Page 1 6700 6700 6900 6900 6960 6960 User's Manual Dukane Part No. 403 - 619- 00 Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 4900 Dukane products are manufactured www.dukane.com in ISO registered facilities...
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 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 Revision Number Summary Date - 00 Initial Release 01/28/2022 Page iii Dukane Manual Part No. 403-619-00...
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Page 5: Table Of Contents
Section 7 - Tooling Installation Section 8 - Machine Operation Section 9 - Optimizing Performance Section 10 - Troubleshooting Section 11 - Maintenance Section 12 - Contacting Dukane Section 13 - Specifications Section 14 - Appendices Index Page v Dukane Manual Part No. 403-619-00...
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Page 7: Section 1 - Introduction
Key Features ....... . 5 Page 1 Dukane Manual Part No. 403-619-00...
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Page 9 (e.g. –1, –2, –3) while the tables use Roman sequence numerals (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. Page 3 Dukane Manual Part No. 403-619-00...
Page 10 The linear vibration welder excels at joining large assemblies and parts made from glass–filled and high performance plastics. The VW6X00 family is Dukane’s fifth generation linear vibration welder. These systems all share the same bridge components. Software and controls are significantly improved in this fifth generation, along with a servo driven lift table.
Page 11 Selectable Trigger by position or by zero motion. and-place systems, conveyor pass-through and/or part feed systems. Control for automation can be added to • A New Proprietary Dukane Two-Phase Drive has been the core software. incorporated into these 6000 Series vibration welders. •...
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Page 13: Section 2 - Health And Safety
Operational Safety ....... . . 13 Page 7 Dukane Manual Part No. 403-619-00...
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Page 15 No Unauthorized Modifications - Do not modify must be guarded as necessary. your welder in any way unless authorized to do so by Dukane. Unauthorized modifications may cause injury Dukane does not assume any to the operator and/or equipment damage. In addition,...
Page 16 Linear Vibration Welder 6000 Series User’s Manual Continued from Previous Page General Considerations Foot Switch - Do not use a foot switch. Using a foot switch CAUTION in place of the optical touch finger switches (activation  switches) violates OSHA regulations.
Page 17 Electrical Safety Figure 2-1 480VAC 3-Phase AC Plug Configuration AC Power Receptacle The power cord used on the Dukane vibration welder, Models 6300 and 6700, has a three-pole, four-blade, 480V grounding type plug designed for 3-Phase 480 VAC at 277V 30 amps.
Page 18 Linear Vibration Welder 6000 Series User’s Manual WARNING Never operate the vibration welder with the electrical service door open. This is an unsafe practice and can result in injury or death. Figure 2- 4 Handle–Style AC Power Disconnect with Lockout and Tag...
Page 19 Breaking the light beam while the doors are in transition will cause the machine to halt operation. The light curtains are identified in Figure 2-7. Figure 2-7 Light Curtains, Electrical Cabinet Service Door and Disconnect Page 13 Dukane Manual Part No. 403-619-00...
Page 20 Linear Vibration Welder 6000 Series User’s Manual WARNING Never operate the vibra- tion welder with any of Figure 2-8 Rear Service Doors the service doors open. This is an unsafe prac- tice and can result in injury or death. ...
Page 21: Section 3 - Installation
Compressed Air ........21 Page 15 Dukane Manual Part No. 403-619-00...
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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. Figure 3-2 System Documentation Storage Pocket Page 17 Dukane Manual Part No. 403-619-00...
Page 24 Linear Vibration Welder 6000 Series User’s Manual Floor Area The floor area required for the vibration welder depends on the model and capacity of the machine. Detailed dimensions are given in Section 13 – Specifications. Forklift Channels The vibration welder has built–in forklift channels. Cover plates for the front and rear channels are supplied.
Page 25: Ac Power
AC Power. 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. 403-619-00...
Page 26 Linear Vibration Welder 6000 Series User’s Manual AC Disconnect Switch The AC power cord is directly connected internally to the AC disconnect switch. To turn the AC power OFF, twist the red circular knob counterclockwise until it is pointing left to the Green OFF position as shown in Figure 3-6.
Page 27: Compressed Air
WARNING Never attempt to remove the filter housing while the compressed air is on. Turn off the compressed air us- ing the pneumatic lockout device and make sure the pressure gauge reads zero. Page 21 Dukane Manual Part No. 403-619-00...
Page 28 Linear Vibration Welder 6000 Series User’s Manual Machine Air The welder requires a supply of clean, dry, compressed air at 75 to 90 psi. The connection is made using 1 /2 inch (12mm for international models) O.D. tubing at the pneumatic lockout device. Turn the valve to the right as shown in Figure 3-9 to open the valve and apply the compressed air.
Page 29 The table will move to its home position, the message will MACHINE READY FOR SETUP change to and a message may appear providing status and instructions. Follow the on-screen instructions when those appear. Figure 3-11 Machine at Home Position Page 23 Dukane Manual Part No. 403-619-00...
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Page 31: Section 4 - Display And Controls
AC Utility Outlet ....... . . 31 Vacuum On/Off Button ......31 Page 25 Dukane Manual Part No. 403-619-00...
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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. 403-619-00...
Page 34 Linear Vibration Welder 6000 Series User’s Manual E-STOP Reset (button) Pressing the button enables the operator to reset the welder when it is initially turned on or to clear an aborted cycle caused by: NOTE 1. Pushing the (E-STOP) button.
Page 35: Operational Switches
LED at the right rear also illuminates to indicate the switch has been activated. Figure 4-3 Switch Box: Operate, E-STOP Button and Vacuum Button Page 29 Dukane Manual Part No. 403-619-00...
Page 36: Light Curtain
Linear Vibration Welder 6000 Series User’s Manual J - Light Curtain The light curtains are identified in Figure 4-2. The right light curtain (receiver) contains five status at the top of the housing. See Figure 4-4. If these are green, the...
Page 37: Ac Utility Outlet
See Figure 6-31 on Page 75. If Vacuum is set to “Off” or any of the vacuum settings are set to “Auto”, the vacuum switch will not work in Manual mode. Figure 4- 5 Right Operate Switch and Vacuum Button Page 31 Dukane Manual Part No. 403-619-00...
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Page 39: Section 5 - Normal Weld Cycle
Parts Removed........37 Page 33 Dukane Manual Part No. 403-619-00...
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Page 41: Parts Loaded
To recover from a light curtain fault, press the HOME MACHINE button. If the compressed air supply is not turned on, the doors will not be able to move and the welder will stop and must be reset. Page 35 Dukane Manual Part No. 403-619-00...
Page 42: Clamping Phase
Linear Vibration Welder 6000 Series User’s Manual If the compressed air supply is not turned on, the door will not be able to move. In this case, the lift table will begin to move, but will stop after a short time because the door- open sensor has not been released.
Page 43: Release Phase
Figure 5-5. A new set of parts is installed in the tooling, and the weld cycle can be started again. Welded Assembly Lower Tooling Lift Table Figure 5 - 5 Assembled Parts Unloaded from Welder Page 37 Dukane Manual Part No. 403-619-00...
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Page 45: Section 6 - Touch Screen
Touch Screen Banner ........97 Page 39 Dukane Manual Part No. 403-619-00...
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Page 47: Introduction
Primary buttons are large and grouped in one of two location bars – top and side bars as shown in the figure below. Banner Top Button Bar Side Button Figure 6 - 1 Button Bars Page 41 Dukane Manual Part No. 403-619-00...
Page 48: Button Appearance
Linear Vibration Welder 6000 Series User’s Manual Large Button Appearance When touched and activated, large buttons change appearance as shown in Figure 6-2. When a large button on the side bar is touched, the button changes color - from light gray, to dark gray. If a button has a virtual LED indicator, when activated, the LED is GREEN;...
Page 49 GREEN. See the examples in Figure 6-3. Also see Valves and Sensors as a part of the Tool Setup screen description below. Active Buttons Figure 6 - 3 Small Active Buttons Page 43 Dukane Manual Part No. 403-619-00...
Page 50: Making Selections
Linear Vibration Welder 6000 Series User’s Manual Making Selections From a Pull-down Menu In the example shown in Figure 6-4 - a detail of the Tool Setup menu - Valve 1 will extend At Cycle Start. To make this selection: 1.
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 accepted. Figure 6 - 7 Virtual Keypad Page 45 Dukane Manual Part No. 403-619-00...
Page 52: Top Button Bar - Quick Look
Linear Vibration Welder 6000 Series User’s Manual Top Button Bar - Quick Look Job File - The file name identi- fying the current setup. Units of Measure - Push this button to Date and Time - These change the units of measure displayed values are assigned by on the screen.
Page 53: Side Button Bar - Quick Look
Open continuously until the door comes to the desired Figure 6 - 10 Sliding Door Pop-Up Window position. Table Up / Table Down Touch the Table Up and Table Down buttons to manually raise and lower the lower fixture table. Page 47 Dukane Manual Part No. 403-619-00...
Page 54 Linear Vibration Welder 6000 Series User’s Manual Home Machine Homing the machine brings the welder to a defined starting point. To home the machine: 1. Touch the Home Machine button. 2. The doors will move to the fully open position and the table will move down to it's starting position.
Page 55: Logging In And Out
Utilities menu has been activated, and is shown on the main screen as shown in Figure 6-12 below. Utilities is active. Setup Mode is active. Touch, Change Password. Figure 6 - 12 Log In - 1 Page 49 Dukane Manual Part No. 403-619-00...
Page 56 Linear Vibration Welder 6000 Series User’s Manual Create a new user profile and set the password: Delete User – Under Delete Selected User, select a user’s name from the User to Delete pull-down Login as Administrator. menu. Then touch the Delete User button to remove Setup Mode must be active.
Page 57 4. Enter the password. When finished making the ✔ entry, touch the key. 5. The Log In box will show who is logged in. User Login will close of the correct password is entered. Page 51 Dukane Manual Part No. 403-619-00...
Page 58 Linear Vibration Welder 6000 Series User’s Manual Log Out 1. To log out, touch the Log In box. 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 Log In box.
Page 59: Operation
Top Button Bar – Operate, I/O Table, and M/E are available. Side Button Bar – Home Machine, Alarms, Language (Primary and Secondary), and Context Help are available. Run Mode is active. Figure 6-15 Run Mode is Active Page 53 Dukane Manual Part No. 403-619-00...
Page 60: Setup Mode
Linear Vibration Welder 6000 Series User’s Manual Setup Mode Figure 6-16 below shows that the dual-function mode button (Setup / Run) has been pressed so that Setup Mode is active. Notice that ALL choices are available for Setup Mode along the top button bar and bottom button bar: •...
Page 61: Operate Screen
Hold Time – The amount of time the lift table maintains the clamping portion of the weld cycle. This allows the welded surface to become solid. Hold time will start after the weld time has been reached. Page 55 Dukane Manual Part No. 403-619-00...
Page 62 Linear Vibration Welder 6000 Series User’s Manual Total Collapse – A combination of weld and hold distance. Weld Force – The force that is applied across the work piece during the weld time. Amplitude – This peak-to-peak value is the total amount of horizontal movement of the tooling.
Page 63 Programming the process limits is done in Setup Mode. See Section 6 - Setup for more information. Figure 6-18 shows how the Alarm Limits pop-up window appears on the Operate screen. Figure 6-18 Run Mode - Alarm Limits Pop-up Window Page 57 Dukane Manual Part No. 403-619-00...
Page 64 Linear Vibration Welder 6000 Series User’s Manual Upper Limit – This is the maximum allowable value that could occur during a weld cycle. A green background for the entry box means the actual value is less than the upper limit. As is the case in the example, a red background for the entry box indicates the actual value is greater than the maximum value.
Page 65 Save to USB – Touch the Save to USB button to copy the most current History Log to USB 1 or USB 2. If you would like to copy more than one History Log, go to Utilities>Data Log Control>History Log - to view options. Page 59 Dukane Manual Part No. 403-619-00...
Page 66 Linear Vibration Welder 6000 Series User’s Manual Event Log (Run & Setup Mode) The Event Log makes a record of every event. It records the user, which setup is used, and any process parameters that are changed. The Log also keeps a record of the old values and new values.
Page 67 Figure 6-21. Figure 6-21 Run Mode - Graph Screen The graph illustrates a graph of the Total Collapse, Amplitude, and Force for the last cycle. Page 61 Dukane Manual Part No. 403-619-00...
Page 68: Setup Screen
Linear Vibration Welder 6000 Series User’s Manual Setup Screen (Setup Mode Only) The Setup view is only selectable when in Setup Mode. Setup is used to program most elements of the weld cycle. Touch the Setup button on the Top Button Bar to activate the Setup screen.
Page 69 This trigger method automatically sets the table slowdown position to 2" (50 mm) before the programmed trigger position. Program the desired position in the Table Position entry box. Page 63 Dukane Manual Part No. 403-619-00...
Page 70 Linear Vibration Welder 6000 Series User’s Manual Weld By Choose from two weld modes. Distance – This is the amount of added collapse (distance) needed beyond the starting weld position. Welding continues at the specified pressure until the weld distance is achieved, or until the weld time limit has been reached.
Page 71 Trigger Minimum or a fault is generated. Trigger Set represents the ideal location for parts clamping to occur. Touch the DISABLE button when no trigger limits are desired. Figure 6-24 Setup Mode - Set Trigger Limits Page 65 Dukane Manual Part No. 403-619-00...
Page 72 Linear Vibration Welder 6000 Series User’s Manual Table Options The Table Options screen allows the operator to set these parameters: • Table up and down speeds (in Setup Mode • Table position, • Part clamp speed, • Table lift pressure (force), •...
Page 73 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 67 Dukane Manual Part No. 403-619-00...
Page 74 Linear Vibration Welder 6000 Series User’s Manual Autotune Mode NOTE Use this feature to automatically determine the resonant The acceptable frequency range is frequency of the vibrating Assembly. 200 Hz – 240 Hz. (The upper assembly includes the springs, carriers and tooling.)
Page 75 Touch this button to turn fea- the tool weight compensation process. The ture on or off. Green means Sample In Progress bar starts to fill up. ON; red means OFF. Figure 6-28 Tool Weight Compensation Pop-up Window Page 69 Dukane Manual Part No. 403-619-00...
Page 76 Linear Vibration Welder 6000 Series User’s Manual Save Setup Touch the button to save the current setup. Touch the Reload Setup button to reload data to the current setup. Touch the File Control button to open the file control (Setup) pop-up window.
Page 77 3. Edit the process parameters. 4. Press Save Setup to update the setup. 5. To verify that the change was made to the updated setup, press Load Setup. 6. Check the parameters that were changed. Page 71 Dukane Manual Part No. 403-619-00...
Page 78: Tool Setup Screen
Linear Vibration Welder 6000 Series User’s Manual Tool Setup Screen (Setup Mode Only) Tool Setup relates to programming the valves and sensors associated with the welder’s tooling. Touch the Tool Setup button on the top button bar to activate the Tool Setup screen.
Page 79 Status Status Output ON Valve extending (yellow) (green). Sensor ON Valve retracting (green) (green). Table 6-III Table 6-II Valve Sensor Status Valve Status NOTE Each valve is paired with extend and retract sensors. Page 73 Dukane Manual Part No. 403-619-00...
Page 80 Linear Vibration Welder 6000 Series User’s Manual Part Presence Sensor Status The table below provides a key to the status symbols used with the Part Present sensors. Sensor disabled (dark gray). Sensor enabled (light gray) Part Present Sensor Output ON...
Page 81 • AUTO ON/AUTO OFF • AUTO DELAY • AUTO LIGHT CURTAIN • OFF DURING WELD Figure 6-31 Test Valves Pop-up Window Test Vacuum Test Vacuum – Touch the button to test the vacuum function. Page 75 Dukane Manual Part No. 403-619-00...
Page 82 Linear Vibration Welder 6000 Series User’s Manual Save Setup Touch the button to save the current setup. Reload Setup Touch the button to reload data to the current setup. File Control Touch the button to open the File Control pop-up window.
Page 83 Maximum of 15 characters, the name is saved with the setup. Figure 6-33 Valve/Sensor Naming NOTE Valve names and sensor names are now presented in fault messages when a specific valve or sensor faults out. Page 77 Dukane Manual Part No. 403-619-00...
Page 84: Utilities Screen
Linear Vibration Welder 6000 Series User’s Manual Utilities Screen (Setup Mode Only) Utilities relates to system settings, calibration, security, diagnostics, and data management. Touch the Utilities button on the top button bar to activate the Utilities screen. A sample screen is shown in Figure 6-34. Definitions of terms are shown below as well.
Page 85 There is only one screen in the System Settings window: • Display Settings – IP Address, Subnet Mask, Date and Time are located here. All of these settings may be changed to suit the application. Page 79 Dukane Manual Part No. 403-619-00...
Page 86 Linear Vibration Welder 6000 Series User’s Manual Calibration XDUC (Position Transducer) Touch the Calibration XDUC (Position Transducer) button at the top of the Utilities screen, to activate the calibration screen shown in Figure 6-36 below. Figure 6-36 Utilities > Calibration - Position Transducer Pop-up Window...
Page 87 Allows 1 to 3 seconds for the PLC to detect a feedback signal, before No Feedback Detected alarm is triggered. Input Raw – Transducer output value being read from the analog input card. Volts – Transducer output voltage. Page 81 Dukane Manual Part No. 403-619-00...
Page 88 Linear Vibration Welder 6000 Series User’s Manual SDM (System Diagnostics Manager) For technician use only. Five sample screen images are shown in Figures 6-38 through 6-42. Figure 6-38 System Diagnostics Manager > System Page 82 Dukane Manual Part No. 403-619-00...
Page 89 Section 6 - Touch Screen Figure 6-39 Systems Diagnostics Manager > Software Page 83 Dukane Manual Part No. 403-619-00...
Page 90 Linear Vibration Welder 6000 Series User’s Manual Figure 6-40 Systems Diagnostics Manager > Hardware Page 84 Dukane Manual Part No. 403-619-00...
Page 91 Section 6 - Touch Screen Figure 6-41 Systems Diagnostics Manager > Logger Page 85 Dukane Manual Part No. 403-619-00...
Page 92 Linear Vibration Welder 6000 Series User’s Manual Figure 6-42 Systems Diagnostics Manager > Profiler Page 86 Dukane Manual Part No. 403-619-00...
Page 93 Change Password Help Touch the Change Password Help button to get instructions on changing the current password. Create User Help Touch the Create User Help button to get instructions on creating a new user. Page 87 Dukane Manual Part No. 403-619-00...
Page 94: I/O Table
Linear Vibration Welder 6000 Series User’s Manual I/O Table (Run & Setup Mode) With I/O Table the user can monitor the status of all input and output cards. Figure 6-43 Run Mode - I/O Screen NOTE Table and Door Buttons...
Page 95: Alarms
DOWN machine cycle is allowed. The alarm message will provide alarms screen to scroll through alarms. enough information to aid in correcting the problem. Fault Reset Clears the faults that have been corrected. Page 89 Dukane Manual Part No. 403-619-00...
Page 96 Linear Vibration Welder 6000 Series User’s Manual Alarm History Touch this button to display the Alarm History alarm history screen. See the sample screen shown in Figure 6-45 below. Figure 6-45 Alarms - History Sample Screen Page 90 Dukane Manual Part No. 403-619-00...
Page 97 Check that sensors are functioning properly. Solutions: Check the wiring. Check that sensors are functioning properly. Check that sensors are secured and free from any obstruction. Table 6-VI Alarms and Messages (Page 1 of 6) Continued Page 91 Dukane Manual Part No. 403-619-00...
Page 98 Linear Vibration Welder 6000 Series User’s Manual ALARMS MESSAGE Chip Communication Loss of communication on the drive board between processors. Solutions: Cycle power to the welder Call Dukane service Current Overload The load has exceeded the drive's capability. Solutions: Increase current delay to 3 seconds.
Page 99 Check the parts for proper loading. Check the “Min. Trigger Limit” value; it may be set incorrectly. Check “Trigger Position” value, may be set incorrectly. Table 6- V I Alarms and Messages (Page 3 of 6) Continued Page 93 Dukane Manual Part No. 403-619-00...
Page 100 Linear Vibration Welder 6000 Series User’s Manual ALARMS MESSAGE No Feedback Detected The PLC did not detect any amplitude feedback. Solutions: Increase the feedback delay to 3 seconds. Check your weld force; it could be set too high for the application. For example, 4000 lbs of weld force could restrict horizontal displacement, essentially stalling the machine.
Page 101 SMR-x Potential System Maintenance Required. Go to Setup Mode > Cycle Start to continue and contact Dukane. (x = error number) SMR-F Fatal System Fault. Contact Dukane. Stanchion Detect Stanchions are not retracted. Solutions: Home machine. Insure Stanchion pins are lowered.
Page 102 Linear Vibration Welder 6000 Series User’s Manual ALARMS MESSAGE Under Voltage Drive line voltage less than 432 Vac (480 Vac - 10%) for more than 1 second when not welding. Solution: Monitor incoming power line voltage. Reduce welding force to lower load on the drive.
Page 103: 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. Table 6-VII Touch Screen Banner Messages Page 97 Dukane Manual Part No. 403-619-00...
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Page 105: Section 7 - Tooling Installation
Tune Drive to Tooling ......102 Upper and Lower Tooling Bolt Patterns ....104 Page 99 Dukane Manual Part No. 403-619-00...
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Page 107: Install Tooling Assembly
Finger tighten all accessible upper and lower mounting bolts. NOTE For more information about balance of welding tools, refer to our Application Note 510, Importance of Balanced Vibration Welding Tools, on the Dukane website at: https://documents.dukane.com/AppNote/AN510.pdf Page 101 Dukane Manual Part No. 403-619-00...
Page 108: Torque Mounting Bolts
Linear Vibration Welder 6000 Series User’s Manual CAUTION Torque Mounting Bolts Make sure to retract the stan- E-STOP 1. Press chion alignment pins before 2. Disconnect and lockout the AC power. proceeding to tune the drive heads. 3. Close and lockout the machine air.
Page 109 4. Clear any alarms. 5. Press E-STOP RESET 6. Follow any other on screen instructions. Machine ready for 7. The display should indicate: cycle 8. The welder is now ready to load parts and begin welding Page 103 Dukane Manual Part No. 403-619-00...
Page 110: Upper And Lower Tooling Bolt Patterns
Linear Vibration Welder 6000 Series User’s Manual FIXTURE HOLE PATTERNS AND DIMENSIONS VW6300 TABLE 24X M12x1.75  .472  12.0] 9.000 DOWEL PIN 8.250 HOLES 6.024 5.500 .000 5.500 6.024 8.250 9.000 .250 11.6 - .500 - 12.7 OPENING FOR BUCKET UPPER TOOL 14X M12x1.75...
Page 111 .000 32X M12x1.75 5.570 8.250 9.750 9.843 12.000 UPPER TOOLING 6.750 4.729 [R13] 3.131 .000 28X M12x1.75 3.131 4.729 6.750 Figure 7 - 3 Model 6700 Upper and Lower Tooling Bolt Patterns Page 105 Dukane Manual Part No. 403-619-00...
Page 112 Linear Vibration Welder 6000 Series User’s Manual FIXTURE HOLE PATTERNS AND DIMENSIONS VW6700-LPT LIFT TABLE 12.000 9.843 9.750 8.250 5.570 2X 12MM DOWEL PIN HOLES OPENING .000 32X M12x1.75 5.570 8.250 9.750 9.843 12.000 UPPER TOOLING 9.252 6.102 2.953 .000 2.953...
Page 113 46X M12x1.75 5.570 8.250 9.750 9.843 12.000 UPPER TOOLING 6.750 4.937 3.131 .000 3.131 4.937 6.750 42X 42X M12x1.75 Figure 7 - 5 Model 6900 Upper and Lower Tooling Bolt Patterns Page 107 Dukane Manual Part No. 403-619-00...
Page 114 Linear Vibration Welder 6000 Series User’s Manual FIXTURE HOLE PATTERNS AND DIMENSIONS VW6900-LPT LIFT TABLE 12.000 9.843 9.750 8.250 5.570 OPENING .000 46X M12x1.75 5.570 8.250 9.750 9.843 12.000 UPPER TOOLING 9.252 6.102 2.953 .000 2.953 6.102 9.252 66X M16x1.5 Figure 7 ...
Page 115 12.000  .473 PIN HOLE  12.0] UPPER TOOLING 6.750 4.937 3.131 .000 3.131 4.937 6.750 42X 42X M12x1.75 Figure 7 - 7 Model 6960 Upper and Lower Tooling Bolt Patterns Page 109 Dukane Manual Part No. 403-619-00...
Page 116 Linear Vibration Welder 6000 Series User’s Manual FIXTURE HOLE PATTERNS AND DIMENSIONS VW6960-LPT LIFTING TABLE 54X M12x1.75 12.000 9.750 9.000 8.250 5.000 .000 5.000 8.250 9.000 9.750 12.000  .473 PIN HOLE  12.0] UPPER TOOLING 9.252 6.102 2.953 .000 2.953...
Page 117: Section 8 - Machine Operation
Resetting the Machine ......116 Page 111 Dukane Manual Part No. 403-619-00...
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Page 119: Machine Startup
The table will move to its home position, the message will change to MACHINE READY FOR SETUP and a message may appear providing status and instructions. Follow the on-screen instructions when those appear. Figure 8 - 1 HOME Procedure Screen Page 113 Dukane Manual Part No. 403-619-00...
Page 120: Selecting A Setup File
Linear Vibration Welder 6000 Series User’s Manual Selecting a Setup File Load an Existing File Instructions for loading an existing setup file are given in USER OPTIONS MODE Section 6 – Touch Screen - > Load Setup These steps review that information.
Page 121: 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 115 Dukane Manual Part No. 403-619-00...
Page 122: Stopping The Weld Cycle
Linear Vibration Welder 6000 Series User’s Manual Stopping the Weld Cycle E–STOP Buttons To stop a weld cycle, press one of the two buttons. E-STOP The welder stops immediately and the servo table stops. The IN CYCLE ALARM green light will go out, and the red lamp will flash.
Page 123: Section 9 - Optimizing Performance
Hold Force ........120 Page 117 Dukane Manual Part No. 403-619-00...
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Page 125 Figure 9-3. Do not confuse weld distance which is the collapse distance with weld penetration which is how Time deep the melt flow penetrates. Figure 9 - 1 Relationship of Melt Penetration to Melt Temperature Through the Four Phases Page 119 Dukane Manual Part No. 403-619-00...
Page 126 Linear Vibration Welder 6000 Series User’s Manual Weld Amplitude Material – POM (Acetal, Delrin) Weld Distance = 1.0mm Amplitude has less effect upon the weld strength than weld time. Figure 9 -2 shows the relationship of weld strength for generic POM as a function of weld force for a fixed weld depth and two different amplitudes.
Page 127: Section 10 - Troubleshooting
Common FAQs ........127 Page 121 Dukane Manual Part No. 403-619-00...
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Page 129 The lithium material may be considered toxic, reactive or corrosive. The person disposing of the material is responsible for any hazard created in doing so. State and local regulations may exist regarding the disposal of these materials. Figure 10- 2 Page 123 Dukane Manual Part No. 403-619-00...
Page 130 Linear Vibration Welder 6000 Series User’s Manual Figure 10- 3 Interior of Electrical Cabinet with Major Components Identified Page 124 Dukane Manual Part No. 403-619-00...
Page 131 Table 6- I ALARMS messages relating to a drive overload are: 1. CHECK FREQUENCY INVERTER 2. FREQUENCY ERROR 3. CURRENT OVERLOAD 4. VOLTAGE OVERLOAD Figure 10- 5 480 VAC Fuse Block and Removal Tabs Continued Page 125 Dukane Manual Part No. 403-619-00...
Page 132 Increase the value that corresponds to the error message. We strongly recommend that you consult Dukane prior to changing these values. Page 126 Dukane Manual Part No. 403-619-00...
Page 133 LPS–3 corrosion inhibitor or contact Dukane. sound level than we tested the machine for in our factory. If you buy a Dukane machine with tooling, we 8. Q: The machine has two cycle activation switches, so always check the total noise of the machine and tooling why do I only have to activate one to start a cycle? together.
Page 134 If the strange sound A: There is either a serious problem with the machine, persists, call Dukane and ask us to listen to it over the or there is some decoupling occurring between the telephone.
Page 135: Section 11 - Maintenance
Grease Fittings .........134 Page 129 Dukane Manual Part No. 403-619-00...
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Page 137: Touch Screen Display
A drain hose is attached to the ply, and disconnect the air bottom of the filter housing which exits at the bottom of line from the filter inlet. the machine. Continued Page 131 Dukane Manual Part No. 403-619-00...
Page 138: Mechanical System
Linear Vibration Welder 6000 Series User’s Manual Continued from Previous Page Mechanical System Keep this in mind as moisture draining to the floor could cause a problem. The total drain line length should be less then 16.5 ft (5 m). The internal float will open under Grease Fittings pressure above 22 psi (0.15 MPa) when approximately...
Page 139: Tooling Care
User Options>Utilities>Calibrate correctly. For important information on proper bolt Position Transducer screen (Figure 6-36, Page 79). torquing, see "TOOLING BOLT LENGTH" on page 101. Figure 11–4 Table Vertical Position Encoder Page 133 Dukane Manual Part No. 403-619-00...
Page 140: Grease Fittings
Linear Vibration Welder 6000 Series User’s Manual Grease Fittings Recommended grease guns from HIWIN: Article number: 5-12-0009 After every 108,000,000 mm (about 100,000 cycles) of Designation: GN-080M travel the ball screws must be re-lubricated! Grease gun for 70g bellows cartridge The machine logs the travel of the table and warns the operator to re-lubricate the ball screws when necessary.
Page 141: Section 12 - Contacting Dukane
Section 12 - Contacting Dukane SECTION 12 Contacting Dukane Page 135 Dukane Manual Part No. 403-619-00...
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Page 143 Section 12 - Contacting Dukane Contacting Dukane Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • Model number, line voltage and serial number. • Alarm messages from the touch screen display. • Problem description and steps taken to resolve it.
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Page 145: Section 13 - Specifications
Space Requirements Drawings ..... . 146 Regulatory Agency Compliance ..... . 150 Page 139 Dukane Manual Part No. 403-619-00...
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Page 147: Tooling Specifications
Table 13 - I also gives the lift table size, weight and lift force for each model. The lift table dimensions are effectively the largest rectangular tooling that can normally be accommodated. Page 141 Dukane Manual Part No. 403-619-00...
Page 148: Tooling Weights And Dimensions
Linear Vibration Welder 6000 Series User’s Manual Tooling Weights and Dimensions Table 13 - I Upper and Lower Tooling Weight and Dimensions Page 142 Dukane Manual Part No. 403-619-00...
Page 149: Approximate Shipping Weights
** Add for adjustable leveling feet height - between 1 - 3 in (25 - 76 mm) Table 13 - III Welder Dimensions - in (mm) NOTE See Space Requirements Drawings starting on Page 146. Page 143 Dukane Manual Part No. 403-619-00...
Page 150: Operating Environment
Linear Vibration Welder 6000 Series User’s Manual Operating Environment Operate the vibration welder within these guidelines: Temperature: 40°F to 95°F (+5°C to +35°C) Air Particulates: Keep the equipment dry. Minimize exposure to moisture, dust, dirt, smoke and mold. Humidity: 5% to 95% Non–condensing @ +5°C to +30°C...
Page 151: Power Requirements
(See Figure 3 - 2, Page 17). 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 145 Dukane Manual Part No. 403-619-00...
Page 152: Space Requirements Drawings
Linear Vibration Welder 6000 Series User’s Manual Space Requirements Drawings MODEL 6300 FLOOR SPACE REQUIREMENTS 49.0 [1246] R19.4 [R494] DOOR SWING AIR DROP 75 PSI MIN, 2 SCFM 68.8 [1748] ACCESS HATCH 49.0 R19.4 [1245] [R492] HMI SWING RECOMMENDED MINIMUM CLEAR AREA FOR TOOL CHANGE (31"...
Page 153 53.3 ACCESS HATCH [1355] DOOR SWING R19.3 [R490] HMI SWING 19.2 [488] RECOMMENDED MINIMUM CLEAR AREA FOR TOOL CHANGE (51.5" W X 36" D) Figure 13–4 Model 6700 & 6700-LPT Floor Space Requirements Page 147 Dukane Manual Part No. 403-619-00...
Page 154 Linear Vibration Welder 6000 Series User’s Manual MODEL 6900 & 6900-LPT FLOOR SPACE REQUIREMENTS 125.5 [3187] 97.0 [2465] R38.8 [R985] DOOR SWING AIR DROP 75 PSI MIN, 2 SCFM 39.1 [994] R13.9 [R353] DOOR SWING 57.1 ACCESS HATCH ACCESS HATCH 62.0...
Page 155 ACCESS HATCH ACCESS HATCH 80.1 [2034] R19.6 [R497] DOOR SWING RECOMMENDED MINIMUM CLEAR AREA FOR TOOL CHANGE (53" W X 36" D) Figure 13 - 6 Model 6960 / 6960-LPT Floor Space Requirements Page 149 Dukane Manual Part No. 403-619-00...
Page 156: Regulatory Agency Compliance
Linear Vibration Welder 6000 Series User’s Manual Regulatory Agency Compliance UL & CSA The equipment complies with these standards: The equipment complies with the following Federal Communications Commission regulations. Underwriters Laboratories (UL): • The limits for FCC measurement procedure MP-5, UL61010-1 “Methods of Measurement of Radio Noise Emissions...
Page 157: Section 14 - Appendices
VW6960 ........158 Page 151 Dukane Manual Part No. 403-619-00...
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Page 159: Appendix A, Parts List
Power Feed, 24 JT-2200-551 BR-X20BM11 B & R Bus Module with Power Bus Connector JT-2200-552 BR-X20BM01 B & R Bus Module with Power Bus Separation Table 14-1: VW6300 Parts List (Continued on Next Page) Page 153 Dukane Manual Part No. 403-619-00...
Page 160: Vw6700
Linear Vibration Welder 6000 Series User’s Manual Keep in Dukane part Manufacturer part Manufacturer Item Quantity stock? number number Main Drive and Controls JT-2200-553 BR-X20TB12 B & R Standard Terminal Block (12 pt) JT-2200-553 BR-X20TB12 B & R Standard Terminal Block (12 pt)
Page 161 5PC9:436590.004-00 B & R 15" PPC100 Lighting JT-2200-13 F17T8-TL741 Various Fluorescent Lamp Lift Table JT-6700-319 EGR-30-R1320-C HIWIN Bearing Rail JT-6700-320 QEW-30-CC-ZA-C HIWIN Bearing Block Table 14-2: VW6700 Parts List (Continued on Next Page) Page 155 Dukane Manual Part No. 403-619-00...
Page 162: Vw6900
Linear Vibration Welder 6000 Series User’s Manual Keep Dukane part Manufacturer part Manufacturer Item Quantity number number stock? Pneumatic JT-2300-24 NZM103HT-K5LZ-E55CL SMC Vacuum Ejector JT-2300-51 NCDMC125-1600C Air Cylinder JT-2300-502 VQ4301-5 Air Valve Dbl Sol 24 V Closed Center (For Doors and Tooling)
Page 163 Air Valve Dbl Sol 24 V Closed Center (For Doors and Tooling) JT-2300-503 VQ4401-5 Air Valve Dbl Sol 24 V Open Center (Tooling) JT-2300-504 ARBQ4000-ND-P-1 Air Regulator VQ Interface Table 14-3: VW6900 Parts List Page 157 Dukane Manual Part No. 403-619-00...
Page 164: Vw6960
Linear Vibration Welder 6000 Series User’s Manual NOTE VW6960 Parts List These are the most commonly used parts. Consult your schematics for the exact parts list. Keep Dukane part Manufacturer part Manufacturer Item Quantity number number stock? Door Components JT-2200-88...
Page 165 ARBQ4000-ND-P-1 Interface Regulator Under Valve JT-2300-502 VQ4301-5 24 VDC, Double Sol Air Valve, Closed Center (For Door and Tooling) JT-2300-24 NZM103HT-K5LZ-E55CL SMC Vacuum Ejector JT-6960-307 NCGCA40-1850 Air Cylinder Table 14-4: VW6960 Parts List Page 159 Dukane Manual Part No. 403-619-00...
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Page 167: Index
Index Index Page 161 Dukane Manual Part No. 403-619-00...
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Page 169 Disengaging Switch Coupling 20 Drawings and Tables 3 Compressed Air 21 Dukane 135 Unpacking 17 Contacting 135 Welder Placement 17 Energy Sources 17 Floor Area 18 Forklift Channels 18 Electrical Cabinet Interior 124 E–STOP Buttons 28 Page 163 Dukane Manual Part No. 403-619-00...
Page 170 Linear Vibration Welder 6000 Series User’s Manual Password Configuration 49 Leveling 19 Password Required 49 Part Handling Considerations 17 Performance Ventilation 17 Hold Force 120 Weld Amplitude 120 Weld Distance 119 Light Curtain 30 Weld Force 120 Limit Indicators 57...
Page 171 Touch Screen Menus 44 Introduction 44 Primary Menu Buttons 46 Weld Amplitude 64 Run Mode 53 Weld by Distance 64 Counter Reset Buttons 56 Weld by Time 64 I/O Table 88 Weld Cycle 33 Operate 53 Page 165 Dukane Manual Part No. 403-619-00...
Page 172 Linear Vibration Welder 6000 Series User’s Manual Access Door Closes 35 Clamping Phase 36 Hold Phase 36 Initiate Weld Cycle 35 Parts Loaded 35 Parts Removed 37 Release Phase 37 Welding Phase 36 Welder Overview 4 Key Features 5 Welding Problems and Solutions 129...
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Page 174 Dukane can assure you that based on partnership for continuous improve- we have in place a well–defined and systematic ment. This concept is key in that Dukane no approach to quality design, manufacturing, longer focuses on inspection, but on individual delivery and service.
Page 175 Linear Vibration Welder 6000 Series User's Manua Part No. 403 – 6 19-00 Printed in the United States of America Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900...

This manual is also suitable for:

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Dukane 6000 Series User Manual

Linear Vibration Welder

Section 3 Installation

Section 4

Section 5

Section 6

Section 7 Tooling Installation

Section 8

Section 11

Section 13 Specifications

Section 14 Appendices

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