Dukane 5000 Series User Manual page 143

5. Q: There's a red box that says SENSOR 1 (or
SENSOR 2) on my screen and it won't go away, and
I can't run a cycle. What do I do now?
A: If you are using part-in-place detection, the part-
in-place sensor is not detecting a part loaded into
the tooling. If there are no part-in-place sensors in
your tooling, go to the USER OPTIONS >Tool
.
Options>Sensors
6. Q: What does it mean when I get an Autotune
Error?
A: There is either a serious problem with the machine,
there is some decoupling occurring between the
machine and tool or within the upper tool or, more
likely, the upper tool is outside of the weight range of
the machine.
7. Q: There are a lot of tooling bolts. How many do I
really HAVE to install?
A: The best answer to that question is ALL of them.
There are some cases where you can use fewer. The
only legitimate reason for not using all of the bolts
is that some part of the tooling obscures some of the
holes. You must also torque the bolts to 100 foot-
pounds (136 Nt-m). If you do not, the upper tool
can become decoupled from the springs, resulting in
possible damage to the tool or machine. Similarly, a
loose lower tool will result in poor welding and can
damage the tooling or machine.
8. Q: What do you mean by acoustically coupled?
A: Acoustic coupling is a term we use to describe the
tendency of a multipart mass to vibrate as though it were
one piece. If the upper vibration tool has some loose
bolts in it, the individual pieces can vibrate relative
to each other, which causes significant problems. The
tooling is then said to be decoupled from the springs.
Both the machine and tooling can be damaged if this
condition exists for a prolonged period.
9. Q: Why do I have to Autotune the tooling?
A: 1. During an Autotune the machine seeks the
optimal operating frequency for that particular upper
tool/spring assembly. If an Autotune procedure is not
done, the machine will be fighting the natural resonance
of the tooling/frame assembly, which may result in poor
and/or inconsistent weld quality.
A: 2
Dukane Manual Part No. 403-589-01
Continued from Previous Page
Put the sensors in BYPASS mode.
Fighting the natural resonance of the tooling/frame
assembly results in wasted energy. Since you cannot
create or destroy energy, only change its form, this
wasted energy shows up as heat, especially in the coils.
Overheated coils will fail prematurely, resulting in
unnecessary downtime and expense.
10. Q: The machine has two cycle activation switches, so
why do I only have to activate one to start a cycle?
A: Machines equipped with light curtains are not
required to be equipped with two-hand anti-tie-down
cycle actuation, so as a convenience we allow the
operator to use either of the switches to start the cycle.
11. Q: This machine is much louder than 80db. What can
I do about it?
A: If the machine is slightly louder than 80db, it is
probably running an application with a higher basic
sound level than we tested the machine for in our factory.
If you buy a Dukane machine with tooling, we always
check the total noise of the machine and tooling together.
Our standard sound insulation package is designed to
deal with the majority of vibration welding applications.
Consult Dukane about the possible addition of custom
sound insulation. If the machine is significantly louder
than 80db, you probably have not installed the fork
tube covers that came with the machine (Figures 3- 4
and 3-5, Pages 18 and 19). When we ship a machine,
the covers are shipped in a corrugated box in the bottom
of the electrical cabinet.
.
Section 10 - Troubleshooting
Continued
Page 137