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72
Dukane Manual Part No. 403–566–01
DPC
™
II Plus and EZ Welder System – User’s Manual
AUTO Probe
The cable connection diagram for connecting an
automated probe or an automated thruster is shown
in Section 3 in Figures 3–5 and 3–7. The flow chart
for the Process Control menu using Auto Probe is
shown in Figure 7–21. If you do not have a Power
Output module installed, the Energy Weld Method
menu will not be displayed.
The Auto Probe Setup logic adds a Process Con-
trol menu before the Weld Method decision menu.
Compare the flowchart in Figure 7–21 to the pre-
vious MPC flowchart in Figure 7–12. The Pro-
cess Control menu offers two additional settings
to control the welding process. After the normal
Weld Method is programmed, Hold time and
Afterburst settings are available.
1. The HOLD TIME parameter (T
hold
) determines
the length of time the probe is held in contact
with the parts after the welding cycle has
stopped. Holding permits the material to so-
lidify under pressure before the head retracts.
2. In some applications, the material being
welded can stick to the horn as it retracts. A
short burst of ultrasonic energy called
AFTERBURST prevents this. This operation is
defined by two values. The delay after the start
of the upstroke before the burst starts (T
delay
)
and the duration of the burst signal (T
burst
).
The maximum value of both of these param-
eters is 0.999 second.
AUTO STOP Option
The Auto Stop option is shown in Figure 7–13. It is
designed for use with automation equipment and is
available in both the Timed and Untimed Auto Probe
Trigger Method. To use this option, move the SH704
jumper block to JU715 (see Figure 5–12). If Auto
Stop is enabled, then a stop signal on pin 9 of the
HD–15 SYSTEM IN connector will be recognized.
This permits external automation equipment to stop
the welding cycle. If Auto Stop is set to disable,
then a signal on pin 9 will be ignored.
T
weld
RTW
= Ready To Weld
LEGEND
= Front Panel ENTER Key
(Section 4.3 – Menu Keys)
ENTER
= Parameter Value Entry
T = Time
E = Energy
WELD
METHOD
HOLD
TIME
PROCESS CONTROL
AFTER–
BURST
RTW
RTW
TIMED
AUTO
PROBE
UNTIMED
AUTO
PROBE
Step 1
Step 2
Step 3
WELD METHOD
TIME ENERGY
GND.
DETECT
UNTIMED AUTO PROBE
TRIGGER METHOD
TIMED AUTO PROBE
ENABLE or DISABLE
AUTO STOP
ENTER
ENTER
ENTER
ENTER
ENTER
ENTER
ENTER
ENTER
ENTER
T
delay
T
hold
T
delay
T
burst
T
weld
E
weld
T
max
T
max
T
scrub
E
/
D
ENTER
Enable/
Disable
Maximum
E
weld
Minimum
E
weld
= 12,000 Joules
= 1 Joule*
Maximum
T
max
Minimum
T
max
= 30.000 Seconds
= 0.001 Second*
Maximum
T
weld
Minimum
T
weld
= 30.000 Seconds
= 0.001 Second*
Maximum
T
hold
Minimum
T
hold
= 30.000 Seconds
= 0.001 Second*
Maximum
T
delay
Minimum
T
delay
= 30.000 Seconds
= 0.000 Second
Maximum
T
delay
Minimum
T
delay
= 0.999 Second
= 0.000 Second
Maximum
T
burst
Minimum
T
burst
= 0.999 Second
= 0.001 Second*
Maximum
T
scrub
Minimum
T
scrub
= 0.150 Seconds
= 0.001 Second*
* These values can be set to zero, but will not produce any
output. The values listed represent the resolution and are
the smallest values that will produce any output signal.
Figure 7–21 Auto Probe Setup Flow Chart
- User’s Manual 1
- PRINTED ON RECYCLED PAPER 2
- Number History Date 3
- Revision Revision 3
- TABLE OF CONTENTS 5
- Table of Contents 7
- SECTION 1 11
- Important User Information 13
- Manual Organization 14
- Section 1 – Introduction 15
- DPC II Plus Overview 16
- EZ Welder 16
- Overview 16
- DPC II Plus 17
- Key Features 17
- SECTION 2 19
- Health and Safety Tips 21
- Plastics Health Notice 22
- Electrical Safety Grounding 22
- Instructions 22
- RFI Considerations 23
- SECTION 3 25
- Shipping Contents 27
- DPC Placement 27
- Rack Mounting 28
- (DPC II Plus only) 29
- Connect the Cables 30
- Jumper Block 31
- Part No. 200–1293 31
- Multiple Probe System 32
- Automated Thruster System 33
- Dukane Press System 34
- Electrical Power Switch 35
- SECTION 4 37
- Front Panel Layout 39
- 1. AC Power Section 40
- 2. Generator Status Panel 40
- System Status Display 41
- System Power Output Display 42
- 3. Process Control Panel 43
- PROCESS CONTROL 45
- WELD MODE 45
- HOLD TIME 45
- AFTERBURST 45
- SECTION 5 47
- Rear Panel Layout 49
- System Input Connector 50
- Input Signal Description 51
- System Output Connector 52
- Output Signal Description 53
- ON LINE 54
- Remote Amplitude Control 56
- Power Signal Output Module 57
- Press Control Module 58
- Section 5 – Rear Connectors 59
- Multi–Probe Master Module 60
- Multi–Probe Slave Module 60
- Jumper Block Options 61
- System Control Inputs 62
- SECTION 6 65
- Process Setup Menu 67
- TRIGGER METHOD 69
- SECTION 7 73
- Process Control Menu 75
- WELD TIME 77
- 0.500 SEC 77
- AUTO STOP 78
- WELD METHOD 79
- WELD BY TIME 79
- WELD BY ENERGY 79
- GROUND DETECT 79
- WELD ENERGY 80
- 125 J 80
- SCRUB TIME 81
- 0.075 SEC 81
- AUTO Probe 82
- WELD METHOD 83
- AFTERBURST DELAY 84
- 0.150 SEC 84
- Initiate Mode 86
- Auto Stop 86
- Head Up On Auto Stop 86
- Trigger Type 86
- Single/Dual Pressure Mode 86
- #1 TIME ENERGY 87
- WELD METHOD P1 88
- WELD METHOD P2 89
- WELD ENERGY P2 89
- 75 J 89
- HOLD TIME 90
- 0.500 SEC 90
- AFTERBURST DURATION 90
- 0.250 SEC 90
- 0.750 SEC 91
- AMPLITUDE 92
- 75 % 92
- Parameter Min–Max Values 95
- SECTION 8 97
- Process Limits Menu 99
- LIMIT DEFINITION 100
- TOTAL TIME 101
- TOTAL ENERGY 101
- Dual Pressure Mode 102
- LIMIT DEFINITION 103
- SECTION 9 105
- Utilities Menu 107
- 1# 109
- OK TO COPY SETUP? 109
- NO 109
- YES 109
- COPY FROM 109
- Confirm Erase All Setups 110
- Erasing All Setups In Process 110
- Part Count Selection Menu 110
- Confirm Counter Enabled 110
- Confirm Reset Part Count 110
- Preset Part Count 111
- Cycle Press Off Line 111
- SECTION 10 113
- The Ultrasonic Probe 115
- Ultrasonic Horn 116
- Stack Assembly 117
- Attaching The Mounting 118
- Stud To A Horn Or A Booster 118
- Attaching The Horn To A 119
- Booster, Booster To A 119
- Probe, Or Horn To A Probe 119
- • 40kHz Stacks - 130 inch-lbs 120
- • 20kHz Stacks - 200 inch-lbs 120
- Stack Disassembly 121
- ISASSEMBLY 122
- Booster Notes 124
- Mounting The Stack 125
- SECTION 11 127
- Startup and Self–Test 129
- DPC System Test 130
- System Operation 131
- SECTION 12 133
- No Ultrasonic Output 135
- Generator 136
- Operate Input 136
- Generator FAULTs 137
- Generator Errors 138
- Section 12 – Troubleshooting 139
- Error Messages 141
- SECTION 13 143
- Front Panel 145
- Rear Panel 145
- Stack Surfaces 146
- Crowning 147
- Center Depression 147
- Corrosion 147
- Reconditioning 148
- Manual Resurfacing 149
- SECTION 14 151
- Contacting Dukane 153
- (630) 797–4987 154
- SECTION 15 155
- Regulatory Agency Compliance 157
- Dimensions 158
- Power Supply Requirements 159
- 2200-LN4-PE-L2 160
- SECTION 16 161
- Section 16 – Warranty 163
- APPENDIX A 165
- Appendix A – List of Figures 167
- APPENDIX B 169
- APPENDIX C 171
- Manual Switch Circuit 173
- Automation Switch Circuits 174
- Non–Isolated Switch Circuits 175
- Current Source Switch 176
- Isolated Switch Circuit 177
- Dukane ISO 189
- 40356601 190
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