Dukane VWA-4300 User Manual
  1. Manuals
  2. Brands
  3. Dukane Manuals
  4. Welding System
  5. VWA-4300
  6. User manual
Dukane VWA-4300 User Manual

Dukane VWA-4300 User Manual

Linear vibration welder 4000 series
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Intelligent Assembly Solutions
Linear Vibration Welder
4000 Series
Model VWA-4300/4500/4700/4900
User's Manual
Dukane Part No. 403 - 592-00
-
-
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797
4900 • FAX (630) 797
4949
ISO 9001
Dukane products are manufactured in ISO
www.dukane.com/us
registered facilities.

Advertisement

Table of Contents
loading

Related Manuals for Dukane VWA-4300

Summary of Contents for Dukane VWA-4300

  • Page 1 4000 Series Model VWA-4300/4500/4700/4900 User's Manual Dukane Part No. 403 - 592-00 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 4900 • FAX (630) 797 4949 ISO 9001 Dukane products are manufactured in ISO www.dukane.com/us...
  • Page 2 The information contained in this manual is distributed on an “as is” basis, without warranty. While every precaution has been taken in the preparation of this manual, Dukane Corporation shall not have any liability to any person or entity with respect to any liability, loss, or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual, or by the hardware products described herein.

  • Page 3: Revision History

    Revision History Revision Revision Number Summary Date - 00 Original release. 03/05/2014 Page iii Dukane Manual Part No. 403-592-00...
  • Page 4 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page iv Dukane Manual Part No. 403-592-00...

  • Page 5: Table Of Contents

    Section 5 - Normal Weld Cycle .........33 Parts Loaded............... 35 Initiate Weld Cycle .............. 35 Access Door Closes............35 Clamping Phase..............36 Welding Phase ..............36 Hold Phase ................. 36 Release Phase..............37 Parts Removed ..............37 Continued Page v Dukane Manual Part No. 403-592-00...

  • Page 6: Screen Layout

    Section 8 - Machine Operation ......105 Section 9 - Optimizing Performance ...... 111 Section 10 - Troubleshooting .........117 Section 11 - Maintenance ........131 Section 12 - Contacting Dukane ......137 Section 13 - Specifications ........141 Tooling Specifications ............143 Weights, Dimensions ............144 Operating Environment .............

  • Page 7: Section 1- Introduction

    Key Features ....... . 5 Page 1 Dukane Manual Part No. 403-592-00...
  • Page 8 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 2 Dukane Manual Part No. 403-592-00...

  • Page 9: General User Information

    (e.g. –I, –II, –III). As an example, Figure 3–2 would be the second illustration in Section Three while   Table 3–II would be the second table in Section Three. Condition Operator Electrical Protection or Practice Hazard (hearing) Page 3 Dukane Manual Part No. 403-592-00...

  • Page 10: Welder Overview

    Linear Vibration Welder 4000 Series, Model VWA User’s Manual Welder Overview The new and larger color operator interface is also a com- mercial unit containing Dukane’s field–tested and proven The linear vibration welder excels at joining large as- control software and interface. Every subassembly has semblies and parts made from glass–filled and high...

  • Page 11: Key Features

    • Commercial Subassemblies are used to ensure a longer and more economical service life, than units built with proprietary components. These readily available items also lessen the need for expensive field service calls Page 5 Dukane Manual Part No. 403-592-00...
  • Page 12 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 6 Dukane Manual Part No. 403-592-00...

  • Page 13: Section 2 - Health And Safety

    Hydraulic Safety ........14 Page 7 Dukane Manual Part No. 403-592-00...
  • Page 14 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 8 Dukane Manual Part No. 403-592-00...

  • Page 15: General Considerations

    Dukane Corporation. The magnetic drivers produce This is an unsafe practice high electrical voltages which could cause injury or and can result in injury or death.

  • Page 16: General Considerations

    AC power cords are removed from their receptacles. After the cables have been securely connected and the connections and cable routing checked a final time, the power may be restored. Page 10 Dukane Manual Part No. 403-592-00...

  • Page 17: Special Health Notice - Plastics

    480VAC 3-Phase AC Plug Configuration Electrical Safety Figure 2-1 AC Power Receptacle 480V 277V The power cord used on the Dukane vibration welder, 480V Models 4300, 4500, and 4700, has a three-pole, four- 480V 277V blade, grounding type plug designed for 3-Phase 480 VAC at 30 Amps.

  • Page 18: Pneumatic Safety

    Refer to Section 11 - Maintenance for information on the filter Exterior Pneumatic Lockout Device with Figure 2-5 Lockout and Tag element and how to replace it. Page 12 Dukane Manual Part No. 403-592-00...

  • Page 19: Operational Safety

    The light curtains are identified in Figure 2-7. Light Curtains Electrical Cabinet Service Door NOTE Figures represent typical hardware and placement but may not show individual cus- tom options. Light Curtains, Electrical Cabinet Service Figure 2-7 Door and Disconnect Page 13 Dukane Manual Part No. 403-592-00...

  • Page 20: Hydraulic Safety

    The rear service doors also serve as acoustic shields. Cabinet Cabinet Service Door Cabinet Service Door Service Door Lockout Lockout Interlock Lockout Interlock Interlock Receptacle REceptacle REceptacle Rear Service Door Interlocks Figure 2-9 Page 14 Dukane Manual Part No. 403-592-00...

  • Page 21: Section 3 - Installation

    Hydraulic Drive ........22 Page 15 Dukane Manual Part No. 403-592-00...
  • Page 22 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 16 Dukane Manual Part No. 403-592-00...

  • Page 23: Unpacking

    See the space requirements drawings in Section 13 - Specifications. Energy Sources Refer to Section 13 - Specifications for the AC power requirements and for the compressed air requirements of your model. System Documentation Storage Pocket Figure 3-2 Page 17 Dukane Manual Part No. 403-592-00...

  • Page 24: Cover Plates

    The covers are shown in Figure 3-5. The cov- dampers to reduce the re- ers must be installed so the vibration welder will meet verberations from the steel the specified sound emission requirements of 80 dBA channels. during operation. Page 18 Dukane Manual Part No. 403-592-00...

  • Page 25: Ac Power

    AC Power on Page 146. power at the main dis- connect switch before servicing or working on the welder. Failure to turn off the AC power is an unsafe practice and can result in injury or death. Page 19 Dukane Manual Part No. 403-592-00...

  • Page 26: Disengaging Switch Coupling

    CE–Compliant Disconnect in ON Position Figure 3-7 1. Red Knob at 2. Yellow Tab 1. Red Knob at 2. Yellow Tab OFF Position Pressed To OFF Position Pressed To Right Right Disengaging the Disconnect Switch Figure 3-8 Page 20 Dukane Manual Part No. 403-592-00...

  • Page 27: Compressed Air

    Refer to Section 11 - Maintenance, for complete infor- pressure gauge reads zero. mation on the instructions for replacing the filter element. Page 21 Dukane Manual Part No. 403-592-00...

  • Page 28: Hydraulic Drive

    4300 3.14 3140 4500 3.14 4710 4700 4.91 7360 4900 4.91 7360 1 lb = 0.4536 Kg; 1 lb = 4.448 Nt; 1 Nt = 1 Joule/meter Lift/Clamp Force by Model Table 3-II Page 22 Dukane Manual Part No. 403-592-00...

  • Page 29: Adding Hydraulic Fluid

    Hydraulic fluid level should be maintained so that it always shows in the fluid level sight glass. This is important to prevent condensation from collecting on the inside of the reservoir and the heat exchanger tubes. Page 23 Dukane Manual Part No. 403-592-00...
  • Page 30 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 24 Dukane Manual Part No. 403-592-00...

  • Page 31: Section 4 - Display And Controls

    Vacuum On/Off Button ......31 Page 25 Dukane Manual Part No. 403-592-00...
  • Page 32 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 26 Dukane Manual Part No. 403-592-00...

  • Page 33: Control Panel Layout

    The light flashes in either the SETUP modes, and continues to flash, until the alarm condition has been cleared. Page 27 Dukane Manual Part No. 403-592-00...
  • Page 34 Both emergency stop buttons must be in their reset posi- tion before the lift table can be lowered and the welder restarted. Page 28 Dukane Manual Part No. 403-592-00...

  • Page 35: Operational Switches

    Figure 4-3 and 4-5. When the operator places his finger in Figures represent typical hardware and the tray, a second at the right rear also illuminates to placement but may not show individual cus- indicate the switch has been activated. tom options. Page 29 Dukane Manual Part No. 403-592-00...

  • Page 36: Light Curtain

    To recover, press the Machine Reset touch screen but- ton. Reference Section 8 – Machine Operation, Home Procedure, Page 107. Light Curtain Status LEDs Figure 4–4 Page 30 Dukane Manual Part No. 403-592-00...

  • Page 37: Ac Utility Outlet

    See Page 69 for more information. Right Operate Switch and Vacuum Button Figure 4- 5 NOTE Vacuum must be turned on before the Vacuum ON/Off Button will work. Page 31 Dukane Manual Part No. 403-592-00...
  • Page 38 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 32 Dukane Manual Part No. 403-592-00...

  • Page 39: Section 5 - Normal Weld Cycle

    Parts Removed........37 Page 33 Dukane Manual Part No. 403-592-00...
  • Page 40 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 34 Dukane Manual Part No. 403-592-00...

  • Page 41: Parts Loaded

    To recover from a light curtain fault, press the Machine Reset button. Reference Section 8 – Machine Operation, Home Procedure, Page 107. Page 35 Dukane Manual Part No. 403-592-00...

  • Page 42: Clamping Phase

    The hold pressure is specified separately from the welding pressure to control flash and produce a stronger weld by reducing shear thinning. Page 36 Dukane Manual Part No. 403-592-00...

  • Page 43: Release Phase

    Welded Assembly Lift Table Lift Table Lowering to Starting Position Figure 5 - 4 Welded Assembly Lower Tooling Lift Table Assembled Parts Unloaded from Welder Figure 5 - 5 Page 37 Dukane Manual Part No. 403-592-00...
  • Page 44 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 38 Dukane Manual Part No. 403-592-00...

  • Page 45: Section 6 - Touch Screen Menus

    Touch Screen Banner ........91 Page 39 Dukane Manual Part No. 403-592-00...
  • Page 46 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 40 Dukane Manual Part No. 403-592-00...

  • Page 47: Introduction

    – at the top of the screen in the "Header" or at the left side of the screen in the "Tool Bar" as shown in the figure below. Header Tool Bar Primary Button Location Figure 6 -1 Page 41 Dukane Manual Part No. 403-592-00...

  • Page 48: Button Appearance

    If the text of the button label appears as if it is faded, the function is not available. Active Button Inactive Button Available Function Unavailable Function Large Active Buttons Figure 6 -2 Page 42 Dukane Manual Part No. 403-592-00...

  • Page 49: Other Visual Cues

    In the case of the button shown in Figure 6-4 to the right, when Vacuum Output for Y27 became active, the corre- sponding button color changed from GRAY to GREEN. In addition the word Off changed to On. Small Button Appearance Figure 6 -4 Page 43 Dukane Manual Part No. 403-592-00...

  • Page 50: Making Selections

    2. From the pop-up menu, touch BYPASS. The selection is highlighted. 3. Confirm the selection by touching OK . The confirmed selection will then appear in the Sensor 1 box. Pop-Up Menu Detail Figure 6 -5 Page 44 Dukane Manual Part No. 403-592-00...

  • Page 51: Virtual Keyboard And Keypad

    1. Touch the appropriate keys, and the results appear on the keypad display. 2. When finished making the entry, touch the key. ✔ 3. Whatever was entered in the preview area is then Virtual Keypad Figure 6 -7 accepted. Page 45 Dukane Manual Part No. 403-592-00...

  • Page 52: Header - Quick Look

    These Tool Bar functions are not avail- chosen – Run Mode or Setup Mode. able in Run Mode: Sliding Door, Table In Run Mode, Setup, Utilities, I/O Setup, Dukane can Up/Down, and Machine Reset. be viewed, but cannot be changed.

  • Page 53: Tool Bar - Quick Look

    The Figure to the right shows that while in Setup mode, and while using the Operate screen, the Context Help but- ton was pressed. Figure 6 -10 Using Context Help Page 47 Dukane Manual Part No. 403-592-00...
  • Page 54 3. Completed items are marked with a green check mark. 4. With all items completed, and with the machine in the Home position, press the Quit button. Figure 6 -12 Machine Reset Pop-up Window Page 48 Dukane Manual Part No. 403-592-00...

  • Page 55: Choose A Language

    How to Select a Language 1. Touch either the Primary or Secondary button. 2. The screen image will change according to the lan- guage chosen. Page 49 Dukane Manual Part No. 403-592-00...

  • Page 56: Logging In And Out

    6. Logout as Administrator. for deletion. Then touch the Delete User button to 7. Login using new user name and the default password. remove the name from the list. Figure 6 -14 Log In - 1 Page 50 Dukane Manual Part No. 403-592-00...

  • Page 57: Options

    The Current User portion of the login screen will display the current logged-in user and gives that user the option to change their password. 6. To logout of the system, press Logout. Page 51 Dukane Manual Part No. 403-592-00...
  • Page 58 2. A User Login window appears. 3. Touch the Logout button on the User Login window. 4. Confirm that logout is completed by checking what appears in the Logged In button on the tool bar. Page 52 Dukane Manual Part No. 403-592-00...

  • Page 59: Operation

    Help are available to the operator. Tool Bar – Alarms, Language (Primary and Secondary), and Help are available to the operator. Run Mode is active. Dual function button: Setup/Run. Figure 6-16 Run Mode is Active Page 53 Dukane Manual Part No. 403-592-00...

  • Page 60: Alarm Limits

    Alarm Limits, and History, are the available button choices within the Operate screen itself. Available buttons from the top button bar (besides Operate) are Setup, Utilities, and Log In/Out and the M / E button (Metric/English). Page 54 Dukane Manual Part No. 403-592-00...
  • Page 61 For example: An amplitude of 1.3mm means the upper tool- ing fixture is driven 0.65mm to the left, back to the center, then 0.65mm to the right. The fixture goes back to center for a total cycle amplitude of 1.3mm. Page 55 Dukane Manual Part No. 403-592-00...
  • Page 62 A red background for the entry box means the actual value is less than the lower limit. Touch the Close button to close the Alarm Limits pop-up window. Page 56 Dukane Manual Part No. 403-592-00...
  • Page 63 Setup files to be saved in directories in the root directory named *_Setups and Parts and Graphics files saved in directories in the root directory named *_Logs. All files can be copied to a USB storage device using stan- dard windows procedures. Page 57 Dukane Manual Part No. 403-592-00...

  • Page 64: Graph

    Figure 6-20 Run Mode - Graph Screen The graph illustrates a graph of the Total Collapse, NOTE Amplitude, and Force for the last cycle. Graphing data is stored on the hard drive of the PC. Page 58 Dukane Manual Part No. 403-592-00...

  • Page 65: Setup Mode

    Reset, Alarms, Language (Primary and Second- ary), and Help are choices. Operate Figure 6-21 Setup Mode - Operate Screen NOTE Refer to Run Mode, Page 53 for more information about the Operate screen. Page 59 Dukane Manual Part No. 403-592-00...
  • Page 66 – The name of the setup can be up to 30 characters long. Trigger By – Choose from two trigger methods: Trigger by Zero Motion – Vibration is started when the lift table stops moving. Continued Page 60 Dukane Manual Part No. 403-592-00...

  • Page 67: Set Table Slowdown

    Touch this button reached. when the table has reached the desired position. This will be the new slowdown position. Figure 6-23 Setup Mode - Set Table Slowdown Position Page 61 Dukane Manual Part No. 403-592-00...

  • Page 68: Trigger By Position

    • Program the desired distance value by touching the distance entry box to the right of Position. See the figure below. Enter position distance. Figure 6-24 Setup Mode - Set Trigger Position Page 62 Dukane Manual Part No. 403-592-00...

  • Page 69: Hold Force

    – This is the amount of time the lift table main- Hold Time tains its clamping force on the work allowing the welded surface to solidify. Hold time starts after the primary mode limit (distance or time) is reached. Page 63 Dukane Manual Part No. 403-592-00...

  • Page 70: Table Load Position

    1. Touch the Table Load Position entry box. 2. The pop-up window shown in the figure below appears. 3. Follow the instructions in the pop-up window, and set the load position Figure 6-25 Setup Mode - Table Load Position Page 64 Dukane Manual Part No. 403-592-00...

  • Page 71: Upper And Lower Limits

    1. Touch the entry box for the value to be entered, and the virtual keypad appears allowing the user to make a numerical entry. 2. Continue entering values in the entry boxes for both upper and lower limits until finished. Page 65 Dukane Manual Part No. 403-592-00...

  • Page 72: Autotune Mode

    The operator sets the counter with a preset range between Benefits: welder parts run cooler, and there 1 and 300 cycles. is reduced energy use. This results in lower stresses to welder parts and extends equip- ment life. Page 66 Dukane Manual Part No. 403-592-00...
  • Page 73 Reset Offset - Touch Capture Offset - Touch this button to reset the this button to start the tool weight offset. tool weight compensa- tion process. Figure 6-28 Tool Weight Compensation Pop-up Window Page 67 Dukane Manual Part No. 403-592-00...
  • Page 74 Context Help pushbut- Touch the Rename Setup ton on the left-side toolbar. This function Rename Setup button to rename the setup will provide specific help for the function that is currently selected. being displayed. Page 68 Dukane Manual Part No. 403-592-00...

  • Page 75: Plc I/O Status

    Auto - Typically an auto start is used when vacuum is Clear All – Touch the Clear All button to remove all required on the upper part of the tool. This is also called programming for valves and valve sensors. top loading. Continued Page 69 Dukane Manual Part No. 403-592-00...
  • Page 76 Touch the Save Setup Touch the Erase I/O Setup Save I/O Setup button to save the current Erase I/O Setup button to erase an I/O setup. setup. Continued Page 70 Dukane Manual Part No. 403-592-00...
  • Page 77 AT END OF HOLD AT DOOR CLOSED AT TABLE HOME AT TABLE HOME AT DOOR OPEN AT EJECT AT START OF WELD AT START OF WELD PART LOCATORS Valve Extend, Retract Selections Table 6-I Continued Page 71 Dukane Manual Part No. 403-592-00...
  • Page 78 Each sensor can be programmed for: NOTE BYPASS Each valve is paired with two PART IN PLACE, valve sensors. EXTEND, or RETRACT Figure 6-32 Utilities Screen -I/O Setup > Sensors Continued Page 72 Dukane Manual Part No. 403-592-00...
  • Page 79 There are a possible six part present sensors to program. Each sensor can be programmed for: • BYPASS, or • ENABLE Figure 6-33 Utilities Screen -I/O Setup > Part Present Sensors Page 73 Dukane Manual Part No. 403-592-00...
  • Page 80 PLC's file structure for: erased, and loaded. Setup Files, I/O Setup Files, Parts Files, and Graphics Files. BROWSE Push Button Figure 6-34 Utilities Screen > Options Page 74 Dukane Manual Part No. 403-592-00...
  • Page 81 • To Delete User - 1. Highlight user name. 2. Press Delete User. 3. Confirm by pressing Yes on popup box. Press No if a mistake was made. Figure 6-35 Utilities Screen > Security > Users Page 75 Dukane Manual Part No. 403-592-00...
  • Page 82 2. Make desired modifications. push button 3. Press Modify Group • To Delete a Group - 1. Select a Group name. push button 2. Press Delete Group Figure 6-36 Utilities Screen > Security > Groups Page 76 Dukane Manual Part No. 403-592-00...

  • Page 83: Tool Id Is Off

    - A sample screen is shown Utilities > Dukane below in Figure 6-37. This portion of the Utilities screen is for Dukane personnel only. Figure 6-37 Utilities Screen > Dukane Utilities - Tool ID is Off Use this “toggle switch” to turn...
  • Page 84 This feature is for use by servicing personnel only. Service personnel will touch the Dukane Access button at the top of the Utilities > Dukane screen, to activate the access screen shown in Figure 6-38 below. Follow the on-screen instructions to complete the process to gain access.
  • Page 85 Touch the Calibration XDUC (Position Transducer) button at the top of the Utilities screen, to activate the calibration screen shown in Figure 6-39 below. Figure 6-39 Utilities Screen > Dukane >Calibration XDUC NOTE Calibration Sequence The position transducer was calibrated at 1.

  • Page 86: Valve Calibration

    Utilities > Dukane > Valve Calibration This feature is for use by servicing personnel only. Figure 6-40 Utilities Screen > Dukane > Valve Calibration Valve calibration needs to be carried out by the mainte- Analog Input 3: Pressure feedback-data read from nance personnel or manufacturer’s service technicians...
  • Page 87 1000, 1500, 3000, 4500 and 5000lbs. In valve calibration mode the Hold Force is used to test the calibration. End of valve calibration. Figure 6-41 Welder Interior - Proportional Relief Valve Calibration Setup Page 81 Dukane Manual Part No. 403-592-00...
  • Page 88 Door Close buttons are active only when located at the bottom of this pop-up window as shown in Setup Mode is active. The buttons are Figure 6-42 above. disabled in Run Mode. Page 82 Dukane Manual Part No. 403-592-00...

  • Page 89: Alarms

    If an alarm reappears immediately after a reset, then there is a problem that needs correcting before a machine cycle is allowed. The alarm message will provide enough information to aid in correcting the problem. Page 83 Dukane Manual Part No. 403-592-00...

  • Page 90: Alarm History

    Linear Vibration Welder 4000 Series, Model VWA User’s Manual Alarm History Touch this button to display the alarm history screen. See the sample screen shown in Figure 6-44 below. Figure 6-44 Alarms - History Sample Screen Page 84 Dukane Manual Part No. 403-592-00...

  • Page 91: Alarms Table

    Auto-tune the system. Lower weld pressure. Call technical support. Cycle Aborted Light curtains were obstructed during a cycle, or some other fault aborted the cycle. Alarms and Messages (Page 1 of 6) Table 6-II Page 85 Dukane Manual Part No. 403-592-00...

  • Page 92: E-Stop Or Service Door Open

    Check if the tooling supports tool ID. If yes, confirm the cable is connected. If no, then turn off tool ID. Test the cable by performing a point to point continuity test. Reference the schematics. Alarms and Messages (Page 2 of 6) Table 6-II Page 86 Dukane Manual Part No. 403-592-00...

  • Page 93: No Feedback Detected

    E-Stop the machine, power is removed from the “dump valve”. Check pressure switch setting. Default set point is 70psi. If pressure drops below the set point, the welder will alarm. Alarms and Messages (Page 3 of 6) Table 6-II Page 87 Dukane Manual Part No. 403-592-00...

  • Page 94: Process Limit

    [Valve 3B] has been triggered, but sensor was not acknowledged. Solutions: Check that actuated device is not obstructed. Check the air pressure setting on the valve. Check sensor position; make adjustment if necessary. Alarms and Messages (Page 4 of 6) Table 6-II Page 88 Dukane Manual Part No. 403-592-00...

  • Page 95: Sensor Valve 4A Extended

    [Valve 6B] has been triggered, but sensor was not acknowledged. Solutions: Check that actuated device is not obstructed. Check the air pressure setting on the valve. Check sensor position; make adjustment if necessary. Alarms and Messages (Page 5 of 6) Table 6-II Page 89 Dukane Manual Part No. 403-592-00...

  • Page 96: Trigger Time Out

    VW3500\4500: between 35 - 90 lbs VW3900/4900: between 110-200 lbs Weld time has expired before weld distance could be achieved. Weld Time Limit "has expired". Alarms and Messages (Page 6 of 6) Table 6-II Page 90 Dukane Manual Part No. 403-592-00...

  • Page 97: Touch Screen Banner

    One or more part presence sensors are enabled but don’t detect Waiting for Part and Place Sensors the presence of a part. The machine will not cycle until the part is detected. Touch Screen Banner Messages Table 6-III Page 91 Dukane Manual Part No. 403-592-00...
  • Page 98 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 92 Dukane Manual Part No. 403-592-00...

  • Page 99: Section 7 - Tooling Installation

    Tune Drive to Tooling ......102 Page 93 Dukane Manual Part No. 403-592-00...
  • Page 100 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 94 Dukane Manual Part No. 403-592-00...

  • Page 101: Initial Machine Startup

    If the light does not go out, check the rear service doors. They should be securely closed, and the door interlocks should be engaged. E-Stop Buttons E–STOP and Reset Buttons Figure 7- 3 Page 95 Dukane Manual Part No. 403-592-00...

  • Page 102: Initiate Home Procedure

    See Figure 7-5. The Machine Reset button is active only in the Setup mode. Follow the on-screen instructions when those appear. Press Machine Reset to home the machine. Homing the Machine Figure 7- 5 Page 96 Dukane Manual Part No. 403-592-00...

  • Page 103: Install Tooling Assembly

    See Figure 7-  6 . 7. Check final alignment of the tooling. 8. Finger tighten all accessible upper and lower mounting bolts. Page 97 Dukane Manual Part No. 403-592-00...

  • Page 104: Upper And Lower Tooling Bolt Patterns

    [306] 5.000 [127] 6.024 [153] 8.250 [210] 9.000 [229] LOWER TOOLING M12-1.75 TAP 5.250 4.410 2.638 (24 PLCS) [112] [133] [67] Model 4300 Upper and Lower Tooling Bolt Patterns Figure 7 - 7 Page 98 Dukane Manual Part No. 403-592-00...
  • Page 105 6.024 [153] 5.000 [127] 1.00 [25.4] RAD. 0.000 5.000 [127] 6.024 [153] 8.250 [210] 9.000 [229] M12-1.75 LOWER (36 PLCS) TOOLING Model 4500 Upper and Lower Tooling Bolt Patterns Figure 7 - 8 Page 99 Dukane Manual Part No. 403-592-00...
  • Page 106 (28 PLCS) 12.000 9.750 [248] 8.250 [210] 6.000 [152] 0.000 6.000 8.250 9.750 [248] 12.000 [305] M12-1.75 LOWER (32 PLCS) TOOLING Model 4700 Upper and Lower Tooling Bolt Patterns Figure 7 - 9 Page 100 Dukane Manual Part No. 403-592-00...
  • Page 107 [305] 9.750 [248] 8.250 [210] 6.000 1.00 [152] 0.000 6.000 [152] 8.250 [210] 9.750 [248] 12.000 [305] M12-1.75 LOWER (48 PLCS) TOOLING Figure 7- 10 Model 4900 Upper and Lower Tooling Bolt Patterns Page 101 Dukane Manual Part No. 403-592-00...

  • Page 108: Torque Mounting Bolts

    The results: wasted energy and are designed to be identical will have a possible inferior welding. slightly different tuning load due to machin- ing and bolt torquing stresses. Continued Page 102 Dukane Manual Part No. 403-592-00...
  • Page 109 4. Clear any alarms. 5. Press E-STOP RESET. 6. Follow any other on screen instructions. 7. The display should indicate: Machine Ready for Cycle. 8. The welder is now ready to load parts and begin welding. Page 103 Dukane Manual Part No. 403-592-00...
  • Page 110 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 104 Dukane Manual Part No. 403-592-00...

  • Page 111: Section 8 - Machine Operation

    Resetting the Machine ......110 Page 105 Dukane Manual Part No. 403-592-00...
  • Page 112 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 106 Dukane Manual Part No. 403-592-00...

  • Page 113: Machine Startup

    Machine Reset toolbar. See Figure 8  -   1 . The but- ton is active only in Setup mode. Follow the on-screen instructions when those appear. HOME Procedure Screen Figure 8 - 1 Page 107 Dukane Manual Part No. 403-592-00...

  • Page 114: Selecting A Setup File

    Detailed instructions for setting up a new file are given in Section 6 – on Page 68. Set Limits Instructions for setting limits are given in Refer to Figure 6  - 26, Page 65. Load Setup Figure 8 - 3 Page 108 Dukane Manual Part No. 403-592-00...

  • Page 115: Starting A Weld Cycle

    Press either of the operate switches to start a cycle. The front access door closes, the parts are welded and the door opens. 5. Remove Parts Remove the assembled parts, and repeat the cycle. Page 109 Dukane Manual Part No. 403-592-00...

  • Page 116: Stopping The Weld Cycle

    2. Clear all E-STOPs, and press RESET . 3. Turn on the hydraulics. 4. Clear alarms. 5. Press and hold the (HOME button until machine is home. See Figure 8-4b to the right. Machine Reset Pop-up Window Figure 8-4b Page 110 Dukane Manual Part No. 403-592-00...

  • Page 117: Section 9 - Optimizing Performance

    Pneumatic Flow ........115 Page 111 Dukane Manual Part No. 403-592-00...
  • Page 118 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 112 Dukane Manual Part No. 403-592-00...

  • Page 119: Welding Parameters

    Figure 9-3. Do not confuse weld distance which Time is the collapse distance with weld penetration which is Relationship of Melt Penetration to Melt Figure 9 - 1 how deep the melt flow penetrates. Temperature Through the Four Phases Page 113 Dukane Manual Part No. 403-592-00...

  • Page 120: Weld Amplitude

    MPa; 1 MPa = 1.450x10 psi; 1 MPa = 1x10 Nt m transition or crystallization temperature. A holding time Approximate Welding Pressure for Table 9- I of between one and five seconds is usually enough. Common Thermoplastics Page 114 Dukane Manual Part No. 403-592-00...

  • Page 121: Hydraulic Flow

    The door flow control valves are identified Main Pressure in Figure 9-5. They are also labeled on the top of the Regulator distribution manifold. Gauge Access Door Flow Control Valves Pneumatic Flow Adjustment Valves Figure 9 - 5 Page 115 Dukane Manual Part No. 403-592-00...
  • Page 122 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 116 Dukane Manual Part No. 403-592-00...

  • Page 123: Section 10 - Troubleshooting

    Hydraulics........126 Lift Table Moves Too Slowly .............. 126 Lift Table Will Not Move ..............126 Common FAQs ..............127 Page 117 Dukane Manual Part No. 403-592-00...
  • Page 124 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 118 Dukane Manual Part No. 403-592-00...

  • Page 125: Electronics Control

    PLC memory. If the is red, battery life is low. The battery should Serial Port - Allows for communication with Dukane be replaced. Amplitude Regulation Board If you do not have a spare battery and want to prevent...

  • Page 126: Ac Utility Outlet

    AC Utility Outlets Variable Drive Hydraulic Pump Breaker AC Outlet Breaker System Cabinet Air Intake Low Voltage Documentation (Cooling Fan) Power Supply Interior of Electrical Cabinet with Major Components Identified Figure 10- 2 Page 120 Dukane Manual Part No. 403-592-00...

  • Page 127: Plc Programming Key- Allen Bradley

    10-3. To interpret these LEDs on your PLC, please refer to Table 10-I on the next page. Alternately, you may find PLC NOTE support literature on the Allen Bradley website. For SLC 5/05 information, refer to Allen Bradley's publication 1747-UMO11G-EN-P. Continued Page 121 Dukane Manual Part No. 403-592-00...
  • Page 128 The processor is trying to establish communication, but there are no other active nodes on teh DH-485 network. DH-485 mode A fatal error is present (no communication). DH-485 mode Allen Bradley PLC Status Indicators and Indication Table 10- I Page 122 Dukane Manual Part No. 403-592-00...

  • Page 129: Mitsubishi

    Flashing when a program error occurs. ERROR Lights when a CPU error occurs. Mitsubishi PLC Status LEDs Table 10- II Mitsubishi PLC Status LEDs Figure 10- 4 NOTE See Appendix D, Page 145 for battery replacement. Page 123 Dukane Manual Part No. 403-592-00...

  • Page 130: Electrical Power

    3. Unscrew the filler cap (Figure 11  -   3 ). Pull the bas- Each Corner) Each Corner) ket and filter and check for any blockage or foreign 480VAC Fuse Block and Removal Tabs Figure 10- 6 material. Continued Page 124 Dukane Manual Part No. 403-592-00...

  • Page 131: Hydraulic Overload

    Increase the value that corresponds to the error message. We strongly recommend that you consult Dukane prior to changing these values. Refer to Overload Settings, and Figure 6  - 39, Page 79.

  • Page 132: Hydraulics

    No NO HYDRAULIC PRESSURE 05/01/2012 01 : 55:47 PM Hydraulic pump is on but no pressure is detected. Alarm Screen - No Hydraulic Pressure Figure 10 - 9 Continued Page 126 Dukane Manual Part No. 403-592-00...

  • Page 133: Common Faqs

    Figure 10 - 10 a year (in severe environments you might want to do it more often) with a good general-purpose industrial grease 4. Q: An alarm message says: E- STOP OR SERVICE Continued Page 127 Dukane Manual Part No. 403-592-00...

  • Page 134: E-Stop Reset

    If There are some cases where you can use fewer. The you buy a Dukane machine with tooling, we always only legitimate reason for not using all of the bolts check the total noise of the machine and tooling together.
  • Page 135 If the strange stanchions that act as stops to prevent the tool being sound persists, call Dukane and ask us to listen to it damaged if the machine is cycled with no parts in the over the telephone.
  • Page 136 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 130 Dukane Manual Part No. 403-592-00...

  • Page 137: Section 11 - Maintenance

    Mechanical System ....... 136 Grease Fittings ..................136 Table Position Encoder ..............136 Tooling Care ..................136 Page 131 Dukane Manual Part No. 403-592-00...
  • Page 138 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 132 Dukane Manual Part No. 403-592-00...

  • Page 139: Touch Screen Display

    Continued Page 133 Dukane Manual Part No. 403-592-00...

  • Page 140: Hydraulic System

    (don't use) because the drain plug does not have a shut-off valve. After draining the reservoir, some fluid will remain in Figure 11 - 3 Draining and Adding Hydraulic Fluid Continued Page 134 Dukane Manual Part No. 403-592-00...

  • Page 141: Back Pressure Gauge

    Table 11 - I is Part No. . Also check the air vent and Elevated Temperatures 0075R010BN3HC filter by pushing in the cap and twisting counterclockwise (CCW) . Replace the air filter if needed. Page 135 Dukane Manual Part No. 403-592-00...

  • Page 142: Mechanical System

    If the encoder readout is not accurate measuring the table position, check that the encoder is firmly at- tached to the table and properly calibrated by use of Grease Grease the Utilities>Dukane>Calibration XDUC screen (Figure Fitting Fitting 6-39, Page 79). Tooling Care Tooling left unused and open to the air may develop Figure 11- 6 Close-up Of Grease Fittings No.

  • Page 143: Section 12 - Contacting Dukane

    Section 12 - Contacting Dukane SECTION 12 Contacting Dukane Page 137 Dukane Manual Part No. 403-592-00...
  • Page 144 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 138 Dukane Manual Part No. 403-592-00...

  • Page 145: Intelligent Assembly Solutions

    Section 12 - Contacting Dukane Contacting Dukane Identify Equipment When contacting Dukane about a service–related prob- lem, be prepared to give the following information: • Model number, line voltage and serial number. • Alarm messages from the touch screen display.
  • Page 146 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 140 Dukane Manual Part No. 403-592-00...

  • Page 147: Section 13 - Specifications

    Space Requirements Drawings ..... . 147 Regulatory Agency Compliance ..... . 151 Page 141 Dukane Manual Part No. 403-592-00...
  • Page 148 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 142 Dukane Manual Part No. 403-592-00...

  • Page 149: Tooling Specifications

    5500 lb / 2268 Kg Force Table 13 - I Upper and Lower Tooling Weight and Dimensions NOTE Minimum table shut height for all models is 6 inches. Maximum daylight frame for all models is 25 inches. Page 143 Dukane Manual Part No. 403-592-00...

  • Page 150: Weights, Dimensions

    ** Add for adjustable leveling feet height - between 1 - 3 in (25 - 76 mm) Welder Dimensions - in (mm) Table 13 - III NOTE See Space Requirements Drawings starting on Page 147. Page 144 Dukane Manual Part No. 403-592-00...

  • Page 151: Operating Environment

    40°F to 95°F (+5°C to +35°C) Temperature: Keep the equipment dry. Air Particulates: Minimize exposure to moisture, dust, dirt, smoke and mold. 5% to 95% Non–condensing @ Humidity: +5°C to +30°C Sea level to 15,000' (4,570 m) Altitude: Page 145 Dukane Manual Part No. 403-592-00...

  • Page 152: Power Requirements

    4900 plied. Table 13-IV AC Power Requirements Compressed Air The welder requires a supply of clean, dry, compressed air at 75 to 90 psi (0.52 to 0.62 MPascal or 5.1 to 6.1 Bar). Page 146 Dukane Manual Part No. 403-592-00...

  • Page 153: Space Requirements Drawings

    Section 13 - Specifications Space Requirements Drawings Figure 13 - 3 Model 4300 Floor Space Requirements Page 147 Dukane Manual Part No. 403-592-00...
  • Page 154 Linear Vibration Welder 4000 Series, Model VWA User’s Manual Figure 13–4 Model 4500 Floor Space Requirements Page 148 Dukane Manual Part No. 403-592-00...
  • Page 155 Section 13 - Specifications Figure 13 - 5 Model 4700 Floor Space Requirements (29 - Inch Rear Service Doors) Page 149 Dukane Manual Part No. 403-592-00...
  • Page 156 Linear Vibration Welder 4000 Series, Model VWA User’s Manual Figure 13 - 6 Model 4900 Floor Space Requirements Page 150 Dukane Manual Part No. 403-592-00...

  • Page 157: Regulatory Agency Compliance

    DO NOT make any modifications to CE stands for Conformité Europeéne (European the PLC, its program, or to the vibra- Conformity). The equipment complies with the fol- tion welder as delivered by Dukane. lowing CE requirements. Unauthorized changes made to the •...
  • Page 158 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 152 Dukane Manual Part No. 403-592-00...

  • Page 159: Section 14 - Appendices

    Appendix C, List of Tables ......164 Appendix D, Mitsubishi PLC ......165 Page 153 Dukane Manual Part No. 403-592-00...
  • Page 160 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 154 Dukane Manual Part No. 403-592-00...

  • Page 161: Appendix A - Joint Design Guidelines

    The designs shown below are examples. Proper joint design involves many factors including application requirements and material. Call Dukane’s Application Lab for addition information. We are plastic welding scientists and engineers and experts in plastic assembly. We are your problem solvers and technical advisors.
  • Page 162 0.020" - 0.040" (0.5mm - 1.0mm) Vibration Clearance 0.040" (1.0mm) minimum Melt Down 0.040" - 0.060" (1.0mm - 1.5mm) Wall Thickness Minimum 0.120" (3mm) Collapsed Vibration Butt Joint with External Flash Trap Figure A - 2 Page 156 Dukane Manual Part No. 403-592-00...

  • Page 163: Vibration Rib Joint

    0.040" - 0.060" (1mm - 1.5mm) Rib Width Minimum 0.040" (1mm) Support Rib Height 0.080" - 0.120" (2mm - 3mm) Wall Thickness Minimum 0.060" (1.5mm) Collapsed Support Vibration Direction Vibration Rib Joint Figure A - 3 Page 157 Dukane Manual Part No. 403-592-00...
  • Page 164 Side Wall Height 0.080" (2mm) Melt Down 0.060" (1.5mm) Side Wall Width 0.060" (1.5mm) Tongue Width A + 0.080" (2mm) Wall Thickness 0.120" (3mm) Collapsed Vibration Butt Joint with Flash Traps Figure A - 4 Page 158 Dukane Manual Part No. 403-592-00...

  • Page 165: Weld Distance

    Redesign parts with reinforcing ribs and/or tongue and groove joints. Excessive filler or uneven distribu- Reduce amount of filler. Improve processing conditions tion. to ensure even distribution of filler. Common Welding Problems and Solutions Table A- I Page 159 Dukane Manual Part No. 403-592-00...
  • Page 166 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 160 Dukane Manual Part No. 403-592-00...

  • Page 167: Appendix B List Of Figures

    Parts Loaded in Tooling ....................35 Parts Clamped Together at Trigger................36 Parts Being Welded Together ..................37 Lift Table Lowering to Starting Position .................37 Assembled Parts Unloaded from Welder ..............37 Primary Button Location ....................41 Continued Page 161 Dukane Manual Part No. 403-592-00...
  • Page 168 Utilities Screen - Options ....................74 6-35 Utilities Screen > Security > Users ................75 6-36 Utilities Screen > Security > Groups ................76 6-37 Utilities Screen > Dukane ....................77 6-38 Utilities Screen > Dukane > Dukane Access ..............78 Continued Page 162 Dukane Manual Part No. 403-592-00...
  • Page 169 Appendix B List of Figures Continued from Previous Page Description Page 6-39 Utilities Screen > Dukane > Calibration XDUC .............79 6-40 Utilities Screen > Dukane > Valve Calibration ...............80 6-41 Welder Interior - Proportional Relief Valve Calibration Setup ........81 6-42 PLC I/O Screen ......................82...
  • Page 170 Model 4900 Floor Space Requirements ..............150 Vibration Butt Joint ......................155 Vibration Butt Joint with External Flash Trap ...............156 Vibration Rib Joint .......................157 Vibration Butt Joint with Flash Traps ................158 Mitsubishi Battery Location ..................166 Mitsubishi Battery Date of Manufacture...............166 Page 164 Dukane Manual Part No. 403-592-00...

  • Page 171: Appendix C - List Of Tables

    Upper and Lower Tooling Weights and Dimensions ............. 143 13-II Approximate Shipping Weights ..................144 13-III Welder Dimensions ....................... 144 13-IV AC Power Requirements ....................146 Common Welding Problems and Solutions ..............159 Page 165 Dukane Manual Part No. 403-592-00...

  • Page 172: Appendix D - Mitsubishi Plc

    Mitsubishi Battery Date of Manufacture Figure D-2 Disposal • Please contact a company certified in the disposal of electronic waste for environmentally safe recycling and disposal of this product. Page 166 Dukane Manual Part No. 403-592-00...

  • Page 173: Index

    Index Index Page 167 Dukane Manual Part No. 403-592-00...
  • Page 174 Linear Vibration Welder 4000 Series, Model VWA User’s Manual This page intentionally left blank Page 168 Dukane Manual Part No. 403-592-00...
  • Page 175 AC Power Disconnect 11 Website 139 AC Power Receptacle 11 Control Panel Layout 27 Electrical Cabinet Door 11 Controls and Display General Considerations 9 In Cycle 27 Cable Connections 10 Current Amplitude 66 Page 169 Dukane Manual Part No. 403-592-00...
  • Page 176 Vibration Butt Joint with External Flash Trap 156 Initiate Weld Cycle 35 Vibration Butt Joint with Flash Traps 158 Notes, Cautions and Warnings 3 Vibration Rib Joint 157 Welding Problems and Solutions 159 Optimizing Performance 111 Page 170 Dukane Manual Part No. 403-592-00...
  • Page 177 Tooling Size & Weight 143 Graph 58 Stanchion Alignment Pin 102 Header - Quick Look 46 Starting A Weld Cycle 109 History 57 Stopping the Weld Cycle 110 Introduction 41 System documentation 17 Page 171 Dukane Manual Part No. 403-592-00...
  • Page 178 Moisture Trap 133 Upper and Lower Limits 65 Utilities 69 Dukane 77 Calibration XDUC 79 Valve Calibration 80 I/O Setup 69 Options 74 PLC I/O Status 82 Security 75 Tool ID is Off 77 Page 172 Dukane Manual Part No. 403-592-00...
  • Page 179 By passing its audit, Dukane can assure based on partnership for continuous improve- you that we have in place a well–defined and ment. This concept is key in that Dukane no systematic approach to quality design, manu- longer focuses on inspection, but on individual facturing, delivery and service.
  • Page 180 Linear Vibration Welder VWA 4000 - User's Manua Part No. 403  –   5 92–  0 0 Printed in the United States of America Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949...

This manual is also suitable for:

Vwa-4700Vwa-4900Vwa-4500

Table of Contents