electrically identical to The DPC 3 uses pins 5 amp 7 for Ground pin 8 on the System Input connector This permits The DPC 4 uses pins 6 amp 7 for Ground you to use J902 to initiate operation without having To keep your custom automation circuits com to run a separate connection to pin 8 of the System patible with DPC models only use pin 7 for a Input connector Figure 5 9 identifies the ground connection to the Press Base connector numbers for both J902 and J901 It should be pointed out however that the does have an Automation Input on pin 8 Place Switch in WELD PRE
50. J902 Press Base Connector Pinout iiic rb 48 J901 Thr ster Connector PIFIGIE 49 Process Control Menu elec toss 84 Parameter Min Max Values 85 Recognized Limits in Dual Pressure Mixed Mode Welding Cycle 89 Recognized Limits in Dual Pressure Uniform Mode Welding Cycle 89 Recognized Limits in a Single Pressure Welding Cycle 89 Stud Torque Unit CONVerSIONS 108 Horn Booster Torque Unit Conversions 110 II Plus Generator Model and Power Supply requirements 149 Dukane Corporation DIAS e Ultrasonics Division Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 160 Dukane Manual Part No 403 551 03 APPENDIX C User Supplied Circuitry e Manual Control Switch e Automation Control Switch e solated Automation Control Manual Switch CITCUIT i e ens 163 Automation Switch 5 164 Non Isolated Switch Circuits 165 Current SIE eant ciat 165 166 Isolated Switch Circuit 167 Dukane Corporation 0 e Ultrasonics Division Dynamic Process Controller DPC Plus User s Manual Thi
51. Mating Surfaces Horn 136 Maximum Parameter Values 112 1 85 Maximum Weld 72 75 172 Dukane Manual Part No 403 551 03 Index Maximum Weld 67 70 71 79 Menu Confirmation 00 35 Menu Data ry 35 Menu Selection 2022 1 4 35 Menu nnns 59 66 68 72 75 M nu msnen m 29 33 34 77 Number Pete 150 Mounted 4 111 MODE KY 34 74 77 Mode MenU 75 79 Model Number Tag Location 22 paid nit rnd derat darc acento 19 51 MPC Probe Auto 68 ENUY 69 71 Maximum Weld 70 Weld Energy Menu 70 Method Menu
52. Optical Isolation Circuit Jumper Block SH707 Position JU725 1 Refer to Figure 5 12 1 No Connection Pin 42 amp Pin 7 Figure 4 Current Source Switch 166 Dukane Manual Part No 403 551 03 Appendix C User Supplied Circuitry Isolated Switch Circuit Isolated Current Source Circuit Figure C 5 illustrates a fully isolated circuit con nected to the Isolated Automation Inputs This re quires an external power supply to drive the switch The SH707 jumper block needs to be placed in the JU726 position refer to Figure 5 12 5 to 24V Automation Power Source No Connection Pin 1 Isolated Input High Side Pin 43 Operate Pin 5 Press Control Pin 49 Auto Stop Isolated User Current Supplied Source Switch Circuitry Isolated Input Low Side Pin 4 Iso Common No Connection Pin 2 amp Pin 7 V Automation Ground Figure C 5 Isolated Current Source DPC Internal Internal Power Supply DPC Plus 22V Circuitry Current Limit Circuit 250mA max 12 5 mA max Current Limit Circuit 12 5 mA max We Optical Isolation Circuit Jumper Block SH707 Position JU726 Refer to Figure 5 12 Dukane Manual Part No 403 551 03 167 Dynamic Process Controller DPC Plus User s Manual This page intentionally left blank 168 Dukane Manual Part No 403 551 03 INDEX A
53. RG62B U Operational Control Part No 200 1104 14 Gauge Wire 110 VAC or 220 VAC 8 conductor cable Part No 200 1124 arth Ground 14 Gauge Wire Figure 3 8 DPC Il Plus Dukane Press Cable Connections Grounding Lug 24 Dukane Manual Part 403 551 03 Section 3 Unpacking and Installation Emergency Stop Switch Figure 3 9 is a simplified example that demon strates the basic requirements to interface with the DPC II Plus on J902 This is excerpted from Ap plication Note AN201 available on our website Note that the emergency stop inputs cannot just be tied together from multiple DPCs when used Emergency Stop Switch Cable No 200 1124 Figure 3 9 J902 Emergency Stop Interface Example Electrical Power Switch The rear panel AC breaker switch Figure 3 10 is wired in series with the front panel breaker switch shown in Figure 4 2 When the rear breaker switch is off it isolates the AC power feed in the chassis for safety considerations Both the front panel and rear panel switches must be on to supply AC power to the DPC generator on a common welding process Multiple DPCs re quire individual contacts for each unit Check with your local safety compliance office before altering the factory connections The user is responsible for complying with all requirements of the safety regulatory agencies governing the geographic location where the Dukane equipmen
54. Red used by Belden may appear brown Sw Oper Input Iso Auto Stop Selection MSB 15 F P Lock Table 5 System Input Cable Color Code P N 200 1203 Black may be faint Don t confuse with 9 Red used by Belden may appear brown ES IS 1 1 This input be changed to a source or fully 150 lated input by jumper block SH707 See Figures 5 11 5 12 and Appendix C Pin 10 Not Used Isolated input reserved for future use Pin 11 Hand Probe Press Inhibit The adapter cable P N 200 1203 has pin 11 grounded to indicate a hand probe is connected Pins 12 13 14 Remote Setup These pins are used to select one of eight setup files When using the multi probe controller mod ule MPC these bits also select which probe is activated A dry contact closure between pins 12 13 or 14 and ground pins 2 or 7 will activate one of the setup files The pin combinations to select setup files 1 through 8 are given in Table 5 1 Note that file 1 is the default selection Pin 15 F P Lock A dry contact closure between pin 15 and ground pins 2 or 7 will lock out the front panel TEST key and prevent it from being activated This also prevents any programming changes Dukane Manual Part No 403 551 03 41 Dynamic Process Controller DPC II Plus User s Manual System Output Connector The System Output panel connector is a DB
55. Setup mode each time it is pressed Pro cess Setup is the root menu to select all subsequent sub menus The Press menu option is only present ifa Press Control Module is installed The energy value isonly displayed if a Power Output module is installed The Process Control menu sets the welding param eters Limit Definition menu sets the bounds for sus pect parts and bad parts Utilities menu enables you to save copy and erase setup files count parts which are out of limit and configure status outputs Process Control Menu By pressing the up arrow and down arrow keys you can navigate the triangle pointer to select the Only present if Press Control Module UNTIMED PROBE 4 LIMIT DEFINITION SUSPECT LIMITS BAD LIMITS STATUS OUTPUTS E Process Control Limit Definition or Utilities menu Press the ENTER key to activate the selected menu The Process Control Menu selects the trig ger method the welding mode and sets the values for the welding parameters This menu s structure is the most complex of the three However since the DPC II Plus reconfigures the user interface to be consistent with the installed modules only the relevant portion ofthe menu structure is displayed The flow chart for the Process Control menu is shown in Figure 6 6 The menu structure builds logically upon itself starting with the Hand Probe on the right side and progressing with more op tions towards the Press menu on the left Process
56. Te oreet eL 75 79 33 82 WELD PZ KEY S 34 82 Weld aae 67 69 78 Weld Time Min Max 2 0 0 1 6 85 Weld Time Limits 89 Wrench Horn amp Booster 14 107 Dukane Manual Part 403 551 03 177 Dynamic Process Controller DPC Plus User s Manual This page intentionally left blank 178 Dukane Manual Part No 403 551 03 DukaneISQ 1 ISO CERTIFICATION 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 service This cer tificate reinforces Dukane s status as a quality vendor of technology and products To achieve ISO 9001 2000 certification you must prove to one of the quality system regis trar groups that you meet three requirements 1 Leadership 2 Involvement 3 Quality in Line Organizations and Quality System Infrastructure The ISO 9001 2000 standard establishes a mini mum requirement for these requirements and starts transitioning the company from a traditional inspection oriented quality system to one based on partnership for continuous improvement This concept
57. Thruster System Step 1 Ground the DPC II Plus and the connector J902 on the Press Control Thruster as shown in Figure 3 7 Module If the automation system does Step2 Attach the high voltage RG62B U coax not have a connection to J902 you may need a jumper block Part No 200 1293 to replace the normally closed contact from the press base Emergency Stop cable from the rear panel DPC II Plus connector J1 to the ultrasound input J1 on the thruster see Figure 3 7 safety switch Step 3 Connect the Automation Control cable from the user supplied automation Step 6 Connect the Operational Control cable equipment to the System Input rear from the user supplied automation panel HD 15 connector equipment to the 36 contact Thruster Step 4 Attach the Status Output cable from the control connector 7901 on the Press Control Module user supplied automation equipment to the Status Output DB 25 connector Step 7 Attach the power cord to the DPC II Plus and plug the other end into an Step 5 Connect the Press Base Input cable approved AC outlet from J35 on the Press Base to the DB 9 80 100 psi Air Supply Top Of Stroke a Optional J901 Operational Control PIN 438 528 Part No 200 1104 Ultrasound 2 Grounding DUKANE CORP ST CHARLES IL 60174 MADE IN USA
58. Unpacking and Installation explains the DPC II Plus placement and setup It also shows the cable connections for quick start operation Section 4 Controls describes the function of the front panel controls menu keys and status display Section 5 Connectors gives the function pinout and sig nal description of the rear panel connectors on the DPC II Plus Operation of the optional modules is described in detail The internal jumper blocks to control process automation are also identified Section 6 Process Setup describes the overall menu or ganization of the DPC II Plus the setup and operate modes and gives a brief summary of the three main menus Section 7 Process Control Menu describes the Hand Probe Timed Auto MPC and Press mode menus and the Weld Methods It also covers the user interface configuration and param eter values Section 8 Limit Definition Menu describes the Suspect Limit and Bad Limit menus in detail Section 9 Utilities Menu describes the Setup File Utilities Part Count and Status Output menus in detail Section 10 Hand Probe and Stack Assembly describes the assembly and mounting of both hand probes and probe stack assemblies Section 11 System Checkout describes basic system tests to ensure that the DPC II Plus is func tioning properly 4 Dukane Manual Part No 403 551 03 Section 1 Introduction Section 12 Troubleshooting provides helpful tips on solv
59. also accompany the CAUTION and WARNING blocks to indicate whether the notice pertains to a condition or practice an electrical safety issue or a hand protection issue Drawings and Tables The figures and tables are identified by the sec tion number followed by a sequence number The sequence number begins with one in each sec tion The figures and tables are numbered sepa rately The figures use arabic sequence numbers e g 1 2 3 while the tables use roman se quence numerals e g I As an ex ample Figure 3 2 would be the second illustra NOTE NOTE statements provide additional informa tion or highlight procedures WARNING M point out conditions if practices that could re sult in personal injury or loss of life a ummmmmmmmmmmmmmm25 a 278 WARNING statements a 3N tion in section three while Table 3 II would be Condition Electrical Hand the second table in section three Practice Hazard Hazard Dukane Manual Part No 403 551 03 3 Dynamic Process Controller DPC Plus User s Manual Manual Organization Section 1 Introduction describes the manual organization and the key features ofthe Dukane DPC M Dy namic Process Controller II Plus Generator Section 2 Safety discusses OSHA regulations and safety considerations Section 3
60. 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 SYSTEM POWER OUTPUT 0 20 40 60 80 100 PERCENTAGE AVAILABLE POWER NOTE If the INPUT TEST indicator does not flash check the AC line input Both the rear panel and front panel AC breaker switches must be in the ON position and the DPC line cord must be properly connected to a live AC outlet If the INPUT TEST indicator flashes and then remains in a steady red state 1 The AC line level may be out of speci fied operating range The DPC may have an internal 3 The INPUT TEST indicator in the Status Dis fault preventing normal opertion play B flashes red for 5 to 10 seconds This Figure 11 1 Front Panel Startup Controls and Indicators 2 indicates the power up self test is running When the test has successfully completed the INPUT TEST indicator goes dark ew NOTE 4p Ine dd moror ui d If a Press Control module is installed and should then light up The yellow OFF LINE sta the ON LINE and OFF LINE indicators do not tus indicator D in Figure 11 1 should also light check the follwoing items be lit After subsequent power cycles
61. dois Oe Tete wow ee 29 AC Power Switch Breaker 0 19 25 30 39 AC Reguitemishibs 149 LESEN 73 74 80 85 AIF CIFCUlatiOE PS OR IE LI A E 17 135 JUD MSti 34 82 Amplitude e 82 Amplitude Control Module 46 Amplitude Monitor OUEDUE cias eod auod lU BAR Ra 32 44 PIA FTD 33 34 Auto Probe Mode 2 0 72 Auto Probe 1 73 Auto Stop 72 T ENUY mr 73 74 73 i Maximum Weld Time eese nnn 72 4 EP TEE 72 73 TK 73 j P E A 73 ii Method 73 Auto Stop DESI 69 AUTO Stop 68 72 76 Automated Probe SUSEBIm 20 Automated Thruster System e dua 23 Automation Circuits 163 164 Aut mation Control INPUTS ausa a Roe 40 41 Automation Equipment 1
62. ing the most common problems Section 13 Maintenance lists a schedule of suggested pre ventive maintenance items Section 14 Contacting Dukane provides information on contacting or obtaining support from your Du kane Ultrasonics team Section 15 Specifications lists the DPC II Plus dimen sions power and space requirements It also interprets the model number coding Section 16 Warranty contains a copy of our equipment warranty and tooling warranty Appendices A List of Figures B List of Tables C Sample Circuitry for user supplied automation Index Dukane Manual Part No 403 551 03 5 Dynamic Process Controller DPC Plus User s Manual DPC II Plus Overview The DPC II Plus is the newest model in Dukane s Dy namic 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 re quire 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 Plus ideal for automated control systems Signal conditioning and electrical isolation are also provided Like other DPC models the II Plus includes the same internal ultrasonic generator circuitry and features Op tional modules are available to enhance the DPC s abil ity to meet a wide variety of process requirements The most common
63. initiated the welding processes continues nor mally Momentary is recommended for most welding processes except hand probes If MAINTAINED is selected the trigger must be maintained during the entire portion of the weld cycle If the trigger signal is momentarily lost while the ultrasonic signal is on the weld cycle is terminated This mode is recom mended for special applications It has an ad vantage over momentary trigger in that it will generate a TRIGGER LOST error message if you suddenly lose trigger force see Error Messages in Section 12 Troubleshooting This may hap pen when welding soft plastic or small parts Single Dual Pressure Mode The SINGLE PRESSURE mode has the same pro gramming sequence as Weld method in the pre vious Timed Auto Probe The DUAL PRESSURE mode eliminates ground detect and allows Time or Energy target values to be used at both pres sure trigger points The modes can be mixed us 76 Dukane Manual Part No 403 551 03 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 with out Ground Detect Note that the Auto Probe Trig ger Method bypasses the Single Dual Pressure Weld Mode and jumps directly to Weld Method PRESS Mode Example We will now go through programming a typical press configuration with no automation and
64. is key in that Dukane no longer focuses on inspection but on individual processes Dukane s quality management system is based on the following three objectives 1 Customer oriented quality The aim is to improve customer satisfaction 2 Quality is determined by people The aim is to improve the internal organization and cooperation between staff members 3 Quality is a continuous improvement The aim is to continuously improve the internal organization and the competitive position 9001 2000 CERTIFIED Dukane products are manufactured in ISO registered facilities DUKANE CORPORATION WHO ARE WE We are plastic welding technoligists We are scientists We are employees and businessmen We are instructors We are engineers We are specialists in electronics and experts in plastic assembly We are salesmen We do basic research and we manufacture machines We are problem solvers and we are technical advisors We Are Your Partners REGIONAL OFFICES Northeast Region Rocco Telese 14 Delmar Drive Suite 6B Brookfield CT 06084 203 740 0089 2 Central Region Jason Barton 4424 Aicholtz Road Suite G Cincinnati OH 45245 513 752 8803 6 2 Automotive Automotive Region Lab Raymond LaFlamme 11235 Stark Road Livonia MI 48150 734 513 4038 Corporate Office and Training Center Regional Office A Application Laboratory Service Center A T
65. lnitiate Mode 76 78 5 Maximum Weld 79 gt ger Method 77 EX Uo 76 78 y Method nennen nennt nnns 78 79 76 78 79 Press Operate Palm Switches 101 Press Setup Example Proce ain assis enp aranea aite datae 77 81 24 Probe Auto 65 MU EE 72 1 oen 40 Maintenance 0 0 136 o 68 2 121 107 112 HET dotar mee 115 s Mme Delay to pu 69 MEMES VOC UNG D oa a 125 Process Control Flowchart enne nennen nennen 59 Men ume Ino re 58 59 65 66 84 Trigger Method Menu 66 Process Limits
66. on the booster mounting rings are always inserted from the output end toward the input end see Figure 10 7 How To Tell If The Booster Is Amplifying Or Reducing Boosters have a die stamped number on their sur face that indicates their gain or reduction Ifthe num ber is greater than 1 0 e g 1 5 it is an amplifying booster If the number is less than 1 0 e g 0 6 it is a reducing or reverse booster A neutral booster has no gain and has 1 0 stamped on it neutral or cou pling booster is used to provide another probe stack clamping location for added stability 114 Dukane Manual Part No 403 551 03 Section 10 Probes and Probe Stracks Mounting The Stack A probe horn assembly or probe booster horn as sembly stack can be mounted into a customer provided machine to ensure stability and proper alignment during operation or for automated op eration A stack is secured in a machine by clamp ing the probe and booster when present at des ignated locations Clamping at these designated locations provides stability to the stack and at the same time does not interfere with the transmis sion of ultrasonic vibrations of the stack compo nents The following rules apply when mounting a probe system stack 1 Aprobe may be clamped anywhere along its body except the 41530 If it has a side mounted BNC then it may require a thin mounting ring if it is to be clamped near the top It may also be clamped
67. or No entry to continue the process Select YES from the menu and press the ENTER key to proceed A typical con formation menu is shown in Figure 4 10 RESET PART COUNT YES Figure 4 10 Typical Confirmation Screen Data Entry Menu The data entry screens have the parameter name on the first line and the parameter value on the third line Use the left and right triangle keys to select the digit and the Increment and Decre ment keys to change the value Press the EN TER key to accept the value A typical data entry screen is shown in Figure 4 11 WELD TIME L j L 1 Figure 4 11 Typical Data Entry Screen Dukane Manual Part No 403 551 03 35 Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 36 Dukane Manual Part No 403 551 03 SECTION 5 Rear Connectors e Rear Panel Layout e System Input e System Output e Optional Modules e Internal Jumper Blocks Rear Panel Layout estet 39 System Input Connector ees 40 System Output Connector 42 Remote Amplitude Control 46 Power Output Module Option 47 Press Control Module Option 48 Multi Probe Module Options 51 Jumper Block Options 52 Status Driver Normal Selection State
68. 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 connector at the end ofthe probe cable Step 3 Connect the other end of the adapter to the System In HD 15 connector on the rear of the DPC II Plus Step 4 Attach the high voltage ultrasound coaxial cable to rear panel J1 connector Step 5 Optional If your system has a Press Control Module you will also need a jumper block Part No 200 1293 to replace the normally closed contact from the Emergency Stop safety switch Step 6 Attach the power cord to the DPC II Plus and plug the other end into an approved AC outlet Automated Probe System Step 1 Ground the DPC II Plus chassis and the probe support Step2 Attach the high voltage coax cable from the probe mount to the rear panel DPC connector J1 see Figure 3 5 Step 3 Connect the automation control cable from the user supplied automation equipment to the System Input rear panel HD 15 connector Figure 3 5 20 Dukane Manual Part No 403 551 03 Section 3 Unpacking and Installation Jumper Block 12 200 1293 Grounding Lug I e WARNING
69. second pass through Process Con trol 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 Figure 7 46 Press Hold Time Data Entry We return for a third time to the Process Control menu This time the A fterburst option is automati cally selected as shown in Figure 7 47 PROCESS CONTROL WELO MODE HOLO TIME AFTERBURST Figure 7 47 Third Pass Through Process Control Menu Press the ENTER key to display the Afterburst menu This permits you to enable or bypass the afterburst option To bypass the afterburst option select DISABLE and press the ENTER key You then jump back to Process Control as shown in Figure 7 51 To select an afterburst move the cur sor down to ENABLE as shown in Figure 7 48 and press the ENTER key AFTERBURST DISABLE ENABLE Figure 7 48 Press Afterburst Enable Menu The data entry screen for the afterburst delay ap pears as shown in Figure 7 49 Enter a value for the delay time and press the ENTER key AFTERBURST DELAY Figure 7 49 Press Afterburst Delay Data Entry The data entry screen for the afterburst duration appears as shown in Figure 7 50 Enter a value for the burst time and press the ENTER key HFTERBURST OURATION Figure 7 50 Press Afterburst Duration Data Entry The Process Control menu screen appe
70. the correct size in the socket head of stud to remove the stud from the horn or booster Removing Replaceable Tips From A Horn Use an open end wrench of the correct size to fit the wrench flats of the detachable tip Use a span ner wrench on horns with spanner wrench holes or an open wrench on horns with wrench flats to provide an opposite force and keep the horn from turning in your hand Refer to Figure 10 9 for the correct tip removal procedure NOTE Do not hold a booster by the mounting rings when removing the stud from the booster Use a spanner or open end wrench to provide op posite force and keep the horn or booster from turning in your hand when loosening the stud Use a spanner wrench on horns and boosters with spanner wrench holes Use an open end wrench on horns and boosters with wrench flats Dukane Manual Part No 403 551 03 113 Dynamic Process Controller DPC Plus 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 gt 1 0 the larger diameter end is the input end On a re ducing booster gain 1 0 the larger diam eter end is the output end On a neutral acting booster the diameters are equal 3 Thecap screws
71. the cursor to BAD LIMIT SELECTION You normally select the alternate unit of mea surement for bad and suspect limits If you are welding by time Seconds all the weld cycles have the same weld time There should be no measurable deviation from the target time value There will however be some variation in the power drawn by each part Since the time is con stant the power and thus the energy will vary slightly between parts The limit check therefore should be in units of energy Joules Too low an energy draw might result from a mechanical stop interfering with travel much energy drawn may be caused by a misaligned part resulting in a large mating surface area If you are using dual pressure mixed mode a good limits check would set the companion limit for each pressure plus the total time and en ergy limits In a dual pressure uniform mode only the alternate units for P1 P2 and TOTAL will be meaningful LIMITS in the Limit Definition menu and press ENTER The value is now associated with a Bad Limit and will now terminate the weld cycle if the measured value fall outside the boundary limits Process Limits Select either Suspect Limits or Bad Limits and press the ENTER key The choice can be easily changed later The Process Limits menu 15 then displayed This is shown in Figure 8 3 as it would appear for a single pressure mode weld cycle PROCESS LIMITS TIME ENERGY Figur
72. tion requires another type of cable check with the local Dukane products representative and fol low local regulations concerning proper wiring and grounding Considerations In addition to the safety considerations proper grounding at the generator power cord is essen tial for the effective suppression of RFI Radio Frequency Interference Every DPC contains a RFI filter which blocks noise on the AC power line from entering the DPC control circuitry This filter also prevents ultrasonic RFI from being fed back into the AC power line In order for the RFI filter to operate properly it is necessary to ad equately ground the DPC Run an additional grounding wire from the rear grounding connec tion see Figure 2 4 to the nearest grounded metal pipe or equivalent earth ground by means of a ground clamp Use at least an 14 AWG wire for the connection to the DPC chassis Stranded is more flexible and easier to work with than solid wire However if you use stranded wire crimp spade lugs on the end to ensure a good connection If you have a color choice green is the commonly accepted color for an electrical ground connection If you have connected the DPC to a Press and or Thruster use a star connection from the earth ground to the DPC and Press as illustrated in Figure 2 5 14 AWG wire has a diameter of 1 63mm 0 064 Run seperate ground wires from each piece of equipment to the earth ground See the appropri
73. tip Proper Installation Operate system components only after they are properly installed and checked No Unauthorized Modifications Do not modify your system in any way unless authorized to do so by Dukane Corporation Unauthorized modifica tions may cause injury to the operator and or equip ment damage In addition unauthorized modifi cations will void the equipment warranty Keep the Cover On Do not remove the equip ment cover unless specifically directed to do so by Dukane Corporation The generator produces haz ardous electrical voltages which could cause in jury Grounded Electrical Power Operate this equip ment only with a properly grounded electrical con nection See Electrical Safety Grounding Instruc tions on the next page Comply with Regulations You may be required to add accessories to bring the system into com pliance with applicable OSHA regulations Dukane Manual Part No 403 551 03 11 Dynamic Process Controller DPC Plus User s Manual Plastics Health Notice Before using any Dukane ultrasonic welding sys tem be sure you are familiar with OSHA regula tions 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 haz ardous Make sure there is proper ventilation whenever these plastics are processed Electrical Safety Groundin
74. us ing dual pressure mode We will assume that a Power Output module is also installed If your configuration does not have this module you can still follow along and substitute Time anywhere we have selected Energy We will start from an initial DPC power up so cycle the AC power switch off then back on If you are using a dual pressure press make sure the pres sure select switch is in the WELD position The screen first displays the firmware revision and then the hardware configuration as shown in Figures 7 1 and 7 2 The screen then displays the previ ous weld cycle data on the Operate screen This 15 shown in Figure 7 4 which is repeated here as Fig ure 7 31 If you do not have a Power Output mod ule your screen will look like Figure 7 3 ENERGY 1 TIME Figure 7 31 Previous Welding Cycle Data Press the MODE key once see Figure 7 32 and the screen changes from the Operate screen to the Process Setup menu as shown in Figure 7 33 Mode Key Enter Key Figure 7 32 Mode and Enter Menu Keys PROC 1 PROCES PROCES UTILITIES Figure 7 33 Process Setup Menu Process Control is selected by default Press the ENTER key to display the Trigger Method menu shown below in Figure 7 34 TRIGGER METHOD AUTO PROBE UNTIMED AUTO PROBE Figure 7 34 Press Trigger Method Menu The PRESS option should be selected by default If it isn t use the increment key u
75. when viewed from the front is the air intake and the left hand side is the exhaust Allow at least 2 inches 5 cm on either side for air circulation as shown in Figure 13 1 Intake Vent for Thermostatically nii lt apa DPC Plus Figure 13 1 Location of DPC Air Cooling Vents Allow spa 2 inches 9 cm on each side ce for ventilation Dukane Manual Part 403 551 03 135 Dynamic Process Controller DPC II Plus User s Manual Top Cover Keep the cover on at all times The chassis is ro bust enough to hold considerable weight How ever avoid placing excessively heavy objects on top ofthe chassis which may bend or dent the top cover resulting in damage to internal components Replaceable Parts The DPC is self contained and has no parts that are replaceable by the user If a part needs replace ment contact your local Dukane representative See Section 14 for contact information Stack Surfaces Stack Maintenance Itis essential that the mating surfaces ofthe acous tic stack components be flat and smooth When the components are joined together and tightened there must not be any air gap between the surfaces If there is any air gap there will be a loss in power and efficiency Air has much higher transmission losses than the metal horn Whenever the wavefront encounters an air gap the propagation velocity is significantly reduced and attenuated This res
76. 03 551 03 93 Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 94 Dukane Manual Part No 403 551 03 SECTION 9 Utilities Menu Setup Utilities e Part Count e Status Outputs Cycle Press Off Line Setup Utilities iussione itte 97 rj E ipo 98 COPY A ES il oc Dp PER 99 Erase usen ordi pe DR ebat 99 Rart COUN FPEM 100 Reset Part 100 Count Suspect Bad Parts enr tenere tran 100 Preset Part 101 Stat s 101 Cycle Press Off Line ccrte 101 Dukane Corporation DU A e Ultrasonics Division Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 96 Dukane Manual Part No 403 551 03 Section 9 Utilities Menu Utilities Menu The Utilities Menu 15 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 They only share a common thread of performing utilitarian functions UTILITIES UTILITIES lt gt PROCESS SETUP STA
77. 1 5 MOMENTARY MAINTAINED ENABLE DISABLE 1 aru V PROCESS CONTROL WELD HOLD AFTER MODE TIME BURST Step 3 Press Trigger ENTER ENTER Method Only pos WELD MODE Probe PRESSURE PRESSURE Bypasses SINGLE Single Dual PRESSURE Pressure PRESS Ero PRESS WELD METHOD Figure 7 30 Press Auto Probe Setup Flow Chart Dynamic Process Controller DPC Plus 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 The DUAL PRESSURE mode eliminates ground detect for obvious reasons and allows welding by Time or Energy at both pressure level settings Initiate Mode When using a press the usual choice is to select MANUAL for the Initiate Mode This permits the dual palm switches to initiate the operate sequence If AUTO mode is selected then an external initiate signal must be supplied to either pins 3 and 4 Iso Oper In or pin 8 Sw Oper In of the HD 15 Sys tem In connector Refer back to Figure 5 2 and Table 5 1 for more information Auto Stop The normal configuration when using a press 1s to set Auto Stop to DISABLE This permits the stan dard emergency OFF
78. 1 03 17 Dynamic Process Controller DPC Plus 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 08 1155 The DPC illustrated has the standard angled front panel of impact resistant ABS plastic Allow 5 inches 13 cm of space behind the DPC for cables 55 Dynamic Process Controller DPC II Plus Approximate 17 35 inches 44 cm gt 19 inches 48 Figure 3 2 Rack mounted DPC Using Bracket Kit 18 Dukane Manual Part 403 551 03 Section 3 Unpacking and Installation Rear Panel Overview Familiarize yourself with the connection points for power ground ultrasound output system I O and the optional modules on the rear of the DPC II Plus shown below in Figure 3 3 The standard modules and connectors are labeled with the black boxes The optional modules are labeled with ital ics The EEPROM Serial Programming Port is used to upgrade the DPC firmware The ground ing lugs serial number tags etc are located in the same position on all DPC II DPC II Plus DPC III and DPC IV generators Slave Multi Probe Controller Module Grounding Lug Rear AC Power Switch PATENT 4 277 710 Gy gt RNING POWER LINE MUST BE GROUNDED AT OUTLET LINE VOLTAGE 4 200 240Vac 50 60Hz 16 MODEL 31
79. 5 is proportional to the output signal amplitude The scale is 10 0V 10096 This allows automation equipment to monitor the DPC amplitude setting Pin 16 Pwr Sig This output is only available when the optional Power Signal Output module part 438 826 is installed The signal on pin 16 is proportional to the true RMS ultrasonic output power being drawn from the DPC The scale is 1 Watt on the 20kHz 30kHz and 40kHz models The maximum full scale output is 4 095V 4 095 Watts On the 50kHz and 70kHz models the scale factor 15 10mV 1 Watt with a maximum scaled output of 409 5 Watts Pin 17 Pwr Reg Status This option is not currently available 44 Dukane Manual Part 403 551 03 Section 5 Rear Connectors Pin 18 MPC Ready An active low output on pin 18 indicates the MPC module Multi Probe Controller is ready and will accept probe selection changes on the Remote Setup inputs Pin 19 Iso Power Fail An active low output indicates that AC power is within operating range This output will turn off high im pedance state which no longer sinks current if the AC power fails or is switched off Pin 20 Iso Bad Suspect Part An active low output that indicates the weld cycle is outside the boundary limits set in the Bad Limits menu This signal activates when the ultrasonic out put is terminated at the end of the weld The de fault setting is maintained which means the signal rema
80. 50 HN4 L2 200 240 50 60 Hz 15A Figure 3 3 DPC II Plus Rear Panel and Optional Modules Ground the System The DPC II Plus includes an internal RFI filter The standard building AC ground connection is normally not sufficient to completely suppress the RFI Attach a ground cable from the DPC grounding lug located next to the rear AC power switch to an earth ground If you are using a press or automated probe system each piece of equipment must also be solidly grounded Refer to Figure 2 5 and Figures 3 4 through 3 8 for the proper grounding arrangement NOTE Not all of the modules illustrated below can be installed simultaneously They are shown to rep resent the various configurations that can be assembled to meet specific requirements EEPROM Serial Programming Port Master Multi Probe Controller Module Press Control Power Signal Output Module Remote Amplitude Control Module SERIAL NUMBER 15162096 3 DUKANE CORP ST CHARLES IL 6 174 MATE INUS A WARNING POWER LINE MUST BE GRQUNDED AT OUTLET REMOVE ALL POWER REMOVING COVER OR CONNA DISCONNECTING CABL s Connector J1 Ultrasound Connector Output BNC Dukane Manual Part No 403 551 03 19 Dynamic Process Controller DPC II Plus 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
81. 551 03 DPC II Plus Manual Revision History Revision Revision Number Contents Date 00 Original release 2002 13 01 Modify Table 5 V on page 48 Pin 9 is 22V DC 2004 May 14 Update telephone numbers and emails in Section 14 Revise ISO 9001 Certification to ISO 9001 2000 Clarify AFTERBURST option bypass on page 73 and 80 02 Emergency Stop Switch Interface Diagram on page 25 2005 Jan 11 DPC II Plus Software now at version 1 50 New consolidated warranty 03 Updated power requirements in Table 15 I 2005 22 Update Figure 15 2 Interpreting DPC II Plus Model No Add Figure 5 10 Press Board Cycle Activation Jumper Block on p 50 Update TOC Appendix A and Index Dukane Corporation Ultrasonics Division Dukane Manual Part No 403 551 03 DPC II Plus User s Manual This page intentionally left blank iv Dukane Manual Part No 403 551 03 Table of Contents TABLE Or CONTENTS Section 1 Introduction TT o 1 3 Read The Manual First uio DUBII ID ca cas aid 3 Caution and 3 Drawings Lape hed bua cad 3 4 DPC II Plus n aua cnp tena 6 Key DPC II
82. 57 DPC Plus Process Setup m 57 Process Setup Main Menu Structure 58 Process Control Menu 59 Limit Definition Menu Flowchart 60 Utilities Menu 61 DPC ll Plus Startup Menu 65 DPC Il Plus Configuratiari 65 DPC Il Plus Time Weld Cycle Display i tette 65 DPC II Plus Energy Weld Cycle Display 65 PROCESS uu epu n 66 Process Control Trigger Method Menu 66 Hand Probe Flow uictis etienne orbi ipd Erebi 66 Hand Probe Weld Method Menu tee 67 Hand Probe Weld Time Mert teet teinte tetto 67 Hand Probe Weld Energy Menu ttes 67 Hand Probe Maximum Weld Time Menu 67 Multi Probe Controller 2 2 68 Auto Stop Weld Menu 68 Probe Time Delay 2 2 2 222 69 Weld Method Selection 2 2 7 2 69 MPC Probe Weld Time Menu 69 MPC Probe Weld Energy Menu 70 MPC Probe Maximum Weld Time 22 70 Ground Detect Fixture 70 Ground
83. AL REMOTE Figure 9 5 Setup Types Selection Menu Press the ENTER key to display the setup entry screen which is shown in Figure 9 6 You can en ter eight different setups named 1 to 8 Use the increment up arrow and decrement down arrow keys to change the setup number ENTER NEW SETUP Figure 9 6 Enter New Setup Menu Pressing the ENTER key displays the Process Setup menu shown in here Figure 9 2 and earlier in Fig ures 7 5 7 29 and 7 37 This enables you to be gin modifying the setup information If the setup has not been configured a message briefly appears Figure 9 7 before displaying the Process Setup menu The flow follows the logic paths described in Section 7 Process Control Menu THE CURRENT STEUP 15 EMPTY AND NEEDS TO BE CONFIGURED Figure 9 7 New Setup Configuration Message If Remote setup is chosen the PLC controls Re mote Setup Selection Bits which determine which setup file is selected The file number is deter mined by the Setup ID defined in Table 5 1 98 Dukane Manual Part No 403 551 03 Section 9 Utilities Menu Copy A Setup Starting from the Utilities menu in Figure 9 4 move the cursor down to Copy A Setup and press the ENTER key The display first requests the source file number This is shown in Figure 9 8 COPY FROM Figure 9 8 Source File Location Entry Use the increment and or decrement key to select a source file and press the ENT
84. 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 en sures that the minimum value is less than the maxi mum value before permitting the value to be en tered The error screen shown in Figure 8 7 ap pears briefly and returns to the minimum limit value entry screen Reduce the minimum value or press the CANCEL key to step back to the maximum limit value entry screen and increase its value until the logical condition is satisfied LIMIT HUST LESS THAN UPPER LIMIT Figure 8 7 Minimum Value Error Message After the minimum and maximum values have been entered the display shows the Process Lim its Menu Figure 8 3 Press the CANCEL key to return to the Limit Definition Menu Figure 8 2 Press CANCEL again to return to the Process Setup Menu Figure 8 1 Dual Pressure Mode If a dual pressure mode has been programmed the limits selection also includes total values in the Process Limits menu Figure 8 5 First choose one ofthe two top parameters by selecting either Time or Energy with the cursor Pressing the ENTER key displays the limit parameter selec tion which is shown in Figure 8 8 PR zem IMITS WELD ENERGY P1 WELD ENERGY P2 Figure 8 8 Dual Pressure Limits Selection Menu To detect a suspect or bad weld cycle the mini mum and maximum values for each pressure limit
85. CE Certification means that the DPC II Plus meets the required European standards to be sold and used in Europe SO 9001 Certification means that the DPC II Plus is manufactured to very high quality standards and assures you of Dukane s commitment to being a quality vendor and its goal of continuous improvement 8 Dukane Manual Part No 403 551 03 SECTION 2 Safety Tips Health amp Safety e RFI Considerations Health amp Safety 11 Plastics Health Notice 12 Electrical Grounding 12 RFI Considerations 13 Dukane Corporation DUKAN Ultrasonics Division Dynamic Process Controller DPC Plus User s Manual This page intentionally left blank 10 Dukane Manual Part No 403 551 03 Section 2 Safety Tips Health and Safety Tips Please observe these health and safety recommen dations for safe efficient and injury free opera tion of your equipment In this manual the term system refers to a complete group of components associated with the welding of plastic or metal parts also known as an ultrasonic assembly sys tem typical system consists of a generator and or ultrasonic process controller start and stop switches power controls connecting cables and the probe assembly which includes the transducer booster horn and replaceable horn
86. D TIMED AUTO PROBE UNTIMED AUTO PROBE LEGEND AUTO STOP RTW Ready To Weld Front Panel ENTER Key ENTER Section 4 3 Menu Keys T Time E Energy Maximum 30 000 Seconds Minimum T4 0 000 Second UNTIMED AUTO PROBE PROCESS CONTROL WELD METHOD TIME BURST Step 1 Parameter Value Entry Step 2 Step 3 Maximum 30 000 Seconds Minimum 0 001 Second ENTER Enable Disable WELD METHOD Maximum T ejg 30 000 Seconds Minimum 0 001 Second Maximum 12 000 Joules Minimum E peld 1 Maximum T pax 30 000 Seconds _ Minimum 0 001 Second Maximum 0 150 Seconds Minimum 0 001 Second Maximum T delay 0 999 Second Minimum 0 000 Second Maximum 0 999 Second Minimum 0 001 Second These values can be set to zero but will not produce any output The values listed represent the resolution and are the smallest values that will produce any output signal Figure 7 21 Auto Probe Setup Flow Chart Dukane Manual Part No 403 551 03 Section 7 Process Control Menu Untimed Auto Probe Delay The generator is triggered by external automa tion equipment The automation control provides the ultrasound start and stop signal In certain operations a delay may be required to allow the clamping hea
87. DPC Plus User s Manual This page intentionally left blank 16 Dukane Manual Part No 403 551 03 Section 3 Unpacking and Installation Shipping Contents m DPC Plus User s Manual 403 551 02 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 1 In spect the DPC for damage Report any damage immediately to Dukane Ultrasonics Support Ser vice DPC Placement Placement of the DPC depends on whether it is a benchtop or rack mounted configuration Benchtop Place the DPC on a flat surface with its front panel easily accessible Make certain the placement and cabling do not interfere with the assembly opera tion Allow 5 inches 13 cm at the rear of the DPC for cable clearance Allow 2 inches 5 cm of space on either side of the DPC for air circulation Re fer to the illustration in Figure 3 1 Allow 5 inches 13 cm space for cables behind the DPC Intake Vent for Thermostatically Dynamic Process Controller DPC Ii PLUS Exhaust Air from Flow Thru Cooling Tunnel Allow space for ventilation 2 inches 5 cm on each side Figure 3 1 Installing a Benchtop DPC Dukane Manual Part 403 55
88. Detect Scrub Time Data Entry 71 Auto Probe Setup Flowchart 72 Process Control Weld Method Selection 73 Process Control Hold Time 13 Auto Probe Hold Time Data Entry 5 73 Auto Probe Afterburst Selection 73 Auto Probe Afterburst Enable 73 Auto Probe Afterburst Delay Data Entry 74 Auto Probe Afterburst Duration Data Entry 74 PROCESS SOTUD MCI TT 74 Press Auto Probe Setup Flowchart 3 75 Startup Welding Cycle Data Screen 77 Enter Meny 77 Process TT ian 77 Press Trigger Method MenU icici Toa Deco 77 Press Initiate Mode tecto et air 78 Press Trigger tnt ttn 78 First Pass Through Process Control Menu Leer ers 78 Single or Dual Pressure Selection Menu 78 Pressure One Weld Method Selection 78 Pressure One Weld Time Data
89. Dukane Manual Part No 403 551 03 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 be comes active The weld cycle is terminated TIMER STOP SIGNAL DETECTED During the weld cycle the TIMER STOP signal becomes active The weld cycle is terminated SYSTEM O ERLOAD SIGNAL DETECTED During the weld cycle the SYSTEM OVER LOAD signal becomes active The weld cycle is terminated AUTOMATION FAULT SIGNAL DETECTED During the weld cycle the AUTOMATION FAULT signal becomes active The weld cycle is terminated RIGHT SAFETY SWITCH RELEASED TOO SOON If the Initiate Mode is set to MANUAL the right safety switch was released too soon at the start of the weld cycle Both switches must be held until the trigger switch is ac tivated The weld cycle is terminated LEFT SAFETY SWITCH RELEASED SOON If the Initiate Mode is set to MANUAL the left safety switch was released too soon at the start of the weld cycle Both switches must be held until the trigger switch is ac tivated The weld cycle is terminated SYSTEM OFF LINE The SYSTEM OFF LINE signal is active The DPC generator must be ON LINE in order to produce an ultra
90. ENTER This subsequent menu is shown in Figure 9 21 Figure 9 21 Cycle Press Selection Menu This option works only with the palm operate switches on the press base When the DPC front panel status is set OFF LINE it cannot be triggered to cycle the press During testing or fixture setup it may be necessary to cycle the press without pro ducing an ultrasonic output signal This menu op tion permits cycling the press with the DPC set to OFF LINE To enable this menu option move the cursor key up one line to YES and press the ENTER key The press can now be cycled by pressing both palm activation switches without producing an ul trasonic output signal An Automation Input signal pin 8 of J902 will not cycle the press with this menu option with the DPC set to OFF LINE Dukane Manual Part No 403 551 03 101 Dynamic Process Controller DPC Plus User s Manual This page intentionally left blank 102 Dukane Manual Part No 403 551 03 SECTION 10 Probes amp Probe Stacks Theory of Operation Probe Configuration e Probe Stack Assembly e Booster Notes e Probe Stack Mounting The Ultrasonic Probe 55555 105 Theory of Operation soos vacet EPOR DR 105 Probe Configuration qu cti D Ox DEREN 105 Ultrasonic 106 esi MF 106 Stack 107 Installing Replaceable
91. ER key Next the display requests a destination for the file as shown in Figure 9 9 Again use the increment and or dec rement key to select a destination and press the ENTER key COPY Erase Setups Again starting from the Utilities menu in Figure 9 4 move the cursor down to Erase Setups and press the ENTER key The menu gives us a choice to erase the current setup or to erase all setups This menu is shown in Figure 9 11 ERASE SETUPS ERASE CURRENT SETUP ils edes ALE cen e TT eds Figure 9 11 Erase Setups Selection Menu The current setup is the one chosen from the Se lect Setup menu Press the enter key and the menu prompts you with a confirmation messages indi cating the setup to be deleted This is shown in Figure 9 12 ERASE SETUP 1 NO YES Figure 9 9 Destination File Location Entry The display will ask for confirmation before pro ceeding This screen is shown in Figure 9 10 MES Figure 9 10 Confirm Copy Files To proceed move the cursor down to YES and press the ENTER key The file is copied and the display returns to the Setup Utilities selection menu shown in Figure 9 4 Figure 9 12 Confirm Erase Selected Setup To erase the indicated setup move the cursor down to YES and press ENTER The display will display the message that the setup is being erased Figure 9 13 and return to the Process Setup menu Fig ure 9
92. Entry 78 156 Dukane Manual Part No 403 551 03 Appendix A List of Figures Figure 7 41 Pressure Two Weld Method Selection Menu 79 Figure 7 42 Pressure Two Weld Energy Data 80 Figure 7 43 Pressure Two Weld Time Data Entry 79 Figure 7 44 Dual Pressure Time Only Menus 79 Figure 7 45 Second Pass Through Process Control Menu 79 Figure 7 46 Press Hold Time Data 80 Figure 7 47 Third Pass Through Process Control 80 Figure 7 48 Press Afterburst Enable Menu 2 2 80 Figure 7 49 Press Afterburst Delay Data Entry 80 Figure 7 50 Press Afterburst Duration Data Entry 80 Figure 7 51 Return to Process Control 2202 2 80 Figure 7 52 Process Setup MIBPIU 81 Figure 7 53 Dual Pressure Welding Cycle 81 Figure 7 54 o cR t 81 Figure 7 55 Min and Max Values for Hold Time 81 Figur
93. Figure 4 8 Press CAN CEL to return to the previous menu The up arrow key increments the data value each time it is pushed Hold ing the key in continuously incre ments the value This key is also used to move the cursor up one line on a menu selection screen Pressing the HOLD key immediately brings you to the Hold Time data entry menu You can quickly check and or change the setting using the four arrow keys Pressing ENTER completes the process and returns you to your last menu screen Pressing the WELD P1 key displays the parameter s for the first pressure setting The value s can be quickly checked and or altered without go ing back through the menu sequence Pressing ENTER completes the pro cess and returns you to your last menu screen HOLD D WELD 79 gt Pressing the left arrow key selects the next digit to the left of a param eter setting The key is used when entering values and moves the flash ing bar under the selected digit The selection wraps around to the right digit after the left most digit posi tion is reached Increment General Information Pressure 1 Weld Left Pressure 2 2 2 Amplitude Adjust Decrement Figure 4 7 Menu Keys POPC Plus v1 50 PRESS ENERGY ORE INFO dukcarp cam us Figure 4 8 GEN INFO Display NOTE For three of the hot keys HOLD WELD P1 and WELD P2 data can on
94. II Plus system default configuration U S Control DPC II system only Not applicable for a DPC II Plus Auto Control DPC II system only Not applicable for a DPC II Plus 50 Dukane Manual Part No 403 551 03 Section 5 Rear Connectors Multi Probe Master Module Part No 110 3954 This optional module enables the DPC II Plus to activate any one of four ultrasonic probes Each probe can have its own setup file which is selected by the Setup ID pins 12 13 amp 14 ofthe HD 15 System Input connector The functions are listed in Table 5 1 and 5 Rear panel bicolor LED status indicators for each probe output illuminate green when the probe channel is selected and red when the U S is active Both a MPC Master and Slave module are shown below in Figure 5 11 Internal logic prevents more than one probe from being activated at a time or probe switching signals when the U S is on A ring down circuit permits switching only when U S output is zero Internal fault logic senses any malfunction and deactivates the MPC Ready output The Multi Probe Controller cannot be used with a press module The MPC master has an extra wide back panel which blocks the press module back panel when the MPC master module is installed MPC Slave Module P N 110 3956 MPC Master Module 110 3954 Multi Probe Slave Module Part No 110 3956 This optional module adds four additional probe selection channels to the DPC II Plu
95. Input must be used to trigger the Ultrasonic output The system control inputs are user configurable Refer to Sec tion 5 Jumper Block SH707 for a detailed descrip tion of the options The factory default setting JU724 18 a contact closure to ground If you are using the isolated source jumper position JU 726 then the input requires a minimum of 5V to trig ger the generator NOTE Figure 5 3 shows the male cable end of the System Input connector and is repeated here The cable end connector is a mirror image of the female panel connector shown in Figure 5 2 Make sure you have correctly wired the connector if you are using custom automa tion signals 11 12 13 14 15 126 Dukane Manual Part No 403 551 03 Section 12 Troubleshooting Generator FAULTs OVERLOAD Ifthe generator OVERLOAD light comes on it in dicates excessive power 18 being drawn This could be caused by a mismatch between the ultrasonic signal and the resonant characteristics ofthe acous tic stack Improperly assembled probes may draw excessive power if their components were not properly torqued to specifications Make sure you have the correct probe and horn A 40kHz probe and a 20kHz DPC may result in an instantaneous overload The same is true for the reverse combi nation Excessive power drawn by the load may result in damage to the probe and horn OVERTEMP Ifthe OVERTEMP indicator comes on it indicates t
96. Inside Rear Cover J Joules Definition 70 Jumper Blocks Internal 2 55 5 o rore a 52 54 69 Jumper Block Press Control Module 4 4 1 20 119 1901 Thruster Connector 2 2 2 2 48 J902 Press Base eee cedet crede teo re Puede gae ka eu Ey da d dads 48 49 K Key Features of DPC 7 Keys Mert c 30 119 121 128 135 M 34 81 Keys Menu eter decet 29 33 34 77 L LED P 29 35 135 Left mtt 33 Line Voltage Regulation 7 Limit Definition 60 91 93 E A 90 ENUY 92 Dual Pressure 92 MENU ME PH 90 Min Max 1 11 1 89 Selection Criteria 90 V v SURES Pressure Mode 91 90 Load Dias euni oni onera eda cap 8 M Maintenance Scheduled sess 111 137 Master MPC Module 51
97. MC 81 Process Control 82 Section 8 Process Limits Menu esee 87 Process ide 89 Limit D PIEVE 90 Suspect and ECT o o o 90 Process LIMITS asiria EEEE E EEEE ASETAS 90 Mod MN TT RT 91 Dual Pressure ioiei iaiia 92 Section 9 Utilities 95 pu Utilities i e cc va 97 Select SEED a roa tt rb ey ls daos nd 98 56000 a ag aa AD 99 Setups Mop 99 Part iy dM t D 100 Reset Part COUNT necp door spec exe 100 Count Suspect sid 100 Preset Part COUTE 101 oats ex Data etait ta 101 Cycle Press Off Line 101 Section 11 Probes Probe Stacks 103 The Ultrasonic Probe 105 Theory of aah tae tee acre 105 Probe COP TUT ACU soe anions 105 Ultrasonic eh OT 106 BOOSTEP 106 Stack Assembly T 107 Installing Replaceabls TIE ent
98. MMON 58 Proc ss unu Und dnd ua 60 m T 61 Section 7 Process Setup Menu 63 Hand Probs 65 Untimed Hand PROG aru Ia Pa Cu 66 PMT Hand Prob eb 66 Timed Hand Probe 67 68 PUNO Stop 68 Untimed MPC Probe Probe Delay 68 Weld TiMe e m 69 Weld Method Energy Ronan 70 Weld Method Ground Detect 70 A to Plo De ER TT Tm 71 Auto Stop OPTION assis piatti aad Eu rad RR deu da da d ud 72 Untimed Aute Probe Delay uci Ie ade etel 73 Timed Auto Probe Weld Method renta 73 RTT EET 73 73 Press Mode ccs 75 Initiate M d 0192200 dera 76 Auto NR i B 76 Head UPON AUTO STOD MC 76 Trigger Typ a a aiaa ai 76 Single Dual Pressure Mode 76 vi Dukane Manual Part No 403 551 03 Table of Contents Press Mode Example 77 M
99. PROCESS PROCESS CONT CONTRO PROCESS Limits UTILITIES factured Dukane isses 0 in ISO registere ISO 9001 20 DPC Plus User s Manual Copyright 2002 2005 Dukane Corporation Ultrasonics Division 2900 Dukane Drive St Charles IL 60174 USA Notice of Rights rights reserved No part of this manual including the inte rior design cover design and icons may be reproduced trans mitted or utilized in any form or by any means electronic mechanical photocopying recording or by any information storage and retrieval system without written permission from Dukane Corporation Notice of Liability The information contained 15 this manual is distributed on an is basis without warranty While every precaution has been taken in the preparation of this manual Dukane Corpo ration shall not have any liability to any person or entity with respect to any liability loss or damaged caused or alleged to be caused directly or indirectly by the instructions contained in this manual or by the hardware and software products de scribed herein Printed in the United States of America D PRINTED ON RECYCLED PAPER Dukane Part Number 403 551 03 Dukane ultrasonic equipment is manufactured under one or more of the following U S Patents 3 780 926 3 825 481 4 131 505 4 277 710 5 798 599 and 5 880 580 DPC is a trademark of Dukane Corporation ii Dukane Manual Part No 403
100. PUT TEST TOS AOR 128 TEST Key dnte 128 Troubleshooting 129 Error Messages 131 Section 13 Care 133 Front Panelas T 135 Rear Paneb 135 135 Stack SUrTACES 7777 2240 136 Stack Maintenance nd di eau anda a Ra 136 Stack gh qu olg PRSE MR 136 Ever O 136 Uneven ContaCt RN 136 137 Mugello 137 137 Probe 138 Dd uuo 138 Machining the Mating 50 138 Manual RE 19 138 viii Dukane Manual Part No 403 551 03 Table of Contents Section 14 Contacting Dukane 141 Ultrasonics Division Main Office tpa ev vivens 143 Email Addresses mE 144 Telephone EXTENSIONS tuta RERVR AS TERR SENA ES nrs 144 Section 15 5
101. Part 403 551 03 SECTION 7 Process Control Menu e Hand Probe e MPC Probe e Auto Probe e Press Mode e Hot Keys Hand Probe M 65 Untimed Hand 66 Timed Hand 66 Timed Hand Probe Energy 67 MPC 68 Auto Stop 68 Untimed MPC Probe Probe Delay 68 Weld Method 69 Weld Method Energy 70 Weld Method Ground 70 PUTO VOWS REPE 71 Auto Stop 72 Untimed Auto Probe 73 Timed Auto Probe Weld Method 73 73 AfterbursSt ERREUR 73 Sio E 75 Initiate AMNIS IT 76 BUTO STOD 76 Head Up Auto 50 rs inciter tenete 76 e LEO Du 76 Single Dual Pressure Mode 76 Press Mode Example 77 ame 81 Process Control 82 Dukane Corporation DU Ultrasonics Division Dynamic Process Controller DPC II Plus User s Manual
102. Plus Features eU MN DARREN 7 Section 2 Safety 11 M 9 11 Plastics Health Notite 12 Electrical Grounding Das uode 12 REI Corsidebat ONS uit eia 13 Section 3 Unpacking amp Installation 15 Shipping Carton Contents Aides FINI PURO NN NIS SHO MSUR RUU SEEK UK 17 DPC PR Ce UW p I T UU TTE 17 Benchtop H 17 Rack MOUNTING X 18 Rear Panel 19 Ground the 19 Connect the Cables 20 Plath PIOUS Sy St CONN T 20 Automated Probe System 20 M ltiple Probe Syst m 22 Automated Thruster System 23 D ukane Press 24 Emergency Stop Switch 440 nnen 25 Rear Electrical Power Switch e 25 Section 4 Controls 27 Fron
103. SSURE Position Before Table 5 VI below gives the pinout and signal 3 description for J901 which is the 36 pin Thruster id n ERU HE connector This connector is the same type found ooo on the DPC III and DPC IV The cable specified is Part No 200 1104 which is interchangeable with both DPC III and DPC IV generators TIU UNA gt wsserie0 Low ste ester drvert ground quee eite get p dps dry contact switch C osure 14 Input Ground Detect Normally Open dry contact switch closure to ground 15 Input Trigger Switch Normally Open dry contact switch closure to ground Normally Open dry contact switch oos ome closure to ground 17 Input Pre trigger Switch Normally Open dry contact switch closure to ground 4 19 20 22 24 26 22 55 Internal Power to Press 6 8 10 12 25 27 28 29 Ground 22V Return Power and Signal Ground 30 31 32 34 36 7 9 11 18 2i 23 33 35 Table 5 VI J901 Thruster Connector Pinout Dukane Manual Part No 403 551 03 49 Dynamic Process Controller DPC II Plus User s Manual 0909 906 E L ZRS 4 0 1902 506 Noe 190 VRS 1 0905 4 CR813 F 1 C909 amp CR903 VR929 901 T Re05 R906 S E gezz Huo2 E
104. Selection Jumper Block SH702 Pin 4 output on DB 25 JU703 Ultrasound Active Status JU704 Overload Fault Factory Default JU705 Over temperature Fault JU706 System Fault JU707 Any Fault Automation Cycle Stop or End Of Weld Selection Jumper Block SH704 JU713 Normally OFF Factory Default Use depends upon custom automation configuration JU714 Normally ON JU715 Automation Stop Fault Move jumper to this position to use Auto Stop Figure 7 13 JU716 Automation End of Weld Factory Default Switch Debounce Filter Time Delay Selection Jumper Block SH705 JU717 No Time Delay used for electronic switches JU718 1 msec JU719 10 msec Factory Default JU720 22 msec Timer Board Enable Bypass Jumper Block SH706 JU723 Timer Board Enable normally selected for a DPC II Plus JU722 Timer Board Bypass Factory Default used for standard DPC II 52 Dukane Manual Part No 403 551 03 Section 5 Rear Connectors 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 be tween input and 22 VDC JU726 Isolated Source Input can be either sink ing or sourcing signal of 5 to 24 VDC is required at the isolated inputs The cur rent is internally limited to 12 5mA 1 c ec 39 eT f C714 L Ju e3 TIMER BD ENABLE R769 AMPLITUDE
105. TUS OUTPUTS CYCLE PRESS OFF LINE SETUP UTILITIES SELECT COPY ERASE STATUS PART OUTPUTS COUNT GT LOCAL REMOTE ERASE ERASE LOCAL REMOTE RAS SETUP SETUPS Figure 9 1 Utilities Menu Flow Chart Dukane Manual Part 403 551 03 97 Dynamic Process Controller DPC II Plus 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 Se ie CONTROL LIMITS TX UTE TES 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 SETUP UTILITIES IPART COUNT STATUS OUTPUTS CYCLE FRESS OFF LIME Figure 9 3 Setup Utilities Menu Pressing the ENTER key moves to the next menu screen which is the Setup Utilities selection shown in Figure 9 4 Notice the first line is indented which means it is a menu title not a selectable option From this menu we can choose to either select copy or erase the setups UTILITIES 1 SELECT SETUP EXHI SE TUE Mm ERASE SETUPS Figure 9 4 Setup Utilities Selection Menu Select Setup Pressing the ENTER key displays a decision menu from which you can enable either a local or re mote setup control This is shown in Figure 9 5 SETUP T PES LOC
106. Ulfibel 53 secre entente een na enean 19 39 40 125 JnputsSignal Descriptions 41 lt Status 43 Dukane Manual Part 403 551 03 175 Dynamic Process Controller DPC II Plus User s Manual System Output Connector essen 19 39 42 PowerOutbut DISDIAV NAR M s Nd dE 32 HEU ERU 120 T Buen E T E m 105 Telephone Numbers uina ca 144 Teste II 119 DEEP 120 TEST MUN 30 120 128 TESTS F e eet 41 120 Thruster Cable Connector eese 23 24 48 49 Time Delay Menu Probe 69 Time Maximum Weld essen nnne 67 70 71 79 Time Welding mete 67 69 Timed Probe C RTRTTEPRERTNEIITUNRTIM 66 73 Tips 107 113 tes e 106 TOP OF SUN PR 23 Torg e een Se en ne Ra 107 108 110 Torque Units Conversio
107. ached to the booster first or the booster is attached to the probe first ASSEMBLY a HOUSING Mounting Stud Spanner Insert Into Booster Input Wrench End First and Tighten Hole to Torque Specs Typical Booster Input End Threads Shallower Than Output End 5 Booster Mounting Ring Do not clamp BOOSTER Output End Threads Deeper Than Input End Cap Screws Face Toward Input Mounting Stud Insert Into Horn Spanner First and Tighten to Torque Specs Output End End Figure 10 7 Probe Stack with Booster Assembly and Disassembly Ultrasound Coaxial Connector il PROBE STACK ASSEMBLY Booster Mounting Ring Do not clamp DISASSEMBLY 112 Dukane Manual Part No 403 551 03 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 pro vide sufficient torque to loosen a joint Figure 10 8 Seperating The Horn From The Booster On boosters and horns with wrench flats use only the correct size wrench to provide sufficient torque to loosen a joint when necessary Removing The Mounting Stud From A Horn Or Booster Only use an allen wrench of
108. acoustic stack This build up interferes with the efficient transfer of ultrasonic energy to the parts to be welded It may contribute to a loss in performance Evidence of corrosion build up in cludes discolored mating surfaces or surfaces en crusted with hard deposits To extend equipment life and maintain performance levels minimize the system s exposure to corrosive sources Dukane Manual Part No 403 551 03 137 Dynamic Process Controller DPC II Plus 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 Machining the Mating Surfaces Instructions on how to properly machine the stack components is beyond the scope of this manual Please call Dukane s Tooling Support Team for ma chining information A list of Dukane contacts is provided in Section 14 Manual Resurfacing To manually resurface the stack component mat ing surfaces follow the steps given here 1 Disassemble the acoustic stack and wipe all the mating surfaces clean Use a clean cloth or a paper towel 2 Examine all the surfaces If any are corroded discolored or coated with hard deposits they should be reconditioned 3 Ifthe surfaces appear
109. all Dukane be liable for any compensatory consequential special punitive or contingent damages or for damages arising from any delay in performance by Dukane under this warranty 154 Dukane Manual Part No 403 551 03 APPENDIX List of Figures Figure 2 1 120Volt Grounded 3 Prong 12 Figure 2 2 220Volt Grounded 3 Prong Receptacle 12 Figure 2 3 gt International 220 240V 13 Figure 2 4 Grounding Arrangement 13 Figure 2 5 Press Grounding Arrangement 13 Figure 3 1 Installing a Benchtop DPC 17 Figure 3 2 Rack mounted DPC Using Bracket 18 Figure 3 3 DPC Plus Rear Panel Optional 19 Figure3 4 Plus Hand Probe Cabling 5 2 2 222 21 Figure 3 5 DPC Il Plus Automated Probe Cabling Connections 21 Figure 3 6 DPC II Plus Multiple Probe Cabling Connections 22 Figure 3 7 DPC II Plus Automated Thruster Cabling Connections 23 Figure 3 8 DPC Plus Dukane Press Cabling Connections 24 Figure 3 9 Emergency Stop Switch Interface 25 Figure 3 10 Rear Pan
110. amp Auto Probe 7 11 7 18 0 000 Second 30 000 Seconds 7 7 Press amp Auto Probe Time amp Energy 7 27 7 49 0 000 Second 0 999 Second 7 7 gt Table 7 II Parameter Values Any Timed Probe Timed Hand Probe 12000 Joulest 20kHz 30kHz and 40kHz DPC II Plus Timed MPC Probe 1200 0 Joulest 50kHz and 70kHz DPC II Plus Timed Auto Probe Requires Power Output Module NOTE The 50kHz 150 Watt DPC II Plus and the 70 2 100 Watt DPC Plus have a maximum weld energy setting Eweld of 1200 0 Joules The reduced scaling permits the DPC to achieve better adjustment resolution at low power levels All other models covered in this manual have a maximum weld energy of 12 000 Joules Dukane Manual Part 403 551 03 85 Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 86 Dukane Manual Part No 403 551 03 SECTION 8 Process Limits Menu Limit Definition e Suspect and Bad Limits e Process Limits Process Limits 89 Limit Definition ucc toto tides 90 Suspect and Bad Limits x ttti 90 Process 46 22 2222 000020 90 Single Pressure reciban 91 Dual Pressure Mode 92 Dukane Corporation oU s Ultrasonics Division Dynamic Process Controller DPC II Plus User s Manual This page
111. arget Value Amplitude Adjust Figure 7 54 Keys Press the HOLD key and the menu displays the value entered for the hold time see Figure 7 46 Press the GEN INFO key to display the minimum and maximum values for hold time This is illus trated in Figure 7 55 Press the CANCEL key to return to the Hold Time menu and once more to return to the Process Setup menu HOLD TIME MAXIMUM ALUE MINIMUM YALUE O Figure 7 55 Min and Max Values for Hold Time To modify the Hold Time use the arrow keys to change the value as shown in Figure 7 56 To ac HOLD TIME Figure 7 56 Modified Hold Time Dukane Manual Part No 403 551 03 81 Dynamic Process Controller DPC Plus User s Manual cept the new value press the ENTER key This will return you to the Process Setup menu shown in NOTE Figure 7 52 To return to Process Setup without If you have a dual pressure press connected to T the DPC II Plus make sure the pressure select f the hold t the CANCEL key SERM m NE DE CANCEL KEY Switch is in the WELD position before turning on The WELD P1 and WELD P2 hot keys function in the DPC AC power The DPC scans for installed the same manner If a single pressure mode is se modules connected press and probe etc at lected Figure 7 38 SINGLE PRESSURE then only power up If the switch is in HOLD position
112. ars again with Weld Mode selected This screen below in Figure 7 51 looks just like Figure 7 37 CONTROL 5 PRO C E 5 5 WELD HOLO 8 HFTERBURST Figure 7 51 Return To Process Control Menu 80 Dukane Manual Part No 403 551 03 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 S ENS CONTROL LIMITS PROCES PROC id ds UTILITIES Figure 7 52 Process Setup Menu Press the MODE key to display the welding pa rameters menu Notice it now has three values P1 P2 and Total This is different from the oper ate screen in Figure 7 31 because we are now con figured for a dual pressure mode instead of single pressure ENERGY LI 0 000 TOTAL 0 000 Figure 7 53 Dual Pressure Welding Cycle Data Press the MODE key again to return to the Pro cess Setup menu HOT Keys In Section Four Controls and Displays we ex plained the function of the menu keys including the four hot keys HOLD WELD P1 WELD P2 and ADJUST The hot keys are identified in Fig ure 7 54 Since we have now programmed values for these parameters we can use the hot keys to check or alter their values P1 Weld Target Value Hold Time Minimum amp Maximum Values P2 Weld T
113. ayed Use the left and right arrow keys to select the digit position and the up and down ar row keys to increment or decrement the value PRESET PRRT COUNT Figure 9 19 Counter Preset Value The underscore indicates the digit position which is initially under right most digit To preset the counter press ENTER and you are returned to the part count selection menu shown in Figure 9 16 Status Outputs The third option in the Utilities Menu see Figure 9 3 is Status Outputs Moving the cursor down to Status Outputs and pressing the ENTER key dis plays the Status Output Selection menu This menu option permits you to set the four Iso lated Status Outputs as either maintained or pulsed The default setting is maintained If the output is set to pulsed the output pulse width is 100 msec The status output selection menu is shown in Fig ure 9 20 To change the mode move the cursor to PULSED and press ENTER OUTPUTS MAINTAINED PULSED Figure 9 20 Status Output Mode Selection The four outputs controlled by this menu are 1 Isolated Bad Part on Pin 20 2 Isolated Good Part on Pin 21 3 Isolated Ready on Pin 22 4 Isolated In Dwell on Pin 23 For a complete description of each signal refer back to Table 5 IV Cycle Press Off Line The last option in the Utilities Menu Figure 9 3 is Cycle Press Off Line To access this option move the cursor down to the last line and press
114. below the BNC connector 2 Secure a probe horn stack by clamping the probe in two places 3 Secure a probe booster horn stack by clamping the probe in one place and the booster in one place 4 Never clamp the horn NOTE Never hold a probe by the housing or booster by the mounting rings when tightening or loos ening from an adjoining component see Figures 10 6 and 10 7 to identify these parts Always use the proper spanner wrenches when tight ening or loosening the horn or booster Dukane Manual Part No 403 551 03 115 Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 116 Dukane Manual Part No 403 551 03 SECTION 11 DPC Checkout e Startup Self Test e System Test Probe Operation e Stopping the Weld Cycle Startup and Self Test 119 System NE 120 System Operation 121 Stopping the Weld 121 Manual SYSTEMS esp 121 Automated 5 121 ziehen PET 121 Dukane Corporation DUKA s Ultrasonics Division Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 118 Dukane Manual Part No 403 551 03 Section 11 Checkout Startup and Self Test 1 Push the rear panel AC
115. c exposure period weld cycle exceeds 250 milliseconds Ultrasonic Equipment and tooling used in continuous duty cycle modes such as but not limited to continuous cut and seal and food processing are warranted for 2000 hours or 12 months from shipment whichever occurs first Any ultrasonic horn or tool quoted and sold as Experimental is not warranted This warranty does not cover failures of equipment and components attributable to improper cooling or overheating of the transducer Ultrasonic Horn Analyzers have a 12 month warranty Ultrasonic Transducers have a one time replacement warranty Normal wear items and consumables excluded from any warranty coverage include but are not limited to filters fuses light bulbs lubricants gaskets and seals cast urethane fixture components laser flashlamps laser beam delivery optics and lasing gases The forgoing warranty is the sole and exclusive warranty and is made in lieu of all other warranties express implied or statutory including without limitation any warranties of merchantability fitness for a particular purpose description quality productiveness or any other warranty The remedy set forth in this warranty policy is the sole and exclusive remedy of Purchaser and in no event shall Dukane be liable for any compensatory consequential special punitive or contingent damages or for damages arising from any delay in performance by Dukane under this warranty
116. ces sive power beyond the generators rated output is be ing drawn The ultrasonic signal is shut down when an overload condition is detected The front panel status display will indicate OVERLOAD The over load signal resets when the operate input deactivates or the TEST switch 15 released NOTE Active Low outputs are open collector Darlington transistors that sink current to ground either chassis ground or isolated com mon 20 maximum Custom automation users must supply their own pullups See Appendix C for sample circuits Dukane Manual Part No 403 551 03 43 Dynamic Process Controller DPC Plus User s Manual Pin 10 ON LINE An active low output on pin 10 indicates the gen erator is on line and is capable of being triggered externally The front panel status display will indi cate ON LINE Pin 11 Gnd Pin 11 is 22VDC and Status Out return It is tied to the chassis ground Pin 12 Current Loop Fault An active low output on pin 12 indicates the 4 20mA current loop output has a fault This output is only available when a Remote Amplitude Control mod ule is installed Pin 13 Monitor Gnd Pin 13 provides a return path to the chassis ground for the monitor outputs on pins 14 15 and 16 Pin 14 Freq Out The signal on pin 14 is the actual output frequency It is a sine wave with an amplitude of 31 Vrms maxi mum Pin 15 Amp Out The signal on pin 1
117. combination includes the Timer board and a Press control board Other options include an Remote Amplitude control a Power Signal module for Weld by Energy requirements and up to two Multi Probe controller modules for driving multiple probe sys tems In most cases DPC II Plus systems in the field can be upgraded on site if they already have the stan dard Timer board Like the other DPC models all II Plus units except the highest power models feature a universal power sup ply with dual line voltage input 1 In addition the equip ment 1 designed and tested to comply with the and CE regulations that apply to this product 1 See Table 15 I Dukane Manual Part No 403 551 03 Section 1 Introduction DPC Il Plus Key Features Timer Board option provides weld and hold time control and stores up to eight setup files Press Board option provides control for a Dukane ultrasonic press and thruster Multi Point Control Module option permits one DPC to handle up to eight probes in an automation environment DPC II Plus or DPC II Plug and Weld system recognizes when modules are added or removed from the system Process Control Menu automatically reconfigures the user interface to conform to the modules or hand probes currently installed 4 Line LCD Display gives the complete parameter setting to speedup the setup process System Connections are provided for automation equipment to monitor and control
118. d and terminated when the horn touches the Ground metal fixture during the welding cycle For the ground detect fea Figure 7 19 Ground Detect Fixture Isolation Fixture 70 Dukane Manual Part No 403 551 03 Section 7 Process Control Menu ture to function properly the fixture must be elec trically 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 fix ture The ground detection is a current limited 5V DC signal on pin 14 of J901 which is the Thruster connector on the Press Control module Ground detect is normally used with a press system The MPC module cannot be used simultaneously with a Press Control module If the ground de tect function is needed with a MPC configuration connect the ground detect wire from the isolated fixture to the Iso Auto Stop pin 9 on the System Input HD 15 connector This is a current limited 22V DC signal Move the SH704 jumper block to JU715 and refer to the discussion of the Auto Stop option under Figure 7 13 since pin 9 is used to stop the weld in both cases Max Weld Time Maximum Weld Time is the value at which the weld ing process terminates regardless of whether the ground detect signal or scrub process has been ac tivated The data entry screen for maximum weld time looks the same as the screens shown in Fig ures 7 11 and 7 18 Set the maximum weld time to a value greater than t
119. d press ENTER Now enter the maxi mum weld time as shown in Figures 7 11 Press ENTER to complete the process You will return to the Process Setup menu Figure 7 5 NOTE The flowchart beginning with powerup to the Process Setup menu Figure 7 5 and the Trigger Method screen Figure 7 6 is shown in Figure 6 5 A portion of the drawing is repeated here 1 TIME ENERGY t 0 000 1 Figure 7 3 and 7 4 Only present if Power Output Module is installed PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES TRIGGER METHOD TIMED PROBE 4 UNTIMED PROBE WELD ENERGY Figure 7 10 Probe Weld Energy WELD TIME 1 000 SEC Figure 7 11 Hand Probe Max Weld Time Dukane Manual Part 403 551 03 67 Dynamic Process Controller DPC II Plus User s Manual MPC Probe The cable connection diagram for connecting the Multi Probe Controller module is shown in Sec tion 3 in Figure 3 6 The flow chart for the Pro cess Control menu with a Multi Probe Controller installed is shown in Figure 7 12 If you do not have a Power Output module installed the Energy Weld Method menu will not be displayed The Multi Probe Controller MPC flow chart adds three options to the basic Hand Probe flow chart shown in Figure 7 7 1 An AUTO STOP option is included which be enabled or disabled 2 A delay time value can be entered for untim
120. d s to fully engage before starting the ultrasound The probe delay time menu for untimed operation was shown previously in Fig ure 7 14 This parameter sets the post trigger delay The maximum value which can be entered is 30 000 seconds The minimum value for the Delay Time is 0 000 second which effectively dis ables any delay Process Control Weld Method In Timed Auto Probe mode after choosing the Auto Stop option and pressing ENTER the next menu displayed is titled Process Control as shown in Fig ure 7 22 The Process Control Menu includes the Weld Method and adds two more menu screens Refer back to the Hand Probe and MPC Probe sec tions for information on the Time Energy and Ground Detect Welding method menus CONTROL HOLO TIME 5 55 WELD Figure 7 22 Process Control Weld Method Menu Process Control Hold Time After the Weld Method has been chosen and pa rameter values entered the menu flow returns back to Process Control but with Hold Time automati cally selected This is shown below in Figure 7 23 CONTROL METHOO HOLO TIME HFTERBURST PROCESS Figure 7 23 Auto Probe Process Control Hold Time Menu The data entry screen for Hold Time is shown in Figure 7 24 The maximum allowable holding time is 30 000 seconds HOLD TIME 1 200 SEC Figure 7 24 Auto Probe Hold Time Data Entry Screen Process Control Afterburst
121. e 7 56 Modified Hold Time ertet 81 Figure 7 57 Amplitude 82 Figure 7 58 Process Control Menu Flowchart 83 Figure 8 1 Process Setup Main Menu a ou 90 Figure 8 2 Limit Definition Menu 90 Figure 8 3 Single Pressure Process Limits Menu 90 Figure 8 4 Limit Definition Flowchart eoe iie oit 91 Figure 8 5 Dual Pressure Process Limits Menu 91 Figure 8 6 Single Pressure Max Energy Data Entry 92 Figure 8 7 Minimum Value Error Message 92 Figure 8 8 Dual Pressure Limits Selection 92 Figure 8 9 Maximum Energy Data Entry 1st entente eter torret 92 Figure 8 10 CANCEL Key Return Path Flow Chart 92 Figure 9 1 Utilities 97 Figure 9 2 Process Setup Main 98 Figure 9 3 Setup Utilities Mail 98 Figure 9 4 Setup Utilities Selection Menu 98 Figure 9 5 Setup Types Selection 98 Figure 9 6 Enter New Setup eben 98 Figure 9 7 New Setup Configuration Mes
122. e 8 3 Single Pressure Process Limits Menu 90 Dukane Manual Part No 403 551 03 Section 8 Process Limits Menu PROCESS LIMITS lt gt PROCESS SETUP SUSPECT BAD Total Limits Available Only in 1 Dual Pressure Mode Figure 8 4 Limit Definition Flow Chart For a dual pressure mode both the normal limits and the total limits are displayed as shown in Figure 8 5 ENERGY TOTAL TIME TOTAL ENERGY Figure 8 5 Dual Pressure Process Limits Menu LIMITS LIMIT DEFINITION Figure 8 1 Figure 8 2 PROCESS LIMITS WELD WELD lt ENERGY 1 ENERGY P2 PROCESS LIMITS WE E QoS Dual gt Pressure NO Mode Dual YES Pressure Mode NO In Dual Pressure mode the Weld Methods can be mixed In the flowchart the single pressure limits are on the right side and the dual pressure total limits sec tion are in the shaded area on the left side Single Pressure Mode If a single pressure mode has been programmed the limits begin with the selection of Time or En ergy in the Process Limits menu Figure 8 3 Pressing the ENTER key displays the limit param eter selection which is shown in Figure 8 6 Dukane Manual Part No 403 551 03 91 Dynamic Process Controller DPC II Plus User s Manual WELD ENERGY MAXIMUM LIMIT ao 70 J Figure 8 6 Single Pressure Max Energy Data Entry
123. ed Automation Stop input signal to pin 9 of the HD 15 SYSTEM INPUT con nector see Table 5 1 The SH707 jumper block see Figure 5 11 de termines whether the the signal is isolated or non isolated and sourc ing or sinking E 1 NON ISO SINK 40724 NON ISO SOURCE 40785 ISOLATED JU eb Use the Left and Right arrow keys to move the cursor to the desired digit position and the Up and Down arrow keys to increment or decrement the value When the desired value is displayed press ENTER to return to the main PROCESS SETUP menu shown in Figure 7 5 NOTE The RTW symbol RTW Ready To Weld at the bottom of each logical branch in the flowchart means the DPC Il Plus is logically capable of being triggered to generate an ultrasonic output This is indicated on the display screen by the presence of the PROCESS SETUP menu shown in Figure 7 5 Dukane Manual Part No 403 551 03 69 Dynamic Process Controller DPC II Plus 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 WELO 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 DEFINITION Power is defined as Energy per unit of Time i e h
124. ed operation 3 A weld method called GROUND DETECT is now available This method requires values to be entered for the maximum weld time Tmax and for a parameter called scrub time Tscrub AUTO STOP Option This menu is shown in Figure 7 13 To use this option move the SH704 jumper block to JU715 see Figure 5 12 Use the down arrow key to se lect EHRBLE and press ENTER to continue AUTO STOP DISABLE ENABLE Figure 7 13 MPC Probe Auto Stop Mode Menu When Auto Stop is enabled a signal on pin 9 of the HD 15 SYSTEM IN connector will be recognized This permits external automation equipment to stop the welding cycle If Auto Stop is set to disable then the signal will be ignored Ifthe SH704 jumper block is left in the End Of Weld factory default position JU716 only the welding is stopped Any pro grammed Hold or Afterburst discussed later will still be executed regardless of the Auto Stop mode AUTO refers to Automation not automatic 68 TRIGGER METHOD TIMED MPC PROBE UNTIMED MPC PROBE AUTO STOP UNTIMED MPC PROBE Maximum T delay 30 000 Seconds Minimum 0 000 Second LEGEND RTW Ready To Weld Front Panel ENTER Key Section 4 3 Menu Keys Parameter Value Entry T Time E Energy WELD METHOD GND TIME ENERGY DETECT Maximum 30 000 Seconds Minimum 0 001 Second Maximum E ejg 12 000 Joules Minimum E 1
125. eering of standard and customized systems Food Processing 630 797 4920 4938 For information about using ultrasonics in food processing International 630 797 4915 For questions about international locations support etc Marketing 630 797 4906 For product literature and trade show information Metal Welding 630 797 4953 For information about any aspect of metal welding Sales 630 797 4918 Your local Dukane representative is the main source of product and order information however you may have a need to contact Sales RR RO Service amp Parts 630 762 4090 24 hour Emergency Service For equipment servicing or replacement parts Effective May 10 2004 Technical Writing 630 797 4907 630 797 4987 For information and comments about user s n manual content Tooling Support 630 797 4930 For information about tooling horns and fixturing Training Hotline 630 797 4904 We offer a curriculum of educational programs at our corporate headquarters in St Charles Illinois Please call the Dukane Ultrasonics Training Hotline for a free Education Catalog or with any questions you may have 144 Dukane Manual Part No 403 551 03 SECTION 15 Specifications e Regulatory Compliance e Dimensions Power Requirements and Model Ratings e N Regulatory
126. el 2 POWER RATING Tz Time Only 010 100W E Time amp Energy 015 150W 035 350 050 500W 070 700W 100 1000 W Press Control Board 120 2 1200W 170 2 1700W 220 2200 W TRANSDUCERS 300 3000 W 2 2 Ceramics 400 4000 W 350W amp 700W 40kHz All 50kHz and 70kHz INPUT POWER MODULE 4 4 Ceramics L Low Power Module All 20kHz amp 30kHz units All models except and the 1000W 40 2 those listed below 6 6 Ceramics H High Power Module Custom 1700W amp 2200W 20kHz 1500W 30kHz 1000W 40kHz X Extra High Power Module 4000W 15kHz 3000W 20kHz Power Factor Corrected Non Power Factor Figure 15 2 Interpeting the DPC II Plus Model Number NOTE Figure 15 2 is designed to help you determine which options your DPC has It is not meant to suggest that all combinations of these op tions are possible 150 Dukane Manual Part No 403 551 03 SECTION 16 Warranty Domestic Warranty e International Warranty Domestic Warranty c ccrecacceussesssssenrorceesecidddes 153 International Warranty 154 Dukane Corporation UIN NIS Ultrasonics Division Dynamic Process Controller DPC Plus User s Manual This page intentionally left blank 152 Dukane Manual Part No 403 551 03 Section 16 Warranty DUKANE CORPORATION NORTH AMERICAN WARRANTY POLICY Subject to the terms limi
127. el AC Breaker 25 Figure 4 1 DPC Plus Control Panel Layout 29 Figure 4 2 Front Panel AC Power Section 2 30 Figure 4 3 Generator Control 30 Figure 4 4 System Status Display 20221 31 Figure 4 5 Power Output Display Normal 32 Figure 4 6 Power Output Display Warning 32 Figure 4 7 Menu xoci rectissime teen Cada a odiosa odisse tide uade 33 Figure 4 8 INFO Menu Display 33 Figure 4 9 Menu Display Typical Selection Menu 25 Figure 4 10 Menu Display Typical Confirmation 5 25 Figure 4 11 Menu Display Typical Data Entry Screen 35 Figure 5 1 Plus Rear Panel 39 Figure 5 2 HD 15 System Input Connector 40 Figure 5 3 Cable End of System Input 40 Figure 5 4 DB 25 System Output 42 Figure 5 5 Remote Amplitude Control 46 Figure 5 6 Current Loop Transfer Function Graph i i ees 46 Figure 5
128. en remains in a steady red state there are two possible causes 1 The AC line level may be out of the speci fied operating range Check the AC power to determine if it is within the limits specified in Section 15 2 If the AC power is within specifications the DPC has an internal circuit fault prevent ing normal operation Contact your local Du kane representative Does Not Flash Ifthe INPUT TEST indicator does not flash dur ing power up check the AC line input Both the rear panel and front panel AC breaker switches must be in the ON position and the DPC line cord must be properly connected to a live AC outlet The generator will not turn on if the line voltage is below the rated mini mum The INPUT TEST indicator should light up even without a probe connected TEST Control Key The TEST key should cause the first green bar on the power display to light even without a probe see System Test in Section 11 and Fig ure 11 2 Ifthe TEST control key will not trig ger the INPUT TEST light check that pin 15 of the System Input is not grounded A con tact closure between this pin and ground pin 2 or 7 will lock out the front panel TEST key 128 Dukane Manual Part No 403 551 03 Section 12 Troubleshooting Plug in AC Powercord into outlet TEST 1 Both the front and rear AC breaker switches on indicator the DPC must be turned on Figure 3 9 and 4 2 lights up 2 Make sure the AC outlet has p
129. er the generator The Power Output display will light up to in dicate the percentage of power being delivered to the probe while the trigger switch is en gaged The Power Output display should never reach 10096 during normal operation The Power Output display should go blank in dicating zero output power after the probe trig ger is released Stopping the Weld Cycle Hand Probe System Release the trigger switch on the hand probe to stop the welding cycle Automated System The customer supplied external controls pro vide the means to stop the welding cycle for an automated system Press System Push in the Emergency Stop button on the press base to stop the welding cycle End of Day Push the OFF LINE generator control key on the front panel I in Figure 11 3 The yellow OFF LINE status indicator J in Fig ure 11 3 should be illuminated SYSTEM POWER OUTPUT 0 20 40 60 80 100 PERCENTAGE OF AVAILABLE POWER Figure 11 3 Stopping the Weld Cycle Dukane Manual Part No 403 551 03 121 Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 122 Dukane Manual Part No 403 551 03 SEcTION 12 Troubleshooting e No Ultrasonic Output Generator Faults INPUT TEST Indicatorr TEST Control Key Troubleshooting Flowchart e Error Messages No Ultrasonic 125 je
130. erational Control System Output Remote Ampltd Contro 0452 ST CHARLES IL 60174 1 ULSA WARNING POWER LINE MUST GROUNDED AT OUTLET REMOVE ALL POWER BEFORE REMOVING COVER OR CONNECTING OR DISCONNECTING CABLES ULTRASOUND Ultrasound Output Dukane Manual Part No 403 551 03 39 Dynamic Process Controller DPC II Plus 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 1 below lists the pinout and signal name for the System Input con nector A complete description ofthe 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 This cable is used to connect the DPC to custom automation equipment to control the welding process 15 14 13 12 11 11 12 13 14 15 Figure 5 2 HD 15F System Input Connector Figure 5 3 Cable end of SYSTEM IN connector Pin I pore 1 2 22VDC ined to 250 mA madmum limited to 250 mA maximum The connector pinout in Figure 5 2 is 2 Gnd 22 0 Return DPC Chassis Ground the female DPC panel connector The SECHS es male cable end is a mirror image and is so Oper In solated Operate Inpu s
131. fore the Weld Method decision menu Compare the flowchart in Figure 7 21 to the pre vious MPC flowchart in Figure 7 12 The Pro cess Control menu offers two additional settings to control the welding process After the normal Weld Method is programmed Hold time and Afterburst settings are available 1 The HOLD TIME parameter determines the length of time the probe is held in contact with the parts after the welding cycle has stopped Holding permits the material to so lidify under pressure before the head retracts 2 In some applications the material being welded can stick to the horn as it retracts A short burst of ultrasonic energy called AFTERBURST prevents this This operation is defined by two values The delay after the start of the upstroke before the burst starts Tdelay and the duration of the burst signal Tburst The maximum value of both of these param eters is 0 999 second AUTO STOP Option The Auto Stop option is shown in Figure 7 13 It is designed for use with automation equipment and is available in both the Timed and Untimed Auto Probe Trigger Method To use this option move the SH704 jumper block to JU715 see Figure 5 12 If Auto Stop is enabled then a stop signal on pin 9 of the HD 15 SYSTEM IN connector will be recognized This permits external automation equipment to stop the welding cycle If Auto Stop is set to disable then a signal on pin 9 will be ignored 72 TRIGGER METHO
132. function press the ENTER key The confirmation screen shown in Figure 9 17 15 displayed next RESET PRRT COUNT NO MES Figure 9 17 Confirm Reset Part Count Use the decrement key to move the cursor down one line to YES and press the ENTER key The counter will be reset and the menu returns to the part count selection menu shown in Figure 9 16 Count Suspect Bad Part The second option controls the suspect bad part counter The counter can be set to count all parts or only the good parts To configure the counter move the cursor down to COUNT SUS BAD PART see Figure 9 16 and press ENTER A confirmation screen shown in Figure 9 18 is then displayed COUNT SUS BAD PART 4 TES Figure 9 18 Confirm Counter Enabled To count all parts move the cursor to YES press ENTER and the menu returns to the part count se lection screen shown in Figure 9 16 To exclude bad suspect parts move the cursor to NO and press ENTER The bad suspect parts are ignored and only good parts are counted The menu returns to the part count selection screen shown in Figure 9 16 100 Dukane Manual Part 403 551 03 Section 9 Utilities Menu Preset Part Count This option allows you to preset a value maxi mum 60 000 in the counter Again from the part count selection menu move the cursor to the bot tom line next to PRESET PART COUNT and press ENTER A data entry screen for presetting the value is displ
133. g Instructions For safety the power cords used on all Dukane products have a three prong grounding type plug Approved 2 pole 3 wire grounding receptacle BRYANT No 5621 or equivalent to NEMA 5 15R or 5 20R Figure 2 1 Example of 120 Volt Grounded 3 Prong Receptacle Approved 2 pole 3 wire grounding receptacle HUBBELL No 5652 or equivalent to NEMA 6 15R or 6 20R Figure 2 2 Example of 220 Volt Grounded 3 Prong Receptacle CAUTION If you must have a two prong electrical recep tacle we strongly recommend that you re place it with a properly grounded three prong type Have a qualified electrician replace it fol lowing the National Elec tric Code and any local codes and ordinances that apply See Figures 2 1 and 2 2 CAUTION If there is any question about the grounding of your receptacle have it checked by a qualified electrician Do not cut off the power cord grounding prong or al ter the plug in any way If an extension cord is needed use a three wire cord that is in good condition The cord should have an ad equate power rating to do the job safely It must be plugged into a grounded receptacle Do not use a two wire extension cord with this product 12 Dukane Manual Part No 403 551 03 Section 2 Safety Tips The power cable normally provided for interna tional use is compatible with many power outlets refer to Figure 2 3 However if your applica
134. hat one ofthe generator s power modules has over heated This may occur due to a cooling fan fail ure or excessive dust inside the cooling channel The module s temperature sensor will automati cally shut down the generator The generator will automatically reset and turn off the OVERTEMP indicator when the module temperature drops be low the 75 167 trip point FAULT Ifthe generator FAULT light comes on it indicates an out of tolerance voltage condition This could be related to one of two conditions 1 AC line voltage out of tolerance Refer to Table 15 for the AC voltage specifications 2 Internal DC power supply problems 5VDC 12VDC 12VDC or 24VDC Ifthe AC line voltage is within tolerance then the DPC has an internal fault Contact your local Dukane representative NOTE The OVERLOAD OVERTEMP and FAULT indica tors are triggered by independent sensors It is possible to get more than one error indicator The ultrasonic output is disabled on any one of the errors Dukane Manual Part No 403 551 03 127 Dynamic Process Controller DPC II Plus 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 indi cates 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 th
135. he mechanical vibrations from the probe to the parts to be welded Optional components include special replaceable tips which can be threaded on to the tip ofthe horn and a booster to amplify the mechanical vibrations of the horn A basic hand held probe system 1s shown in Figure 10 1 The hand probe is easily identified by its trigger actuator and permanently attached cable Normally a booster is not used with a hand probe as this increases the length and weight and reduces its versatility The optional threaded titanium tip can be used when the application calls for a staking profile or a pointed spot weld Re placeable tips are not commonly used in high vol ume production environments A mounted probe lacks the trigger actuator and has a HV BNC connector for attaching the high voltage coaxial cable A mounted probe may also have a booster to change its output amplitude Figure 10 1 Hand Probe Horn and Tip Dukane Manual Part No 403 551 03 105 Dynamic Process Controller DPC Plus User s Manual Ultrasonic Horn The horn transfers the ultrasonic mechanical vi brations originating at the transducer in the probe housing to the plastic parts through direct physi cal contact The horn is precision machined and designed to vibrate at either 20kHz 30kHz 40kHz 50kHz or 70kHz The tuning is accom plished using electronic frequency measurement Inherent variations in material composition pre vent tuni
136. he time required to com plete the welding cycle including the scrub time Scrub Time Scrub Time is an extension of the welding cycle which is generated when the ground detect signal would normally end the weld cycle This is typi cally used in cutting operations Often the horn cuts through the material at a single point This activates the ground detect to end the weld cycle But the cut may not be complete and the addi tional scrub time keeps the ultrasound signal on to complete the cut The data entry screen for scrub time is shown in Figure 7 20 The maximum al lowable time value is 0 150 seconds SCRUB TIME DOs ESI Figure 7 20 Ground Detect Scrub Time Data Entry NOTE The word AUTO in the menu options is short for Automation not automatic Any menu that contains the word AUTO means the DPC II Plus will require an external signal s from custom automation equipment for correct operation Dukane Manual Part No 403 551 03 71 Dynamic Process Controller DPC II Plus User s Manual AUTO Probe The cable connection diagram for connecting an automated probe or an automated thruster is Shown in Section 3 in Figures 3 5 and 3 7 The flow chart for the Process Control menu using Auto Probe is shown in Figure 7 21 If you do not have a Power Output module installed the Energy Weld Method menu will not be displayed The Auto Probe Setup logic adds a Process Con trol menu be
137. hown in Figure 5 3 Iso Common Isolated Input Common jumper is selected 5 9 SH707 Iso Press Isolated Press Isolated Press Control 6 Not Used Spare Input Pin 7 Gnd 22 0 Return DPC Chassis Ground Sw Oper Input Switch Closure Operate Input Setup File Selected Iso Auto Stop Isolated Automation Stop Input oR jojojo Filel Probel Isolated Automation End Of Weld 0 0 1 2 2 set by jumper 5 704 see Figure 5 12 1 Probe3 r Not Used Reserved for Future Use Prea HPPI Hand Probe Press Inhibit ri 0 5 Probe5 Setup 1 0 Bit O Remote Setup Selection Bit 0 LSB 110 1 nio Setup 1 0 Bit 2 Setup Selection Bit 2 MSB Note 1 Grounded to DPC chassis F P Lock Front Panel Control Lock 0 Pin Open no connection Table 5 I System Input Connector Signals Table 5 II Remote Setup File Selection 40 Dukane Manual Part No 403 551 03 Section 5 Rear Connectors Input Signal Description Pin 1 224 This pin can supply 22VDC at up to 250mA to power the user s automation controls Pin 2 Gnd Pin 2 and 7 are the 22VDC and Operate returns and are tied to the chassis ground Pin 3 Isolated Operate In This pin is used to initiate the operate sequence The factory default setting is a non isolated
138. ice across the emery cloth as covered in the previous step Give the part a final one third turn and repeat the two strokes described in Step 6 Reexamine the mating surfaces Repeat Steps 6 through 8 until the corrosion has been re moved Clean any grit from the resurfaced element and the stud mounting threads using a clean cloth or paper towel Ifyou had to remove the mounting studs they need to be reinserted Before they are rein serted it is necessary to ensure proper thread engagement a Inspect and clean the stud b Clean the threaded hole with a clean cloth c Thread the stud into the hole Tighten the stud to the torque specifications given in Table 10 II Reassemble the stack and install it using the procedure in Section 10 using Figures 10 6 and 10 7 as guides Complete the Operational Test in Section 11 NOTE If the studs are overtightened the threads may deform Removing a stud that has been over tightened could damage the threads in the horn booster If this should happen retap the horn booster threads and replace the stud with a new one Dukane Manual Part 403 551 03 139 Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 140 Dukane Manual Part No 403 551 03 SECTION 14 Contacting Dukane e Corporate Office e Extensions amp eMails SN Ultrasonics Division Main Office
139. in place of the block labeled Low Side Switch Sinks Current To Ground Isolated Input Pin 43 Operate Pin 5 Press Control User Pin 49 Auto Stop Supplied Switch Circuitry Low Side Switch Sinks Current to Ground DPC Ground Pin 2 or 7 Figure C 3 Current Sink Switch DPC Internal mh Internal Pavel Supply DPC Plus 22V Circuitry Current Limit Circuit 250mA max Current Limit Circuit 12 5 mA max Optical Isolation Circuit Jumper Block SH707 Position JU724 Refer to Figure 5 12 Dukane Manual Part No 403 551 03 165 Dynamic Process Controller DPC II Plus User s Manual Current Source Control Circuit Figure C 4 illustrates an automation control cir cuit connected to the highside of one of the Iso lated 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 posi tion see Figure 5 12 Any of the examples in Figure 2 can be used in place of the block la beled High Side Switch Sources Current DPC Internal Internal Power Supply DPC II Plus 22V Circuitry Current User Limit Circuit Supplied 250 max Switch Circuitry High Side Switch Sources Current DPC II Plus 22V Power Isolated Input 12 5 MA max Pin 3 Operate rrent Pin 5 Press Control Pin 9 Auto Stop 12 5 mA max 3 Wu
140. in press mode It 1 titled Weld Mode and offers a choice of welding modes You must have a dual pressure press to use the dual pressure mode A single pres sure press displays Weld Method see Figure 7 15 WELD MODE SINGLE ss URE OUAL FRE Figure 7 38 Single or Dual Pressure Selection Menu To demonstrate the complete set of options we will select DUAL PRESSURE and push the ENTER key We can select time or energy as the welding parameter during the P1 portion of the welding cycle This corresponds to the block labeled PRES SURE 1 in Figure 7 58 Select WELD BY TIME and press the ENTER key WELD METHOD WELD BY TIME WELD BY ENERGY Figure 7 39 Pressure One Weld Method Selection Menu A data entry screen appears requesting the value of the weld time for pressure one On the flow chart Figure 7 30 this is labeled 77 44 The data entry screen is shown below in Figure 7 40 WELD TIME Pt Figure 7 40 Pressure One Weld Time Data Entry 78 Dukane Manual Part 403 551 03 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 Pressure Two Weld Method Selection Menu This time select WELD BY ENERGY and press the ENTER key This brings up the data entry
141. ing 630 797 4930 For information on tooling fixtures and horns Department email Addresses Applications usappsedukcorp com Engineering usengedukcorp com Service amp Parts usservice dukcorp com TOON ustooling dukcorp com Our Website Dukane Ultrasonics is on the world wide web at http www dukcorp com us and then go to your area of interest NOTE See the next page for additional department phone numbers and email addresses Dukane Manual Part 403 551 03 143 Dynamic Process Controller DPC II Plus User s Manual Ultrasonics Division email Addresses Applications usappsedukcorp com usengGdukcorp com Food Processing usfoodprocedukcorp com International Sales usintledukcorp com Marketing usmktg dukcorp com SalBSs 2 ussales dukcorp com Support Service amp Parts usservice dukcorp com Technical Writing ustechwriting dukcorp com M ustooling dukcorp com ustraining dukcorp com Ultrasonics Division Phone Numbers Application Support 630 797 4930 For applications and or process technology questions Engineering 630 797 4950 For engin
142. ins active until the beginning ofthe next cycle If the Utilities menu option is set to momentary the signal is pulsed for 100 msec Pin 21 Iso Good Part An active low output that indicates the weld cycle did not cross the boundary limits set in the Suspect or Bad Limits menu This signal activates when the ul trasonic output is terminated at the end of the weld The default setting is maintained which means the signal remains active until the beginning ofthe next cycle Ifthe Utilities menu option is set to momen tary the signal is pulsed for 100 msec Pin 22 Iso Ready An active low output that occurs at the end of all portions of the weld cycle The signal remains ac tive until the beginning of the next cycle Pin 23 Iso In Dwell This output is active low while the ultrasonic output signal has been turned off during the HOLD time of the weld cycle Pin 24 Iso Common Pin 24 provides the return path for the isolated out put signals on pins 19 20 21 22 and 23 Pin 25 Not Used Pin 25 1s reserved for future use FOOTNOTES 1 Requires a Remote Amplitude Control module 2 Requires a Power Signal Output module 3 Not presently available 4 Requires a Multi Probe Controller module 5 Requires the standard DPC Plus timer feature Dukane Manual Part No 403 551 03 45 Dynamic Process Controller DPC II Plus User s Manual
143. intentionally left blank 88 Dukane Manual Part No 403 551 03 Section 8 Process Limits Menu Process Limits Menu The Process Limits Menu allows you to define upper and lower bounds for suspect parts or for bad parts The limits are available in both units of time and units of energy depending upon the welding method chosen in Process Control setup In addition if a dual pressure welding method is selected total time and or total energy limits are also available for suspect or bad parts The same memory location is used for suspect and bad part limits The difference is that exceeding a bad part limit terminates the weld cycle Ex ceeding a suspect limit allows the weld cycle to continue until it finishes normally or exceeds a Total limit There are 12 different limit settings which are broken down as follows 1 There are two possible BAD PART UPPER TIME LIMITS one for each pressure level Ib There are two possible BAD PART UPPER ENERGY LIMITS one for each pressure level 1 There is one TOTAL BAD PART UPPER TIME LIMIT and one TOTAL BAD PART UPPER ENERGY LIMIT This makes a total of six BAD PART UPPER LIMITS 2 There are six BAD PART LOWER LIMITS During a dual pressure mode welding cycle how ever only six ofthe limits eight in mixed mode are applicable In single pressure mode this drops to two usable limits at any one time since the totals are available only in dual mode For ex ample you can set both u
144. ir Figure num ber Table 7 on the next page lists the data entry screens and references their Figure number It also gives the minimum and maximum values for each of the parameters The only variation between models is for weld energy The high frequency 50kHz and 70kHz models have a lower power output and the scale factor change enables 0 1 Joule resolution at these lower power levels STRRTUP pec DPC Plus Firmware Version and Date Firmware Version and Date 6 1 7 1 Press Board or Power Output CONFIGURATION installed Modules WELO CYCLE DATA Previous Weld Cycle Data 6 3 7 3 7 4 7 53 PR CESS SETUP Root Menu 7 4 7 29 7 52 TRIGGER Probe Timed or Untimed Timed or Untimed TRIGGER METHOD Re IC rre meme neo meet 7 Table 7 1 Process Control Menu Listing 84 Dukane Manual Part No 403 551 03 Section 7 Process Control Menu Parameter Menu Name Description Trigger Method Weld Method Figure No Minimum Value Maximum Value Tdelay Probe Delay Post Trigger Delay Untimed MPC Auto Probe Untimed Probe Only 0 000 Second 30 000 Seconds mew gt Tmax Weld Time Welding Time Limit Press amp Any Timed Probe Energy 7 11 7 18 0 000 Second 30 000 Seconds max Max Weld Time Welding Time Limit Press MPC
145. irst 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 Step3 Attach another high voltage coax cable from the rear MPC channel 1 probe output to the first probe Attach a separate cable from each output channel to each probe Step 4 Connect the automation control cable from the user supplied automation equipment to the System Input rear panel HD 15 connector Step 5 Attach the status output cable from the user supplied automation equipment to the System Output DB 25 connector NOTE Step 6 Attach the power cord to the DPC The automated system cabling schematics in Fig Plus and plug the other end into an ures 3 5 3 6 and 3 7 are intended to represent approved AC outlet connections for a typical automation system Your system cabling may vary slightly from the diagrams P N 200 479 Grounding Lug zz Ultrasound Input s Multi Probe 14 Gauge Master Module Wire Ultrasonic Input RG62B U Coax 1 Coaxial Cable s RG62B U Automation Control P N 200 1203 Automation Equipment Status Output P N 200 1302 14 Gauge Wire Earth Ground Figure 3 6 DPC II Plus Multiple Probe Conntroller Cable Connections 22 Dukane Manual Part No 403 551 03 Section 3 Unpacking and Installation Automated
146. ly be entered or modified after the programming setup is completed Dukane Manual Part No 403 551 03 33 Dynamic Process Controller DPC II Plus User s Manual Pressing the MODE key toggles be tween the Weld mode displays val ues 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 pa rameter setting The key is used when entering values and moves the flashing bar under the selected digit The selection wraps around to the left digit after the right most digit position is reached V UJ Pressing the WELD P2 key displays WELD the parameter s for the second pressure setting only if a dual For any of the four hot keys HOLD WELD P1 sure mode has been previously se WELD P2 or AMP ADJUST pressing the lected The value s can be quickly CANCEL key instead of ENTER returns you to the last menu screen without altering the value checked and or altered without go ing back through the menu se quence Pressing ENTER completes the process and returns you to your last menu screen Pressing this key displays the current AMP ultrasound amplitude setting This can be adjusted from 40 to 100 x NOTE using the up and down ATOW keys Reducing the amplitude with the AMP ADJUST marked and respectively Press key reduces the maximum po
147. must be set In dual pressure mode a logical de cision function indicated on the flowchart by the diamond with 2P inside diverts the sequence after the 1 values have been entered and returns back to the limit selection menu for the P2 value You must however move the cursor to the P2 limit before pressing ENTER otherwise you will return back through the P1 section Pressing the CAN CEL key will return you to 1 2 selection menu shown in Figure 8 8 The data entry screens for dual pressure mode also identify the P1 or P2 pressure phase The screen for entering the P1 Maximum Energy Limit is shown in Figure 8 9 WELD ENERGY MAXIMUM LIMIT g0 J Figure 8 9 P1 Maximum Energy Data Entry After the minimum and maximum limit values have been entered the display returns to the Pro cess Limit menu shown in Figure 8 5 Press the CANCEL key to return to the Limit Definition Menu Figure 8 2 Press CANCEL again to re turn to the Process Setup Menu Figure 8 1 The return sequence flowchart for the CANCEL key is shown in Figure 8 10 Only the energy loops are labeled to avoid confusion but the time loops have the same return sequence 92 Dukane Manual Part 403 551 03 Section 8 Process Limits Menu PROCESS LIMITS LIMIT DEFINITION SUSPECT PROCESS TIME ENERGY TOTAL TIME SINGLE Figure 8 10 CANCEL Key Return Path Flow Chart Dukane Manual Part 4
148. n of the menu structure relating to hand probe operation is displayed The only op tion for the Process Control screen is the Trigger Method which is shown in Figure 7 6 TRIGGER NETNOD TIMED HAND PROBE HAND PROBE Figure 7 6 Process Control Trigger Method Menu The flow chart for the Process Control menu with hand probe connected is shown in Figure 7 7 If you do not have a Power Output module installed the Energy Weld Method will not be displayed Untimed Hand Probe Untimed Hand Probe operation has no parameters to enter The generator is triggered whenever the hand probe trigger is engaged and continues until the trigger is released Press ENTER and you are ready to weld RTW Timed Hand Probe In Timed Hand Probe mode the welding stops when ever the trigger is released or the specified weld time 66 TRIGGER METHOD TIMED HAND PROBE UNTIMED HAND PROBE Figure 7 6 UNTIMED HAND PROBE LEGEND RTW Ready To Weld Front Panel ENTER Key Section 4 3 Menu Keys Parameter Value Entry S T Time E Energy Figure 7 9 WELD METHOD TIME ENERGY Maximum 12 000 Joules 1 Figure 7 10 Minimum E Maximum 30 000 Seconds Minimum 0 001 Second Maximum 29 999 Seconds Figure 7 8 3 Minimum 0 001 Second These values can be set to zero but will not produce any output The values listed represent
149. nance Grease may be omitted if mylar washers are preferred on systems that require frequent changes Mylar is plastic and will creep under compression so mylar is not recommended for system that are not changed frequently Fail ure to follow these instructions may result in the mating surfaces bonding and difficulty re NOTE Always remove a probe stack from the ma chine in which it is mounted before attaching or removing a horn lt Figure 10 4 Stack Assembly Procedure Dukane Manual Part No 403 551 03 109 Dynamic Process Controller DPC Plus 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 cor rect procedure Refer to Table 10 II for torque units conversions Be careful not overtighten 40kHz Stacks 130 inch Ibs 20kHz Stacks 200 inch Ibs NOTE Horn and booster torque specifications are higher than stud torque specs Be sure to tighten the horn or booster joints to the higher torque limits Do not tighten the studs to these higher rat ings as it may induce unnecessary stress in the Table 10 Horn Booster Torque Unit assembly
150. ndicating normal operation in Figure 11 2 4 The ON LINE status indicator goes blank This indicates the ultrasonic probe is activated The probe should operate without any unusual noise The probe will operate as long as the TEST key is pressed 5 When the TEST key is released the ON LINE status indicator lights up again and the Power Output display goes blank NOTE Neither a press system automation system hand probe or TEST key can trigger the gen erator to produce an ultrasound output if the DPC Il Plus is OFF LINE The Front Panel Control Lock Pin No 15 on the HD 15 System Input connector will dis able the TEST key from producing an output Refer to Section 5 Table 5 1 The F P Control Lock will also inhibit any pro gramming changes The menu navigation will function normally but data entry is inhibited 120 Dukane Manual Part No 403 551 03 Section 11 DPC Checkout System Operation Il 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 Program the appropriate weld method and time or energy to achieve the desired welding results Apply the probe to the components to be ultra sonically joined and press the probe s activation switch or press the palm switches on the press base In automation systems the customer sup plies external controls to trigg
151. nel Cleaning Do not use any solvents or abrasive cleaners on the front panel Do not spray cleaner directly onto the front panel Apply a small amount of com puter cleaner to a soft towel first Clean the panel with the moistened towel Do not spray or apply the cleaner directly to the DPC Do not allow any liquid to collect around the AC power switch Display Do not use a sharp object on the display Control Keys Use your finger to press the control keys Do not use sharp objects on the keys If your hands are greasy or contaminated with dirt use a soft ob ject like a pencil eraser to push the keys Rear Panel Connectors The rear panel System Input and Status Output each have a pair of 4 40 threaded nuts to secure the connectors Do not overtighten them Exhaust Air from Flow Thru Cooling Tunnel m E Po Dynamic Process Controller AC Power Cord The AC power cord should be kept in good condi tion and free from any cuts The AC plug should be straight with no bent prongs Grounding Stud The rear chassis earth ground connection see Fig ures 2 5 and 3 3 is a 10 24 x 1 2 threaded stud Do not overtighten the nut Chassis Side Ventilation Slots Keep the two side ventilation slots free from ob structions If excessive dust or dirt collects on the slots wipe or vacuum them clean Do not use com pressed air to clean them as this may force the dirt inside the chassis The right hand slot
152. ng EN60204 1 1993 Safety of Machinery Electrical Equipment of Machines Part 1 Specification for General Requirements Dukane Manual Part No 403 551 03 147 Dynamic Process Controller DPC Plus User s Manual Dimensions 23 78 in 604 mm Allow 2 in 5 Heated space for ventilation Exhaust Air Allow 4 in 10 cm space for cables Allow 4 in 10 cm space for cables Allow 2 in 5 cm space for ventilation Cooling Air Inlet 17 17 in 436 WARNING POWER LINE MUST GROUNDED OUTLET Multi Probe Slave Module Power Signal Output Multi Probe Master Module Press Control Board Figure 15 1 Generator 3 View and Dimensions Operating Environment Operate the DPC II Plus within these guidelines Storage guidelines Temperature 40 to 100 5 to 38 Temperature 4 F to 158 F 20 to 70 Pressure Ambient Humidity 596 to 95 Non condensing Air Particulates Keep the DPC dry 0 C to 30 C Minimize exposure to moisture Vibration 2 5G dust dirt smoke and mold Humidity 5 to 95 Non condensing 0 C to 30 C Vibration 1 0G 148 Dukane Manual Part 403 551 03 Section 15 Specifications AC Power Requirements The AC
153. ng by dimensional machining alone There are many different horn profile styles de pending upon the process requirements Factors which affect the horn design are the materials to be welded and the method of assembly Horns are usually constructed from aluminum hard ened steel or titanium As the frequency in creases vibration amplitude typically decreases but internal stress in the horn increases Higher frequencies are used for delicate parts that can not handle a lot of amplitude Some factors to keep in mind for high frequency e g 40kHz ultrasonic welding versus low frequency e g 20kHz ultrasonic welding are listed here 1 Stress in the horn is higher at high frequencies 2 Wearon the horn is greater at high frequencies 3 Clean and flat mating surfaces between the horn booster and transducer are more critical at high frequencies Booster The function of a booster 15 to alter the gain 1 e output amplitude of the probe A booster is am plifying if its gain is greater than one and reducing if its gain 15 less than one A neutral or coupling booster is used to provide an additional clamping location for added probe stack stability A probe designed to be mounted in a fixture along with a booster and horn is shown in Figure 10 2 This is commonly referred to as a stack As indicated the components are secured with threaded studs Probe Housing Booster Figure 10 2 Probe Booster and Horn 106
154. ng stud The mounting rings have a shear pin which could snap under ex cessive torque Use a spanner wrench on horns with spanner wrench holes or an open end wrench on horns with wrench flats to keep the horn or booster from turning in your hand e 70 inch Ibs for an 8mm threaded stud 100 inch Ibs for a 3 8 x 24 threaded stud e 160 inch Ibs for a 1 2 x 20 threaded stud Table 10 1 Stud Torque Unit Conversions Always assemble the mounting studs that mate boost ers transducers and horns to the input end of the horn or the input end of the booster first This is shown in Figures 10 6 and 10 7 NEVER thread a stud into the transducer or the out put end of the booster first See Booster Notes in this section for correctly identifying the output end NOTE Do not apply any grease to the stud threads or the tapped hole This may cause the stud to loosen If the stud wanders within the joint it can vibrate resulting in excessive heat In some cases this can melt the tooling material NOTE To convert inch lbs to ft lbs divide by 12 To convert inch lbs to Nm divide by 8 852 To convert ft lbs to Nm multiply by 1 356 To convert Nm to ft lbs multiply by 0 7376 Torque specifications have a tolerance of about See Figure 10 4 for a handy conversion graph of a booster 108 Dukane Manual Part No 403 551 03 Section 10 Probes and Probe Stracks
155. nu which is covered in the next section P1 Upper TIME ENERGY Limit P1 Lower TIME ENERGY Limit Recognized Limits in a Single Pressure Welding Cycle T y P1 T E Table 8 Dukane Manual Part 403 551 03 89 Dynamic Process Controller DPC II Plus User s Manual Limit Definition To access the Limit settings start from the Pro cess Setup menu shown in Figure 8 1 PROCE 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 in dicated at the top of Figure 8 4 which is the flow chart for the Limit Definition Both the suspect Limits and Bad Limits share the same logical structure so no distinction is made between them in this flow chart LIMIT DEFINITION SI SPEET LIMITS BAD LIMITS Figure 8 2 Limit Definition Menu Suspect amp Bad Limits You can select either a Suspect or Bad Part Limit A Suspect Limit allows the weld cycle to continue but causes an error indication in the display gt or lt for upper or lower limit If a Bad Limit is exceeded the weld cycle is terminated and an error indication is displayed gt gt or lt lt for upper or lower limit until the next weld cycle is initiated A bad limit and suspect limit value share the same memory location To change a Suspect Limit value to a Bad Limit value move
156. ooling Lab 8 Western Serv Cntr A Film amp Fabric Appl Lab Midwest Region Jerry Wibben 2900 Dukane Drive St Charles IL 60174 630 797 4921 Mexico Sales amp 5 Serv Cntr 5 Western Region amp Alaska James Jackstein 162 East Manilla Drive 84020 6 801 523 6191 6 Mexico amp Caribbean S Mexico Service Center 22 Nelson Romero Alejandro Alex Juarez gt 2900 Dukane Drive Dukane Corporation S St Charles IL 60174 Vulcano No 1618 D 630 797 4915 Col Nueva Linda Vista Guadalupe NL CP 67110 Mexico TEL 011 52 81 8364 9313 DPC II Plus User s Manual Part No 403 551 03 1 00 00 Printed in the United States of America Dukane Corporation e Ultrasonics Division 2900 Dukane Drive St Charles Illinois 60174 USA e TEL 630 797 4900 FAX 630 797 4949 www dukcorp com us
157. or DPC Power Source Figure C 4 To Automation Control Signal DPC Ground Figure 3 DPC Isolated Input 1 Figure C 4 HD 15 System Input User Supplied Connector Transistor Driver Circuit 5 DPC Isolated Input 2 Figure 3 or DPC Power Source Figure C 4 To Automation Control Signal DPC Ground Figure C 3 or DPC Isolated Input 1 Figure 4 HD 15 System Input Connector DPC Isolated Input 2 Figure 3 DPC Power Source Figure 4 DPC Switch Input Automation User Supplied Control Relay Signal Normally Open Contact DPC Ground Figure 3 or DPC Isolated Input 1 Figure 4 or DPC Ground HD 15 System Input User Supplied Connector DPC Isolated Input 2 Figure or Opto Coupler DPC Power Source Figure C 4 To Automation Control Signal 3 DPC Ground Figure 3 or DPC Isolated Input 1 Figure 4 Figure 2 Automation Control Switches 164 Dukane Manual Part No 403 551 03 Appendix C User Supplied Circuitry Non Isolated Switch Circuits Current Sink Control Circuit Figure C 3 illustrates an automation control cir cuit connected to the low side of one of the Iso lated 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
158. or in stalling removing modules from the DPC II Plus Make sure BOTH the front and rear panel AC power breaker switches are in the OFF position Failure to turn off the power may re sult in damage to the DPC and or the modules The DPC must also be properly grounded as discussed in Section 3 to prevent any static discharge damage We highly recommend that you read this ter completely Even though some of the con figurations may not be applicable to your pro cess the options and menu selections are cov ered in a sequential fashion If you jump directly to the menu structure of interest you will miss some of the preliminary topics 1 TIME Figure 7 3 DPC II Plus Time Weld Cycle Display 1 TIME ENERGY Figure 7 4 DPC II Plus Energy Weld Cycle Display Dukane Manual Part No 403 551 03 65 Dynamic Process Controller DPC II Plus User s Manual Press the MODE key to display the Process Setup menu In Process Setup the cursor should be point ing 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 se lected menu PROCESS LIMITS Figure 7 5 Process Setup Menu Since the DPC II Plus reconfigures the user inter face to be consistent with the installed modules only the portio
159. ow fast energy is produced or consumed Energy is defined as the capacity to do Work The release of energy does work and in do ing work on something adds energy to it Work and energy are equivalent concepts The Weld By Energy mode measures energy in units of Joules By definition a Watt power is one Joule energy per Second time Therefore a Joule is equivalent to one Watt Second WELD ENERGY MAX WELD TIME Figure 7 17 Probe Weld Energy Press ENTER and the maximum weld time data i250 SEC entry screen is displayed as shown in Figure 7 18 This is the time limit on the welding process if the specified energy has not been reached Enter a value which permits the desired weld Figure 7 18 Probe Maximum Weld Time energy to be reached Press the ENTER key to return home to the Process Setup menu Weld Method Ground Detect The GROUND DETECT The horn is grounded and acts as welding method is available in both MPC a switch closure when it contacts the fixture Probe and Auto Probe configurations In Use plastic insulating wash ers between the bolts and fixture Center the washers so the bolts do not touch Install a plastic insulator between the fixture and the base Washer Plastic Insulating ground detect mode connect 108196 the ultrasonic signal is one Plastic initiated when the op erate input is triggere
160. ower INPUT TEST PIE flashes for gt Verify that the AC voltage is within specifications 5 10 sec INPUT TES indicator Verify that the AC voltage is within specifications goes out Green 1 Defective power indicator lamp light on 2 Internal fault contact Dukane Service FAULT indicator Verify that the AC voltage is within specifications off Continued on next page Figure 12 3 Troubleshooting Flowchart Part 1 Dukane Manual Part No 403 551 03 129 Dynamic Process Controller DPC II Plus User s Manual Continued from previous page OVER TEMP Allow module s to cool down Check cooling fan and indicator cooling channel for excessive dust build up off OVER 1 Make sure correct probe is connected to generator LOAD 2 Check the ultrasonic coaxial cable for shorts indicator 3 Try changing the probe and or cable o 4 Make sure probe stack is properly assembled 1 If Press Module installed check J902 ON LINE k 2 Check Emergency Stop is not pushed in y works 2 3 Internal fault contact Dukane Service 1 If Press Module installed check J902 2 Internal fault contact Dukane Service Disconnect the probe cables from DPC The TEST key should work even without a probe or SYSTEM cable Make sure FP Control Lock is not enabled Table 5 1 Figure 12 4 Troubleshooting Flowchart Part 2 130
161. p arrow to po sition the cursor and then press ENTER Dukane Manual Part No 403 551 03 77 Dynamic Process Controller DPC Plus 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 AUTO STOP menus when we select manual mode The next menu displayed is TRIGGER TYPE which is shown in Figure 7 36 TRIGGER TYPE MAINTAINED HOMENTARY Figure 7 36 Press Trigger Type The trigger type used for most welding conditions should be Use the down arrow key to select Momentary and press ENTER We are now at the central Process Control menu It is shown below in Figure 7 37 PROCESS CONTROL WELD MODE HOLD TIME B RFTERBURST Figure 7 37 First Pass Through Process Control Menu The cursor is pointing to Weld Mode by default Note there is a small difference between the word ing of the Process Control menu for Press and for Auto Probe The Press option reads Weld Mode whereas the Auto Probe menu reads Weld Method We leave WELO MODE selected and press ENTER The next menu Figure 7 38 appears only
162. play 3 System Power Output Display Generator Control Keys The Generator Control Key section consists of three keys as shown in Figure 4 3 ONLINE This places the generator in an opera tional state It can produce an ultra sonic output signal when triggered TEST The TEST key momentary activates the generator to provide ultrasound out put for test or setup purposes TEST will only work in the ON LINE state OFFLINE This key places the generator in a standby mode This prevents the gen erator from producing an ultrasonic output signal Green Power Indicator Front AC Power Switch Figure 4 2 Front Panel AC Power Section OFF LINE Key Figure 4 3 Generator Control Keys NOTE If a Press module is installed these keys are only active if the Emergency Stop is not engaged If the Emergency Stop switch is depressed the System Status Display will not be lit and the Control Keys inactive 30 Dukane Manual Part No 403 551 03 Section 4 Controls amp Displays System Status Display The System Status Display indicates one of the six system states If that state is active the correspond ing label is lit in the display Figure 4 4 shows the System Status Display with the ON LINE state acti vated The six status conditions are described here FAULT This indicator lights when out of toler ance voltage fluctuations occur that are related to one of the follo
163. pose 107 Mounting Stud to Horn Booster uui isti read cdit idis aus d tun 108 Horm to BOOSEGI ooo ite tedio eater Tu ee Dien dd dup usd 109 B oster to Probe M TED ETE 109 Horn to MEMENTO 109 Torque Unit 110 Stack Se SSE qol oem 111 Booster MP Cc TT 114 115 Dukane Manual Part No 403 551 03 vii DPC II Plus User s Manual Section 11 DPC 117 Sta rt p and Self Test eaae SER RESP 119 120 Probe Ope ratiON e 121 Stopping the Weld Cycle NUR ERN 121 121 A tomated T P 121 Eng of Day E US 121 Section 12 Troubleshooting eet pei R MR boite 123 No Ultrasonic OUEDUE 125 iss pep Hon 125 M I 125 m OOO M 126 Operate NU D 126 TT 127 OVERLOAD Indicator a 127 OVERTEMP Indicato qud c tua dh 127 FAULT Indicator 127 Gerieratelr E MN MR VN NEUEM MEE 128 IN
164. power requirements depend on the frequency and power rating of the II Table 15 below lists both the nominal AC requirements maximum current drawn before overload and the service rating of the AC outlet each model of the DPC II Plus is designed for DPC II Plus Peak Power AC Outlet Frequency Model Rating Watts Nominal AC Power Requirements Current Rating 1400 4000 190 260V 50 60 Hz 30 Amps 30 Amps 95 130V 50 60 Hz 8 Amps 15 Amps 2050 500 190 260V 50 60 Hz 4 Amps 15 Amps 95 130V 50 60 Hz 15 Amps 15 Amps 2120 1200 190 260V 50 60 Hz 8 Amps 15 Amps 2170 1700 190 260V 50 60 Hz 12 Amps 15 Amps 2220 2200 190 260V 50 60 Hz 15 Amps 15 Amps 2300 3000 190 260V 50 60 Hz 25 Amps 30 Amps 30 kHz 3150 1500 190 260V 50 60 Hz 12 Amps 15 Amps 95 130V 50 60 Hz 6 Amps 15 Amps 4035 350 190 260V 50 60 Hz 4 Amps 15 Amps 95 130 50 60 Hz 12 Amps 15 Amps 4070 700 190 260V 50 60 Hz 8 Amps 15 Amps 95 130V 50 60 Hz 15 Amps 15 Amps 4100 1000 190 260V 50 60 Hz 8 Amps 15 Amps 5015 150 70 kHz 7010 100 Table 15 I DPC Il Plus Generator Model and Power Supply Requirements Dukane Manual Part No 403 551 03 149 Dynamic Process Controller DPC Plus User s Manual Interpreting the DPC Il Plus Model Number Generator Controller Level luxu ael 2200 HN4 PE L2 FREQUENCY 1215 kHz 2 20 kHz 3 30 kHz 4 40 kHz 5 50 kHz _ 7 70 kHz L2 lev
165. pper time and energy limits but only the upper time limit is recognized in the weld by time mode Table 8 1 summarizes the 8 limits recognized in a dual pressure mixed mode welding cycle Table 8 II summarizes the 6 limits recognized in a dual pressure uniform mode welding cycle Table 8 lists the 2 limits recognized in a single DEFINITION A mixed mode is a dual pressure weld cycle in which one unit of measurement e g time is used for Pressure 1 and the other unit of mea surement e g energy is used for Pressure 2 uniform mode is a dual pressure weld cycle in which the same unit of measurement e g time is used for both Pressure 1 and Pressure 2 Cycle State P1 T E y P2 Total Ty Total Ey P1 T E P2 E T Total Total E Table 8 I Parameter Limit Type P1 Upper TIME ENERGY Limit Recognized Limits in a Dual Pressure Mixed Mode Welding Cycle Cycle State P1 T y P1 Upper TIME ENERGY Limit P2 P2 Upper TIME ENERGY Limit Total T E Total Upper TIME ENERGY Limit P1 T E P1 Lower TIME ENERGY Limit P2 T E P2 Lower TIME ENERGY Limit Total T E Lower TIME ENERGY Limit Table 8 Recognized Limits in a Dual Pressure Uniform Mode Welding Cycle Parameter Limit Type Cycle State Parameter Limit Type pressure welding cycle A Bad Parts Counter is also available in the Utili ties me
166. primarily 4 lt lt 20mA for system testing when a current loop is unavailable Remote Amplitude Current Loop Control Module Fault Indicator P N 438 799 NOTE If you have a Re mote Amplitude Control module in stalled its setting will override any front panel setting The front panel menu will accept the value but the output amplitude will be determined by the 4 20mA Current Loop Connector loop current ui E a 3 T o 5 2 Figure 5 5 Remote Amplitude Control Module 46 Dukane Manual Part 403 551 03 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 The scale factor is the same on all three outputs On the 20kHz 30kHz and 40kHz models it is 1mV 1 Watt and the maximum full scale output is 4 095 Watts On the 50kHz and 70kHz models the scale factor is 10mV 1 Watt with a maximum output of 409 Watts l A miniature phone jack is provided on the top of the rear panel
167. ration This screen is shown in Figure 7 28 Again enter the desired signal duration and press the ENTER key AFTERBURST DURATION Figure 7 28 Auto Probe Afterburst Duration Data Entry This returns you to the Process Control menu as shown in Figure 7 22 Press the CANCEL key once or the MODE key twice to return to the root Pro cess Setup menu shown in Figure 7 29 PROC PROCES PROCES UTILITIES 999 LIMITS NOTE The RTW symbol in the flow chart is signified by the display of the PROCESS CONTROL menu From the PROCESS CONTROL menu press the MODE key twice or the CANCEL key once to re turn to the root PROCESS SETUP menu PROCESS SETUP PROCESS CONTROL 4 PROCESS LIMITS UTILITIES PROCESS CONTROL WELO MODE 4 HOLO TIME RFTERBURST Figure 7 29 Process Setup Menu 74 Dukane Manual Part No 403 551 03 Section 7 Process Control Menu PRESS Mode The cable connection diagram for connecting a DPC Plus to a Dukane press is shown in Sec tion 3 in Figures 3 8 The flow chart for the Pro cess Control menu is shown in Figure 7 30 If a Press Control module is not installed this menu will not be displayed If you do not have a Power Output module installed the Energy Weld Method menu options will not appear either The Press Setup logic features two areas of enhance ment over the Auto Probe logic The PRESS TRIG GER METHOD has th
168. ree additional control options in the Auto Stop logical branch the Auto Probe trigger methods are still available The WELD MODE menu is also expanded and offers a choice of SINGLE PRESSURE or DUAL PRESSURE mode Compare the flowchart in Figure 7 30 to the previ ous Auto Probe flowchart in Figure 7 21 1 The TRIGGER PRESS mode has an INITIATE menu preceding Auto Stop The MANUAL mode is the recommended set ting This permits the dual palm switches on the press base to initiate the operate sequence 2 If ENABLE was selected in the AUTO STOP menu the HERD UP ON AUTO STOP menu is displayed Auto Stop has been covered previ ously under MPC Probe and AUTO Probe The HEALD UP menu determines whether the press head remains at its last position or retracts when an external Auto Stop signal is detected NOTE The symbol legend for the Press Mode flow chart is the same as the other flow charts It is re peated here for your convenience LEGEND RTW Ready To Weld Front Panel ENTER Key ENTER Section 4 3 Menu Keys Parameter Value Entry T Time E Energy Dukane Manual Part No 403 551 03 TRIGGER METHOD PRESS TIMED AUTO PROBE UNTIMED AUTO PROBE 1 1 1 ENTER INITIATE MODE i 5 ENTER AUTO STOP ENABLE DISABLE HEAD UP ON TRIGGER TYPE
169. s This gives a total of eight probe channels The slave module cannot be used alone It must be used with the master module An internal connector supplies the ultrasound signal from the Master module As with the Master module each output channel has a bicolor LED status indicator that illuminates green when the probe channel is selected and red when the U S is active NOTE The Ultrasound input on the MPC Master must be connected to the DPC Ultrasound output connector J1 with a RG62B U coax This is indicated as Cable 2 in Figure 3 6 Ultrasound Input from J1 8 Ultrasound Outputs 4 per Module Figure 5 11 Master and Slave Multi Probe Controller MPC modules Dukane Manual Part No 403 551 03 51 Dynamic Process Controller DPC II Plus User s Manual Jumper Block Options The DPC II Plus may be customized to your spe cific requirements by means of internal jumpers lo cated on the main printed circuit board Below is a list of the jumper blocks their default factory set tings and their alternate positions Figures 5 12 and 5 13 on the following pages show the location of the jumper blocks in more detail The factory de fault setting is indicated by a diamond next to the description in Figure 5 13 Status Driver Normal State Selection Jumper Block SH701 Pin 4 output on DB 25 JU701 Normally OFF Factory Default JU702 Normally ON Status Driver
170. s page intentionally left blank 162 Dukane Manual Part No 403 551 03 Appendix C User Supplied Circuitry Manual Switch Circuit Figure C 1 is an example of a typical user sup plied 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 77 or Pin 2 System Input Cable DPC Switch Input Pin 48 Operate or Pin 15 F P Lockout User Manual II Plus Supplied Control HD 15 System Switch iis Switch Input Connector DPC Ground Pin 42 or 47 Figure C 1 Manual Control Switch NOTE The drawings and circuits shown in this sec tion are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Dukane does not assume respon sibility or liability for actual use based upon the examples shown in this section Dukane Manual Part No 403 551 03 163 Dynamic Process Controller DPC II Plus User s Manual Automation Switch Circuits Figure 2 shows examples of various types of user supplied automation control circuits con nected to the DPC Input These examples can be used in place ofthe low side or high side switches in Figure 3 and Figure C 4 HD 15 System Input User Supplied Connector Open Collector Darlington Driver DPC Isolated Input 2 Figure 3
171. sage 98 Figure 9 8 Source File Location 2 99 Figure 9 9 Destination File Location 2 2 99 Figure 9 10 Confirm Copy Files iioi ur here 99 Figure 9 11 Erase Setups Selection 99 Figure 9 12 Confirm Erase Selected 99 Figure 9 13 Erase Setup 58 eerte nie tnmen Rot 99 Figure 9 14 Confirm Erase All 2 nnns 100 Figure 9 15 Erasing All Setups In 5 100 Figure 9 16 Part Count Selection Menu 100 Figure 9 17 Confirm Reset Part COUDL 100 Figure 9 18 Confirm Counter Enabled 100 Figure 9 19 Counter Preset Value 22 101 Figure 9 20 Status Output Mode 22 5 101 Figure 9 21 Cycle Press Selection Menu 2 101 Dukane Manual Part No 403 551 03 157 Dynamic Process Controller DPC II Plus 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 Figure 11 1 Figure 11 2 Figure 11 3 Figure 12 1 Figure 12 2 Figure 12 3 Figure 12 4 Figure 13 1 Figure 13 2 Figure 13 3 Figure 13 4 Figure 13 5 Figure 13 6 Figure
172. screen for pressure two as shown below in Figure 7 42 If you do not have a Power Output module the energy option will not appear Figure 7 44 shows the logical flow for dual pressure mode without the energy option WELD ENERGY 2 Figure 7 42 Pressure Two Weld Energy Data Entry Again use the arrow keys to enter the weld en ergy This parameter is labeled E2weiq on the flow chart Press the ENTER key when you have fin ished to bring up the data entry screen for P2 Maximum Weld Time as shown in Figure 7 43 This value sets the time limit to reach the P2 weld energy This time limit applies only to the P2 cycle WELD TIME P2 Figure 7 43 Pressure Two Weld Time Data Entry Dual Pressure Weld Mode Menus w o Power Output Module WELO MODE SINGLE PRESSURE DUAL PRESSURE WELD TIME P2 0 250 SEC Figure 7 44 Dual Pressure Time Only Menus If we select energy for the P1 cycle it will have its own maximum weld time limit Press the ENTER key to return to the Process Control menu as shown in Figure 7 45 PROCESS CONTROL WELD MODE HOLD TIME RFTERBURST Figure 7 45 Second Pass Through Process Control Menu Dukane Manual Part No 403 551 03 79 Dynamic Process Controller DPC Plus User s Manual From here on the menu follows the same logical sequence as Auto Probe Hold Time is automatically selected for the
173. sink requiring a dry contact closure to ground pins 2 or 7 This input can be changed to a source or fully isolated input by jumper block SH707 See Figures 5 11 5 12 and Appendix C Pin 4 Isolated Common This pin is used as the isolated return common if jumper block SH707 15 configured as a fully 150 lated input position JU726 See Figures 5 11 5 12 and Figure C 5 Pin 5 Isolated Press Control This input is designed to be used in conjunction with the optional Press Control Board The signal is used to activate the thruster up and down The factory default setting is a non isolated sink re quiring a dry contact closure to ground pins 2 or 7 This input can be changed to a source or fully isolated input by jumper block SH707 See Fig ures 5 11 5 12 and Appendix C Pin 6 Not Used Isolated input reserved for future use Pin 7 Gnd Pin 2 and 7 are the 22VDC and Operate returns and are tied to the chassis ground Pin 8 Operate A dry contact closure no voltage between pin 8 and ground pins 2 or 7 will initiate the operate sequence and is functionally the same as pin 3 Pin 9 Isolated Auto Stop This signal stops the operation sequence The fac tory default setting is a non isolated sink requir ing a dry contact closure to ground pins 2 or 7 Pm coor may appear brown 2 Black Gnd Also connected to connector metal shell 3 Blue BIk Iso Oper In 5 Blue Wht Iso Auto
174. sonic output signal FRONT PANEL LOCKED KEYPAD ENTRY ALLOWED If the F P LOCK signal is active the menu navigation functions normally but data entry or program modifications are in hibited For more information refer to Section 5 Table 5 1 and the Input Sig nal Description following the table Dukane Manual Part 403 551 03 131 Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 132 Dukane Manual Part No 403 551 03 SECTION 13 Care amp Maintenance Front Panel e Rear Panel Chasis e Probes Reconditioning Front SNB 135 Rear PANE 135 Chasis EE 135 Stack Surfaces M 136 Stack IMainterialice tacts eter vor Tera es 136 Stack INSPECTION 136 Even Contact 136 Uneven Contact 136 eem 137 Center DepressiOlt suadeo id dames intact 137 137 Reconditioning 138 Bul 138 Machining the Mating 5 138 Manual Resurfacing 138 Dukane Corporation oU IS Ultrasonics Division Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 134 Dukane Manual Part No 403 551 03 Section 13 Care amp Maintenance Front Pa
175. sted outside of these hours is available on a charge basis equal to 150 of Dukane s prevailing rate for technical service work Any equipment or tooling that proves to be defective in material or workmanship during the stated warranty period will be repaired or replaced at the sole discretion of Dukane Corporation when Dukane is promptly notified in writing During the warranty period defective equipment components or tooling that are returned properly packed with all transportation charges prepaid will be repaired or replaced and returned to the end user without charge Shipments of warranty parts will be via standard non expedited delivery service Expedited shipment requests are subject to freight charges to the Purchaser Computers PLCs CRTs LCDs touch screens and keyboards separate and or incorporated as an integral part of a system will carry a one 1 year warranty from the date of shipment when used under normal operating conditions and not subjected to misuse abuse or neglect For all other equipment components or parts included in equipment or systems from Dukane but not manufactured by Dukane or its affiliates this warranty shall be limited in time and extent to the warranty given to Dukane by the OEM EQUIPMENT WARRANTY EXCLUSIONS OR EXCEPTIONS When specified in our quotation a limited warranty may apply to certain components of the equipment and or for certain types of applications of the equipment including those noted belo
176. switch on the front of the press base to halt the weld cycle If Auto Stop is set to ENABLE then an external signal must be supplied to pin 9 Iso Auto Stop of the HD 15 System In connector Refer back to the discussion under Figure 7 13 and also to Table 5 1 for more detailed information Head Up On Auto Stop If DISABLE was selected in the AUTO STOF menu the HEAD LIP ON AUTO STOP menu is bypassed If ENABLE was selected in AUTO STOP the HEAD UP menu is displayed It offers two choices for head position If ENABLE is selected for the Head Up op tion the head retracts when an Auto Stop signal is detected If the DISABLE option is selected the press head remains stationary after an Auto Stop signal Note that this option and Auto Stop are only avail able when the Initiate Mode has been set to Auto NOTE The word AUTO in the menu options is short for Automation not automatic Any menu that contains the word AUTO means the DPC II Plus will require an external signal s from custom automation equipment for correct operation Trigger Type If DISABLE was selected in the AUTO STOF menu the TRIGGER TYPE menu is displayed next Other wise it follows the HEAD LIP ON AUTO STOP menu If MOMENTARY is selected the trigger switch is ignored after the first contact closure The DPC external bus scan time is 1 msec so the minimum signal duration is gt 1 msec If the trigger switch opens after the weld cycle is
177. t will be operated DPC II or DPC II Plus Emergency Stop Features 22 DC To Dukane Pneumatic Press E Stop Switch 24 DC Grounding Lug Rear AC Breaker Power Switch MODEL 200 210 V unl Figure 3 10 Rear Panel AC Breaker Switch Dukane Manual Part No 403 551 03 25 Dynamic Process Controller DPC Plus User s Manual This page intentionally left blank 26 Dukane Manual Part No 403 551 03 SECTION 4 Controls amp Displays e Front Panel Layout e AC Power e Generator Status Panel e Menu Function Keys Control Menu Display Front Panel Layout susce rotto 29 AC POWE 30 Generator Status 30 Generator Control Keys s sore 30 System Status 31 System Power Output 1 32 Process Control 33 Menu Function 33 Control Menu Display 35 Dukane Corporation e Ultrasonics Division Dynamic Process Controller DPC II Plus User s Manual This page intentionally left blank 28 Dukane Manual Part No 403 551 03 Section 4 Controls amp Displays Front Panel Layout This section describes the DPC II Plus front panel con trols status power output and menu displays The
178. t Panel 29 AC o M S 30 Generator Status 30 Generator Control I aiuti Does teeiet onec irneto 30 System Status DISD AY 31 System Power Output Display een kata ere thank n 32 Process 23 Process Control Keys MESE 33 Menu Display Ae 35 Dukane Manual Part No 403 551 03 V DPC II Plus User s Manual Section 5 Rear Connectors 37 hear Panel a ieor Paana 39 System Input EU d dU 40 System Output COnnector 42 Remote Amplitude 46 Power Output Module Option sa EY ras ra fi Te 47 Press Control Module Option aa REN 48 Multr Probe Module OPTIONS 50 Jumper Block 51 Card Slot and Jumper Block etra qot eret lee drin rentes 52 Jumper Block SUS ict lated receded sodio dais ud and 53 Section 5 Menu Structure iii Rush 55 Process 57 Process CO
179. t green vertical bars indicating 1096 to 8096 power output are dis played during normal operation Fig ure 4 5 shows the display indicating 80 output power Yellow Two yellow bars for 9095 and 10096 power output warn that the genera tor is operating near its maximum rated output Red The last red bar indicates that the generator is in an overload condition delivering more than its rated out put power Figure 4 6 shows the red overload and two yellow warning in dicators The red warning indicator lights up just prior to an overload condition The ultrasonic signal is shut down when an overload condi tion occurs Figure 4 5 Normal Operation Figure 4 6 Warning Indicators a NOTE The available output power is directly propor tional to the Amplitude setting Example A 2200 Watt rated DPC set to 80 Amplitude will overload at 1760 Watts 2200W x 0 80 1760 Watts 32 Dukane Manual Part 403 551 03 Section 4 Controls amp Displays 3 Process Control Panel Menu Function Keys The twelve 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 dis plays the DPC model the firmware version and the installed modules A readout for a DPC II Plus equipped with both a Press Control module and a Power Signal Output Module is shown in
180. t or tooling and duration is based upon a single shift per day five day per week operation The warranty period on rentals of new equipment that are converted to a purchase are deemed to have commenced on the initial date of rental These warranties are limited to equipment and tooling operated and maintained per Dukane s written instructions and used under normal operating conditions These warranties do not include normal wear or normal wear items and do not cover damage attributable to misuse improper installation faulty repair unauthorized alteration or modification neglect or accident Misuse includes operation of equipment with tooling that is not qualified for the equipment or properly installed on the equipment The warranty on all Dukane equipment and tooling purchased and installed in North America is a parts and labor warranty only Equipment installed outside of North America regardless of where it was purchased is covered by Dukane s International Warranty Policy In all cases when on site service is required Travel amp Living T amp L expenses will be billed at cost Warranty service labor including travel time at the customer s site is provided on a Monday through Friday excluding holidays 7 a m to 7 p m basis Any warranty service requested outside of these hours is available on a charge basis equal to 150 of Dukane s prevailing rate for technical service work Any equipment or tooling that proves to be defecti
181. tations and exclusions set forth below Dukane Corporation IAS Division Dukane warrants to the original Purchaser unless otherwise expressly agreed to in writing by Dukane that all equipment and tooling designed and built by Dukane will be free from defects in material or workmanship Normal wear items are not covered by this warranty Warranty duration shall be defined as documented herein and in conjunction with any exceptions or exclusions in the accompanying Dukane quotation to the Purchaser Equipment Type Equipment Warranty Duration Other Comments Custom Systems 12 months on all Dukane designed and built content Dukane standard product included in custom systems that is not part of our standard product are covered by the applicable product warranty manufacturer OEM warranty is applicable optics are warranted for only 30 days Ultrasonic Welder 36 months See WARRANTY EXCLUSIONS OR EXCEPTIONS below Vibration Welder 24 months All Production 12 months one time replacement 6 month none Tooling one time replacement for carbide tipped horns Prototype Tooling All tooling made from Renshape 460 Renwood Prototype Renshape 460 Renwood tools employ are only warranted for 200 part cycles reusable content and therefore remain the property All other prototype tooling is warranted as of Dukane described in each specific proposal All Dukane warranties commence on the date of the original shipment of the equipmen
182. the the Weld P1 key will display information Press DPC II Plus may not correctly recognize the press ing the Weld P2 hot key flashes a brief message oe Switch Must Be In WELD PRESSURE Position Before Turning The DPC Power On reading THIS BUTTON 15 ONLY AYAILABLE FOR DUAL PRESSURE WELD MODE The AMP ADJUST hot key permits you to adjust the output amplitude from 40 to 100 This is accomplished using the up and down arrow keys A modified output level menu is shown in Figure 7 57 Press the ENTER key to accept the value or CANCEL to return to Process Setup AMPLITUDE I Figure 7 57 Amplitude Adjust NOTE If you have a Remote Amplitude Control mod Process Control Recap ule installed its gain setting will override the front panel menu The front panel menu will accept We have examined all four modes available in the chi the value but the output amplitude will still be Process Control menu Hand Probe MPC Probe determined by the 4 20 loop current Refer Auto Probe and Press Figure 6 6 showed the Pro back to Section 5 and Figure 5 6 for more de cess Control flow chart It did not however indi tailed specifications cate the parameters and where their values were entered We have added that information and the complete flowchart is shown in Figure 7 58 The symbol legend in the upper right hand corner of the flow chart explains the Figure number refer
183. the DPC 1 A Press Base cable P N 200 1124 must will return to its last state ON LINE or OFF be connected to J35 on the press and LINE when the front panel AC power switch J902 on the DPC Cable 3 in Figure 3 8 is turned ON again 2 The Emergency Stop switch must be in its reset position pulled out 3 In place of a press cable a jumper block Dukane P N 200 1293 can be installed on J902 see Figure 3 4 5 Press the ON LINE generator control key on the front panel labeled E in Figure 11 1 The green ON LINE indicator in the Status Display labeled F in Figure 11 2 should now be lit Dukane Manual Part No 403 551 03 119 Dynamic Process Controller DPC Plus 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 con tact with anything Do not hold the probe if you are not accustomed to ultrasonic welding The initial ultrasonic sensation may surprise you and cause you to drop the probe Momentarily press the generator control TEST key G in Figure 11 2 The following conditions should occur SYSTEM POWER OUTPUT cay 0 120 40 60 80 100 Figure 11 2 System Test Controls and Indicators 3 One green segment of the System Power Out put bar display will light up i
184. the ultrasonic welding process Modular Design simplifies upgrades and increases flexibility as your application requirements change Flow Through Cooling Tunnel is thermostatically controlled to reduce thermal gradients and increase component life Pulse Width Modulation is Dukane s patented circuitry that allows the DPC power supply to efficiently control the voltage sent to the transducer in the acoustic stack Linear Ramp Softstart circuitry is provided allowing the acoustic stack to be brought to operating amplitude smoothly minimizing the startup shock stress Auto Trac Tuning automatically tracks the resonant frequency of the acoustic stack horn booster transducer and adjusts the generator output frequency to match it 2 continued on next page 2 Within specified ranges Dukane Manual Part No 403 551 03 Dynamic Process Controller DPC Plus User s Manual Dual Line Voltage Universal Power Supply means that the DPC II will operate worldwide Auto Ranging means that adjustments by the operator related to power input are unnecessary Within specified ranges 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 High Performance fan and heatsink extend component life
185. to be in good condition proceed to step 11 4 Remove the mounting stud s if any are in stalled 5 Tapea clean sheet of 7400 grit or finer em ery cloth grit side up to a clean flat surface such as a piece of plate glass 6 Holdthe stack component with one hand near the bottom as shown in Figure 13 7 This view shows the thumb covering one of the three spanner wrench holes Without applying any downward pressure carefully stroke the part in one direction across the emery cloth The component s NOTE Before deciding to recondition the mating sur faces yourself consider calling Dukane Corporation s Tooling Support team to discuss the situation This is especially important if the mating surfaces are uneven because machin ing of the component s may be required Factory personnel can offer their skills and ex perience to help you determine the options for your particular needs See Section 14 for a list of Dukane contacts 138 Dukane Manual Part No 403 551 03 Section 13 Care amp Maintenance 10 11 12 13 Figure 13 7 Manual Resurfacing weight alone is enough pressure as the part is moved across the emery cloth Complete a second stroke across the cloth just like the first 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 tw
186. ults in considerable loss In some cases the union be tween the mating surfaces could be so poor as to prevent the probe stack from operating This could result in excessive power drawn from the genera tor and may damage the mating surfaces Figure 13 2 shows the mating surfaces on a typical probe and booster assembly Mating Surfaces B S A Figure 13 2 Location of Stack Mating Surfaces Stack Inspection Examine the mating surfaces ofthe horn and probe and booster 1f applicable Look for a shiny bur nished area This indicates where the surfaces have been in contact It will indicate whether the sur faces are flat and making good contact or if they are uneven and making poor contact Inspection Schedule To establish a maintenance schedule inspect the mating surfaces after the first 200 400 hours of operation If they require cleaning halve the next inspection time If the surfaces do not require re conditioning then double the next inspection time Surfaces with Even Contact A flat surface will make even contact and its sur face will be evenly burnished across the entire con tact area Fig ure 13 3 shows a sur face that has made even contact Hole for Mounting 7 Burnished Area Figure 13 3 Flat Surface With Even Contact Surfaces with Uneven Contact A surface that is not completely flat will make uneven contact Its surface will be burnished onl
187. using an open end wrench of the correct size to fit the wrench flats of the tip This 15 illustrated in Figure 10 3 If necessary usea spanner wrench on horns with spanner wrench holes or an open end wrench on horns with wrench flats to keep the horn from turning in your hand A canvas strap wrench is permissible if it does not gouge NOTE or scratch the horn Dukane Part No for the 20kHz spanner wrenches 5 721 68 e 70 inch lbs for an 8mm threaded tip e 100 inch Ibs for a 3 8 x 24 threaded tip Dukane Part No for the 40kHz spanner wrenches is 721 44 e 160 inch lbs for a 1 2 x 20 threaded tip Dukane Manual Part No 403 551 03 107 Dynamic Process Controller DPC II Plus User s Manual Attaching The Mounting Stud To A Horn Or A Booster 1 Inspectthe stud for cracks or damaged threads Replace the stud if it is cracked or otherwise damaged 2 Remove any foreign matter from the threaded stud and the mating hole 3 Thread the mounting stud into the input end of the horn or the input end of the booster and tighten to the following torque specifica tions using an allen wrench in the socket head of the mounting stud Table 10 1 lists the torque specifications in units for both English and Metric systems of measurements Figure 10 5 is a handy conversion graph if you require intermediate values not listed in the tables DO NOT hold the booster by the mounting rings when tighteni
188. ve in material or workmanship during the stated warranty period will be repaired or replaced at the sole discretion of Dukane Corporation when Dukane is promptly notified in writing During the warranty period defective equipment components or tooling that are returned properly packed with all transportation charges prepaid will be repaired or replaced and returned to the end user without charge Shipments of warranty parts will be via standard non expedited delivery service Expedited shipment requests are subject to freight charges to the Purchaser Computers PLCs CRTs LCDs touch screens and keyboards separate and or incorporated as an integral part of a system will carry a one 1 year warranty from the date of shipment when used under normal operating conditions and not subjected to misuse abuse or neglect For all other equipment components or parts included in equipment or systems from Dukane but not manufactured by Dukane or its affiliates this warranty shall be limited in time and extent to the warranty given to Dukane by the OEM EQUIPMENT WARRANTY EXCLUSIONS OR EXCEPTIONS When specified in our quotation a limited warranty may apply to certain components of the equipment and or for certain types of applications of the equipment including those noted below This warranty is void if the ultrasonic welder and or tooling i e horn s and fixture s are used for applications requiring metal to metal contact when the ultrasoni
189. w This warranty is void if the ultrasonic welder and or tooling i e horn s and fixture s are used for applications requiring metal to metal contact when the ultrasonic exposure period weld cycle exceeds 250 milliseconds Ultrasonic Equipment and tooling used in continuous duty cycle modes such as but not limited to continuous cut and seal and food processing are warranted for 2000 hours or 12 months from shipment whichever occurs first Any ultrasonic horn or tool quoted and sold as Experimental is not warranted This warranty does not cover failures of equipment and components attributable to improper cooling or overheating of the transducer Ultrasonic Horn Analyzers have a 12 month warranty Ultrasonic Transducers have a one time replacement warranty Normal wear items and consumables excluded from any warranty coverage include but are not limited to filters fuses light bulbs lubricants gaskets and seals cast urethane fixture components laser flashlamps laser beam delivery optics and lasing gases The forgoing warranty is the sole and exclusive warranty and is made in lieu of all other warranties express implied or statutory including without limitation any warranties of merchantability fitness for a particular purpose description quality productiveness or any other warranty The remedy set forth in this warranty policy is the sole and exclusive remedy of Purchaser and in no event sh
190. wer available If ENTER to confirm the value the amplitude is reduced to 40 the lowest The down arrow key decrements the setting the maximum available power will be data value each time it is pushed limited to 40 of the rated output power Holding the key in continuously dec rements the value This key is also used to move the cursor down one line on a menu selection screen Pressing the ENTER key com ENTER pletes the menu operation and dis plays the next decision or naviga tion menu Pressing the CANCEL key discards CANCEL any values you may have changed lt and returns you to the previous de cision or navigation menu UJ 4 Dukane Manual Part No 403 551 03 Section 4 Controls amp Displays Process Control Menu Display The menu display is a backlit 4 LCD with 20 characters per line The top line ofthe display con tains the menu title with a few exceptions Selection Menus The selection menus have a triangular cursor at the far right of the display These menus may also be thought of as a decision menu Move the cursor to the menu choice and press the ENTER key to select your choice Pressing the CANCEL key re turns to the previous selection menu A typical se lection menu is shown in Figure 4 9 CONTROL T PROCESS WELD MODE HOLD TIME AFTERBURST Figure 4 9 Typical Selection menu Confirmation Menus A confirmation menu requests a Yes
191. wing condi tions 1 AC Line Voltage 2 Internal DC Power Supply 5 VDC 12 VDC 12V DC or 24V DC INPUT TEST This indicator normally flashes red dur ing a power up test If there is a prob lem a steady red light appears This Figure 4 4 System Status Display means that either the input AC line volt age is out of tolerance or an internal fault has occurred in the generator OVERLOAD This red indicator lights when either of the following conditions occur 1 An instantaneous overload caused by a mismatch between the ultrasonic signal and the resonant characteristics of the acoustic stack transducer booster and horn INPUT TEST OVERLOAD ON LINE OVERTEMP 2 Excessive power beyond the generator s rated output is being drawn ON LINE generator is capable of operation OVERTEMP One of the power modules has over heated and the generator has shut down This may be caused by excessive dust in the cooling channel or a cooling fan failure The generator will automatically reset when the module temperature drops below the trip point which is 75 C 167 F OFF LINE The generator is in a standby mode The ultrasound output cannot be activated Dukane Manual Part 403 551 03 31 Dynamic Process Controller DPC II Plus User s Manual System Power Output Display The tricolor System Power Output Display indi cates the percentage of ultrasonic power being drawn by the load Green Eigh
192. y in the area where it has made contact Figure 13 4 shows what such a surface would look like The inner and outer areas have no marks on it indicat ing there has been no contact in these areas Burnished Area Figure 13 4 Flat Surface With Uneven Contact 136 Dukane Manual Part No 403 551 03 Section 13 Care amp Maintenance Crowning A surface which is burnished only in the inner ring area around the stud indicates the surface is con vex or crowned An example of this is shown in figure 13 5 To get an idea of amount of devia tion 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 Straight Edge Figure 13 5 Crowned Surface Center Depression A surface which is burnished only in the outer ring area around the edge indicates the surface 1s con cave or depressed An example of this is shown in figure 13 6 To get an idea of amount of deviation from a flat surface place a straight edge along the stack element Since its surface 15 higher at the edge than at the center there will be a visible gap near the center indicating the depth of the depression Straight Edge Figure 13 6 Center Depression Corrosion Corrosion is a factor to consider when determin ing the overall system performance Over time corrosion can build up on the mating surfaces of the

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