Page 1 Model VW - 5700 / 5900 / 5960 - LPT User's Manual Dukane Part No. 403 - 589- 01 Dukane IAS, LLC • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 4900 • FAX (630) 797 4949...
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 3/9/2017 - 01 Updated parts list, LPT model info, 8/9/2017 CSA details added Page iii Dukane Manual Part No. 403-589-01...
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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. 403-589-01...
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Page 7: Section 1- Introduction
Key Features ....... . 5 Page 1 Dukane Manual Part No. 403-589-01...
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Page 9 (e.g. –I, –II, –III). As an example, Figure 3–2 would be the second illustration in Section Three while   Table 3–II would be the second table in Section Three. Condition Operator Electrical Or Practice Protection Hazard (Hearing) Page 3 Dukane Manual Part No. 403-589-01...
Page 10 Every subassembly The VW5X00 (Vibration Welder 5300/5500/5700/5900) has been selected to provide the maximum reliability with family is Dukane’s fourth generation linear vibration a long and economical service life. The electrical cabinet welder. These systems all share the same basic has been redesigned to increase reliability, minimize mechanical components.
Page 11 • A two-phase drive has been incorporated into these • Digital Auto -Tuning accurately and automatically 5000 Series vibration welders. adjusts the frequency of the magnetic drivers to within 0.01 Hz. This provides optimum performance for each • Standard Software supports five part presence sensor separate tooling assembly.
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Page 13: Section 2 - Health And Safety
Hydraulic Safety ........14 Page 7 Dukane Manual Part No. 403-589-01...
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Page 15 Dukane does not assume any Dukane. Unauthorized modifications may cause injury responsibility or liability for to the operator and/or equipment damage. In addition, fixtures manufactured by the...
Page 16 Linear Vibration Welder 5000 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, 480V Models 5300, 5500, and 5700, has a three-pole, four- 277V blade, grounding type plug designed for 3-Phase 480 VAC...
Page 18 Linear Vibration Welder 5000 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 Light Curtains Service Door 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. 403-589-01...
Page 20 Linear Vibration Welder 5000 Series User’s Manual Hydraulic Safety Hydraulic Cabinet The hydraulic system is self-contained. It normally Service Doors operates at between 1,000 and 1,200 psi. It is however Cooling Air capable of operating up to 1,500 psi. It is unsafe to...
Page 21: Section 3 - Installation
Hydraulic Drive ........22 Page 15 Dukane Manual Part No. 403-589-01...
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Page 23: Unpacking
See the space requirements drawings in Section 13 - Specifications. Energy Sources Figure 3-2 System Documentation Storage Pocket Refer to Section 13 - Specifications for the AC power requirements and for the compressed air requirements of your model. Page 17 Dukane Manual Part No. 403-589-01...
Page 24 Linear Vibration Welder 5000 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. The left side of the welder does not require access and can be placed close to a wall if desired.
Page 25: Ac Power
Always turn off the AC power at the main dis- connect switch before servicing or working on the welder. Failure to turn off the AC power is an unsafe practice and can result in injury or death. Page 19 Dukane Manual Part No. 403-589-01...
Page 26 Linear Vibration Welder 5000 Series User’s Manual AC Disconnect Switch RED Handle RED Handle Green OFF Green OFF Pointing Left Pointing Left Position Position 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
Refer to Section 11 - Maintenance, for complete device and make sure the information on the instructions for replacing the filter pressure gauge reads zero. element. Page 21 Dukane Manual Part No. 403-589-01...
Page 28: Hydraulic Drive
Linear Vibration Welder 5000 Series User’s Manual Heat Exchanger Hydraulic Drive Hydraulic Fluid Cap Hydraulic Hydraulic Pressure Electric Pump Gauge Motor Self–Contained System The lift table is raised and lowered by hydraulic pressure. The hydraulic system has its own motor, pump, filter, reservoir, cooling system and programmable regulator.
Page 29 Hydraulic fluid level should be maintained so that it always shows in the fluid level sight glass. This is important to prevent condensation from collecting on the inside of the reservoir and the heat exchanger tubes. Page 23 Dukane Manual Part No. 403-589-01...
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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. 403-589-01...
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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. 403-589-01...
Page 34 Linear Vibration Welder 5000 Series User’s Manual E 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
Figure 4-3 and 4-5. When the operator places his finger in the tray, a second at the right rear also illuminates to Figure 4-3 Left Operate and E-STOP Button indicate the switch has been activated. Page 29 Dukane Manual Part No. 403-589-01...
Page 36: Light Curtain
Linear Vibration Welder 5000 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
67. If Vacuum is set to “Off” or any of the vauum 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. 403-589-01...
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Page 39: Section 5 - Normal Weld Cycle
Parts Removed........37 Page 33 Dukane Manual Part No. 403-589-01...
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Page 41: Parts Loaded
To recover from a light curtain fault, press the HOME MACHINE button. Reference Section 8 – Machine Operation, Home Procedure, Page 109. Page 35 Dukane Manual Part No. 403-589-01...
Page 42: Clamping Phase
Linear Vibration Welder 5000 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
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. 403-589-01...
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Page 45: Section 6 - Touch Screen
Touch Screen Banner ........99 Page 39 Dukane Manual Part No. 403-589-01...
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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. 403-589-01...
Page 48: Button Appearance
Linear Vibration Welder 5000 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. 403-589-01...
Page 50: Making Selections
Linear Vibration Welder 5000 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. 403-589-01...
Page 52: Top Button Bar - Quick Look
Linear Vibration Welder 5000 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. 403-589-01...
Page 54 Linear Vibration Welder 5000 Series User’s Manual Home Machine Homing the machine brings the welder to a defined starting point. To home the machine: 1. Touch and hold the Home Machine button until the door moves to its fully open position, and the table moves down to its 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. 403-589-01...
Page 56 Linear Vibration Welder 5000 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. 403-589-01...
Page 58 Linear Vibration Welder 5000 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. 403-589-01...
Page 60: Setup Mode
Linear Vibration Welder 5000 Series User’s Manual Setup Mode Figure 6-22 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. 403-589-01...
Page 62 Linear Vibration Welder 5000 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. 403-589-01...
Page 64 Linear Vibration Welder 5000 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. 403-589-01...
Page 66 Linear Vibration Welder 5000 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. 403-589-01...
Page 68: Setup Screen
Linear Vibration Welder 5000 Series User’s Manual Setup (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" (50mm) before the programmed trigger position. Program the desired position in the Table Position entry box. Page 63 Dukane Manual Part No. 403-589-01...
Page 70 Linear Vibration Welder 5000 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. 403-589-01...
Page 72 Linear Vibration Welder 5000 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. 403-589-01...
Page 74 Linear Vibration Welder 5000 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. 195 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 Sample In Progress bar starts to fill up. ture on or off. Green means ON; red means OFF. Figure 6-28 Tool Weight Compensation Pop-up Window Page 69 Dukane Manual Part No. 403-589-01...
Page 76 Linear Vibration Welder 5000 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. 403-589-01...
Page 78: Tool Setup Screen
Linear Vibration Welder 5000 Series User’s Manual Tool Setup (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-II Valve Status Table 6-III Valve Sensor Status NOTE Each valve is paired with extend and retract sensors. Page 73 Dukane Manual Part No. 403-589-01...
Page 80 Linear Vibration Welder 5000 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. 403-589-01...
Page 82 Linear Vibration Welder 5000 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. 403-589-01...
Page 84: Utilities Screen
Linear Vibration Welder 5000 Series User’s Manual Utilities (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. 403-589-01...
Page 86 Linear Vibration Welder 5000 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. 403-589-01...
Page 88 Linear Vibration Welder 5000 Series User’s Manual Valve Calibration This feature is for use by servicing personnel only. Figure 6-37 Calibration - Valve Valve calibration needs to be carried out by the maintenance personnel or manufacturer’s service technicians after the valve is replaced.
Page 89 Section 6 - Touch Screen 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 83 Dukane Manual Part No. 403-589-01...
Page 90 Linear Vibration Welder 5000 Series User’s Manual Figure 6-39 Systems Diagnostics Manager > Software Page 84 Dukane Manual Part No. 403-589-01...
Page 91 Section 6 - Touch Screen Figure 6-40 Systems Diagnostics Manager > Hardware Page 85 Dukane Manual Part No. 403-589-01...
Page 92 Linear Vibration Welder 5000 Series User’s Manual Figure 6-41 Systems Diagnostics Manager > Logger Page 86 Dukane Manual Part No. 403-589-01...
Page 93 Section 6 - Touch Screen Figure 6-42 Systems Diagnostics Manager > Profiler Page 87 Dukane Manual Part No. 403-589-01...
Page 94 Linear Vibration Welder 5000 Series User’s Manual Energy Savings The system will shut off its hydraulic pump, enclosure fan, work light and vacuum after being idle for the amount of time specified in the menu. Data Log Control Transfers the event log, alarm history and history log from PLC memory to USB drive in CSV format.
Page 95: I/O Table
Setup Mode is active. The buttons are located at the bottom of the I/O screen as shown in Figure disabled in Run Mode. 6-43 above. These buttons are ONLY available in Setup Mode Page 89 Dukane Manual Part No. 403-589-01...
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Page 97: Alarms Table
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 91 Dukane Manual Part No. 403-589-01...
Page 98 Linear Vibration Welder 5000 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 92 Dukane Manual Part No. 403-589-01...
Page 99 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 93 Dukane Manual Part No. 403-589-01...
Page 100 Linear Vibration Welder 5000 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 101 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- VI Alarms and Messages (Page 3 of 6) Continued Page 95 Dukane Manual Part No. 403-589-01...
Page 102 Linear Vibration Welder 5000 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 103 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 104 Linear Vibration Welder 5000 Series User’s Manual ALARMS MESSAGE Trigger Time Out Typically occurs when you trigger by position and the table position is less than the trigger position. Solution: Check the trigger position. Under Voltage Drive line voltage less than 432Vac (480Vac - 10%) for more than 1 second when not welding.
Page 105: 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 99 Dukane Manual Part No. 403-589-01...
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Page 107: Section 7 - Tooling Installation
Tune Drive to Tooling ......106 Upper and Lower Tooling Bolt Patterns ....108 Page 101 Dukane Manual Part No. 403-589-01...
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Page 109: Initial Machine Startup
If the light does not go out, check the rear service doors. They should be securely closed, and E-Stop Buttons the door interlocks should be engaged. Figure 7- 3 E–STOP and Reset Buttons Page 103 Dukane Manual Part No. 403-589-01...
Page 110: Initiate Home Procedure
Linear Vibration Welder 5000 Series User’s Manual Activate Hydraulic Pump To turn on the hydraulic pump, press the green push button. It will light when HYDRAULIC PUMP ON the pump is activated. The screen diplays a OPERATE live readout of lift force - see...
Page 111: Install Tooling Assembly
For more information about balance of weld- ing tools, refer to our Application Note 510, Loosly Install Tooling Importance of Balanced Vibration Weld- ing Tools, on the Dukane website at: http:// Install Lower Mounting Bolts www.dukane.com/us/DL_ApplData.asp Put the aligned upper and lower tooling assembly on the lift table (the tooling stanchion alignment pins should be extended).
Page 112: Torque Mounting Bolts
Linear Vibration Welder 5000 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 113 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 107 Dukane Manual Part No. 403-589-01...
Page 114: Upper And Lower Tooling Bolt Patterns
Linear Vibration Welder 5000 Series User’s Manual 6.024 [153] 5.433 [138] 4.003 [102] 2.894 [73] 12.048 UPPER [306] .000 TOOL OPEN 2.893 [73] 4.002 [102] 5.433 [138] M12-1.75 TAP 6.024 (14 PLCS) [153] 2.625 UPPER TOOLING [67] .75 RAD [19] 9.000...
Page 115 12 mm Metric Pin Hole, 2 Places 0.000 5.000 [127] 6.024 [153] 8.250 [210] 9.000 [229] M12-1.75 LOWER (36 PLCS) TOOLING Figure 7 - 7 Model 5500 Upper and Lower Tooling Bolt Patterns Page 109 Dukane Manual Part No. 403-589-01...
Page 116 Linear Vibration Welder 5000 Series User’s Manual 6.750 [171] 6.159 [156] 4.729 [120] 3.131 [80] [13] 0.000 3.131 [80] 4.729 [120] 6.159 [156] 6.750 UPPER [171] M12-1.75 TOOLING (28 PLCS) 12.000 9.842 [250] 9.750 [248] 8.250 [210] 6.000 [152] 0.000 6.000...
Page 117 [250] 9.750 [248] 8.250 [210] 6.000 [152] 0.000 6.000 8.250 9.750 [248] 9.842 [250] 12.000 [305] M12-1.75 (38 PLCS) LOWER TOOLING Figure 7 - 9 Model 5700LPT Upper and Lower Tooling Bolt Patterns Page 111 Dukane Manual Part No. 403-589-01...
Page 118 Linear Vibration Welder 5000 Series User’s Manual 6.750 [171] 6.159 [156] 4.729 [120] 7.24 0.000 [184] OPEN 4.729 [120] 6.159 [156] 6.750 [171] UPPER M12-1.75 TOOLING (42 PLCS) 15.23 [387] 12.000 [305] 9.842 [250] 9.750 [248] 8.250 [210] 6.000 1.00...
Page 119 12mm Locating Pin Holes (2 PLCS) 0.000 6.000 [152] 8.250 [210] 9.750 [248] 9.842 [250] 12.000 [305] M12-1.75 (54 PLCS) LOWER TOOLING Figure 7- 11 Model 5900LPT Upper and Lower Tooling Bolt Patterns Page 113 Dukane Manual Part No. 403-589-01...
Page 120 Linear Vibration Welder 5000 Series User’s Manual 6.750 [171] 6.159 [156] 4.729 [120] 7.24 0.000 [184] OPEN 4.729 [120] 6.159 [156] 6.750 [171] UPPER M12-1.75 TOOLING (42 PLCS) 15.23 [387] UPPER TOOLING 12.000 [305] 9.840 [250] 9.750 [248] 8.250 [210] OPEN .000...
Page 121 8.250 [210] 9.750 [248] 9.840 [250] METRIC M12-1.75 TAPPED HOLES 12.000 [305] 54 PLCS 62.760 [1594] LOWER TOOLING (LIFT TABLE) Figure 7- 13 Model 5960LPT Upper and Lower Tooling (Lift Table) Bolt Patterns Page 115 Dukane Manual Part No. 403-589-01...
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Page 123: Section 8 - Machine Operation
Resetting the Machine ......122 Page 117 Dukane Manual Part No. 403-589-01...
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Page 125: 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 119 Dukane Manual Part No. 403-589-01...
Page 126: Selecting A Setup File
Linear Vibration Welder 5000 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 127: 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 121 Dukane Manual Part No. 403-589-01...
Page 128: Stopping The Weld Cycle
Linear Vibration Welder 5000 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 hydraulic pump HYDRAULIC PUMP ON stops. The green light and...
Page 129: Section 9 - Optimizing Performance
Pneumatic Flow ........129 Page 123 Dukane Manual Part No. 403-589-01...
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Page 131: Welding Parameters
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 125 Dukane Manual Part No. 403-589-01...
Page 132: Weld Amplitude
Linear Vibration Welder 5000 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 133: Weld Time
Turn the locking rings back down to prevent changes in the settings. The door flow control valves are identified in Figure 9-5. Front door flow control valves Figure 9 - 5 Pneumatic Flow Adjustment Valves Page 127 Dukane Manual Part No. 403-589-01...
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Page 135: Section 10 - Troubleshooting
Common FAQs ........136 Page 129 Dukane Manual Part No. 403-589-01...
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Page 137: Electronic Control
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 Battery location (Allan-Bradley PLC) Page 131 Dukane Manual Part No. 403-589-01...
Page 138 Linear Vibration Welder 5000 Series User’s Manual Cabinet Air Exhaust AC Fuses and Disconnect PLC and I/O Modules Touch Screen Display Variable Drive System Documentation AC Utility Outlets AC Outlet Hydraulic Breaker Pump Breaker Low Voltage Cabinet Air Intake Power Supply...
Page 139: Electrical Power
Figure 10- 5 480VAC Fuse Block and Removal Tabs 3. Unscrew the filler cap (Figure 11 - 3). Pull the basket and filter and check for any blockage or foreign material. Continued Page 133 Dukane Manual Part No. 403-589-01...
Page 140: Drive Alarms
Increase the value that corresponds to the error message. We strongly recommend that you consult Dukane prior to changing these values. Refer to Overload Settings, and Figure 6 -31.
Page 141: Hydraulics
Figure 10 - 9 Alarm Screen - No Hydraulic Pressure voltage power leads feeding power to the main breaker of the welder. Continued Page 135 Dukane Manual Part No. 403-589-01...
Page 142: Common Faqs
Linear Vibration Welder 5000 Series User’s Manual Continued from Previous Page 4. Check that the fluid level in the sight glass is at 50%. The fluid should be clear (not cloudy or dark) with a slight yellow tint. 5. If none of these actions correct the problem, there may be something wrong with your hydraulic unit.
Page 143 HAVE to install? If you buy a Dukane machine with tooling, we always A: The best answer to that question is ALL of them. check the total noise of the machine and tooling together.
Page 144 If the tool. We cannot always construct the tool such that it strange sound persists, call Dukane and ask us to listen would not be damaged if some part of the assembly to it over the telephone.
Page 145: Section 11 - Maintenance
Tooling Care ......... . .144 Page 139 Dukane Manual Part No. 403-589-01...
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Page 147: Touch Screen Display
A line from the filter inlet. drain hose is attached to the bottom of the filter housing which exits at the bottom of the machine. Continued Page 141 Dukane Manual Part No. 403-589-01...
Page 148: Hydraulic System
Linear Vibration Welder 5000 Series User’s Manual Continued from Previous Page 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 pressure above 22 psi (0.15 MPa) when approximately...
Page 149: Back Pressure Gauge
USA, (630) 563–5468. The filter element is Part No. . Also check the air vent filter by 0075R010BN3HC pushing in the cap and twisting counterclockwise (CCW) . Replace the air filter if needed. Page 143 Dukane Manual Part No. 403-589-01...
Page 150: Mechanical System
Linear Vibration Welder 5000 Series User’s Manual Mechanical System Grease Fittings We recommend you grease the zerks once or twice a year with a good general-purpose industrial grease. In severe environments you might want to do it more often. The fittings are located on the top of each of the guide bearings.
Page 151: Section 12 - Contacting Dukane
Section 12 - Contacting Dukane SECTION 12 Contacting Dukane Page 145 Dukane Manual Part No. 403-589-01...
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Page 153 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 155: Section 13 - Specifications
Space Requirements Drawings ..... . 156 Regulatory Agency Compliance ..... . 161 Page 149 Dukane Manual Part No. 403-589-01...
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Page 157: 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 151 Dukane Manual Part No. 403-589-01...
Page 158: Weights, Dimensions
Linear Vibration Welder 5000 Series User’s Manual Table 13 - I Upper and Lower Tooling Weight and Dimensions Page 152 Dukane Manual Part No. 403-589-01...
Page 159 ** 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 147. Page 153 Dukane Manual Part No. 403-589-01...
Page 160: Operating Environment
Linear Vibration Welder 5000 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 161: Power Requirements
(See Figure 3 - 2, Page 17). 5960LPT Table 13-IV AC Power Requirements Compressed Air The welder requires a supply of clean, dry, compressed air at 75 to 90 psi (0.52 to 0.62 MPascal or 5.1 to 6.1 Bar). Page 155 Dukane Manual Part No. 403-589-01...
Page 162: Space Requirements Drawings
Linear Vibration Welder 5000 Series User’s Manual Space Requirements Drawings Figure 13 - 3 Model 5300 Floor Space Requirements Page 156 Dukane Manual Part No. 403-589-01...
Page 163 Section 13 - Specifications Figure 13–4 Model 5500 Floor Space Requirements Page 157 Dukane Manual Part No. 403-589-01...
Page 164 Linear Vibration Welder 5000 Series User’s Manual Figure 13 - 5 Model 5700 / 5700LPT Floor Space Requirements (29 - Inch Rear Service Doors) Page 158 Dukane Manual Part No. 403-589-01...
Page 165 Section 13 - Specifications Figure 13 - 6 Model 5900 / 5900LPT Floor Space Requirements Page 159 Dukane Manual Part No. 403-589-01...
Page 166 Linear Vibration Welder 5000 Series User’s Manual Figure 13 - 7 Model 5960 / 5960LPT Floor Space Requirements Page 160 Dukane Manual Part No. 403-589-01...
Page 167: Regulatory Agency Compliance
IP Rating The vibration welder has an IP (International Protection) rating from the IEC (International Electrotechnical Commission). The rating is IP2X, in compliance with finger-safe industry standards. Page 161 Dukane Manual Part No. 403-589-01...
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Page 169: Section 14 - Appendices
VW5960 ........171 Page 163 Dukane Manual Part No. 403-589-01...
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Page 171: Appendix A, Parts List
BC Power Feed, 24VDC JT-2200-516 BR-X20DI9371 B & R 12 Input, 24VDC, Sink 1 Wire JT-2200-517 BR-X20DO9322 B & R 12 Output, 24VDC, .5A, Source JT-2200-551 BR-X20BM11 B & R Bus Module with Power Bus Connector Page 165 Dukane Manual Part No. 403-589-01...
Page 172: Vw5500
Linear Vibration Welder 5000 Series User’s Manual Keep in Dukane part Manufacturer Manufacturer Item Quantity stock? number part number JT-2200-552 BR-X20BM01 B & R Bus Module with Power Bus Separation JT-2200-553 BR-X20TB12 B & R Standard Terminal Block (12pt) JT-2200-554 BR-X20AC0SL1 B &...
Page 173 B & R 15" PP500 No Windows 436590.001-00 Lighting JT-2200-13 F17T8-TL741 Various Fluorescent Lamp Lift Table JT-1023-22 SR30-TBISSC Bearing Block JT-1023-23 SR30+1240L Bearing Rail Pneumatic JT-2300-503 VQ4401-5 Air Valve Dbl Sol 24V Open Center (Tooling) Page 167 Dukane Manual Part No. 403-589-01...
Page 174: Vw5700
Linear Vibration Welder 5000 Series User’s Manual Keep in Dukane part Manufacturer Manufacturer Item Quantity stock? number part number JT-2300-504 ARBQ4000- Air Regulator VQ Interface ND-P-1 JT-2300-502 VQ4301-5 Air Valve Dbl Sol 24V Closed Center (For Doors and Tooling) JT-2300-24...
Page 175: Vw5900
Rear Pivot, Mag Table 13-7: VW5700 Parts List VW5900 Parts List Keep in Dukane part Manufacturer Manufacturer Item Quantity stock? number part number Door Components JT-2200-88 AEI-AN-5F Automation Inductive Proximity, 8mm, DC, Direct PNP, Page 169 Dukane Manual Part No. 403-589-01...
Page 176 Linear Vibration Welder 5000 Series User’s Manual Keep in Dukane part Manufacturer Manufacturer Item Quantity stock? number part number JT-2000-218 440N-S32016 Allen Bradley Non Contact Interlock Switch, 1NC 1NO, (Front Door Closed) JT-2200-15 440K-C21062 Allen Bradley Safety Interlock (Back Doors)
Page 177: Vw5960
Directional Valve, Ext JT-1900-75 B40033AFD28558 ACT Level/Temp Sensor, Ext Bridge Components JT-1128-00 Dukane Lamination Carrier Assembly 4710 JT-2100-12 Dukane Coil, LPT Vibe Welder with Tall Lamination Stack JT-2100-03 Dukane Amplitude Pick-up Coil Assembly Page 171 Dukane Manual Part No. 403-589-01...
Page 178 Linear Vibration Welder 5000 Series User’s Manual Keep in Dukane part Manufacturer Manufacturer Item Quantity stock? number part number JT-1019-66 Dukane Capsule Pick-up Magnet JT-1022-16 Dukane Linear Transducer Balluff 9W1-A310-M0750-P1-S115 Main Drive and Controls 110-5208B Dukane Vibration Drive 80A JT-2200-560 B &...
Page 179 Index Index Page 173 Dukane Manual Part No. 403-589-01...
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Page 181: Index
Door Indicators 47 Sensor Valve 2A Extended 97 Table Position Buttons 47 Sensor Valve 2B Retracted 97 Drawings and Tables 3 Sensor Valve 3A Extended 97 Dukane 147 Sensor Valve 3B Retracted 97 Contacting 147 Sensor Valve 4A Extended 97 Sensor Valve 4B Retracted 97 Trigger Time Out 98 Electrical Cabinet V1 Invalid Combination 98 Interior 132 V2 Invalid Combination 98 E–STOP Buttons 29 V3 Invalid Combination 98 V4 Invalid Combination 98 Voltage Overload 98 Weld Time Limit "has expired". 98 Filter housing 21 Auto-Ping 68 Forklift Channels 18 Autotune 68 Cover plates 19 Page 175 Dukane Manual Part No. 403-589-01...
Page 182 Linear Vibration Welder 5000 Series User’s Manual Part Handling Considerations 17 Ventilation 17 General User Information 3 Light Curtain 30 Health and Safety 7, 9 Limit Indicators 57 Electrical Safety 11 Load an Existing File 120 AC Power Disconnect 11 Location of Part Data 59 AC Power Receptacle 11 Electrical Cabinet Door 11 General Considerations 9 Machine Operation 117 Cable connections 10 Machine Startup 119 Grounded Electrical Power 9 Resetting Machine 122 Special Health Notice-Plastic 11 Selecting a Setup File 120 Wear ear protectors 10 Load an Existing File 120 Hydraulic Safety 14 Programming a New File 120 Operational Safety 13 Startup 119 Light Curtains, Electrical Cabinet Service Door and Dis- Stopping the Weld Cycle 122...
Page 183 Valve Status 73 5960 Bolt Patterns 114 5960LPT Bolt Patterns 115 Final Tooling Prep 106 Position Upper 105 Sensors 73 Stanchion Alignment Pin 106 Sensor Status 73 Tighten Upper 105 Set to Bypass 73 Torque Mounting Bolts 106 Test V1A and Test V1B 76 Tune Drive 106 Set Limits 120 Tooling Installation 105 Setup File Bolt Patterns 108 Programming a New File 120 Final Tooling Prep 106 Selecting 120 Install Tooling Assembly 105 Set Limits 120 Machine Startup 103 Setup Mode 54 Position Upper Tooling 105 Autotune 68 Tighten Upper Tooling 105 Hold 65 Torque Mounting Bolts 106 Trigger Method 63 Tune Drive to Tooling 106 Page 177 Dukane Manual Part No. 403-589-01...
Page 184 Linear Vibration Welder 5000 Series User’s Manual Tool Weight Compensation 69 Troubleshooting 129 Touch Screen Banner 99 Common FAQs 136 List Drive Alarms 134 Alarm Detected 99 Electrical Power 133 Door out of Position 99 Circuit Breaker 133 Ejecting Part 99 Internal Fuses 133 Hydraulics Off 99 Electronics Control 131 In Cycle 99 Low PLC Battery LED 131 Invalid Tool ID 99 PLC Status LEDs 131 Light Curtain is Obstructed 99 Hydraulic Overload 133 Machine Ready for Cycle 99 Hydraulic System 135 Machine Ready for Setup 99 Lift Table Moves Too Slowly 135 Remove Welded Part 99 Lift Table Will Not Move 135 Stanchions Not Retracted 99...
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Page 187 By passing its audit, Dukane can assure based on partnership for continuous improve- you that we have in place a well–defined and ment. This concept is key in that Dukane no systematic approach to quality design, manu- longer focuses on inspection, but on individual facturing, delivery and service.
Page 188 Linear Vibration Welder 5000 Series User's Manua Part No. 403 – 589-01 Printed in the United States of America Dukane IAS, LLC • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949...

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Dukane 5000 Series User Manual

Linear Vibration Welder

Section 3

Section 4

Section 5

Section 6

Section 7

Section 8

Section 9

Section 10

Electronic Control

Electrical Power

Alarm Messages

Hydraulics

Common Faqs

Section 11

Touch Screen Display

Pneumatic System

Hydraulic System

Mechanical System

Section 13 Specifications

Section 14 Appendices

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