Dukane VWA-4700 Manuals

Manuals and User Guides for Dukane VWA-4700. We have 1 Dukane VWA-4700 manual available for free PDF download: User Manual

Dukane VWA-4700 User Manual

Dukane VWA-4700 User Manual (180 pages)

Linear Vibration Welder 4000 Series

Brand: Dukane | Category: Welding System | Size: 27.05 MB

Table of Contents

Table of Contents

5
- Revision History
  3
- Dukane
  5
- Screen Layout
  6
- Section 1- Introduction
  
  7
  - General User Information
    9
  - Notes, Cautions and Warnings
    9
  - Read this Manual First
    9
  - Welder Overview
    10
  - Key Features
    11
  - Auto-Ping
    11
    
    Color Touch-Screen Display
    11
- Section 2 - Health and Safety
  
  13
  - Health and Safety
    13
  - General Considerations
    15
    
    Grounded Electrical Power
    15
    
    General Considerations
    16
  - Special Health Notice - Plastics
    17
  - Electrical Safety
    17
    
    AC Power Disconnect
    17
    
    AC Power Receptacle
    17
    
    Electrical Cabinet Door
    17
    
    Special Health Notice-Plastic
    17
  - Pneumatic Safety
    18
  - Operational Safety
    19
    
    Lockout Device
    19
  - Hydraulic Safety
    20
  - Hydraulic Drive
    20
Section 3

21
- Section 3 - Installation
  21
  - Installation
    21
  - Unpacking
    23
  - Welder Placement
    23
    
    Energy Sources
    23
    
    Part Handling Considerations
    23
    
    Cover Plates
    24
    
    Floor Area
    24
    
    Forklift Channels
    24
  - AC Power
    25
    
    AC Requirements
    25
    
    Disengaging Switch Coupling
    26
  - Compressed Air
    27
  - Hydraulic Drive
    28
    
    Lift/Clamp Force by Model
    28
    
    Adding Hydraulic Fluid
    29
Section 4

31
- Section 4 - Display and Controls
  31
  - Display and Controls
    31
  - Control Panel Layout
    33
  - Operational Switches
    35
    
    Opti-Touch Operate Switches
    35
  - Light Curtain
    36
  - AC Utility Outlet
    37
  - Vacuum On/Off Button
    37
Section 5

39
- Section 5 - Normal Weld Cycle
  39
  - Normal Weld Cycle
    39
  - Parts Loaded
    41
  - Initiate Weld Cycle
    41
  - Access Door Closes
    41
  - Setup File
    41
  - Clamping Phase
    42
  - Welding Phase
    42
  - Hold Phase
    42
  - Release Phase
    43
  - Parts Removed
    43
Section 6

45
- Section 6 - Touch Screen Menus
  45
  - Introduction
    47
    
    Screen Layout
    47
    
    Button Appearance
    48
    
    Other Visual Cues
    49
    
    Making Selections
    50
    
    Virtual Keyboard and Keypad
    51
    
    Header - Quick Look
    52
    
    Help
    53
    
    Tool Bar - Quick Look
    53
  - Run Mode
    53
  - Sliding Door
    53
    
    Choose a Language
    55
    
    Logging in and out
    56
    
    Options
    57
  - Operation
    59
    
    Operation Run Mode
    59
    
    Run Mode
    59
    
    Alarm Limits
    60
    
    Graph
    64
    
    Setup Mode
    65
  - Set Table Slowdown
    67
  - Trigger by Position
    68
    
    Hold Force
    69
    
    Weld Amplitude
    69
  - Table Load Position
    70
  - Upper and Lower Limits
    71
  - Autotune Mode
    72
  - Current Amplitude
    72
    
    PLC I/O Status
    75
    
    Tool ID Is off
    83
    
    Valve Calibration
    86
    
    Alarms
    89
  - Alarm History
    90
    
    Alarms Table
    91
  - Alarms
    91
    
    Auto-Tune Error
    91
    
    Check Frequency Inverter
    91
    
    Check Front Door
    91
    
    Current Overload
    91
    
    Cycle Aborted
    91
    
    E-Stop or Service Door Open
    92
    
    Front Door Not Closed
    92
    
    No Feedback Detected
    93
    
    No or Low Air Pressure
    93
    
    Process Limit
    94
    
    Sensor Valve 1A Extended
    94
    
    Sensor Valve 1B Retracted
    94
    
    Sensor Valve 2A Extended
    94
    
    Sensor Valve 2B Retracted
    94
    
    Sensor Valve 3A Extended
    94
    
    Sensor Valve 3B Retracted
    94
    
    Sensor Valve 4A Extended
    95
    
    Sensor Valve 4B Retracted
    95
    
    Trigger Time out
    96
    
    Voltage Overload
    96
    
    Weld Time Limit "Has Expired
    96
    
    Alarm Detected
    97
    
    Door out of Position
    97
    
    Hydraulics off
    97
    
    Invalid Tool ID
    97
    
    Light Curtain Is Obstructed
    97
    
    Machine Ready for Cycle
    97
    
    Machine Ready for Setup
    97
    
    Remove Welded Part
    97
    
    Table Not in Load Position
    97
    
    Touch Screen Banner
    97
Section 7

99
- Section 7 - Tooling Installation
  99
  - Initial Machine Startup
    101
  - Inspection
    101
  - Apply Power
    101
  - Hydraulic System
    101
  - Initiate HOME Procedure
    102
    
    Hydraulic Pump on
    102
  - Install Tooling Assembly
    103
  - Position Upper Tooling
    103
  - Welder Shutdown
    103
  - Power Shutdown
    103
  - Mounting Bolts
    103
  - Tighten Upper Tooling
    103
    
    Bolt Patterns
    103
    
    Position Upper
    103
    
    Tighten Upper
    103
  - Upper and Lower Tooling Bolt Patterns
    104
  - Torque Mounting Bolts
    108
  - Final Tooling Prep
    108
  - Tune Drive to Tooling
    108
  - Stanchion Alignment Pin
    108
    
    Tune Drive
    108
Section 8

111
- Section 8 - Machine Operation
  111
  - Machine Operation
    111
  - Machine Startup
    113
  - HOME Procedure
    113
  - Tooling Installation
    113
  - Selecting a Setup File
    114
  - Load an Existing File
    114
  - Programming a New File
    114
  - Set Limits
    114
  - Setup Control
    114
  - Starting a Weld Cycle
    115
  - Touch Screen Banner
    115
  - Stopping the Weld Cycle
    116
  - E-STOP Buttons
    116
  - Light Curtain
    116
  - Resetting the Machine
    116
    
    Main Power
    116
  - Machine Reset
    116
  - Resetting Machine
    116
    
    In Cycle
    116
Section 9

117
- Section 9 - Optimizing Performance
  117
  - Optimizing Performance
    117
  - Welding Parameters
    119
  - Weld Time
    119
  - Weld Distance
    119
    
    Welding Phase
    119
  - Weld Amplitude
    120
  - Weld Force
    120
  - Hold Force
    120
    
    Weld Time
    120
  - Hydraulic Flow
    121
  - Pneumatic Pressure
    121
  - Pneumatic Flow
    121
    
    Hydraulic Pressure
    121
Section 10

123
- Section 10 - Troubleshooting
  
  123
  - Troubleshooting
    123
- Electronics Control
  
  125
  - PLC Battery Backup
    125
  - PLC Backup Battery
    125
    
    Low PLC Battery LED
    125
    
    AC Utility Outlet
    126
  - System Documentation
    126
    
    Leds
    127
    
    PLC Programming Key
    127
    
    PLC Programming Key- allen Bradley
    127
    
    Mitsubishi
    129
- Electrical Power
  
  130
  - Internal Fuses
    130
  - Circuit Breaker
    130
  - Alarm Messages
    130
    
    AC Disconnect Switch
    130
    
    Hydraulic Overload
    130
    
    Drive Alarms
    131
    
    Hydraulic Overload
    131
- Hydraulics
  
  132
  - Lift Table Moves too Slowly
    132
  - Lift Table will Not Move
    132
  - No Hydraulic Pressure
    132
- Common Faqs
  
  133
  - E-Stop Reset
    134
  - Electrical Cabinet
    134
Section 11

137
- Section 11 - Maintenance
  
  137
  - Maintenance
    137
- Touch Screen Display
  
  139
- Pneumatic System
  
  139
  - Compressed Air Filter
    139
  - Moisture Trap
    139
- Hydraulic System
  
  140
  - Hydraulic Pressure
    140
  - Hydraulic Fluid Level
    140
  - Hydraulic Fluid Change
    140
  - Back Pressure Gauge
    141
    
    Hydraulic Fluid Level
    141
- Mechanical System
  
  142
  - Grease Fittings
    142
  - Tooling Care
    142
- Section 12 - Contacting Dukane
  
  143
  - Contacting Dukane
    143
    
    Identify Equipment
    145
    
    Intelligent Assembly Solutions
    145
Section 13 Specifications

147
- Section 13 - Specifications
  147
  - Specifications
    147
    
    Tooling Size & Weight
    149
    
    Tooling Specifications
    149
    
    Weights, Dimensions
    150
    
    Operating Environment
    151
    
    AC Power
    152
    
    Compressed Air
    152
    
    Power Requirements
    152
    
    Space Requirements Drawings
    153
    
    Regulatory Agency Compliance
    157
  - Regulatory Agencycompliance
    157
Section 14 Appendices

159
- Section 14 - Appendices
  
  159
- Appendix A - Joint Design Guidelines
  
  161
- Appendix A, Joint Designs
  
  161
  - Joint Designs
    161
    
    Vibration Butt Joint
    161
    
    Vibration Rib Joint
    163
    
    Weld Distance
    165
  - Welding Problems and Solutions
    165
- Appendix B List of Figures
  
  167
  - Operate
    167
  - List
    167
- Appendix C - List of Tables
  
  171
- Appendix C, List of Tables
  
  171
- Appendix D, Mitsubishi PLC
  
  171
- Appendix D - Mitsubishi PLC
  
  172
  - Mitsubishi PLC
    172
    
    Notes on the Backup Battery
    172
    
    Transport and Storage
    172
- Index
  
  173

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