User Manuals: Dukane 2120 Ultrasonic Welder

Manuals and User Guides for Dukane 2120 Ultrasonic Welder. We have 1 Dukane 2120 Ultrasonic Welder manual available for free PDF download: User Manual

Dukane 2120 User Manual (190 pages)

Dynamic Processor Controller

Brand: Dukane | Category: Welding System | Size: 10 MB

Able of

5
- Table of Contents
  5
- Section 1 - Introduction
  11
  - Before Operating
    13
    
    Read the Manual First
    13
    
    Caution and Warnings
    13
    
    Drawings Labels
    13
  - Manual Organization
    14
  - DPC-II Plus Overview
    16
  - EZ Welder Overview
    16
  - EZ Welder™ Overview
    16
  - Key DPC-II Plus Features
    17
  - Key EZ Welder Features
    18
  - Key EZ Welder™ Features
    18
Ection Safety Tips

19
- Section 2 - Safety Tips
  19
Ection Unpacking & Installation

25
Ection Controls & Displays

37
Ection Rear Connectors

47
- Section 5 - Rear Connectors
  
  47
- Section 6 - Menu Structure
  
  65
Ection Process Control Menu

73
Ection Process Limits Menu

97
- Section 8- Process Limits Menu
  97
Ection Utilities Menu

105
- Section 9 - Utilities Menu
  
  105
- Setup Utilities
  
  107
  - Figure 9-1 Utilities Menu Flowchart
    107
    
    Select Setup
    108
    
    Figure 9-2 Process Setup Main Menu
    108
    
    Figure 9-3 Setup Utilities Menu
    108
    
    Figure 9-4 Setup Utilities Selection Menu
    108
    
    Figure 9-5 Setup Types Selection Menu
    108
    
    Figure 9-6 Enter New Setup Menu
    108
    
    Figure 9-7 New Setup Configuration Message
    108
    
    Copy a Setup
    109
    
    Erase Setups
    109
    
    Figure 9-8 Source File Location Entry
    109
    
    Figure 9-9 Destination File Location Entry
    109
    
    Figure 9-10 Confirm Copy Files
    109
    
    Figure 9-11 Erase Setups Selection Menu
    109
    
    Figure 9-12 Confirm Erase Selected Setup
    109
    
    Figure 9-13 Erase Setup in Progress
    109
- Part Count
  
  110
  - Reset Part Count
    110
  - Count Suspect/Bad Parts
    110
  - Figure 9-14 Confirm Erase All Setups
    110
  - Figure 9-15 Erasing All Setups in Process
    110
  - Figure 9-16 Part Count Selection Menu
    110
  - Figure 9-17 Confirm Reset Part Count
    110
  - Figure 9-18 Confirm Counter Enabled
    110
  - Preset Part Count
    111
- Status Outputs
  
  111
- Cycle Press off Line
  
  111
Ection Probes & Probe Stacks

113
- Section 11 - Probes/Probe Stacks
  
  113
- The Ultrasonic Probe
  
  115
  - Theory of Operation
    115
  - Probe Configuration
    115
  - Figure 10-1 Hand Probe, Horn and Replaceable Tip
    115
  - Ultrasonic Horn
    116
  - Booster
    116
  - Figure 10-2 Probe with Booster and Horn
    116
- Stack Assembly
  
  117
  - Installing Replaceable Tips
    117
  - Figure 10-3 Replaceable Tip Installation
    117
  - Mounting Stud to Horn/Booster
    118
  - Table 10-I Stud Torque Unit Conversions
    118
  - Horn to Booster
    119
  - Booster to Probe
    119
  - Horn to Probe
    119
  - Figure 10-4 Stack Assembly Procedure
    119
- Torque Unit Conversion Chart
  
  120
  - Figure 10-5 Torque Value Conversion Graph
    120
  - Table 10-II Horn/Booster Torque Unit Conversions
    120
- Stack Disassembly
  
  121
- Booster Notes
  
  124
  - Figure 10-9 Removing Replaceable Tip from Horn
    124
- Stack Mounting
  
  125
- Section 11 - DPC Checkout
  
  127
  - Startup and Self-Test
    129
  - Figure 11-1 Front Panel Startup Controls and Indicators
    129
  - System Test
    130
  - Figure 11-2 System Test Controls and Indicators
    130
  - Probe Operation
    131
  - Stopping the Weld Cycle
    131
    
    Manual Systems
    131
    
    Automated System
    131
    
    End of Day
    131
    
    Figure 11-3 Stopping the Weld Cycle
    131
Ection Troubleshooting

133
- Section 12 - Troubleshooting
  
  133
- No Ultrasonic Output
  
  135
  - Probe
    135
  - Cable
    135
  - Figure 12-1 Rear Ultrasound and System in Connectors
    135
  - Generator
    136
  - Operate Input
    136
  - Figure 12-2 Generator on LINE Key and Indicator
    136
- Generator Faults
  
  137
  - OVERLOAD Indicator
    137
  - OVERTEMP Indicator
    137
  - FAULT Indicator
    137
  - Figure 12-3 Troubleshooting Flowchart - Part 1
    137
- Generator Errors
  
  138
  - INPUT TEST Indicator
    138
  - TEST Control Key
    138
  - Figure 12-4 Troubleshooting Flowchart - Part 2
    138
- Troubleshooting Flowchart
  
  139
- Error Messages
  
  141
Ection Care & Maintenance

143
- Section 13 - Care & Maintenance
  
  143
- Front Panel
  
  145
- Rear Panel
  
  145
- Chasis
  
  145
  - Figure 13-1 Location of DPC Air Cooling Vents
    145
- Stack Surfaces
  
  146
  - Stack Maintenance
    146
  - Stack Inspection
    146
  - Even Contact
    146
  - Uneven Contact
    146
  - Figure 13-2 Location of Stack Mating Surfaces
    146
  - Figure 13-3 Flat Surface with Even Contact
    146
  - Figure 13-4 Surface with Uneven Contact
    146
  - Crowning
    147
  - Center Depression
    147
  - Corrosion
    147
  - Figure 13-5 Crowned Surface
    147
  - Figure 13-6 Center Depression
    147
  - Probe Reconditioning
    148
    
    Overview
    148
    
    Machining the Mating Surfaces
    148
    
    Manual Resurfacing
    148
- Reconditioning
  
  148
  - Figure 13-7 Manual Resurfacing
    149
- Section 14 - Contacting Dukane
  
  151
  - Ultrasonics Division Main Office
    153
    
    Identify Equipment
    153
    
    Our Website
    153
  - Email Addresses
    154
  - Telephone Extensions
    154
- Section 15 - Specifications
  
  155
- Section 16 - Warranty
  
  161
  - Domestic Warranty
    163
  - International Warranty
    164
Ppendix List of Figures

165
- Appendix A - List of Figures
  
  165
- Appendix B - List of Tables
  
  169
- Appendix C - User Supplied Circuitry
  
  171
  - Manual Switch Circuit
    173
  - Figure C-1 Manual Control Switch
    173
  - Input Connector
    173
  - Automation Switch Circuits
    174
  - Figure C-2 Automation Control Switches
    174
  - Isolated Automation Controls
    175
  - Figure C-3 Non-Isolated Current Sink Switch
    175
  - Non-Isolated Switch Circuits
    175
    
    Current Sink
    175
    
    Current Sink
    176
    
    Figure C-4 Non-Isolated Current Source Switch
    176
    
    Current Source
    176
    
    Current Source
    177
    
    Figure C-5 Isolated Current Source Circuit
    177
  - Isolated Switch Circuit
    177
- Index
  
  179

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User Manuals: Dukane 2120 Ultrasonic Welder

Dukane 2120 User Manual (190 pages)

Table of Contents

Able of

Ection Safety Tips

Ection Unpacking & Installation

Section 3 - Unpacking & Installation

Shipping Carton Contents

DPC Placement

Rear Panel Overview

Ground the System

Connect the Cables

Ection Controls & Displays

Section 4 - Controls & Displays

Front Panel Layout

Generator Status Panel

AC Power

Process Control Panel

Ection Rear Connectors

Section 5 - Rear Connectors

Section 6 - Menu Structure

Ection Process Control Menu

Section 7 - Process Setup Menu

Hand Probe

MPC Probe

Auto Probe

Press Mode

Press Mode Example

Hot Keys

Process Control Recap

Ection Process Limits Menu

Ection Utilities Menu

Section 9 - Utilities Menu

Setup Utilities

Part Count

Status Outputs

Cycle Press off Line

Ection Probes & Probe Stacks

Section 11 - Probes/Probe Stacks

The Ultrasonic Probe

Stack Assembly

Torque Unit Conversion Chart

Stack Disassembly

Booster Notes

Stack Mounting

Section 11 - DPC Checkout

Ection Troubleshooting

Section 12 - Troubleshooting

No Ultrasonic Output

Generator Faults

Generator Errors

Troubleshooting Flowchart

Error Messages

Ection Care & Maintenance

Section 13 - Care & Maintenance

Front Panel

Rear Panel

Chasis

Stack Surfaces

Reconditioning

Section 14 - Contacting Dukane

Section 15 - Specifications

Section 16 - Warranty

Ppendix List of Figures

Appendix A - List of Figures

Appendix B - List of Tables

Appendix C - User Supplied Circuitry

Index

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