Dukane DPC II Plus User Manual
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Dukane DPC II Plus User Manual

Dukane DPC II Plus User Manual

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User's Manual
Dukane Part No. 403–566-01
Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL +1–630–797–4900 • FAX +1–630–797–4949
Dukane products are manufactured
ISO 9001:2000
www.dukcorp.com/us
in ISO registered facilities

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  • Page 1 User’s Manual Dukane Part No. 403–566-01 Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL +1–630–797–4900 • FAX +1–630–797–4949 Dukane products are manufactured ISO 9001:2000 www.dukcorp.com/us in ISO registered facilities...
  • Page 2 Printed in the United States of America. PRINTED ON RECYCLED PAPER Dukane Part Number: 403–566–01 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 EZ Welder™...
  • Page 3 Added note that photo on page 49 does not apply to EZ system. Added note to Figure 7–30 that P2 branch is for DPC II Plus systems only. EZ Series are single pressure. Updated Dukane’s telephone numbers on pages 143–144. Added Table 15—II for EZ Generator Part Number. –01 Modify Table 5—V on page 48 (Pin 9 is +22V DC)
  • Page 4 DPC II Plus and EZ Welder System – User’s Manual This page intentionally left blank Dukane Manual Part No. 403-556-01...

  • Page 5: Table Of Contents

    Hand Probe System ..................20 Automated Probe System ................20 Multiple Probe System ................22 Automated Thruster System ............... 23 Dukane Press System ................... 24 Emergency Stop Switch Interface ............... 25 Rear Electrical Power Switch ............... 25 Section 4 – Controls & Displays..........27 Front Panel Layout ................
  • Page 6 Timed Auto Probe – Weld Method ............. 73 HoldTime ...................... 73 Afterburst ..................... 73 Press Mode ................... 75 Initiate Mode ....................76 Auto Stop ..................... 76 Head Up On Auto Stop ................76 Trigger Type....................76 Single/Dual Pressure Mode ................. 76 Dukane Manual Part No. 403-556-01...
  • Page 7 Mounting Stud to Horn/Booster ............... 108 Horn to Booster ..................109 Booster to Probe ..................109 Horn to Probe .................... 109 Torque Unit Conversion Chart ............110 Stack Disassembly ................111 Booster Notes ..................114 Stack Mounting .................. 115 Dukane Manual Part No. 403-566-01...
  • Page 8 Even Contact ....................136 Uneven Contact ..................136 Crowning ....................137 Center Depression..................137 Corrosion ....................137 Probe Reconditioning ................ 138 Overview ....................138 Machining the Mating Surfaces ..............138 Manual Resurfacing ................... 138 viii Dukane Manual Part No. 403-556-01...
  • Page 9 Table of Contents Section 14 – Contacting Dukane ......... 141 Ultrasonics Division Main Office ............143 Email Addresses .................. 144 Telephone Extensions ................ 144 Section 15 – Specifications ........... 145 Regulatory Compliance..............147 Federal Communications Commission ............147 CE Marking (Conformité Europeéne) ............147 Dimensions ..................
  • Page 10 DPC II Plus and EZ Welder System – User’s Manual This page intentionally left blank Dukane Manual Part No. 403-556-01...

  • Page 11: Section 1 - Introduction

    Drawings Labels ............. 3 Manual Organization ........4 DPC–II Plus Overview ........6 EZ Welder™ Overview ........6 Key DPC–II Plus Features ......... 7 Key EZ Welder™ Features ....... 8 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 13: Before Operating

    (e.g. –I, –II, –III). As an ex- ample, Figure 3–2 would be the second illustra- tion in section three while Table 3—II would be Condition Hand Electrical or Practice Hazard Hazard the second table in section three. Dukane Manual Part No. 403–566–01...

  • Page 14: Manual Organization

    II Plus and EZ Welder System – User’s Manual ™ Manual Organization Section 1 – Introduction describes the manual organization and the key features of the Dukane DPC ) II Plus Generator. namic Process Controller Section 2 – Safety discusses OSHA regulations and safety considerations.
  • Page 15 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.

  • Page 16: Dpc-Ii Plus Overview

    II Plus and EZ Welder System – 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.

  • Page 17: Key Dpc-Ii Plus Features

    Fan runs only when required to minimize dust buildup. • Pulse Width Modulation is Dukane’s patented circuitry that allows the DPC power supply to eff iciently control the voltage sent to the transducer in the acoustic stack.

  • Page 18: Key Ez Welder Features

    Europe. • ISO 9001 Certification means that the DPC II Plus and EZ are manufactured to very high quality standards and assures you of Dukane’s commitment to being a quality vendor and its goal of continuous improvement. ™...

  • Page 19: Section 2 - Safety Tips

    ECTION Safety Tips • Health & Safety • RFI Considerations Health & Safety Tips........11 Plastics Health Notice ........... 12 Electrical Grounding Safety ........12 RFI Considerations ........13 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 21: Health & Safety Tips

    Keep the Cover On – Do not remove the equip- Parts being joined ultra- ment cover unless specifically directed to do so by sonically sometimes Dukane Corporation. The generator produces haz- vibrate at audible fre- ardous electrical voltages which could cause in- quencies. Wear ear jury.

  • Page 22: Plastics Health Notice

    Electrical Safety Grounding type. Have a qualified electrician replace it fol- Instructions lowing the National Elec- For safety, the power cords used on all Dukane tric Code and any local products have a three-prong, grounding-type plug. codes and ordinances that apply.

  • Page 23: Rfi Considerations

    Grounding Contacts (refer to Figure 2-3.) However, if your applica- tion requires another type of cable, check with the local Dukane products representative, and fol- low local regulations concerning proper wiring and grounding. Typical Outlet...
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  • Page 25: Section 3 - Unpacking & Installation

    Connect the Cables ........20 Hand Probe System ..........20 Automated Probe System ........20 Multiple Probe System .......... 22 Automated Thruster System ......... 23 Dukane Press System ..........24 Rear Electrical Power Switch ......... 25 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 27: Shipping Carton Contents

    Table 3–I. In- CAUTION spect the DPC for damage. Report any damage Allow space for air venti- immediately to Dukane Ultrasonics Support/Ser- lation around the DPC II vice. Plus chassis, the air intake and exhaust.

  • Page 28: Rack Mounting

    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 US-1155.) The DPC illustrated has the standard, angled front panel of impact- resistant ABS plastic.

  • Page 29: Rear Panel Overview

    (Figures 3–4 thru equipment must also be solidly grounded. Refer 3–8) for the correct to Figure 2–5 and Figures 3–4 through 3–8 for grounding connections. the proper grounding arrangement. Dukane Manual Part No. 403–566–01...

  • Page 30: Connect The Cables

    Code and local codes and ordinances. from the user–supplied automation DO NOT cut off the AC power cord equipment to the System Input rear grounding prong or alter the plug in panel HD-15 connector (Figure 3–5). any way. Dukane Manual Part No. 403–566–01...

  • Page 31: Figure 3-4 Dpc Ii Plus And Ez Hand Probe Cabling Connections

    Coaxial Cable Wire RG62B/U Automation Control P/N 200–1203 Automation Equipment Status 110 VAC or Output 220 VAC P/N 200–1302 #14 Gauge Wire Earth Ground Figure 3-5 DPC II Plus and EZ Welder Automated Probe Cable Connections Dukane Manual Part No. 403–566–01...

  • Page 32: Multiple Probe System

    RG62B/U Coax Coaxial Cable(s) RG62B/U Automation Control P/N 200–1203 Automation Equipment Status Output 110 VAC or P/N 200–1302 220 VAC #14 Gauge Wire Earth Ground Figure 3-6 DPC II Plus Multiple Probe Conntroller Cable Connections Dukane Manual Part No. 403–566–01...

  • Page 33: Automated Thruster System

    Part No. 200–1124 110 VAC or — or — 220 VAC Jumper Block Part No. 200–1293 Pins 3 & 9 to J902 Connected #14 Gauge Wire Earth Ground Figure 3-7 DPC II Plus Automated Thruster Cable Connections Dukane Manual Part No. 403–566–01...

  • Page 34: Dukane Press System

    Operational Control Part No. 200–1104 #14 Gauge Wire 110 VAC or 220 VAC 8–conductor cable Part No. 200–1124 #14 Gauge Wire Grounding Lug Earth Ground Figure 3-8 DPC II Plus and EZ Welder Press Cable Connections Dukane Manual Part No. 403–566–01...

  • Page 35: Emergency Stop Switch Interface

    Note that the emergency stop inputs cannot just of the safety regulatory agencies governing the be tied together from multiple DPCs when used geographic location where the Dukane equipment will be operated. Emergency DPC II or...
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  • Page 37: Section 4 - Controls & Displays

    Generator Status Panel ......... 30 Generator Control Keys ........30 System Status Display ........... 31 System Power Output Display ....... 32 Process Control Panel........33 Menu Function Keys ..........33 Control Menu Display .......... 35 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 39: Front Panel Layout

    Figure 4–1A DPC II Plus Front Panel Layout EZ Series v1.50 GEN. WELD HOLD INFO PRESS SYSTEM MORE INFO: FAULT INPUT TEST OVERLOAD www.dukcorp.com/us/ MODE ON LINE OVERTEMP OFF LINE AMP. ENTER CANCEL ADJUST Figure 4–1B DPC EZ Front Panel Layout Dukane Manual Part No. 403–566–01...

  • Page 40: Ac Power

    Emergency Stop is not standby mode. This prevents the gen- engaged. If the Emergency Stop switch is erator from producing an ultrasonic depressed, the System Status Display will output signal. not be lit and the Control Keys inactive. Dukane Manual Part No. 403–566–01...

  • Page 41: System Status Display

    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 No. 403–566–01...

  • Page 42: System Power Output Display

    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 0.80 = 1760 Watts) Dukane Manual Part No. 403–566–01...

  • Page 43: Process Control

    The and WELD P2), data can only be entered or selection wraps around to the right modified after the programming setup is digit after the left most digit posi- completed. tion is reached. Dukane Manual Part No. 403–566–01...
  • Page 44 ENTER plays the next decision or naviga- tion menu. Pressing the CANCEL key discards any values you may have changed CANCEL and returns you to the previous de- cision or navigation menu. Dukane Manual Part No. 403–566–01...

  • Page 45: Menu Display

    A confirmation menu requests a Yes or No entry to continue the process. Select from the menu and press the ENTER key to proceed. A typical con- formation menu is shown in Figure 4–10. RESET PART COUNT Figure 4–10 Typical Confirmation Screen Dukane Manual Part No. 403–566–01...
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  • Page 47: Section 5 - Rear Connectors

    Automation Cycle Stop or End Of Weld ....51 Switch Debounce Filter Time Delay .......51 Timer Board Enable/Bypass ........51 System Control Inputs ..........52 Card Slot and Jumper Block Locations ....52 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 49: Rear Panel Layout

    Abort Control Power Switch Multi–Probe System Master U/S Thruster Input AC Power Input Operational Input (DPC II Plus only) System Ultrasound Control Output Output Figure 5–1 DPC II Plus and EZ Welder Rear Panel Connectors Dukane Manual Part No. 403–566–01...

  • Page 50: System Input Connector

    DO NOT of custom automation will also find a list of wire connect any video monitor devices color codes for the Dukane 200–1203 I/O cable to this connector. Doing so may re- assembly in Table 5—III. This cable is used to...

  • Page 51: Table 5-Ii

    (pins 2 or 7) will lock out the front panel TEST tory default setting is a non-isolated sink requir- key and prevent it from being activated. This also ing a dry contact closure to ground (pins 2 or 7). prevents any programming changes. Dukane Manual Part No. 403–566–01...

  • Page 52: System Output Connector

    25 Female type. Pin numbers are shown in Fig- ure 5–4 and pin assignments are given in Table 5—IV. Dukane cable assembly P/N 200–1302 13 12 11 10 9 8 7 6 5 4 3 2 1 is used to connect the DPC to custom automa- tion equipment to monitor the welding process.
  • Page 53 OVERLOAD. The over- Custom automation users must supply their own load signal resets when the operate input deactivates pullups. See Appendix C for sample circuits. or the TEST switch is released. Dukane Manual Part No. 403–566–01...
  • Page 54 4.095V (4,095 Watts). On the 50kHz and 70kHz models, the scale factor is 10mV = 1 Watt with a maximum scaled output of 409.5 Watts. Pin 17 (Pwr Reg Status) This option is not currently available. Dukane Manual Part No. 403–566–01...
  • Page 55 Requires a Multi–Probe Controller module. This output is active low while the ultrasonic output signal has been turned off during the HOLD time of Requires the standard DPC II Plus timer feature. the weld cycle. Dukane Manual Part No. 403–566–01...

  • Page 56: Remote Amplitude Control

    The front panel menu will accept the value, but the output amplitude will be determined by the 4–20mA Current Loop loop current. Connector Figure 5–5 Remote Amplitude Control Module Dukane Manual Part No. 403–566–01...

  • Page 57: Power Output Module Option

    (Phone Jack) Power Signal 4. Output Zero Output Module Adjustment Energy Module) P/N 438–826 2. Power Signal Output (Test Jacks) Ground (Pin 13) 3. Power Signal Output (Pin 16) Figure 5–7 Power Signal Output Module Dukane Manual Part No. 403–566–01...

  • Page 58: Press Control Module Option

    Press Control Module Part No. 110–3938 This optional module enables the DPC II Plus to control a Dukane Model 210, 220 or 410 press or custom automation. This module is also installed on a EZ Welder™ System. The module is DB–9...

  • Page 59: Table 5- Vi J901 Thruster Connector Pinout

    6, 8, 10, 12, 25, 27, 28, 29 Ground +22V Return Power and Signal Ground 30, 31, 32,34, 36 7, 9, 11, 18 Unused Unused Unused 21, 23, 33, 35 Table 5— J901 Thruster Connector Pinout Dukane Manual Part No. 403–566–01...

  • Page 60: Multi-Probe Module Options

    This is indicated as Cable 2 in Figure 3–6. the press module. MPC Slave Module P/N 110–3956 MPC Master Module P/N 110–3954 Ultrasound 8 Ultrasound Outputs Input from J1 (4 per Module) Figure 5–10 Master and Slave Multi–Probe Controller (MPC) modules Dukane Manual Part No. 403–566–01...

  • Page 61: Jumper Block Options

    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) Dukane Manual Part No. 403–566–01...

  • Page 62: Card Slot And Jumper Block Locations

    U727 NON-ISO SOURCE JU725 R778 P713 CR715 ISOLATED JU726 R744 R797 SH707 R776 R775 CR719 J701 CR717 U723 J702 R777 CR718 R795 SYSTEM OUT SYSTEM IN Figure 5–11 Card Slot, Connector and Jumper Block Locations Dukane Manual Part No. 403–566–01...

  • Page 63: Jumper Block Details

    NORMALLY ON JU702 REMOTE R712 CONTROL BOARD R716 R711 R710 R715 VR705 R707 J710 POWER SIGNAL OUTPUT BOARD R771 C722 C723 Figure 5–12 Jumper Block Detail R772 NON-ISO SINK JU724 NON-ISO SOURCE JU725 JU726 ISOLATED SH707 Dukane Manual Part No. 403–566–01...
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  • Page 65: Section 6 - Menu Structure

    ECTION Menu Structure • Process Setup • Process Control • Process Limits • Utilities Process Setup ..........57 Process Control ..........58 Process Limits ..........60 Utilities ............61 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 67: Process Setup

    This is shown in Figure 6–2. Operate mode to the Setup mode and display the Process Setup menu shown below in Figure 6–4. Figure 6–2 DPC II Plus Configuration Menu Figure 6–4 DPC II Plus Process Setup Menu Dukane Manual Part No. 403–566–01...

  • Page 68: Process Control

    Control is discussed in detail in Section 7. Process Control Menu By pressing the up–arrow and down–arrow keys you can navigate the triangle pointer to select the Dukane Manual Part No. 403–566–01...

  • Page 69: Figure 6-6 Process Control Menu Flowchart

    WELD METHOD WELD METHOD WELD METHOD able on GND. GND. EZ Series TIME ENERGY TIME ENERGY TIME ENERGY DETECT DETECT PRESSURE 2 TIME ENERGY RTW = READY TO WELD Figure 6–6 Process Control Menu Flowchart Dukane Manual Part No. 403–566–01...

  • Page 70: Process Limits

    WELD WELD WELD WELD TIME P1 TIME P2 ENERGY P1 ENERGY P2 TOTAL TOTAL WELD TIME WELD ENERGY Total Limits Available Only with Press Controller in Dual Pressure Mode Figure 6–7 Limit Definition Menu Flowchart Dukane Manual Part No. 403–566–01...

  • Page 71: Utilities

    COPY ERASE SETUP SETUP SETUPS STATUS PART OUTPUTS COUNT SETUP ERASE RESET COUNT PRESET MAINTAINED PULSED TYPE SETUPS PART PART COUNT PARTS COUNT LOCAL REMOTE ERASE ERASE CURRENT SETUP SETUPS Figure 6–8 Utilities Menu Flowchart Dukane Manual Part No. 403–566–01...
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  • Page 73: Section 7 - Process Setup Menu

    Initiate Mode ............76 Auto Stop ............76 Head Up On Auto Stop ........76 Trigger Type............76 Single/Dual Pressure Mode ........76 Press Mode Example ........77 Hot Keys ............81 Process Control Recap........82 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 75: Hand Probe

    Figure 7–4. Figure 7–1 DPC II Plus Startup Menu Figure 7–3 DPC II Plus Time Weld Cycle Display DPC II Plus Configuration Menu DPC II Plus Energy Weld Cycle Display Figure 7–2 Figure 7–4 Dukane Manual Part No. 403–566–01...

  • Page 76: Untimed Hand Probe

    In Timed Hand Probe mode, the welding stops when- ever the trigger is released or the specified weld time Figure 7–7 Hand Probe Flow Chart Dukane Manual Part No. 403–566–01...

  • Page 77: Timed Hand Probe - Energy

    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). Figure 7–11 Hand Probe Max Weld Time Dukane Manual Part No. 403–566–01...

  • Page 78: Mpc Probe

    The values listed represent the resolution and are the smallest values that will produce any output signal. still be executed regardless of the Auto Stop mode. Multi–Probe Controller Flow Chart Figure 7–12 * AUTO refers to Automation not automatic Dukane Manual Part No. 403–566–01...

  • Page 79: Weld Method - Time

    DPC II Plus is logically capable of being triggered to generate an ultrasonic output. This is indicated on the display screen by the presence of the Figure 7–16 MPC Probe Weld Time menu shown in Figure 7–5. Dukane Manual Part No. 403–566–01...

  • Page 80: Weld Method - Energy

    Insulating Sheet erate input is triggered Fixture and terminated when the horn touches the Ground Detect Base metal fixture during Wire the welding cycle. For the ground detect fea- Ground Detect Fixture Isolation Figure 7–19 Dukane Manual Part No. 403–566–01...

  • Page 81: Auto Probe

    7–11 and 7–18. Set the maximum weld time will require an external signal(s) from custom to a value greater than the time required to com- automation equipment for correct operation. plete the welding cycle including the scrub time. Dukane Manual Part No. 403–566–01...

  • Page 82: Auto Stop Option

    If Auto Stop is set to disable, output. The values listed represent the resolution and are the smallest values that will produce any output signal. then a signal on pin 9 will be ignored. Auto Probe Setup Flow Chart Figure 7–21 Dukane Manual Part No. 403–566–01...

  • Page 83: Untimed Auto Probe - Delay

    Setup menu (Figure 7–29). to Process Control but with Hold Time automati- cally selected. This is shown below in Figure 7–23. Figure 7–26 Auto Probe Afterburst Enable Menu Figure 7–23 Auto Probe Process Control Hold Time Menu Dukane Manual Part No. 403–566–01...

  • Page 84: Figure 7-27 Auto Probe Afterburst Delay 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. Process Setup Menu Figure 7–29 Dukane Manual Part No. 403–566–01...

  • Page 85: Press Mode

    PRESS Mode TRIGGER METHOD The cable connection diagram for connecting a PRESS DPC II Plus to a Dukane press is shown in Sec- TIMED AUTO PROBE tion 3 in Figures 3–8. The flow chart for the Pro- UNTIMED AUTO PROBE cess Control menu is shown in Figure 7–30.

  • Page 86: Initiate Mode

    Energy target values to be used at both pres- Note that this option and Auto Stop are only avail- sure trigger points. The modes can be mixed us- able when the Initiate Mode has been set to Auto. Dukane Manual Part No. 403–566–01...

  • Page 87: Press Mode Example

    Operate screen to the If it isn’t, use the increment key (up arrow) to po- Process Setup menu as shown in Figure 7–33. sition the cursor and then press ENTER Dukane Manual Part No. 403–566–01...

  • Page 88: Figure 7-35 Press Initiate Mode 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 Pressure One Weld Time Data Entry Figure 7–40 Dukane Manual Part No. 403–566–01...

  • Page 89: Figure 7-41 Pressure Two Weld Method Selection Menu

    This value sets the time limit to reach the P2 weld menu as shown in Figure 7–45. energy. This time limit applies only to the P2 cycle. Pressure Two Max Weld Time Data Entry Figure 7–43 Figure 7–45 Second Pass Through Process Control Menu Dukane Manual Part No. 403–566–01...

  • Page 90: Figure 7-46 Press Hold Time Data Entry

    Figure 7–51. To select an afterburst, move the cur- sor down to as shown in Figure 7–48 Return To Process Control Menu Figure 7–51 and press the key. ENTER Figure 7–48 Press Afterburst Enable Menu Dukane Manual Part No. 403–566–01...

  • Page 91: Hot Keys

    . 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. Figure 7–56 Modified Hold Time Dukane Manual Part No. 403–566–01...

  • Page 92: Process Control Recap

    Figure number refer- 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. Dukane Manual Part No. 403–566–01...

  • Page 93: Figure 7-58 Process Control Menu Flowchart

    Probe Trigger 7–27 Switch 7–42 7–18 7–10 7–16 7–17 7–16 7–17 7–18 7–18 7–20 7–44 7–28 7–43 7–18 7–20 7–11 7–18 7–20 7–9 7–52 RTW = READY TO WELD Process Control Menu Flowchart Figure 7–58 Dukane Manual Part No. 403–566–01...

  • Page 94: Table 7-I Process Control Menu Listing

    Press Trigger Method Only Single or Dual Pressure 7–38 Press Trigger Method Only Time or Energy 7–39 Dual Pressure Mode Only Time or Energy 7–41 Dual Pressure Mode Only Table 7— Process Control Menu Listing Dukane Manual Part No. 403–566–01...

  • Page 95: Table 7-Ii Parameter Min-Max Values

    ) of 1200.0 Joules. The weld 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 No. 403–566–01...
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  • Page 97: Section 8- Process Limits Menu

    • Process Limits Process Limits Menu........89 Limit Definition ..........90 Suspect and Bad Limits ......... 90 Process Limits ..........90 Single Pressure Mode ........... 91 Dual Pressure Mode ..........92 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 99: Process Limits Menu

    P1 T(E) P1 Lower T ) Limit NERGY A Bad Parts Counter is also available in the Utili- Recognized Limits in a Single–Pressure ties menu which is covered in the next section. Table 8— Welding Cycle Dukane Manual Part No. 403–566–01...

  • Page 100: Limit Definition

    A bad limit and suspect limit value share the same memory location. To change a Suspect Limit value to a Bad Limit value, move the cursor to Single–Pressure Process Limits Menu Figure 8–3 Dukane Manual Part No. 403–566–01...

  • Page 101: Single Pressure Mode

    Time or En- ergy in the Process Limits menu (Figure 8–3). Pressing the ENTER key displays the limit param- Dual–Pressure Process Limits Menu Figure 8–5 eter selection which is shown in Figure 8–6. Dukane Manual Part No. 403–566–01...

  • Page 102: Dual Pressure Mode

    Time or Energy with the cursor. Pressing are labeled to avoid confusion, but the time loops ENTER key displays the limit parameter selec- have the same return sequence. tion which is shown in Figure 8–8. Dukane Manual Part No. 403–566–01...

  • Page 103: Figure 8-10 Cancel Key Return Path Flow Chart

    TIME P2 ENERGY P1 ENERGY P2 CANCEL TOTAL CANCEL WELD ENERGY TOTAL WELD TIME ENTER ENTER ENTER ENTER CANCEL ENTER ENTER ENTER ENTER CANCEL ENTER ENTER ENTER ENTER CANCEL Key Return Path Flow Chart Figure 8–10 Dukane Manual Part No. 403–566–01...
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  • Page 105: Section 9 - Utilities Menu

    Copy A Setup ............99 Erase Setups ............99 Part Count ..........100 Reset Part Count ..........100 Count Suspect/Bad Parts ........100 Preset Part Count ..........101 Status Outputs..........101 Cycle Press Off Line........101 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 107: Setup Utilities

    ENTER ENTER Count? Off Line? OK to ENTER Erase Setups? OK to Erase Count Setups? ENTER ENTER ENTER Parts? ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER ENTER Utilities Menu Flow Chart Figure 9–1 Dukane Manual Part No. 403–566–01...

  • Page 108: Select Setup

    Pressing the ENTER key displays a decision menu mined by the Setup ID defined in Table 5—II. from which you can enable either a local or re- mote setup control. This is shown in Figure 9–5. Dukane Manual Part No. 403–566–01...

  • Page 109: Copy A Setup

    To proceed, move the cursor down to and press key. The file is copied and the display ENTER returns to the Setup Utilities selection menu shown in Figure 9–4. Figure 9–13 Erase Setup In Process Dukane Manual Part No. 403–566–01...

  • Page 110: Part Count

    Part Count Selection Menu Figure 9–16 part count selection screen shown in Figure 9–16. The count replaces the - - - in the upper left of the operate screen (see Figures 7–3. 7–4, 7–31 and 7–53). Dukane Manual Part No. 403–566–01...

  • Page 111: Preset Part Count

    9–20. To change the mode, move the cursor to (pin 8 of J902) will not cycle the press with this PULSED and press ENTER menu option with the DPC set to OFF LINE Status Output Mode Selection Figure 9–20 Dukane Manual Part No. 403–566–01...
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  • Page 113: Section 11 - Probes/Probe Stacks

    Horn to Booster ..........109 Booster to Probe ..........109 Horn to Probe ............ 109 Torque Unit Conversion Chart ..... 110 Stack Disassembly ........111 Booster Notes..........114 Stack Mounting .......... 115 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 115: The Ultrasonic Probe

    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. Hand Probe, Horn and Tip Figure 10–1 Dukane Manual Part No. 403–566–01...

  • Page 116: Ultrasonic Horn

    Figure 10–2. This is commonly referred to as a stack. As indicated, the components are secured with threaded studs. Probe, Booster and Horn Figure 10–2 Dukane Manual Part No. 403–566–01...

  • Page 117: Stack Assembly

    (on horns with wrench flats) to keep the horn from turning in your hand. A canvas NOTE strap wrench is permissible if it does not gouge Dukane Part No for the 20kHz spanner or scratch the horn. wrenches is 721–68 •...

  • Page 118: Mounting Stud To Horn/Booster

    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 of a booster. Dukane Manual Part No. 403–566–01...

  • Page 119: Horn To Booster

    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- Stack Assembly Procedure Figure 10–4 Dukane Manual Part No. 403–566–01...

  • Page 120: Torque Unit Conversion Chart

    Horn/Booster Torque Unit Table 10— assembly. Conversions 20kHz Stack x 20 Stud 40kHz Stack x 24 Stud 8mm Stud in-lbs ft-lbs Torque Value Conversion Graph Figure 10–5 Dukane Manual Part No. 403–566–01...

  • Page 121: Stack Disassembly

    HOUSING HAND Output End PROBE HOUSING HAND PROBE ASSEMBLY Spanner Mounting Stud Wrench (Insert Into Horn Holes First and Tighten to Torque Specs) Input End HORN HORN ISASSEMBLY Figure 10–6 Hand Probe Assembly and Disassembly Dukane Manual Part No. 403–566–01...

  • Page 122: Figure 10-7 Probe Stack With Booster Assembly And Disassembly

    Than Input End) (Cap Screws Face Toward Input) Mounting Stud (Insert Into Horn Spanner First and Tighten Wrench to Torque Specs) Hole Input End Output End HORN ISASSEMBLY Figure 10–7 Probe Stack with Booster Assembly and Disassembly Dukane Manual Part No. 403–566–01...

  • Page 123: Figure 10-8 Separating The Horn From The Booster

    Dukane has a stainless steel tool vise (Part No.UFTV20) for clamping 20kHz boosters Loosen and transducers to facilitate disassembly of...

  • Page 124: Booster Notes

    1.0 stamped on it. A neutral or cou- sults and may cause pling booster is used to provide another probe stack damage to the system. clamping location for added stability. Dukane Manual Part No. 403–566–01...

  • Page 125: Stack Mounting

    10–6 and 10–7 to identify these parts). Always clamping the probe in one place and the use the proper spanner wrenches when tight- booster in one place. ening or loosening the horn or booster. Never clamp the horn. Dukane Manual Part No. 403–566–01...
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  • Page 127: Section 11 - Dpc Checkout

    Startup and Self–Test ........119 System Test ..........120 System Operation ........121 Stopping the Weld Cycle......121 Manual Systems ..........121 Automated System ..........121 End of Day ............121 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 129: Startup And Self-Test

    ON LINE generator control key on 3. In place of a press cable, a jumper block the front panel (labeled E in Figure 11–1.) The (Dukane P/N 200–1293) can be green ON LINE indicator in the Status Display installed on J902 (see Figure 3–4).

  • Page 130: System Test

    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. Dukane Manual Part No. 403–566–01...

  • Page 131: Probe Operation

    TEST LINE LINE Press System Push in the Emergency Stop button on the press base to stop the welding cycle. Stopping the Weld Cycle Figure 11–3 Dukane Manual Part No. 403–566–01...
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  • Page 133: Section 12 - Troubleshooting

    OVERTEMP Indicator ..........127 FAULT Indicator ............. 127 Generator Errors ..........128 INPUT TEST Indicator ..........128 TEST Control Key ..........128 Troubleshooting Flowchart ......129 Error Messages ..........131 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 135: No Ultrasonic Output

    Failure to turn off the AC try a different known good probe to determine if power may result in damage the problem is related to the generator or external to the generator or probe. cables and probe. Dukane Manual Part No. 403–566–01...

  • Page 136: Generator

    (JU724) is 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- 11 12 13 14 15 ger the generator. Dukane Manual Part No. 403–566–01...

  • Page 137: Generator Faults

    15—I for the AC voltage specifications. 2. Internal DC power supply problems (+5VDC, +12VDC, –12VDC or +24VDC). If the AC line voltage is within tolerance, then the DPC has an internal fault. Contact your local Dukane representative. Dukane Manual Part No. 403–566–01...

  • Page 138: Generator Errors

    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. Dukane Manual Part No. 403–566–01...

  • Page 139: Troubleshooting Flowchart

    Verify that the AC voltage is within specifications. indicator goes out Green 1. Defective power indicator lamp. AC power 2. Internal fault – contact Dukane Service. light on FAULT indicator Verify that the AC voltage is within specifications. (Continued on next page) Troubleshooting Flowchart –...
  • Page 140 1. If Press Module installed, check J902. ON LINE 2. Check Emergency Stop is not pushed in. key works 3. Internal fault – contact Dukane Service. OFF LINE 1. If Press Module installed, check J902. key works 2. Internal fault – contact Dukane Service.

  • Page 141: Error Messages

    The weld cycle is terminated. signal is active. The SYSTEM OFF LINE DPC generator must be in order ON LINE to produce an ultrasonic output signal. Dukane Manual Part No. 403–566–01...
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  • Page 143: Section 13 - Care & Maintenance

    Stack Inspection ..........136 Even Contact .............136 Uneven Contact ..........136 Crowning ............137 Center Depression ..........137 Corrosion ............137 Reconditioning ........... 138 Overview ............138 Machining the Mating Surfaces ......138 Manual Resurfacing ...........138 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 145: Front Panel

    4-40 threaded nuts to secure in Figure 13–1. the connectors. Do not overtighten them Intake Vent for Exhaust Air from Thermostatically Controlled Fan Flow–Thru Cooling Tunnel Location of DPC Air Cooling Vents Figure 13–1 Dukane Manual Part No. 403–566–01...

  • Page 146: Stack Surfaces

    To establish a maintenance schedule, inspect the are replaceable by the user. If a part needs replace- mating surfaces after the first 200–400 hours of ment, contact your local Dukane representative. operation. If they require cleaning, halve the next See Section 14 for contact information.

  • Page 147: Crowning

    Since its surface is 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 Dukane Manual Part No. 403–566–01...

  • Page 148: Probe Reconditioning

    See Section 14 for a list of Dukane contacts. Machining the Mating Surfaces Instructions on how to properly machine the stack components is beyond the scope of this manual.

  • Page 149: Figure 13-7 Manual Resurfacing

    Section 10 using Figures 10–6 horn/booster. If this should happen, retap the and 10–7 as guides. horn/booster threads and replace the stud with 13. Complete the Operational Test in Section 11. a new one. Dukane Manual Part No. 403–566–01...
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  • Page 151: Section 14 - Contacting Dukane

    Section 14 – Contacting Dukane ECTION Contacting Dukane • Corporate Office • Extensions & eMails Ultrasonics Division Main Office ....143 Email Addresses .......... 144 Telephone Extensions ........144 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 153: Ultrasonics Division Main Office

    Many problems can be solved over the telephone, so it is 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...

  • Page 154: Email Addresses

    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. Dukane Manual Part No. 403–566–01...

  • Page 155: Section 15 - Specifications

    Regulatory Compliance ....... 147 Federal Communications Commission ....147 CE Marking (Conformité Europeéne) ....147 Dimensions ..........148 Operating Enviornment....... 148 Power Requirements ........149 Interpreting The DPC Model Number ..150 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 157: Regulatory Compliance

    EN50082 using EN61000–4–2 EN61000–4–3 EN61000–4–4 EN61000–4–5 EN61000–4–6 EN61000–4–8 ENV50204 • The Low Voltage Directive 73/23/EEC. • The Machine Directive 89/392/EEC using EN60204–1:1993 Safety of Machinery – Electrical Equipment of Machines. Part 1: Specification for General Requirements. Dukane Manual Part No. 403–566–01...

  • Page 158: Dimensions

    Keep the DPC dry. @ 0 C to +30 C Vibration: 2.5 G Minimize exposure to moisture, dust, dirt,smoke and mold. Humidity: 5% to 95% Non–condensing @ 0 C to +30 C Vibration: 1.0 G Dukane Manual Part No. 403–566–01...

  • Page 159: Power Requirements

    190–260V 50/60 Hz @ 8 Amps 15 Amps 2000EZ 2000 190–260V 50/60 Hz @ 15 Amps 15 Amps 2000EZX 2000 190–260V 50/60 Hz @ 15 Amps 15 Amps DPC EZ Generator Model and Power Supply Requirements Table 15— Dukane Manual Part No. 403–566–01...

  • Page 160: Interpreting The Dpc Model Number

    Figure 15–2 Interpeting the DPC II Plus Model Number NOTE Figure 15-2 is designed to help you determine which options your DPC II Plus has. It is not meant to suggest that all combinations of these options are possible. Dukane Manual Part No. 403–566–01...

  • Page 161: Section 16 - Warranty

    Section 16 – Warranty ECTION Warranty • Domestic Warranty • International Warranty Domestic warranty ........153 International Warranty ........ 154 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 163: Domestic Warranty

    Section 16 – Warranty DUKANE CORPORATION NORTH AMERICAN WARRANTY POLICY WARRANTY EXCLUSIONS OR EXCEPTIONS • • Dukane Manual Part No. 403–566–01...

  • Page 164: International Warranty

    II Plus and EZ Welder System – User’s Manual ™ DUKANE CORPORATION INTERNATIONAL WARRANTY POLICY WARRANTY EXCLUSIONS OR EXCEPTIONS • • Dukane Manual Part No. 403–566–01...

  • Page 165: Appendix A - List Of Figures

    Press Connector Pin Identification ..........48 Figure 5–10 Master and Slave Multi–Probe Controller Modules ......50 Figure 5–11 Card Slot, Connector & Jumper Block Locations ......52 Figure 5–12 Jumper Block Details ..............53 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
  • Page 166 Single or Dual Pressure Selection Menu .......... 78 Figure 7–39 Pressure One Weld Method Selection Menu ........78 Figure 7–40 Pressure One Weld Time Data Entry ..........78 Figure 7–41 Pressure Two Weld Method Selection Menu ........79 Dukane Manual Part No. 403–566–01...
  • Page 167 Confirm Reset Part Count ............100 Figure 9–18 Confirm Counter Enabled ............100 Figure 9–19 Counter Preset Value ..............101 Figure 9–20 Status Output Mode Selection ............101 Figure 9–21 Cycle Press Selection Menu ............101 Dukane Manual Part No. 403–566–01...
  • Page 168 Manual Control Switch ..............163 Figure C–2 Automation Control Switches ............164 Figure C–3 Non–Isolated Current Sink Switch ..........165 Figure C–4 Non–Isolated Current Source Switch ..........166 Figure C–5 Isolated Current Source Circuit ............. 167 Dukane Manual Part No. 403–566–01...

  • Page 169: Appendix B - List Of Tables

    Table 10—II Horn/Booster Torque Unit Conversions ........... 110 Table 15—I DPC II Plus Generator Models and Power Supply requirements ..... 149 Table 15—II DPC EZ Generator Models and Power Supply requirements ....149 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 171: Appendix C - User Supplied Circuitry

    • Isolated Automation Control Manual Switch Circuit ......... 163 Automation Switch Circuits ......164 Non–Isolated Switch Circuits ....... 165 Current Sink ............165 Current Source ........... 166 Isolated Switch Circuit......... 167 Dukane Corporation • • Ultrasonics Division Dukane Manual Part No. 403–566–01...
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  • Page 173: Manual Switch Circuit

    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. 403–566–01...

  • Page 174: Automation Switch Circuits

    Connector DPC Isolated Input 2 (Figure C–3) or User Supplied DPC Power Source (Figure C-4) Opto-Coupler Automation Control Signal DPC Ground (Figure C–3) or DPC Isolated Input 1 (Figure C–4) Automation Control Switches Figure C–2 Dukane Manual Part No. 403–566–01...

  • Page 175: Isolated Automation Controls

    12.5 mA max. Supplied Switch Circuitry Low-Side Switch Sinks Current to Ground Optical Isolation Circuit Jumper Block SH707 Position JU724 (Refer to Figure 5–12) DPC Ground Pin #2 or #7 Current Sink Switch Figure C–3 Dukane Manual Part No. 403–566–01...

  • Page 176: Current Sink

    Limit Circuit Pin #9 – Auto Stop 12.5 mA max. Optical Isolation Circuit Jumper Block SH707 Position JU725 (Refer to Figure 5–12) DPC Ground No Connection Pin #2 & Pin #7 Current Source Switch Figure C–4 Dukane Manual Part No. 403–566–01...

  • Page 177: Current Source

    Optical Isolation Circuit Jumper Block SH707 Position JU726 (Refer to Figure 5–12) Isolated Input Low–Side Pin #4 – Iso Common DPC Ground No Connection Pin #2 & Pin #7 Automation Ground Isolated Current Source Figure C–5 Dukane Manual Part No. 403–566–01...
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  • Page 179: Index

    Benchtop Placement ..................17 Booster ......................106 Booster Gain ....................114 Booster Notes ....................114 Booster Output End Geometry ..............114 Cable Color Code ..................41 Cable Connections ............20–24, 40, 42, 47–49 Cable Part Numbers ................21–24 Dukane Manual Part No. 403–566–01...
  • Page 180 Display, Menu ..................29, 35 Display, Status ................. 31, 19–121 Dwell Time (In–Dwell) Status Output ............45 Dual Pressure Mode ..................76 Dukane Press System ..................24 Dukane Website ..................143 Email Addresses, Dukane ................144 Emergency Stop Switch ..............20, 25, 119 Energy, Welding By ..................
  • Page 181 Hold Time ..................73, 80, 85 Horn ......................106 Horn Assembly .................... 112 Horn Contact Surfaces ................136 Horn Corrosion .................... 137 Horn Disassembly ..................111 Horn Resurfacing ..................138 Hot Keys ....................34, 81 Dukane Manual Part No. 403–566–01...
  • Page 182 “ , Suspect ....................90 Load Regulation ....................8 Maintenance, Scheduled ..............111, 137 Master MPC Module ..................50 Mating Surfaces (Horn) ................136 Maximum Parameter Values ................ 85 Maximum Weld Energy ................72, 75 Dukane Manual Part No. 403–566–01...
  • Page 183 OVERTEMP Status Output ................43 Parameter Values, Min–Max ................ 85 Part Count, Count Sus/Bad Part ..............100 “ “ , Menu ..................100 “ “ , Preset ..................101 Part Count, Reset ..................100 Placement of DPC..................17 Dukane Manual Part No. 403–566–01...
  • Page 184 Process Setup Flowchart ................. 58, 74 Process Setup Menu ................57, 66, 77 Programming Port, Serial ................19 Pulse Width Modulation ................7 Rack Mounting DPC ..................18 Ready Status Output ..................45 Rear Panel Connectors ..............19, 39, 125 Dukane Manual Part No. 403–566–01...
  • Page 185 Switch Circuits, User Supplied ............161–166 System Cabling ................21–24, 119 “ Control Input Jumper ..............52 “ Input Connector ............19, 39, 40, 125 “ Input Signal Descriptions ..............41 “ Fault Status Output ................. 43 Dukane Manual Part No. 403–566–01...
  • Page 186 Power Output Display ..............32 “ Test ....................120 Theory of Operation ................... 105 Telephone Numbers, Dukane ..............144 Test, Self ....................... 119 Test, System ....................120 TEST Key ..................30, 120, 128 TEST, F P Lock ..................41, 120 Thruster Cable Connector ............
  • Page 187 WELD P1 Key ................... 33, 82 WELD P2 Key ................... 34, 82 Weld Time ..................67, 69, 78 Weld Time Min–Max Values ................. 85 Weld Time Limits ................... 89 Wrench, Horn & Booster ................107 Dukane Manual Part No. 403–566–01...
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  • Page 189 This and systematic approach to quality design, concept is key in that Dukane no longer focuses manufacturing, delivery and service. This cer- on inspection, but on individual processes.
  • Page 190 User's Manual – DPC II Plus and EZ Welder System Part No. 403–566–01 40356601 www.dukcorp.com/us $100.00 Printed in the United States of America Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL +1–630–797-4900 • F AX +1–630–797–4949...

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