Home

Ultrasonics

1. csssssssessssseesssseeees 30 Mechanical Stop Adjustment Knch 30 Pressure 2 Adjustment Knob ccisenis zasccencd awacnasnecanncestaseddotdeseceteaannadsnacisiale 30 Ultrasound Active Status Light WELDER OH 31 Indicator Flags eers creas or arated N 31 Pre trigger Adjustment Knob cis ssvisoaexsia sn isssiniancesansa vvuds Age GET 32 End Weld Adjustment Knob cccccccccsscscesscssescesecseescesecseeseesecsseseeseestesees 33 Mechanical Stop Indicator sisscisccavnnsnannsnararnasscinacraninrsarinveatvnsntensaaavinsirinvertnes 34 Uer elei 34 eege 35 Press EE 37 EE EE 37 Emergency OFF Switch EE 37 Activation Switches EE 38 Press Status Display oases acesasiianstsencpachdaenenteeivorveinnemiasedeaneldaeneatarstennitmauks 38 vi Table of Contents Table of Contents Section 4 Press Options Ee 39 RE 39 Purpose geet eegen 39 Ee eegene 39 Installing the Linear Encoder Kit jiaiisisasnsissnardaceiooasiotintonuikanaonneindragiatonueaaieisanss 40 Remove Standard Right Side Panel ccccccccsccsceseceescesecseesteseesteseeseeaees A0 Install Kit Components tege eEdeEEEe NEE A0 EENEG Al WS ENN E A2 Allach Side EE 42 Electronic Pressure Regulator cccccccccsscssesscscescesecseeseesecseeseesecseesecsecseeseeseeas 43 Pressure Transducer scparscrnxseiavindnisinntorsborrasatanteeaaideiieisainrsneilntesatensitaviideessinte 43 ergeet A4 Section 5 Stack Fixture Setup POV E A5 eege emgeet 45 Changing Stack Components
2. Change the shape of the gate Add stiffening ribs to the part Increase the thickness of the material on the underside of the gate area Check for the proper horn part fit Change the horn Solution Reduce the gauge pressure Reduce the weld time primary weld characteristic Change to a lower gain booster to reduce the amplitude Reduce downstroke speed Section 10 Troubleshooting Welding Problem Internal components were damaged during welding Probable Cause Excessive amplitude Excessive exposure to ultrasound Too much energy transmitted into the part The components are improperly mounted E g Parts are mounted too close to the joint area Problem Melting or fracturing of the part occurs Probable Cause Sharp internal corners thin sections Excessive amplitude A long weld time Inherent stress Solution Reduce the amplitude by changing to a lower gain booster Otherwise dampen the excess amplitude Reduce the primary weld characteristic Increase the amplitude by changing to a higher gain booster Reduce the amplitude Reduce the gauge pressure Reduce the weld time primary weld charac teristic Make sure internal components are mounted properly Isolate internal components from the part Move the internal components away from areas of high energy Use an external device to dampen energy locally outside of the joint area Solution Radius all sharp corne
3. Input End Mounting Stud 00 Horn Output End Assembly Figure 5 2 Stack Disassembly and Assembly 46 Section 5 Stack Fixture Setup Stack Removal 1 Push the PUSH FOR EMERGENCY OFF button on the front of the press base 2 Turn off power to the generator and to the Ultra Com NOTE These two steps are necessary to insure that no power would be accidentally applied while removing the stack Press thruster 3 While supporting the stack with one hand loosen the two Electrical Contact socket head bolts that secure the stack access door Leaf DO NOT TOUCH CAUTION When opening or closing the stack access a Stack Contact door support the stack by the horn or the Button exposed part of the booster This will keep it DO NOT TOUCH from falling and from being damaged The When removing access door holds the stack in place when it is closed doch 4 Swing the access door open and pull the stack toward you until the transducer and booster mounting rings clear the stack housing monting ring slots Booster 5 Pull the stack forward and down until the transducer Mounting contact button clears the press thruster electrical contact leaf Refer to Figure 5 3 Ring WARNING Electrical Shock Potential Do not touch the contact button when removing the stack There may be an electrical charge stored in the transducer See Explanation next page Figure 5 3 Stack Remov
4. The base is melting before the head forms Too much pressure is applied before the ultrasound is activated Problem Solution If using a dual pressure system use Pressure 2 in the hold portion of the weld cycle Pressure 2 should be higher than Pressure 1 Increase the hold time distance Increase the stud diameter Reduce the size of the staking cavity Lower the bottom stop Solution Radius the stud at the base Center the stud under the horn cavity Use a knurled tip See the problem section below titled The base is melting before the head forms Use pre triggering The base is melting before the head forms Probable Cause The trigger force is too high The amplitude is insufficient The downstroke speed is too fast 104 Solution Reduce the trigger force Pre trigger the ultrasound Increase the amplitude Use hydraulic speed control Use a slower downstroke speed Section 10 Troubleshooting Staking Problem The formed stud stays in the staking cavity as the horn retracts Probable Cause Solution The head has not solidified before the Increase the hold time horn retracts The horn tip is heating and not Cool the horn tip allowing the head to solidify Use afterburst NOTE The use of a knurled horn tip and a pointed stud can help solve many of the staking problems noted above 105 Ultra 15 kHz Assembly System User s Manual Continuous Welding Problem
5. The stud is melting at the base See the problem on the next page titled The base is melting before the head forms Problem There is excessive flash around the stake head Probable Cause Solution The staking cavity is too small Use a larger cavity in the horn The volume of plastic in the stud Decrease the stud height and or the is excessive diameter The stud is not centered in the Center the stud under the horn cavity horn cavity Problem The surface below the stake head is distorted Probable Cause Solution The part is not supported directly Support the fixture with a metal post beneath the stud being staked under the stud being staked The trigger force is too high Reduce the trigger force Use pre triggering Problem There is a loose fit between the staked head and the part being attached Probable Cause Solution The hole diameter relative to Reduce the hole diameter the stud diameter is too large Continued 103 Ultra 15 kHz Assembly System User s Manual Problem Staking There is a loose fit between the staked head and the part being attached continued Probable Cause The holding force was removed before the stud head could solidify Insufficient force is being applied to the staked head during the hold time Problem The stud is collapsing at its base Probable Cause There is a sharp corner near the base of the stud The stud is not centered in the horn cavity
6. ghte e e e D D s e n fixture and injure the equipment operator This could r e e e N happen if the combined weight of the thruster plus a the acoustic stack is greater than the air cylinder counterbalance s ability to counteract that weight j t To make adjustments N 7 NX Figure 2 3b Tightening 1 Carefully loosen the two clamps on the column by turning the Column Clamps the handles counterclockwise as shown in Figure 2 3a When the clamps are loosened the air cylinder counterbalance on the column helps to support the weight of the thruster Li ting Eye bolt Sa 2 Grasp the handle on the height adjustment wheel as shown in Figure 2 4 Turn the wheel clockwise to raise the thruster Turn it coun terclockwise to lower the thruster e Allen Screw 6 3 When the thruster is at the desired height tighten the clamps by turning their handles clockwise as shown in Figure 2 3b Column Clamps e NOTE Height Height of the entire press thruster Adjustment can be adjusted with the adjustment Wheel wheel as much as 17 5 in 440 mm The thruster slide assembly stroke is a maximum 6 75 in 170 mm Figure 2 4 Press Right Side View 14 Section 2 Installation Thruster Height Adjustment continued 4 After all adjustments are made tighten the 6 Allen Cock ing screws 2 above the top column clamp 2 between the column clamps and 2 bel
7. of crowning illustrated in Figure 9 4 Crown To get some idea of the extent of the problem put a straight edge along the surface of the stack element being inspected SE p e i e Because the stack element as shown in Figure 9 4 is crowned at A S gt Gap the center there are gaps along the outer edge of the element Ii Figure 9 4 Example of Crowning Center Depression An element s surface may also be depressed in the mounting stud area See Figure 9 5 This element would make contact only at the outer edge Gap Straight Again a straight edge placed along the mating surface of the E ge stack element gives an idea of the extent of the problem A gap visible beneath the straight edge near the center of the element shows how deep the depression is Figure 9 5 Center Depression 82 Section 9 Maintenance Surfaces with Uneven Contact continued Corrosion Corrosion is another factor to consider in determining overall system performance In time corrosion can build up on stack mating surfaces and contribute to a loss in performance Evi dence of corrosion includes discolored mating surfaces or sur faces that are encrusted with hard deposits NOTE To extend equipment life and to keep performance levels high minimize the system s exposure to any corrosive source 83 Ultra 15 kHz Assembly System User s Manual Reconditioning Stack Components Overview Stack components nee
8. How much power is being drawn from the generator Discontinue operation if the meter needle moves into the red area or if the OVERLOAD light glows at all The generator will no longer produce an ultrasound signal while in an overload condition CAUTION Repeated operations that draw too much power from the generator can damage system equipment If Overloading Occurs If overloading occurs discontinue the operation Perform the Operational Stack Test described above or see Section 9 Troubleshooting for more information Assembled Part Quality Check assembled part quality for the following a Strength of the joint or seam and b Appearance Does the assembled part meet the quality standards for appearance Making Adjustments If the samples are not acceptable make adjustments as neces sary If further assistance is needed contact Dukane Section 11 lists the Dukane contacts TIP The most important elements to monitor are always dependent on the application For instance Time Distance and En ergy can be critical elements to watch For more informa tion refer to Table 10 1 which gives ex amples of weld characteristics and their relation to sys fem components 75 Ultra 15 kHz Assembly System User s Manual This page intentionally left blank 76 SECTION 8 System Operation e This section provides a start up checklist procedures for starting and stopp
9. J15 Ultra Com Ultrasound from Generator J14 Ultra Com Ultrasound to Thruster J7 Ultra Com Operational Control to Thruster J8 Ultra Com Activation Switches Generator Operational Control JI Generator Ultrasound Out JI Thruster Ultrasound Input J3 Thruster Operational Control J35 Press Base Cables are available in longer lengths through the Dukane Sales Department See Section 11 for contact information Continued 17 Ultra 15 kHz Assembly System User s Manual Press System Connections continued CAUTION Run the generator only after e the ultrasound signal cable is connected and e the transducer is installed in the thruster Otherwise an overload condition could occur with possible damage to the generator Compressed Air Connect a stable supply of clean dry compressed air to the air inlet at the back of the thruster as shown below Make sure the air delivered to the thruster exceeds the expected output pres sure and that it is in the range of 80 100 psi J3 J40 OPERATIONAL TOP OF STROKE CONTROL SWITCH 1 4 Air Inlet Air Lockout Valve CAUTION LOCK OUT VALVE MUST BE CLOSED AND SECURED WITH PADLOCK BEFORE SERVICING THIS EQUIPMENT WARNING WELDING HEAD WILL EXTEND WHEN LOCK OUT ACTIVATED KEEP HANDS AWAY FROM WELDING HEAD WARNING DISCONNECT POWER BEFORE REMOVING COVER f S GROUND Rear of Thruster Figure 2 6
10. Make sure knockout pins are flush with the surface Redesign the fixture to improve the support in critical areas Change to a rigid fixture With a resilient fixture if large sections of urethane are deflecting add a rigid backup Section 10 Troubleshooting Problem Uneven welding occurs continued Probable Cause Part dimensions are incorrect The parts are improperly aligned There is a lack of intimate contact around the joint area Nonuniform horn contact is occurring Mold release is on the joint surface s There is a non uniform distribution of filler in the plastic material The joint design is incorrect There is a materials or resin grade incompatibility problem There is a regrind problem There is moisture in the molded parts Welding Solution Check the part dimensions Re dimension the part if necessary Check the molding conditions Check for part shifting during welding Check the alignment of mating parts Check for alignment of the horn the part and or the fixture Check the part dimensions Check the part tolerances Check for knockout pin marks in the joint area Check for misalignment of the mating part halves Check for sinks Check the fit of the part to the horn Check for proper support in the fixture Clean the mating surfaces Check the molding conditions Check the mold design Redesign the joint Consult with the resin supplier s C
11. Put a sample part in the fixture Place a piece of white paper on top of the sample part Place a piece of carbon paper carbon side down on top of the white paper 4 Enter the following into the Ultra Com Weld time 0 05 Hold Time 0 00 Pressure 20 40 psi System parameters Use default settings 5 Set the trigger control on the thruster so the pressure switch closes after some pressure is applied Turn on the power to the generator and to the Ultra Com Make sure the Mode Selection Keyswitch on the Ultra Com Front Panel is in the OPERATE position 8 Cycle the equipment normally by depressing the left and right base activation switches or by triggering the automa tion switch When one cycle is complete the pressure developed between the horn and the sample part will have left marks from the carbon paper on the white paper If the fixture is not level the carbon markings will be darker in some areas than in others All carbon markings will be uniform when all the proper adjustments have been made Make adjustments and repeat this procedure as necessary until you are confident that the fixture is level 55 Ultra 15 kHz Assembly System User s Manual This page intentionally left blank 56 SECTION 6 4000 Watt Generator e This section describes the connections and controls for the ultrasonic generator Dukane Corporation This page intentionally left blank Dukane Corporation Section 6 4
12. Seal does not meet strength requirements Probable Cause Material traveling too quickly Not enough amplitude Inconsistent blends of synthetic material Problem Welding is inconsistent Probable Cause Nonuniform amplitude horn Variations in anvil fixture Inconsistency of material Problem Seal area too great causes flash Probable Cause Material traveling too slowly Too much amplitude Excessive air pressure Problem Transducer and or horn heating up Probable Cause Not enough air flow to dissipate heat buildup 106 Solution Decrease speed Increase booster ratio Evaluate material Solution Have horn analyzed for amplitude uniformity Check fixture design and dimensions Evaluate material Solution Increase speed Reduce booster ratio Reduce air pressure Solution Continuous duty applications require cooling air in some applications refriger ated air Supply air to the stack interfaces and the horn tips Section 10 Troubleshooting Continuous Welding Problem Excessive horn wear Probable Cause Metal to metal contact between the horn and anvil Problem Overloading generators Probable Cause Loose stack components Horn failure Transducer failure Booster failure Stack frequency shifted out of tolerance Solution Use carbide inserts or coat horn face with carbide Reduce metal to metal contact Solution Disassemble clean and reassembl
13. full zcalel 25 Standard Press Controls Locations 27 Front Panel 15 kHz Tegebeg e erereieed Age 28 ligger Control Eege 34 Rear Press Faber eege 35 Air Lockout Valve Deeg dics naaactscodsataue Agenten 36 Press Ergonomie DOSE punicnssdavaapenseniaiseeeisdentataniatondanouunacecMenmadaaseds 37 Re 39 Linear Encoder Mounting Detail AO Linear Encoder Alignment jiucseicecutsvvanvbeenidespsuasnuesnducasusostonsntanrtesasatoneias Al Stack Components iergendeen 45 Stack Disassembly and Assemblly sssccscsssssrssssresecsesesssessassncsees 46 Stack Remova arren aee eee ee ee E E ce ear 47 Stack eeben eo eT E S a me 49 Assembling Stack Components cccccccssessesecseeseesecseesecsecseesecseeseeseesseas 50 Input Output Ends Identified ccccccccccccssceecsecseesecsecseesecsesseeseeeeseesees 5 Installing the lee asin paintseronazustastena sina ecnecsGorhesansdunsdnsasiniaatavaoneasion Gabsaaltocasss 53 Fixture eelere ugeet 54 Fixture Mounting Hole Measurement c cccccesecseesecssesseeseeesceseesseeseens 55 Generator Front Panel isc 2 ccszecncnsateresareieneinnsiatactateruseatnatatiensemanioiecnieest 61 Generator Rear Eegeregie 63 Generator Identification Number Locator n s 65 Paper Eeer eer me rere rt arty etre 70 Range Control Potentiometer Slot in Home Position c ccccccceesseseeseees 72 Ultra 15 kHz Assembly System User s Manual Table of Contents List of Figures continued eg KE E
14. learning the plastics assembly system s potential through practical hands on process work Watch for Special Paragraphs Watch for these special kinds of paragraphs in this manual NOTE Note statements highlight procedures or provide information CAUTION Caution statements identify conditions or prac tices that could result in damage to the equip ment or other property WARNING Warning statements point out conditions or practices that could result in personal injury or loss of life Ultra 15 kHz Assembly System User s Manual About this Manual Contents This manual e explains installation of the Dukane Ultra 15kHz Assem bly system press and thruster e provides basic information to operate the equipment e gives an orientation to the controls and features you will encounter e discusses optional features e outlines maintenance procedures and e provides troubleshooting information and specifications NOTE The Ultra System requires two manuals This manual covers the Ultra Series 15 kHz press thruster and generator The Ultra Com Process Controller is an integral part of the Ultra System and has its own User s Manual Dukane Part No 403 393C Please refer to that document to program and monitor process control characteristics Organization Before Welding Sections 1 5 Section 1 Introduction and Safety gives a general explana tion of the equipment and covers safety consideratio
15. s Manual This page intentionally left blank 26 SECTION 3 Controls and Indicators e This section describes press thruster controls and indicators Dukane Corporation This page intentionally left blank Dukane Corporation Section 3 Controls and Indicators Overview Material in this section describes the press thruster controls and indicators and it explains what they do Controls and indicators are presented in this section according to where they are found on the press thruster e Front Panel e Rear Panel or e Press Base Rear Panel Front Panel Column Clamps Height Adjustment Wheel Press Base Front View Right Side View Figure 3 1 Standard Press Controls Locations 27 Ultra 15 kHz Assembly System User s Manual Down Speed i Le Control Le 2 Air Gauge S PRESSURE 5 i ressure bd 3 Adjustment Knob DOWN 0 0 MM 10 11 0 am Den A PRESSURE D p 4 A m esie 4 Pressure Select Switch Mechanical Stop Adjustment Knob wull DN Ge E rr Pressure 2 Adjustment Knob Di Wi E Ka 6 4 M g g Sp 50 SZ MECH STOP G Ultrasound Active Status Light Indicator Flags 3 LU UUUUUUU UL SA UUUUUUUUULS Mechanical Stop Indicator Flag UL NOTE Set flag so that the top lines up with the desired setting The example to the left is set for 2 cm UIIDDUDUDUDDUIDUAU
16. s Manual Thruster Only Connections continued Compressed Air Connection NOTE Because the thruster does not use a support package the air source is connected directly to the 100 PSI AIR fitting on the Compressed air must be back of the thruster delivered at a higher pressure than the ex Make sure the air delivered is stable clean dry free of any pected output pressure moisture and lubricant and between 80 100 psi and in a range of 80 100 psi Recheck Connections Recheck all connections and when they are all secure you are ready to connect electrical power Connect Electrical Power As a final step in the cabling of your system connect AC electri cal power to the Ultra Com and to the generator See Section 12 Specifications for input power requirements 3 NOTE See the next page for a flange template to be used in mounting your unit to a baseplate 24 Section 2 Installation FRONT 7 75 inches 196 85 mm 3 875 inches 98 425 mm F C sd J 3 S 2 625 inches l 2 625 inches i 66 675 mm 66 675 mm 3 023 inches 76 783 mm 1 50 inches 38 10 mm po Bolts Use five 1 2 12 mm diameter with appropriate length to hold the flange 2 00 inches 50 80 mm 2 25 inches 2 25 inches H I 57 15 mm Sp 57 15 mm see REAR Flange Template Figure 2 9 Base Flange Template full scale 25 Ultra 15 kHz Assembly System User
17. through the generator power cord The plug on the Ultra 4000 generator fits a 3 wire 2 pole grounded 240 VAC 50 60 Hz 30A single phase outlet The receptacle is a locking type NEMA L6 30R J1 U S Output This receptacle connects to the Ultra Com via a coaxial ultrasound cable Through this cable the generator delivers the 15 kHz ultrasound U S signal to the Ultra Com CAUTION DO NOT run the generator unless the U S Output cable is connected to the Ultra Com unit or dam age to the generator may occur In 15 kHz probe systems this cable is an integral part of the probe Through this cable the generator delivers the 15 kHz ultrasound U S signal to the probe DO NOT run the generator unless this cable is connected to the 15 kHz probe or damage to the generator may occur J20 OPERATIONAL CONTROL The J20 receptacle is only used in continuous firing systems The switch closure that starts and 63 Ultra 15 kHz Assembly System User s Manual Rear Panel continued stops the ultrasound is connected to this receptacle in those systems J23 STATUS RELAY The J23 receptacle is connected to the status relay output circuit board mounted inside the generator It provides a SPDT relay contact output on the rear panel This output is useful when a floating non grounded mechanical switch is needed The user must provide a load to be switched and the power source for the load The power source can be AC or DC within
18. 15 kHz ultrasound signal can be easily heard The paper test provides a visual confirmation of the active ultrasound signal Acceptable Results If all the indicators from Steps 1 4 are acceptable the stack is within the Auto Trac range Proceed to Running Sample Parts and Making Adjustments Unacceptable Results If one or more of the indicators are unacceptable go to Step 5 5 Turn the generator and Ultra Com off Check the stack for correct assembly damaged components or dirty mating surfaces Make any repairs or adjustments to the stack Re check the ultrasound cable for proper connections Repeat Steps 1 through 4 If the test still fails go to Step 6 6 Turn the generator off Remove the stack from the thruster and remove the horn from the stack Resinstall only the trans ducer booster assembly into the thruster Repeat Steps 1 4 of the previous page 70 d e Vi Figure 7 1 Paper Test Section 7 System Test Stack Test continued Good Indications with Horn Removed If good indications are given with the horn removed it means that the horn is outside the specifications required to oper ate within the Auto Trac preset range Reassemble the horn to the stack and go to the Range Adjustment of the Auto Trac Feature that follows Bad Indications with Horn Removed If bad indications are present with the horn removed check the booster and the transducer for the following e any visible
19. 36 88 Supply 119 Auto Trac Tuning 67 B Base see Press Base Before Unpacking 11 Burnished Areas 82 GC Cable Part Numbers 17 23 119 also see Connections Changes Making System 80 To Stack Components 46 52 Checklist Daily Start up 77 Components Standard System 118 Compressed Air 11 19 Connections Cable 16 20 Air Connection 19 Press System 16 19 Optional 20 Thruster System 22 25 Controls Generator Front panel AC Power 61 OPERATE STOP TEST 61 Power Level 62 Press Base Activation Switches 37 38 Emergency OFF Switch 37 Press Status Display 37 38 Rear Panel Air Lockout Valve 35 36 Thruster Air Gauge 28 29 Down Speed Control 28 29 End Weld Adjustment Knob 28 33 Indicator Flags 28 31 Pressure Adjustment Knobs 28 30 Pre trigger Adjustment Knob 28 32 Pressure Select Switch 28 30 Mechanical Stop Indicator 28 34 Trigger Control Knob 28 34 Ultrasound Active Status Light 28 31 D Dimensions 11 12 Dukane Corporation Phone 113 Website 113 E mail 114 Warranty 115 116 Ultra 15 kHz Assembly System User s Manual E Electrical Safety Frounding 8 10 Electronic Pressure Regulator 43 Emergency OFF Switch 37 Emergency Stop Switch Customer 110 Encoder Linear 20 39 42 End Weld Adjustment Knob 33 F Fixture Installation 53 55 Flags Indicator 28 31 Flange Template 26 Front Panel Controls see Controls G Generator 5
20. BEFORE CONNECTING OR DISCONNECTING ANY CABLES WITHIN SYSTEM REFER SERVICING TO QUALIFIED PERSONNEL POWER LINE MUST BE GROUNDED AT OUTLET RO CHART REC FROM GHMERATOR OUTPUT 5 conductor cable Part No 200 417 Cable Connections Coaxial RG11A U Part No 200 1289 STATUS RELAY IST BE DAT ECT U S OUTPUT for a Press System Figure 2 5 Press System Cable Connections Section 2 Installation Press System Connections continued 1 Make the basic cable connections Ga through G as shown in Figure 2 5 and as detailed below When connections are complete the press thruster the Ultra Com and the generator will be interconnected Make any optional Connect any customer supplied equipment such as automation chart recorder or printer 4 Complete basic connections with customer supplied air and electricity Connect the power cords last but do not turn on the power yet Cable Part No Number 5 conductor Oil resistant Coaxial RGIIA U Coaxial RGIIA U 12 conductor Oil resistant 200 418 200 1064 Table 2 2 Press System Basic Connections 8 conductor Oil resistant xk NOTE connections CAUTION Before connecting or disconnecting A cables Put front panel power switches for the Ultra Com and the generator in the OFF position turn off electrical power and remove AC power cords from their re ceptacles J Ultra Com Operational Control
21. Part No 200 417 Part No 438 299 Coaxial RG11A U Part No 200 1289 U S OUTPUT Part No 200 607 4 conductor cable 4 conductor cable Cable Connections for a Thruster System Customer Supplied Activation Switches Section 2 Installation Thruster Only Connections continued Cable Part Cable Length No Number Type m To J20 J6 200 417 Greet Ultra Com Generator Operational Control Operational Control J15 JI 2 200 1289 ere Ultra Com Ultrasound Generator from Generator Ultrasound Out J14 JI 3 200 1289 Keren Ultra Com Thruster Ultrasound to Thruster Ultrasound Input J7 J3 4 200 418 E Ultra Com Operational Thruster Oil resistant Control to Thruster Operational Control 2 conducor J40 5 438 528 Oi resistant Thruster User Supplied Top of Stroke Automation 200 607 4 conducor ToM User Supplied Oil resistant Saly Switches Abort Switch 7 438 299 A conducor Uk ae User Supplied Oil resistant ee Activation Switches Auto Input Table 2 3 Thruster System Basic Cable Connections zk NOTE Cables are available in longer lengths through the Dukane Sales Department See Section 1 for contact information CAUTION Run the generator only after e the ultrasound signal cable is connected and e the transducer is installed in the thruster Otherwise an overload condition could occur with possible damage to the generator 23 Ultra 15 kHz Assembly System User
22. alignment between the horn the horn part and or fixture part and fixture Check the horn part fit Check the part fixture fit Level the fixture where necessary Rigid fixture reflects vibratory energy Dampen the energy by using teflon neo prene cork or urethane in the nest of the fixture 99 Ultra 15 kHz Assembly System User s Manual Insertion Problem The insert pulls out easily in use Probable Cause Solution There is insufficient interference between the hole and the insert The screw bottoms out in the hole The insert gets pushed into the plastic before the plastic melts The ultrasound remains on after insertion is complete The horn retracts before the plastic around the insert is solidified Problem Reduce the size of the molded hole in the plastic Use a shorter screw applies to internally threaded insert Deepen the hole Use hydraulic speed control Increase the amplitude and or decrease the gauge pressure Use pre triggering Reduce the primary weld characteristic Increase the hold time Inconsistent insertion of multiple inserts on the same part occurs Probable Cause The plastic is not melting consistently around all inserts Inserts are pushed into the plastic before the plastic has melted Inserts are seated at different heights within the same part 100 Solution Increase the amplitude Use hydraulic speed control Reduce the down speed Use pr
23. baffles sound enclosures or materials that absorb sound may be located to surround the system Acoustic Stack Hazard When an acoustic stack transducer booster horn and tip is energized by the ultrasound signal it presents a potential hazard Stay clear of an energized stack WARNING Keep head hands limbs and body at least six inches 152 mm away from an operating press thruster A vibrating descending horn can cause burns and or crushing injuries System Abort Switch Install a system abort switch at each operator station when ultrasonic plastic assembly equipment is used with automatic material handling equipment in an automated system Foot Switch Using a foot switch in place of dual palm buttons activation switches violates OSHA regulations Pre trigger Switch Adjustment The pre trigger switch option starts the horn vibrating before contacting the part to be welded The pre trigger must be adjusted so that the ultrasound signal will not start if the horn is more than 1 4 inch 7 mm from the part This ensures safe operation System Electrical Cabling Electrical power must be off when connecting or disconnecting electrical cables CAUTION When making cable connections to system equipment or disconnecting cables from system equipment make sure electrical power to the system is turned off and AC power cords are removed from their receptacles After the cables have been securely con nected and the
24. be sent in for evaluation Move the slot on the control pot to the home position and replace the plug button in the generator front panel 6 While holding the O S T switch in the TEST position slowly turn the control pot in one direction and then the other direction Find a position where all of the bad indicators disappear If the ultrasound signal shuts off release the O S T switch Return the pot to a position where the signal stayed on Repeat this step while turning the pot in the oppostite direction The pot has a mechanical stop just less than 180 degrees from the home position either direction If the signal will not stay on after completing the above steps do not run the horn until it is evaluated Discuss the de tails with Dukane personnel Move the slot on the control pot to the home position and replace the plug button in the generator front panel If there is a position where the bad indicators disappear try turning the pot a bit more to find the position with the lowest possible meter reading Release the O S T switch to the STOP position when this is done and go to Step 7 7 Record the position of the range control pot to operate this particular stack with your Ultra Com generator When using this stack in the future adjust the range control before completing the Operational Stack Test Put the plug button back into the generator front panel and remember to leave the control pot in the 3 and 9 home position
25. detail To make adjustments grasp the inner knob and turn it to make adjustments This knob can be turned as many as nine revolutions Each revolution advances the outer dial one number in the direction the knob was turned A lever between the scales locks the control in position The numbers on the scale give the operator only a relative reading A higher setting indicates more preload force on the part before the ultrasound signal is turned on A lower setting means less force NOTE When a press has a load cell force transducer the trigger control knob is not used The compression force is set electronically Refer to the Ultra Com User s Manual for Trigger Type Force 34 TIP The mechanical stop is used in two ways On swage and insertion applications it is used to stop the weld at a par ticular depth On all other applica tions it is used to pre vent the horn from striking the fixture when an assembly part is not in the fixture This prevents possible dam age to horn fixture Locking Lever Figure 3 3 Trigger Control Knob Section 3 Controls and Indicators Rear Panel The air handling apparatus is accessible from the press rear panel The figure below provides some detail for the air lockout valve NOTE The customer supplies the necessary air handling compo nents for the thruster See Page 24 for thruster s Compressed Air Connection OPERATION
26. eeose EEE aE EE REEE EEEN TEE RDSE 64 Identification Number 65 Section 7 System Test Eeer 67 A fto Trac TUNING WE 67 Operational Stack Vest EE 68 Pre test Checklist E 68 Acoustic Stack Test E 69 Acceptable E E 70 Unacceptable Results icsiicaicsasssarsisareriienrouaoiaiantiernnstnnmaninamuane 70 Range Adjustment of the Auto Trac Feature ccccccccccsscsecseeseeseeseeesseesees 71 Cycling Aere 74 Running Sample Parts acc ces ces cacscencsietarecncnsescndardeneninieneosentimeawiadealenmnaeadeeeen 75 Table of Contents Section 7 continued RT 75 If Overloading e 75 Assembled Part Quality saccssccrsaniaseeccuiccnasnuxdcacaatasezennsceenasinemsonistecneiaevsaiss 75 Making EE 75 Section 8 System Operation OVENI SW Vetes e E TEE A EA SEE 77 Daily Start up Chechlet 77 ll TE 78 Manual Start EE 78 Atomatic EE 78 Stopping the Systemi ersinnen AERES E eH 79 Ve 79 Eine DEE 7 E EE 79 Automated EE 79 Making Changes to the System sass snurscgacandanpnssooienddetanea onasonesaciunpidaoniesedenn 80 Section 9 Maintenance EENEG 81 Stack EE 81 Eeer 81 Inspecting the Stacks E 82 SEET 82 Surfaces with Uneven Contact 82 COWDINO WEE 82 Center Depression EE 82 eege 83 Reconditioning Stack Components E 84 OVETVIEW eege a EEE EEE EE E REEE ANE ANA ET EEE EE EERE E ETSEAN 84 Reconditioning the Mating Surfaces cccccccsscsscscesecssescesecssescessesteseeseeaees 84 Machining easan e ee E E 84 Manual Res rfaciNg widsa
27. frequencies Ear protectors may be worn to re duce annoyance or discomfort from the resulting sound In addition sound baffles sound enclosures or acoustical absorbing material may also be needed 57 Ultra 15 kHz Assembly System User s Manual Safety Considerations continued CAUTION To reduce the risk of fire or electric shock do not expose the generator to rain or moisture CAUTION To reduce the risk of electric shock do not disassemble the generator There are no user serviceable parts inside Refer servicing to Dukane service personnel only Electrical Safety Grounding Instructions The power cord used on the Dukane generator Ultra 4000 Dukane Part Number 15A4000 is equipped with an in line connector assembly The cord must be rated for at least 30 Amps at 240 VAC with a power line frequency of 50 60Hz For your safety and for the safety of others the power recep tacle must be grounded If there is any question as to whether or not the receptacle is properly grounded please have it checked by a qualified electrician In addition to the safety considerations above proper grounding at the generator power cord is essential for the effective opera tion of the RFI Radio Frequency Interference filter in every Dukane generator CAUTION This generator operates only on 240 VAC Do not connect the generator to any other type of electrical service 58 Section 6 4000 Watt Generator
28. is secure welding head Wipe away oil and dirt accumulation from the entire unit NVR Ww bd Inspect the transducer housing and air exhaust opening for signs of dirt or oil Wipe away any accumulations NOTE Because the pressurized air going to the press thruster is specified as free of moisture and oil there should be no oil accumulation on the transducer If oil is present on the trans ducer housing it means oil is coming through the air line Eliminate oil and moisture in the air line One suggestion Try routing the air line for the press through an oil mist reclassifier 88 Section 9 Maintenance Press Thruster Maintenance continued 7 Check the thruster slide for smooth downward operation Wipe away any accumulated grease but do not apply any solvents If movement is not smooth apply a small amount of 30 weight oil to a rag and wipe the two slide rails with it 8 Ensure that all wires and cable connections for the entire system are secure If cables or wires show wear reroute them to eliminate the problem 9 Replace the left and right press housing covers 10 Reconnect the Ultra Com and generator AC power cords to their respective AC receptacles Continued 89 Ultra 15 kHz Assembly System User s Manual This page intentionally left blank 90 SECTION 10 Troubleshooting Dukane Corporation This page intentionally left blank Dukane Corporation Section 10 Troubleshooti
29. press or thruster equip ped with a linear encoder or a press thruster with and End of Weld limit switch installed E Peak P Ultra Com with an energy measurement function MELIN TPAR TOGN energy power module Table 10 1 Equipment Requirements for Primary Weld Characteristics Absolute Distance NOTE The End of Weld limit switch is used to end the ultrasound signal during a weld cycle based on the press head s stroke position In general the switch is not used when a system has an Ultra Com with distance measurement function and a press thruster equipped with a linear encoder 92 Section 10 Troubleshooting Welding Problem Flash occurs See also Uneven welding occurs on Page 96 Probable Cause Energy director is too large Shear interference is too great Weld time is too long Nonuniform joint dimensions Part fit or tolerances Problem Welded assembly is misaligned Probable Cause Parts are not self aligning Improper support in the fixture Wall flexure Joint design is not properly dimensioned Incorrect part tolerance poor molding Solution Reduce the size of the energy director Reduce the weld time primary weld characteristic Reduce the gauge pressure Use an interrupted energy director Reduce the amount of interference Reduce the weld time Re dimension the joint Redesign the joint to be a shear joint or a tongue in groove joint Check the processin
30. the voltage switching capabilities of the inter nal relay The load current must also be within the relay switch ing capacity Ground This terminal provides a location for connecting the generator to earth ground as a backup to the ground connection at the generator power cord Connect this terminal to earth ground via a customer provided ground strap prior to operating the equipment Space Requirements Allow 6 inches 153 mm of space on either side of the genera tor for air circulation Allow 5 inches 127 mm of space to the rear for cable connections See Dimensions to calculate space needed for base placement Generator Dimensions inches mm Height 5 50 140 Width 19 00 483 Depth 20 50 521 Weight Generator 50 lb 22 7 kg 64 Section 6 4000 Watt Generator Operating Environment Operate the generator within these guidelines Temperature 40 100 F 5 38 C Pressure Ambient Air Particulates Keep the equipment dry Do not expose to rain or moisture Minimize exposure to dust dirt smoke and mold Identification Numbers Use Figure 6 3 to help you locate the model and serial number tags on the rear of the 4000 Watt generator The serial number tag is on the left side near the grounding nut The model num ber tag is in the center next to or on the heat sink U S PATENT 4 277 710 WARNING 3 POWER MUST BE e STATUS 2G Ee GROUNDED AT RELAY ST CHARLES IL OUTLET U
31. voltage e Any messages from the DPC display e MMI model number and firmware version e Description of the problem and steps taken to resolve it Local Support Your local Dukane representative can answer all of your questions regarding Dukane equipment as well as provide information on pending orders and quotations Each Dukane representative has received factory training and can assist you in all phases of project life cycle Try our Website Dukane Corporation is on the worldwide web at http www dukcorp com E gelt p co ue At the website you can and then go to your area of interest Re ee ta variety of joining tech Contacts in the Ultrasonics Division nologies e Learn about our products f S and see layout drawings Main Phone 630 797 4900 e Check out the Frequently Sales 630 797 4918 Asked Questions section e Order literature Fax 630 797 4949 e View a list of educational Service amp Parts Fax 630 584 0796 EE See the next page for department extensions Mailing Address Dukane Ultrasonics 2900 Dukane Drive St Charles IL 60174 USA 113 Ultra 15 kHz Assembly System User s Manual Ultrasonics Division E mail Addresses Applications SREL Se Tele E a usapps dukcorp com Engineering edie LEE E AE useng dukcorp com Food Processing Sede eg aati Gece usfoodproc dukcorp com International Sales usintl dukcorp com Marketing et SG re See Gene Boe usmktg dukcorp c
32. 000 Watt Generator 4000 Watt Generator Overview The 4000 Watt generator converts 60 Hz 240 Volts AC power into a 15 000 Hz signal with an amplitude exceeding 1 000 volts This signal is fed through the Ultra Com unit which controls it to the horn assembly in the thruster press Safety Consideration To avoid possible injury and to operate the equipment in a safe and efficient manner please observe the following safety mea sures Note that some of the items are also applicable to system components other than the generator such as the acoustic stack assembly or ultrasonic press Do not operate any system components before they are properly installed Do not make any unauthorized modifications to the control circuitry or other parts of the system This could cause damage to the equipment and or injury to the operator Unauthorized modifications may also void the equipment s warranty Do not operate this equipment without a properly grounded connection Accessories may be required for compliance with ap plicable OSHA regulations for machine guarding and noise exposure When ultrasonic plastic welding equipment is used with automatic material handling equipment such as an automated system a SYSTEM ABORT SWITCH should be used and located at each operator station Do not use of a foot switch in place of dual push button switches This violates OSHA regulations The Ultra 15 kHz Assembly System will produce au dible
33. 000 Watt specification only at 240VAC Operation at less than 240VAC will result in reduced output Operation above 240VAC may result in excessive power output Space Dimensions inches mm coe Component Table 12 2 Component Dimensions NOTE Add about 5 inches 125 mm space above the press and to the rear of the Ultra Com and generator for cable connections Allow 6 inches 150 mm of space on either side of the Ultra Com and generator for air circulation Press dimensions are shown in detail on the next page Weight Ultra Com 16 lb 7 3 kg Press amp Thruster 322 Ib 813 kg thruster only 93 lb 49 kg Generator 50 lb 22 7 kg 119 Ultra 15 kHz Assembly System User s Manual Dimensions inches mm 50 114 LINEAR __ ENCODER OPTIONAL PRESS HORN CENTERLINE oitte N COUNTER PRESS RACK BALANCE ratty E 1 8 58 l 472 Figure 12 1 Press Front View 120 i 14 75 LIFTING 375 EYE BOLT To E 17 50 max 444 y 4 38 66 982 d 44 75 om i 1137 i 40 00 101 a 1016 i 1 l Vy 6 20 l 157 a T i l i 1 rt U kor E I 7 00 min 18 85 max Ee 12 38 Ui 178 479 lt 314 PRESS SHOWN AT LOWEST POSITION 4 F 4 74 12 Y O JL A I 24 83 R 63
34. 1 Figure 12 2 Press Left Side View 452 4 RAD 10mm TAP 12 38 2 Holes ii 337 18 58 472 H d e TT t DIA 24 83 10mm TAP 2 Holes HOLES 631 Figure 12 3 Top View Press Base Section 12 Specifications ca van rei At deepest point 38 66 982 5 82 143 10 00 254 4 74 120 18 56 471 24 83 631 Diameter at base Column C L to Horn C L to Rear of 6 20 157 Thruster ce Table 12 3 Miscellaneous Dimensions Operating Environment Operate the press thruster within these guidelines Temperature 40 100 F 5 38 C Pressure Ambient Air Particulates Keep the equipment dry Do not expose to rain or moisture Minimize exposure to dust dirt smoke and mold CAUTION Make sure the compressed air feeding the press thruster is clean and dry Damage to the equipment will occur if the air contains moisture or oil 121 Ultra 15 kHz Assembly System User s Manual Identification Numbers Use Figure 12 4 as a guide to locate model and serial numbers for your Ultra Com generator thruster and press DT A Thruster Model amp Serial Numbers ay Model amp Serial Numbers Figure 12 4 Locating Model and Serial Numbers 122 Index Dukane Corporation This page intentionally left blank Dukane Corporation Index A Acoustic Stack see Stack Activation Switches 38 Adjustment Knobs see Controls Air Gauge see Controls Filter 89 Lockout Valve 35
35. 12st c uscsasmiesecuevennnrnacrasiatausedenvndruntadalenateertadendse 46 SE A7 Stack Dee ele A9 SE 50 Preassembly EE 50 EE E TEE 51 Horn to Booster or Booster to Transducer Assembly c ccccccsceceeseeeees 51 Installing Kee 53 Erster Aum aledeotessiosenasseniesi 54 Fixture Alignment EE 54 Leveling the Fixture ss seivassnsasaasivn sa vixinnnicninstaonduninnistivnsisn ta ssanotninisnrananinansiiunsacens 56 vii Ultra 15 kHz Assembly System User s Manual Table of Contents Section 6 4000 Watt Generator OyervieW sacs eater aise nace deed 57 Si 57 Electrical Grounding Instructions ccccccssesscsescsscseecesessecacsaesssesacseeenscseeens 58 RPL Fiter eee eee ee RS RAID Oa Ee ee oe OR OE CES nae eer OL ee 59 Regulatory Agency Compliance cccccesscssescesscssescesecseeseesecsteseesecseesesseeseesees 59 Installation EE 60 ett 60 EE 60 Front Panel Controls scccccccps ees ccerceacaxceumasdecueaauasetczeosuedeatenedcecedupessevedabassonecscaecnnes 61 AC Power ON OFF TEE 61 OPERATE STOP TEST Switch 61 OPERATE Eege 61 STOP Position E 61 TEST EE 61 OUTPUT POWER LEVEL eggtoeunengineeesae eege Ee Nee 62 Red OVERLOAD KEE 62 POWER Control Keelt ices eege 62 Auto Trac Range Control Potentiometer ccccccccccsceseescestesecseeseeseeeees 62 Rear BONS tact se ea a E enacted E ese 63 Power EE 63 LEE ER J20 OPERATIONAL Control E 63 J23 STATUS RELAY ett been 64 Groond EE 64 SEE RECHT NSIS sessies nieou
36. 5 8 pan head screws to attach the encoder scale to the plate Encoder Alignment Aligning the linear encoder sets the internal reference GN mark for the encoder This reference mark resets the distance register in the Ultra Com after each cycle and ensures repeatable distance measurements from Encoder cycle to cycle Thruster Cable P Castin 1 Align the encoder scale with the encoder head so Se BR that a 1 mm 039 gap exists between them along the entire stroke range Because this is a a critical measurement in prolonging the life of the optical linear encoder use a feeler gauge to o check the gap width 2 Check to see that the thruster slide moves up and down without interference Adjust encoder head and body as necessary After making final adjustments tighten all screws Figure 4 3 Linear Encoder Alignment WARNING Keep hands and clothing away from the press when it is activated Continued Al Ultra 15 kHz Assembly System User s Manual Linear Encoder Alignment continued Testing 1 Unlock the padlock used on the air lockout valve 2 Connect the encoder cable to connection J12 at the rear of the Ultra Com THRUSTER STROKE ENCODER 3 Turn on the Ultra Com This restores power to the press as well Set the Ultra Com to measure distance 4 Set the air pressure to the desired level 5 Perform the following procedure to test the encoder for the proper setting a Run one weld cycle
37. 7 65 Grounding 58 Identification Numbers 65 Installation 60 Front Panel Controls 61 62 Rear Panel 63 64 RFI Filter 59 Safety 57 Specifications 64 Grounding Instructions 8 10 H Health and Safety 6 8 Height Adjustment Handwheel 5 14 Hydraulic Speed Control see Speed Con trol Identification Numbers 65 122 Inspections Daily 88 Installation Cable Connections see Connections Linear Encoder 39 42 Fixture 53 55 Placement 13 Stack 53 Thruster Only 22 25 Unpacking 12 L Linear Encoder Kit Installation 40 42 Load Cell 44 Index M Maintenance 81 90 Press Thruster 88 89 Making System Changes 80 Mechanical Stop Indicator 28 34 Model Numbers 122 Mounting Hole Measurements Fixture 55 O Operating Environment 121 Operation 77 79 Operational Stack Test 68 73 Optional Connections Linear Encoder 16 22 Top of Stroke Cable 22 OSHA 6 7 P Part Quality 75 Plastics Health Notice 8 Power Draw 75 Press Base 37 Controls 27 Features 5 Maintenance 88 89 Options 39 44 Placement 13 Status Display 37 Without Base 13 Pressure 1 and 2 Adjustment Knobs see Controls Pressure Regulator 43 Pressure Transducer 43 Pre trigger Adjustment Knob see Controls R Rear Panel 35 Regulatory Agency Compliance 117 Resurfacing Mating Surfaces 84 86 RFI Filter 10 S Sample Parts Running 65 Serial Numbers 65 122 Specifications 11
38. 9 121 Stack Assembly 50 Changing Stack Components 46 Description 45 Disassembly 49 Inspection 82 Installing 52 Maintenance 81 83 Ultra 15 kHz Assembly System User s Manual Mounting Studs 51 U Operational Test 58 63 Ultra C Reconditioning 84 86 Ch Zu Removal 47 saad Connections 16 17 22 23 l Description 4 Start up 78 Primary Weld Characteristics 92 sopping ihe Saeni 79 User s Manual 1 2 80 System Changes 80 Unpacking the Equipment 12 User Manual Organization 2 3 T Test System 67 75 W Warranty Thruster USA Canada Mexico 115 Connections 22 25 International 116 Height Adjustment 14 Installing 21 25 Mounting 22 Repositioning a Clamp Handle 14 Top of Press Connectors 19 Top of Stroke Cable 19 22 118 Torque Values Booster and Horn Stud 87 Stack Assembly 87 Trigger Control Knob 28 34 Troubleshooting Continuous Welding 106 107 Equipment 108 111 Insertion 100 102 Process 93 107 Staking 103 105 Welding 93 99 DukaneISQ ISO CERTIFICATION Dukane chose to become ISO 9001 certified in order to demonstrate to our customers our con tinuing commitment to being a quality vendor By passing its audit Dukane can assure you that we have in place a well defined and sys tematic approach to quality design manufac turing delivery and service This certificate re inforces Dukane s status as a quality vendor of technology and products To ach
39. AL a TOP OF STROKE or SWITCH Compressed Air Connection Air Lockout Valve Valve Slide in Open Position CAUTION LOCK OUT VALVE MUST BE CLOSED AND SECURED WITH PADLOCK BEFORE SERVICING THIS EQUIPMENT WARNING WELDING HEAD WILL EXTEND WHEN LOCK OUT ACTIVATED KEEP HANDS AWAY FROM WELDING HEAD WARNING DISCONNECT POWER BEFORE REMOVING COVER Figure 3 4 Rear Press Panel 35 Ultra 15 kHz Assembly System User s Manual Rear Panel continued The air valve is a lockout valve because it can be locked in the closed position When the valve is locked no air will go to the press Figure 3 5 shows where a lock can be put NOTE In the event of unexpected air pressure loss the check With the style of valve shown below the valve slide cannot be moved once the lock is in place As part of the start up procedure unlock the valve and push the valve slide to the OPEN position valve keeps air in the press for a brief time This keeps the press head retracted Side View Air Line Removed Valve Slide e Put Padlock or Cable Lock Thruster Through this Hole Valve in Closed Position Valve in Open Position Figure 3 5 Air Lockout Valve Detail 36 Section 3 Controls and Indicators Press Base The ergonomic base shown in Figure 3 6 consists of a base plate cycle activation switches black palm buttons PUSH FOR EMERGENCY OFF switch red palm button and a status displa
40. Berrend 13 Flange Template Provided cccccccccescsssescesesseesceseeseescesecsseseeseesseseeaes 13 Press System Thruster Height Adtustment 14 Press System Basic Cable Connections c cccccscesseseeseeseeseeseeseeseeseeseeseeseeseens 15 EE 15 Cable Connections for a Press System c ccccsscscsscesessessceecsesseeseeeeeeeeaes 16 REENEN 18 Ee NEE 19 linear Encoder beten gegen 19 TopofStroke Cable ccc eons ered caveniceat aeataomeaddinatusslnustentanmbanaeacaadiae 19 Recheck Connections ace caarasoniseermeancenannindsdentdatnsauiaintctderntiadhientesmastinnes 19 Connect Electrical erer 19 Installing the DEE Eeer 20 Setup It Sw daea kenaa A E E e E A ERRA 20 er EE 20 Ultra 15 kHz Assembly System User s Manual Table of Contents Section 2 Installation continued Space Considerations eege 20 M vnting the EEN 21 Connections for Thruster Only ic acalssci scAnec Sictseacnsewhduaceedostesunoivesbaetbcnctbinacdll 21 Compressed Air Connection ccceccesseseeseesceseeseeseesecseeeeeseeseesesseeseeseeaeenes 24 Recheck Connections EE 24 Connect Electrical Power sccv ecscscsvsstassnteaciedsesesdarwssincdexettesactatancieahenieecntindads 24 Flange EE 25 Section 3 Controls and Indicators eege 27 Eent 29 Down Speed Control DOWN SPEED csssesssesssssesssessssessseesseessseessecesseessesseeeaseeen 29 Air Gauge EENEG 29 Pressure 1 Adjustment Koob 30 Pressure Select Switch WELD PRESSURE HOLD PRESSURE
41. D light will glow The generator overload protection circuit has shut down the ultrasound signal Continued NOTE The generator is operating at the optimum setting for this stack when the meter during this test is between 5 and 15 of the full meter scale Horn and booster amplitude and the mass of the horn determine the amount of energy needed to vibrate the stack This combination of factors for a particular stack de termines whether the opti mum setting is closer to 5 or to 15 TIP To monitor stack perfor mance while in the SETUP mode record data from the Ultra Com POWER dis play a menu item on the Utilities Page when equipment is new and also on a regular basis over the life of the unit This history will be valu able in tracking system performance 69 Ultra 15 kHz Assembly System User s Manual Operational Stack Test continued 4 To see if the ultrasound signal is being transmitted to the horn First fold a small scrap of paper once ordinary 20 copy paper will work for this purpose and place it on the press base or fixture about an inch from the tip of the horn Turn the selector switch to TEST The paper should bend slightly away from the horn as shown in Figure 7 1 If no movement is seen there may be a problem with the stack Release the selector switch so that it returns to the STOP position NOTE Under normal conditions the
42. DIDIDUII LILIE STROKE END WELD HUT i Figure 3 2 Front Panel 15kHz Thruster 28 Section 3 Controls and Indicators Front Panel Symbol Symbol ix Mechanical Stop Weld Pressure Table 3 1 Thruster Symbols Down Speed Control DOWN SPEED This control adjusts the downward velocity of the slide assembly during Downstroke by controlling the rate of air exhaust from the lower part of the air cylinder Pull the red locking ring out to unlock the control knob Then the plastic knob can be turned To increase velocity turn the plastic knob counter clockwise To decrease velocity turn the plastic knob clockwise When you are finished making adjustments push in the red locking ring Air Gauge PRESSURE The gauge displays the amount of pressure being applied during the Weld and Hold portions of the cycle The gauge registers pressure from both Pressure 1 and Pressure 2 regulators respectively 29 Ultra 15 kHz Assembly System User s Manual Continued G Pressure 1 Adjustment Knob Pressure 1 is the pressure inside the air cylinder used as the slide assembly descends during the Weld portion of the cycle and as the slide assembly retracts The adjustment knob connects to an air regulator To set Pressure 1 1 The Pressure Select Switch button is normally in the WELD PRESSURE position 2 Watch the PRESSURE gauge needle and turn the adjust ment knob clockwise to increase air
43. DUKANE Ultrasonics S555 RA 15 kHz Assembly System INSTALLATION and OPERATION Press System Column amp Base Model No FE 15C4001P 15D4001P 15E4001P Matching High y 15T4001P Power Ultra Com D Ne 43C350 Connection i 43D350 ee aac B gt AkW Generator 43E350 Only 15A4000 43T350 Thruster System Model No 15C4001T 15D4001T 15E4001T 15T4001T User s Manual Dukane Part No 403 542 00 1 www dukcorp com Dukane Corporation e Ultrasonics Division e 2900 Dukane Drive e St Charles Illinois 60174 USA e TEL 630 797 4900 e FAX 630 797 4949 ISO 900 Dukane products are manufactured in ISO registered facilities Copyright 2000 2001 Dukane Corporation All rights reserved No part of the material protected by this copyright may be reproduced or utilized in any form or by any means electronic or mechanical including photocopying recording or by any information storage and retrieval system without written permission from Dukane Corporation Printed in the United States of America D i PRINTED ON RECYCLED PAPER Dukane Part Number 403 542 00 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 Ultra 15 kHz Assembly System User s Manual Revision History Revision Revision Number History Date 00 Original release 16 Mar 2001 00 1 Onl
44. Disassembly Use the two spanner wrenches wrenches A and B provided with the press To separate the stack components read and carefully follow the instructions below 1 Place wrench A on the component to be removed and place wrench B on the component next to it Refer to Figure 5 4 2 Turn wrench A in the direction indicated CAUTION Avoid injury when using the spanner wrench es Press down with the palm of the hand on the wrench handle 3 When the component is loose it can be removed by hand NOTE To maintain structural integrity when separating components NEVER hold a transducer by the housing or the booster by its mounting rings Doing so will damage the holding pins in both the transducer and the booster NOTE Use only the tools recommended by Dukane NEVER clamp a horn booster or transducer in a vise or use tools such as pliers visegrips etc Doing so will scratch and or gouge the surfaces and introduce stress risers in the stack The irregular surfaces would affect the stack operation and that could lead to failure of each stack component The stress risers could de velop into cracks causing the stack components to fail Figure 5 4 Stack Disassembly 49 Ultra 15 kHz Assembly System User s Manual Stack Assembly Preassembly Check Before assembling a stack inspect all of the components for possible damage Take a few moments to inspect the surfaces to be joined They should be s
45. IGGER flag increasing the distance traveled before the ultrasound signal is turned on The flag shows where the ultrasound signal will be turned on The signal can start either before the horn contacts the assembly part or after contact is made As the horn descends the ultrasound signal stays on until the weld controlling parameter time distance or energy has been met or until the tops of the STROKE POSITION and END WELD indicator flags are even NOTE To help establish reference points a scale from 000 to 100 has been put on the Pre trigger and End Weld adjustment knobs NOTE Refer to the Ultra Com User s Manual as you decide on the trigger settings Make sure your Ultra Com setup corresponds to the mechanical adjustments you have made to the press itself When pre trigger is not needed for an application turn the knob so the indicator is at the bottom of its slot CAUTION Adjust the pre trigger flag so the ultrasound signal will not start until the horn is 1 4 inch 7 mm or less from the part to be welded Continued 32 Section 3 Controls and Indicators Pre trigger Adjustment Knob continued End Weld Adjustment Knob Turning the knob moves the END WELD indicator flag The top edge of the flag shows where the ultrasound signal will be turned off When the pre trigger control is used to start the ultra sound signal as the horn descends the end weld fea ture can be used to shut of
46. If the encoder position reads nega tive xxx then the encoder is above the 0 reference point used to measure distance by the Ultra Com This is the correct setting Secure the two screws on the encoder head and proceed to Step 6 XXX approximately 125 to 250 b If after running one cycle the encoder position reads positive xxx loosen the two encoder head screws and slide the head down until the reading goes negative xxx Secure the two screws Proceed to Step 6 6 Set the gap between the encoder scale and head using a 039 inch 1 mm feeler gauge blade 7 Measure the gap at the top and bottom of the stroke Allow able tolerance as specified by the encoder manufacturer is 005 range from 034 to 044 inches or 864 to 1 12 mm 8 Loosen and tighten all the screws as necessary and check the measurements again after tightening them Attach Side Panel Install the modified right side panel with its five 5 1 4 turn retaining pins Route the encoder cable through the notch in the thruster s aluminum casting Connect the cable to the J12 connector on the Ultra Com 42 Section 4 Press Options Electronic Pressure Regulator The electronic pressure regulator I P transducer is an electro pneumatic replacement for the manually adjusted air regulator on the press The I P transducer converts electrical signal current I into air pressure P The Electronic Regula tor takes an electrical
47. RFI Filter The Radio Frequency Interference RFI provides the necessary control filtration and distribution of the input power to meet regulatory requirements The filter is required to prevent high frequency noise produced by the generator from interfering with the operation of nearby equipment This RFI has a leakage cur rent less than 3 5mA 50 60Hz line frequency Regulatory Agency Compliance CAUTION DO NOT make any modifications to the gen erator or to its associated cables because the changes may result in violating one or more regulations under which the equipment is manufactured The Ultra 4000 ultrasonic generator has been tested and found to comply with The limits for FCC measurement procedure MP 5 Methods of Measurement of Radio Noise Emissions From ISM Equipment pursuant to FCC code of Federal Title 47 Part 18 for Ultrasonic Equipment 59 Ultra 15 kHz Assembly System User s Manual Installation Site Selection 1 Review the generator s relationship to other system com ponents its power requirements dimensions and weight See Specifications in Section 12 before choosing a place for it 2 Follow the Safety Considerations listed above Connections Make sure the basic generator connections listed in Table 6 1 below are completed See Figures 2 5 and 2 8 in Section 2 of this manual for detailed diagrams and more information CAUTION Before connecting or disconnectin
48. S GENERATOR MODEL 1544000 MADE IN USA NOILWHOdHOO INANA 9SHEZL o00rvst 00006 1300W VSN SIONITI S3THVHO LS DISCONNECT POWERCORD BEFORE JI 240 VAC REMOVING E 50 60 HZ COVER O 30A d OPERATIONAL CONTROL U S OUTPUT Figure 6 3 Generator Identification Number Locator 65 Ultra 15 kHz Assembly System User s Manual This page intentionally left blank 66 SECTION 7 System Test e This section explains how to test the stack before the press is put into full production Dukane Corporation This page intentionally left blank Dukane Corporation Section 7 System Test Overview To operate a Dukane ultrasonic assembly system efficiently the ultrasound signal from the generator must match the frequency and phase characteristics vibrational characteristics of the acous tic stack it drives Each stack has unique vibrational characteris tics depending on the combination of its components In addi tion the characteristics of a particular stack may vary slightly from cycle to cycle because of temperature and loading factors Auto Trac Tuning The generator s Auto Trac feature in combination with Dukane s patented Phase Lock Loop Pulse Width Modulation circuitry enables a match between the generator s signal and the charac teristics of a particular stack The Auto Trac feature automatically adjusts the ultrasound sig nal to match the stack s vibrational characteristics The moment the ult
49. Thruster Air Inlet Detail 18 Section 2 Installation Press System Connections continued Optional Connections Complete cable connections for any optional features Linear Encoder If your unit has the linear distance encoder connect the encoder s free end to connector J12 THRUSTER STROKE ENCODER on the back of the Ultra Com See Pages 39 42 for more infor mation about the encoder Top of Stroke Cable This optional cable connects the thruster s J40 TOP OF STROKE SWITCH connector to the customer s automation system The switch in the thruster opens when the press thruster slide assem bly returns to the fully retracted or top of stroke position This contact closure is typically used with automated systems to indi cate to the controlling mechanism that the slide assembly is fully retracted NOTE Under normal use we recommend that the maximum voltage and current applied to the contacts do not exceed 24 VDC 2 amps Recheck Connections Recheck all connections and when they are all secure you are ready to connect electrical power Connect Electrical Power As a final step in the cabling of your system connect electrical power to the Ultra Com and to the generator See Section 12 Specifications for input power requirements 19 Ultra 15 kHz Assembly System User s Manual Installing the Thruster NOTE Each installation presents its own set of conditions for the in staller The inf
50. actions Section 11 Dukane Corporation Contacts and War ranty gives contact information for members of the Dukane Ultrasonics factory support team The warranty also appears in this section Section 12 Specifications gives technical specs and information about the 4 000 watt generator and the Ad vanced Programmer The Index provides page references for key terms and concepts used in this manual Ultra 15 kHz Assembly System User s Manual System Overview Ultra Series components are among Dukane Corporation s most technologically advanced These components can be manufac tured for a variety of applications Each thruster or press can function independently or a system can also be integrated with a customer s automated machinery The 15 kHz assembly system excels in providing superior weld consistency and extensive control when joining larger parts A typical system includes a thruster a 4 000 watt generator to supply power a press and a Ultra Com High Power Process Controller The Ultra Com is a process controller providing essential control and monitoring features for ultrasonic welding operations An accessory the Advanced Programmer can be added to allow the operator a more efficient method of pro gramming and monitoring the welding process Making the System Operational To operate the system an acoustic stack or simply stack consisting of transducer booster and horn must be added In addition a fix
51. al 6 Lift the stack out of the housing NOTE When changing or inspecting any of the stack components ALWAYS remove the stack from the thruster Continued 47 Ultra 15 kHz Assembly System User s Manual Stack Removal continued Electric Shock Potential Explanation Transducer performance depends on the nature of its piezoelectric makeup Electrical energy is converted to mechanical energy when the stack is in use inside a press thruster After the press has been turned off and handling the stack becomes necessary keep in mind that any electrical charge that has built up inside the trans ducer will discharge from the contact button So when removing a stack from the press thruster do not touch the transducer s contact button Set the transducer aside Wait a few minutes and usually the charge will dissipate completely Once removed from the press thruster the transducer is capable of converting mechanical energy to an electrical charge For instance electrical energy might be produced if the transducer experiences a change in temperature or if the transducer receives a physical blow of some kind Again any electrical charge that results from these kinds of mechanical forces would be focused at the contact button Receiving a transducer shock would be similar to a shock you may experience when touching a household light switch after crossing a carpeted floor 48 Section 5 Stack Fixture Setup Stack
52. an Allen wrench in the socket head of the stud to the following specifications 200 inch pounds 16 6 foot pounds or 22 5 Newton meters for a 3 4 16 threaded stud NOTE Always assemble the mounting studs that mate boosters trans ducer and horns to the input end of the horn or booster Never thread a stud into the transducer or into the output end of the booster first Horn to Booster or Booster to Transducer Assembly Always remove a transducer booster assembly from the thruster before attaching a horn Inspect all surfaces of the components to be joined for stress cracks chips or gouges Any of these irregularities will affect operation and could lead to further equipment damage Refer to Section 9 Maintenance for steps to take in cleaning or smoothing the mating surfaces Be especially sure that the mating surfaces of the two compo nents are clean and flat These surfaces must make good contact for energy to be transmitted properly from one component to the next Pitting corrosion or a build up of grease or dirt on a mating surface will interfere with this energy transfer Make sure the stud in the horn or booster is tight Then clean the stud and its mating hole Coat one of the mating surfaces with a thin layer of high pressure grease See the NOTES on this page Use correctly sized spanner wrenches for components with span ner wrench holes Use an open end wrench on components with wrench flats Use of a c
53. anvas strap wrench or other holding means are acceptable if the tooling will not be gouged NOTE DO NOT apply grease or any other lubricant to the stud Input End gt Threads Shallower Than Output End ee Output End Threads Deeper Than Input End wae End We Output End Figure 5 6 Input Output Ends Identified NOTE Dukane recommends using silicon based Dow Corning 4 or Dow Corning 111 as an alternate to coat one of the mating surfaces If a silicon based grease cannot be used one that is petroleum based is acceptable However that type of grease is likely to leave carbonaceous deposits on the surfaces requiring more mainte nance than would the silicon based product 51 Ultra 15 kHz Assembly System User s Manual 52 Changing Stack Components continued Installing the Stack L Figure 5 7 shows the relationship of the stack to the thruster just before stack installation Place the stack inside the thruster with the transducer and booster resting on grooves designed to match with their mounting rings Make sure the contact button on the top of the transducer meets the electrical contact leaf of the thruster Support the stack in this position with one hand on the horn Close the stack access door with the other hand Start to thread the two socket head bolts that secure the access door If the horn is not properly aligned with the fixture rotate the stack until horn and
54. assembly descends and during the Weld portion of the cycle Pressure 2 regulator is active as the Hold portion of the weld cycle takes place Ultrasound Active Status Light WELDER ON This light glows green whenever the ultrasound signal is applied to the stack Indicator Flags The flags can provide visual feedback for three aspects of the weld process END WELD PRE TRIGGER and STROKE POSITION Only the STROKE POSITION flag moves with the slide assembly itself To find out how far this slide assembly moves When the slide is in its up or retracted position note the top edge of the middle flag is aligned with the 00 on the stroke position scale Then when the slide assembly is fully extended note where the top of the flag is That is the stroke distance See the EXAMPLE below EXAMPLE The STROKE POSITION flag starts at the 0 mark on the scale At the extension of the slide assembly the posi tion of the flag is at the 10 mark Subtract 0 from 10 and the result is 10 centimeters This means that the slide assembly has moved 10 centimeters END WELD and PRE TRIGGER flags move when their corre sponding adjustment knob is turned Readings are taken from the top edge of these flags See and on the next pages for more information Continued 31 Ultra 15 kHz Assembly System User s Manual Indicator Flags continued 9 Pre trigger Adjustment Knob Turning the knob clockwise lowers the PRE TR
55. ator in the OFF position 21 Ultra 15 kHz Assembly System User s Manual 12 conductor cable Part No 200 418 von FESCH ULTRACOM IDUKANE CORPORATION ST CHARLES IL 60174 MADE IN USA THRUSTER STROKE E GE ENCODER Customer we Automation L 120 VOLT 50 60 HZ 0 5 AMP Coaxial RG11A U Part No 200 1289 Part No 438 528 U S PATENT 4 277 710 Ze DUKANE CORP ST CHARLES IL U S GENERATOR Ee W I ep ER EE Fb Ey 8 MODEL 1544000 80 100 psi MADE IN USA Air Supply Sue 50 60 HZ 30A Operational Control Top of Stroke Ultrasound Input Linear Encoder optional Zen m mm pm mm em mm mm pm mm pm mmm mm pm mm pm mm pm mm mm mm mm mm mm pm mm mm mm mm pm mm mm mm mm mm mm len mm vn mm mm mm mm vm Let Customer Supplied Abort Switch Figure 2 8 Thruster Only Cable Connections 22 WARNING POWER MUST BE GROUNDED AT OUTLET DISCONNECT POWERCORD BEFORE REMOVING COVER OPERATIONAL CONTROL Part No 438 299 Part No 200 607 AUTO INPUT SAFETY SWITCHES J9 OPERATIONAL CONTROL OPERATIONAL CONTROL J8 TO THRUSTER TO GENERATOR ZO J7 J6 CHART REC 0000000000000 000000000000 OUTPUT RS 232 SERIAL PORT DEC J33 AUXILLARY WARNING REMOVE ALL POWER BEFORE CONNECTING OR DISCONNECTING ANY CABLES WITHIN SYSTEM REFER SERVICING TO QUALIFIED PERSONNEL POWER LINE MUST BE GROUNDED AT OUTLET 5 conductor cable
56. avel time at the customer s site is provided on a Monday through Friday excluding holidays 7 a m to 7 p m basis Any warranty service requested outside of these hours is available on a charge basis equal to 150 of Dukane s prevailing rate for technical service work Any equipment or tooling that proves to be defective in material or workmanship during the stated warranty period will be repaired or replaced at the sole discretion of Dukane Corporation when Dukane is promptly notified in writing During the warranty period defective equipment components or tooling that are returned properly packed with all transportation charges prepaid will be repaired or replaced and returned to the end user without charge Shipments of warranty parts will be via standard non expedited delivery service Expedited shipment requests are subject to freight charges to the Purchaser Computers PLCs CRTs LCDs touch screens and keyboards separate and or incorporated as an integral part of a system will carry a one 1 year warranty from the date of shipment when used under normal operating conditions and not subjected to misuse abuse or neglect For all other equipment components or parts included in equipment or systems from Dukane but not manufactured by Dukane or its affiliates this warranty shall be limited in time and extent to the warranty given to Dukane by the OEM EQUIPMENT WARRANTY EXCLUSIONS OR EXCEPTIONS When specified in our quotation a lim
57. before using another horn 73 Ultra 15 kHz Assembly System User s Manual Cycling the System d 74 Check that you have correctly performed the following a Installed the stack in the thruster and securely closed the stack access cover b Secured the fixture in place c Completed the Operational Stack Test Select the Ultra Com OPERATE mode with the Front Panel mode select keyswitch Also set the OPERATE STOP TEST switch on the generator to the OPERATE position Verify that all controls on the press thruster and the Ultra Com are set as required for this operation Place a part in the fixture Cycle the system If using the dual push button activation switches to start the system cycle press them both simulta neously and hold them until the ultrasound signal starts Re leasing the activation switches before the ultrasound starts will abort the cycle Section 7 System Test Running Sample Parts When monitoring an application two elements that should al ways be observed are Power Draw and Assembled Part Quality If sample parts are made using an acceptable power draw and if they meet quality standards and any other application depen dent criteria then a full production run can be initiated Power Draw Before cycling the system get in position to watch the Ultra Com Front Panel display where POWER can be shown From the Ultra Com SETUP menu choose UTILITIES then POWER UTILITIES then POWER
58. cates that power is applied to the press The press is ready for operation e ABORT When the PUSH FOR EMERGENCY OFF switch is pushed in the red ABORT status indicator lights up Press operation is no longer possible e IN CYCLE When both left and right activation switches are pressed IN CYCLE lights up on the press status display for as long as the palm switches are activated 38 SECTION 4 Press Options e This section provides information on the common options available for the press Dukane Corporation This page intentionally left blank Dukane Corporation Section 4 Press Options Overview This section provides information for several common options e Linear Encoder e Electronic Pressure Regulator e Pressure Transducer and e Force Transducer Linear Encoder An optional device for your Ultra 15 kHz Assembly System is the linear encoder also known as the distance encoder It may have come with the original system purchase or it may have been purchased as an add on after the initial system installation had been made Purpose The linear encoder accurately mea sures the distance travelled by the slide assembly and ensures that slide assembly movement can be pre cisely controlled and monitored To Ultra Com J12 Components The linear encoder kit P N 438 846 consists of Linear Encoder Scale movable e encoder scale e encoder head and mounting plate e modifi
59. connections and cable routing checked a final time the power may be restored Ultra 15 kHz Assembly System User s Manual Special Health Notice Plastics Before using any Dukane ultrasonic system become familiar with applicable regulations about the particular type of plastic s you are using In the USA check with the U S Department of Labor When plastic materials are being processed they may emit fumes and or gases that could be hazardous Make sure there is proper ventilation whenever these plastics are processed Electrical Safety Grounding Instructions For safety the power cords used on all Dukane products have a three prong grounding type plug The type typically used with the Ultra Com is shown in Figure 1 1 The plug typically used with the 4000 watt generator is shown in Figure 1 3 CAUTION If you must use a two prong electrical receptacle we strongly recommend that you replace it with a properly grounded three prong type Have a qualified electrician replace it following the National Electric Code and any local codes and ordinances that apply See Figures 1 1 and 1 2 Te Di e WS D CAUTION Approved 2 pole 3 wire grounding receptacle BRYANT No 5261 or equivalent to NEMA 5 15R OR 5 20R If there is any question about the grounding of your receptacle have it checked by a qualified Figure 1 1 Example of 120 V electrician Grounded 3 Prong Receptacle Do not cut off the powe
60. d reconditioning when mating surfaces become uneven or corroded These conditions cause poor contact between the mating surfaces This wastes power makes tuning of the acoustic stack difficult can cause heat damage to the transducer and can contribute to a higher system noise level NOTE Before deciding to recondition mating surfaces on your own consider calling Dukane Corporation s Tooling Support to discuss the situation This is especially true if the mating surfaces are uneven because machining of the components may be required Factory personnel can offer their skills and experience for your situation See Section 11 for a list of Dukance contacts Reconditioning the Mating Surfaces Machining Instruction to machine the stack components is beyond the scope of this User s Manual Please call Dukane s Tooling Support team for machining information See Section 11 for a list of Dukane contacts Manual Resurfacing Follow the steps below to manually resurface the stack compo nents mating surfaces 1 Disassemble the acoustic stack and wipe all the mating surfaces with a clean cloth or paper towel 2 Examine all of the surfaces If any is corroded discolored or coated with hard deposits it should be reconditioned Continued 84 Section 9 Maintenance Resurfacing Components continued 3 H If the surfaces appear as if they are in good condition go to Step 11 If necessary remove the mou
61. damage e loose or cracked stud or e pitted or dirty mating surfaces Make any necessary repairs or adjustments Go to Step 7 7 Repeat Steps 1 6 If the bad indicators disappear reattach the horn to the stack and repeat Steps 2 4 e If any bad indications are still present do not run this stack Call Dukane Service for assistance Range Adjustment of the Auto Trac Feature NOTE Do not adjust the Auto Trac range unless the preceding Stack Test procedure directs you to do so New Dukane horns are designed to operate with home for the Auto Trac range control being set at the three o clock nine o clock position If you adjust this control to operate an older or non Dukane horn return it to the home position before trying to run another horn The goal of this adjustment is to run the horn without any of the bad indicators shown in Table 7 1 Continued Z1 Ultra 15 kHz Assembly System User s Manual Auto Trac Range Adjustment continued 1 Make sure that the correct booster and horn specified for the application are installed in the thruster Check the press Ultra Com and generator for proper grounding Check the ultrasound cable connections on the generator Ultra Com and thruster for proper seating and security Verify that the horn is not under load Gin contact with a fixture or part Remove the plug button from the front of the generator to reveal a slot on the Auto Trac range cont
62. e AOKRON N NPY GA M r 12 4 Press Base EE 79 Primary Reference Documents for Subsystems ccccccsscscsseseeseeseseeseseens 80 Location of Stack Mating Surfaces cc cccccccccsccsscseesecsecseeecsecseeesseeseesees 81 Burnished Area Indicates Flat Mating Surfaces cccccccscccsecsseseeteeseeees 82 Burnished Area Indicates Uneven Mating Surfaces ccccccccccesseseeseesees 82 Example E 82 Example of Center Depression cccccccsesecsessescscesseseescseeecseesecseescseeseenees 82 TEEN 85 Ultra Com Input for Emergency Stop Switch 110 Front View of EE 120 Left Side View of Press eege 120 Top View of Press Base cacesssdccazaciactactechcceuniwcensuaveeanvacedheasdnlseiesiceenamiat 120 Location of Model and Serial Numbers ccccccsscssesseseseeseeseseeseeeeaes 122 xii Table of Contents Table of Contents List of Tables 2 1 Approximate Dimensions and Weights cscesserseseseeseteeteereneeseeeteees 11 22 Press System Basic COmMecton sa decititcsciienade secs cewadotnexepssinnadaueeadsabnud caezds 17 2 3 Thruster System Basic Cable Connections cccccccccsccsecssesecsessesesseeseesees 23 SN Waste Symbols aosan csccgsisien asdensedere ni enero ees 29 6 1 Generator Connections ae cie cence yactcccucceseisaceeadatexsierecneducdiuartsearseeasteteenaeeeee 60 7 1 Test Procedure Indications g2sacsieasxcvectessuacrcodeducleotermusssetentelaautiadevedanaens 69 9 1 Booster a
63. e stack Replace horn Replace transducer Replace booster Cool stack with air 107 Ultra 15 kHz Assembly System User s Manual Equipment Troubleshooting Problem Generator Output Power Level Meter indicates OVERLOAD System components may be hot Probable Cause Stack vibrating outside Auto Trac range Horn loose at booster Booster loose at transducer Ultrasound cable connections loose Horn contacts fixutre during weld cycle Welding pressure too high Problem Ultrasound signal does not start Probable Cause No power to generator or Ultra Com ON OFF AC power switches in OFF positon Overload protection circuitry in generator shuts down the ultrasound signal because stack is vibrating outside the Auto Trac range Generator ultrasound signal indicator light does not glow 108 Solution Perform the Operational Stack Test found in Section 6 Tighten Tighten Tighten Adjust fixture Adjust stack components Raise the mechanical stop Also recalculate measurements of part energy director etc Make necessary programming changes to the Ultra Com Adjust pressure setting Solution Restore power Turn power switches ON Perform the Operational Stack Test found in Section 6 Restore power to the generator and twist the OPERATE STOP TEST selector switch to the TEST position for a moment Section 10 Troubleshooting Problem Ultrasound signal does no
64. e the back of the thruster onto the support structure Examples of this structure a weldment a frame or a baseplate 2 Align the thruster with the support structure This can be done by using the thruster bolt holes and or dowel pin holes to align with bolt holes and dowel pins of the support structure See Figure 2 7 The thruster has three threaded mounting holes 3 Insert three mounting bolts 3 8 16 x 1 1 4 hexhead or equivalent with flat washers as shown in Figure 2 7 Horn _ Dowel Pin Hole 2 Fixture Figure 2 7 Mounting the Thruster 4 Adjust the thruster so the horn meets the fixture at the proper angle for your applcation 5 Tighten the bolts Connections for Thruster Only 1 Make the basic cable connections a through 7 as shown in Figure 2 8 and as detailed on the next page When connections are complete the thruster the Ultra Com and the generator will be interconnected 2 Make any optional connections Connect any customer supplied equipment such as automation chart recorder or printer 4 Complete basic connections with customer supplied air and electricity Connect the power cords last but do not turn on the power yet Continued CAUTION AN Before connecting or disconnecting cables for any system com ponent Turn off electrical power Remove power cords from receptacles Put the front panel power switches for both the Ultra Com and the gener
65. e time Ultra Com_ INITIATE MODE not properly set Air filter clogged Connect cables properly Replace switches These normally open switches must be held closed until the ultrasound signal starts Switches must be released between cycles Depress the switches simultaneously From PROCESS CONTROL select INITIATE MODE then MANUAL See Ultra Com User s Manual Clean replace air filter Source air clean dry and at a higher pressure than expected output pressure in the 80 100 psi range Continued 109 Ultra 15 kHz Assembly System User s Manual Problem Press thruster does not move down continued If using an automation switch to start cycle Automation cable is not properly Connect cable properly connected Ultra Com INITIATE MODE not properly From PROCESS CONTROL select INITIATE MODE then set AUTO See Ultra Com User s Manual A system abort switch is closed Look at the press LED base display to see if an ABORT condition exists Try to clear the condition and make sure the red PUSH FOR EMERGENCY OFF button is in the up or ON position The J8 receptacle on the rear panel of the Ultra Com must be connected to either the emergency stop switch incorporated in the Dukane ergonomic base plate or a customer provided emergency stop switch The customer provided emergency stop switch must be configured as indicated in Figure 10 1 below Power to the Dukane thruster is routed through the normall
66. e triggering Evaluate the support provided by the fixture If required re level or shim the fixture Measure the horn tip length to check for dimensional consistency If varying lengths are found send the horn to Dukane for modification Section 10 Troubleshooting Insertion Problem The boss or the plastic around the boss cracks after insertion Probable Cause The insert is pushed in before the plastic has melted The gauge pressure is set too high The boss wall is too thin There is too much interference between the insert and the hole Problem Solution Reduce the down speed gauge pressure and or the amplitude Use pre triggering Reduce the gauge pressure Increase the thickness of the boss wall Increase the hole diameter Use a smaller insert The insert is not driven to the desired depth Probable Cause The ultrasound is not on long enough Flash fills the hole Applies to an internally threaded insert There is insufficient gauge pressure and or power Problem The cycle time is too long Probable Cause There is insufficient ultrasonic power or the generator overloads There is too much interference between the hole and the insert The area of the part being inserted is not being rigidly supported The down speed is slow Solution Increase the primary weld characteristic Check the bottom stop setting Increase the depth of the hole Increase the gauge p
67. ed right side press panel and e mounting hardware Encoder Head stationary NOTE The Ultra Com that controls the system must have the Dis tance option for the encoder to operate Figure 4 1 Linear Encoder Components Continued 39 Ultra 15 kHz Assembly System User s Manual Linerar Encoder continued Installing the Linear Encoder Kit Remove Standard Right Side Panel 1 Close and lock the air lockout valve See Page 36 2 Turn off the Ultra Com and the generator That leaves the press without power 3 Remove the right side panel with the DUKANE Ultra logo on it from the press 4 Remove the side cover held by 2 flat head screws Save the screws 5 If a top of stroke switch is supplied remove it from its switch bracket Then remove the switch bracket from the casting NOTE The encoder scale and head are joined so please do not attempt to separate them unless directed to do so Install Kit Components 1 Attach the new black bracket to the thruster casting using two 10 32 x 3 8 pan head screws Uf you removed the top of stroke switch bracket you can use the screws saved in Step 5 above Place the new black bracket on the casting and put the top of stroke switch bracket on top of the black bracket Secure the bracket s with the screws 2 Apply Loctite to the threads of two 10 32 x 1 2 flat head screws Attach the rectangular machined aluminum plate to the lower part
68. ergonomic base with integrated palm switches comes in a carton resting on a plywood shipping base and the carton bottom Other system components like the Ultra Com and generator are packed separately To unpack a typical press Remove the straps from the carton 2 Open the top of the carton Carefully remove the packing material and any accessories cables and documentation 3 Cut the tape at the bottom corners and unfold the flaps 4 Carefully remove the carton as shown in Figure 2 1 leaving the press on the shipping base Inspect the system compo nents before placing them in position Immediately report any damage found See the NOTE below See Section 12 Specifications Table 12 1 lists the standard components for both press and thruster systems NOTE Questions or problems Call your sales representative or the Sales Department at Dukane Corporation Headquarters for most concerns If reporting damage contact the carrier first Save all shipping containers and packing materials so they can be inspected in processing any claims that may arise For additional help contact Dukane Support Service See Section 11 for contact information Carefully Remove Carton SES SE lt O Figure 2 1 Unpacking Section 2 Installation Placement Press with Base Use a pallet lift platform or its equivalent to raise the assembly until the bottom edge of the base is even with the top of the benchtop as shown in Figu
69. esult in personal injury 1 Move Shipping Cartons Carefully move the shipping NOIE carton s as close to the final installation site as practical Compressed air must be delivered at a higher 2 Utilities Make provision for a stable compressed air supply pressure than the ex that is clean and dry between 80 and 100 psi Also provide pected output pressure for electricity to meet your equipment specifications and in a range of 80 100 psi 3 Space Requirement Check that enough space has been set aside for your installation Approximate dimensions of the major system components are given in Table 2 1 aoe Dimensions inches mm Weights RE 78 1980 E ee BE or oe me Table 2 1 Approximate Dimensions and Weights NOTE Add about 5 inches 125 mm space above the press and to the rear of the Ultra Com and generator for cable con nections Allow 6 inches 150 mm of space on either side of the Ultra Com and generator for air circulation For more information see Installation in the Ultra Com User s Manual 11 Ultra 15 kHz Assembly System User s Manual Unpacking WARNING DO NOT LIFT your press system manually Lifting and or carrying a press manually could result in personal injury Use mechanical means to move and place your press System components are packed in a variety of ways depending on what has been ordered For instance a typical press system thruster column and
70. etup Overview The Dukane Ultra 15 kHz Assembly System is used to assemble parts in a wide variety of applications The ease with which acoustic stack components can be installed and exchanged helps make this possible In addition this flexibiltity makes regular inspections and maintenance of the stack easier to perform This section tells how to change stack components Removing the stack disassembly assembly and installing the stack are covered The information applies to a first time installation as well as when a change to an existing setup is called for Stack Description The stack consists of three primary components see Figure 5 1 e Transducer e Booster and e Horn For an original equipment system the transducer and booster are usually shipped assembled and installed in the thruster The horn horn tips and fixture are shipped separately TRANSDUCER BOOSTER HOR GE Contact Button ene Ring oe er Housing D G e Spanner Wrench Hole typical Mounting Std Figure 5 1 Stack Components A5 Ultra 15 kHz Assembly System User s Manual Changing Stack Components Figure 5 2 gives an illustrated overview of stack component disas sembly and assembly Disassembly Ultrasound Contact Button Transducer Housing Spanner Wrench Hole Typical M ounting bm Booster Input End d Meonting a So Ring ye Booster Output End Threads Deeper H Than Input End 1 1
71. f the ultrasound signal As the horn descends it will reach the point where the STROKE POS indicator flag is even with the END WELD indicator flag The ultrasound signal will shut off at that point When an application does not require the end weld fea ture position the END WELD flag at the bottom of its slot NOTE The End of Weld input for the Ultra Com comes from the End of Weld press indicator flag and it is used to end the weld portion of the cycle based on the press head position The flag can be manu ally raised or lowered to end the weld at an absolute distance The End of Weld feature is generally not used with a press or thruster equipped with a distance encoder 33 Ultra 15 kHz Assembly System User s Manual Indicator Flags continued p Mechanical Stop Indicator This indicator shows where the mechanical stop has been set The stop ends the press downstroke preventing the slide assembly from moving beyond that point a2 Trigger Control Knob This control allows the operator to select what preload or amount of force will be applied to a part before the ultrasound signal is turned on A pressure switch in the slide assembly closes when a specific amount of force applied to the horn is reached The trigger control adjusts the amount of force needed to close that pressure switch When the switch closes the ultra sound signal starts and the horn begins to vibrate See Figure 3 3 for trigger knob
72. fixture are aligned Finish threading the two socket head bolts on the access door until they are snug DO NOT OVERTIGHTEN Figure 5 7 Installing the Stack Section 5 Stack Fixture Setup Fixture Installation To install a fixture you need to do three things 1 Align the fixture with the horn 2 Level the fixture to provide the necessary support 3 Secure the fixture to the mounting surface Fixture Alignment Hold Down Bolts To safely align the fixture under the Corner horn use the following procedure Refer to Figure 5 8 and Figure 5 9 DP Fixture Sat Hold Down Cap Screws 4 Places a I I 1 Press the PUSH FOR EMERGENCEY OFF switch on the press base This allows the acoustic stack assem Ge ergi bly to be lowered by hand while ofr Switch preventing the system from accidentally cycling 2 Turn off the power to the generator and to the Ultra Com to prevent accidental ultrasound Mounting Holes operation Figure 5 8 Fixture Installation 8 Places M10 1 5 3 Place the fixture including the parts to be assembled under the horn 4 Initially align the two fixture slots over two of the eight mounting holes size M10 1 5 located on the base plate 5 Install the two hold down bolts with washers Finger tighten them NOTE The fixture should be flat on the base If the fixture is equipped with leveling screws adjust the screws so that they do not interfere wit
73. g cables for any system component i JIS turn off electrical power ULTRASOUND FROM ULTRASOUND OUTPUT GENERATOR remove cables from recep J20 Je OPERATIONAL CONTROL OPERATIONAL CONTROL Generator Ultra Com Generator Ultra Com tacles and put the front panel power switches for both the Ultra Com and the genera Generator 50 60 Hz tor in the OFF position AC Power Source one 240 VAC J23 STATUS RELAY Generator Optional Customer Automation Table 6 1 Generator Connections 60 Section 6 4000 Watt Generator Front Panel Controls OUTPUT POWER LEVEL WG Key p AC POWER POWER PUSH TO TURN STOP e OPERATE e TEST AUTO Access to AutoTrac Control Pot Figure 6 1 Generator Front Panel AC Power ON OFF Switch This rocker switch under the AC POWER light controls electrical power to the generator When the power is on the indicator light AC POWER is illuminated This switch is also a circuit breaker for overload protection When the circuit breaker opens the switch rocks back to the off position When the circuit breaker rocks the switch to the off position the equipment requires servicing OPERATE STOP TEST Switch This switch provides a means of turning on and off the generator s ability to produce ultrasound The three switch positions are explained below OPERATE Position This is a ready position With the switch in this position the generator will start the ultrasound when
74. g conditions Loosen the part fit Loosen the part tolerances Solution Design a way to align parts as they go into the tooling fixturing Add a means of alignment e g pins and sockets to the mating part halves Redesign the fixture for proper support Add ribs or gussets to the part With a resilient fixture if large sections of urethane are deflecting add a rigid backup Re dimension the parts Tighten the part tolerance Check the processing conditions 93 Ultra 15 kHz Assembly System User s Manual Problem Welding Internal components are being welded together Probable Cause The internal components are made of the same material Problem Solution Make the internal components out of another material Carefully lubricate the internal parts Reduce amplitude by changing to a lower gain booster g Diaphragmming occurs when the center of a part vibrates to cause Diaphragmming occurs stress cracking or melting of that part Probable Cause Excessive amplitude Excessive exposure to ultrasound Improper gate location design thin wall sections The type of horn and or its placement Problem Overwelding occurs Probable Cause Too much energy is being transmitted to the part 94 Solution Reduce the amplitude Dampen the welding area to absorb the amplitude Reduce the weld time by increasing the amplitude and or the gauge pressure Check gate placement
75. h the seating of the fixture on the base plate Continued 53 Ultra 15 kHz Assembly System User s Manual Fixture Alignment continued Corr Rear Cap E 41 Base Plate 7 635 Top View 4 10 y 14 00 y Y 8 250 Front 16 50 Figure 5 9 Fixture Mounting Hole Measurements 6 Place a part in the fixture 7 Grasp the horn firmly and pull the acoustic stack assembly down until the horn is as close to the part as necessary to align the fixture Tighten the fixture hold down bolts to secure the fixture 9 Adjust the mechanical stop See Section 3 Controls and Indicators so the horn will stop above the fixture This will prevent horn damage if the acoustic stack assembly descends when a part is not in the fixture NOTE Some applications may require the horn to be a few thousandths of an inch from contact with the fixture Special applications may require the mechanical stop to be lowered so the horn makes contact with the fixture or anvil When this is required then a ground detect circuit is needed to terminate the weld cycle Refer to the Ultra Com User s Manual for more information about providing a ground detect circuit Section 5 Stack Fixture Setup Leveling the Fixture The following procedure may be helpful in some applica tions in leveling the fixture To perform this procedure you ll need a piece of carbon paper and a piece of white paper
76. heck with the molder Check the molding conditions Specify the parts to be dry as molded Dry parts by heating them before welding oF Ultra 15 kHz Assembly System User s Manual Welding Problem The parts are marking Probable Cause Solution The horn heats up Check for a loose stud tighten if loose Loosen and then retighten the horn tip Refer to Stack Fixture Setup Section 5 Reduce the weld time Ensure that the horn and booster are coupling well Refer to Section 5 Visually check the horn for cracks There are high spots in the part Check the part dimensions Check the fit of the horn to the part Use of raised lettering Use recessed lettering or relieve the horn around the lettering The part does not fit the fixture Check the fixture for proper support properly Check for cavity to cavity variations Redesign the fixture Oxide from the horn is being Place polyethylene film between the horn transferred to the part and the part Use a chrome plated horn and or fixture The parts contain fillers Check the processing conditions Reduce the amount of filler in the plastic Problem Welding process is not in control inconsistent weld results on a part to part basis Probable Cause Solution A mold release agent is used Clean the mating surfaces If a mold release agent is necessary use a paintable printable grade Incorrect part tolerances Tighten the part tolerances Check the pa
77. ieve ISO 9001 certification you must prove to one of the quality system registrar groups that you meet three requirements 1 Leadership 2 Involvement 3 Quality in Line Organizations and Quality System Infrastructure The ISO 9001 standard establishes a minimum requirement for these requirements and starts transitioning the company from a traditional in spection oriented quality system to one based on partnership for continuous improvement This concept is key in that Dukane no longer focuses on inspection but on individual processes Dukane s quality management system is based on the following three objectives 1 Customer oriented quality The aim is to improve customer satisfaction 2 Quality is determined by people The aim is to improve the internal organization and cooperation between staff members 3 Quality is a continuous improvement The aim is to continuously improve the internal organization and the competitive position ISO 9001 CERTIFIED Dukane products are manufactured in ISO registered facilities 15kHz Assembly System User s Manual Part No 403 542 00 100 00 Printed in the United States of America Dukane Corporation e Ultrasonics Division e 2900 Dukane Drive e St Charles Illinois 60174 USA e TEL 630 797 4900 e FAX 630 797 4949
78. ine Version ONLY 23 Mar 2005 Updated telephone numbers and consolidated warranty Ultra 15 kHz Assembly System User s Manual This page intentionally left blank Table of Contents Table of Contents Section 1 Introduction and Safety Before Operating Eouipment 1 Read this Manual First E 1 Read the Supplementary Ultra Com Manual 1 Watch for Special Paragraphs s2cccasceacercacuannssceastavosdssdeessncavse viennvareanteientececas 1 About this Manual tee 2 Contents aed ea e E A eege 2 Organization sinesi E E E T O E E E O EAT 2 System OVerViEW cz cars aca cater gral eeneg 4 Key Features of the Press Thruster cccccccccccscsscsseseesesecsesseseeseeecseseeseesesseeenees 5 Health and Safety Recommendations cccccsssssescesseseescesecseestesecseeseesecseeseeaes 6 Special Health Notice Plastics ccccccccccccsccssesscecseesecsseseesecseescesecsteseesseas 8 Electrical Safety Grounding Instructions ccccccccccsseseeseesesecsesseseeseeecseeseseens 8 120 Volt Ground Adapter sscssccccsncacsnicsesnsrendentekunsecdentinduuncvacedvabcntiendecsteens 9 30 A Generator EEeegieee EEN 9 Additional Grounding E 10 RFI Filter Considerations sa 25cesesnetdccthsadcsaniiesdsieededbitonnnl aieiena ke baerdosbaaeeetaes 10 Section 2 Installation Before Unpacking sy cisicasicrerntasnonsandarsiorieonati en Eege EE 1 Unpacking EE 12 Placement EE 13 Press wilh BOSE earner eee tre CaN oa T ter arty eee cree ner aa 13
79. ing and suggestions when considering system changes Dukane Corporation This page intentionally left blank Dukane Corporation Section 8 System Operation Overview When system installation is complete and sample parts have been successfully assembled the system is ready for an extended run This section of the User s Manual provides a checklist to use before start up and it gives some basic operating instructions on starting and stopping the system Daily Start up Checklist dp 1 2 O OO O O uu Answer each question with a Yes before starting Cables pages 15 25 Are all cables properly connected with retaining rings screwed tightly in place Grounding pages 8 10 Is the customer supplied source ground properly con nected to the Ultra Com generator and press thruster Air Filter For units equipped with the press support package Is the air filter at the rear of the thruster clean Air Lockout Valve page 36 Is the valve unlocked and in the open position Acoustic Stack pages 45 53 Is the stack properly assembled and installed in the thruster and is the stack access cover securely bolted Horn Booster Fixture Are the horn booster and fixture correct for the applica tion to be performed Check all three items for cracks chips and alignment Mechanical Stop page 34 Will the mechanical stop prevent the horn from hitting the fixture when a part
80. is not in the fixture Ultra Com and Generator Ultra Com See User s Manual P N 403 393C Generator See Section 6 of this manual When power to the Ultra Com and generator was turned on did the units complete start up sequences successfully 77 Ultra 15 kHz Assembly System User s Manual Start up continued Start up After completing the Daily Start up Checklist you are ready for system start up See the previous page for the Checklist 1 Turn air power on 2 Perform the Operational Stack Test as outlined in Section 6 of this User s Manual 3 Verify that all controls on the press thruster on the Ultra Com and on the generator are set as required for your par ticular application Place a part in the fixture 5 Start the system manually or automatically Manual Start If using the dual push button activation switches to start the system cycle press them both at the same time and hold them until the ultrasound signal starts NOTE Releasing the buttons before the ultrasound starts causes an error in the start up sequence and the cycle will stop Automatic Start The system may be activated using customer supplied controls that are linked through the Ultra Com to start the cycle automati cally based on a predetermined sequence of events 6 After the system has started monitor the Ultra Com and the generator output for overload indications 78 Section 8 System Operation Stop
81. ismatch between the ultrasound signal and the vibrational characteristics of the stack that the generator is driving It also lights when too much power is drawn from the generator and the meter reading is in the red At either time damage to the generator may occur When the OVERLOAD light glows or flick ers stop operation and retest the stack using the Operational Stack Test POWER Control Knob This control provides for fine adjust ment of the stack amplitude To achieve optimum efficiency from this generator set this control to as high a setting as pos sible Use an exchange of boosters whenever possible to vary the amplitude so that this control may remain at a high setting Auto Trac Range Control Potentiometer A small plug between the POWER knob and the O S T selector switch conceals the Range Control Pot Section 7 of the User s Manual explains how this potentiometer may need adjustment in the process of matching characteristics of an acoustic stack to the generator output 62 Section 6 4000 Watt Generator Rear Panel U S PATENT 4 277 710 WARNING POWER MUST BE e STATUS DUKANE CORP GROUNDED AT RELAY ST CHARLES IL OUTLET U S GENERATOR MODEL 15A4000 MADE IN USA DISCONNECT POWERCORD IN BEFORE 240 VAC REMOVING j 50 60 HZ COVER O 30A OPERATIONAL CONTROL U S OUTPUT Figure 6 2 Generator Rear Panel Power Cord All electrical power for the generator is obtained
82. it receives a signal from the digital timer timed systems or a switch closure continuous firing systems STOP Position This is an off position The generator cannot generate ultrasound when the switch is in this position TEST Position Use this position only for evaluating the vibra tional characteristics of the stack with the Operational Stack Test See Section 7 This position activates the generator ultra sound DO NOT use this position unless an acoustic stack or probe is connected to the generator or damage to the genera 61 Ultra 15 kHz Assembly System User s Manual Front Panel Controls continued tor may result The O S T switch is spring loaded to return from this position to the STOP position automatically when released Therefore the switch must be manually held in the TEST position OUTPUT POWER LEVEL The front panel meter indicates the percentage of power drawn from the generator when the ultra sound is on The power drawn varies with each operation The meter scale ranging from 0 to 10 represents 0 power drawn For instance 2 represents 20 power drawn and 10 represents 100 power drawn If the meter reading is in the red portion of the scale beyond 100 a power overload exists and the red OVERLOAD light will be lit Turn the system off Then retest the stack using the Operational Stack Test in Section 7 Red OVERLOAD Light The red OVERLOAD light is lit to indicate a m
83. itches controls cables transducer booster horn and fixture Proper Installation Operate system components only after they are properly installed No Unauthorized Modifications Do not modify your system in any way unless authorized to do so by Dukane Corporation Unauthorized modifications could cause equipment damage and or injury to the operator In addition unauthorized modifications will void equipment warranty Keep the Cover On Do not remove any equipment cover unless directed to do so by Dukane Corporation CAUTION At some time you may be asked to remove equip ment covers by the Dukane Service Dept person nel Before doing so disconnect the unit electri cally from the incoming line AC power If the unit is a press thruster lock the Air Lockout Valve located on the rear panel in its closed position See Figure 3 5 on Page 36 Grounded Electrical Power Operate this equipment only with a grounded electrical connection See Electrical Safety Ground ing Instructions on Page 8 Comply with Regulations You may be required to add accesso ries to bring the system into compliance with applicable regulations OSHA in the USA for machine guarding and noise exposure Section 1 Introduction and Safety CAUTION Parts being joined ultrasonically with the Ultra 15 kHz press will vibrate at audible frequencies Wear ear protectors to reduce annoying or un comfortable sounds In addition ultrasound
84. ited warranty may apply to certain components of the equipment and or for certain types of applications of the equipment including those noted below Q This warranty is void if the ultrasonic welder and or tooling i e horn s and fixture s are used for applications requiring metal to metal contact when the ultrasonic exposure period weld cycle exceeds 250 milliseconds Ultrasonic Equipment and tooling used in continuous duty cycle modes such as but not limited to continuous cut and seal and food processing are warranted for 2000 hours or 12 months from shipment whichever occurs first Any ultrasonic horn or tool quoted and sold as Experimental is not warranted Q This warranty does not cover failures of equipment and components attributable to improper cooling or overheating of the transducer Ultrasonic Horn Analyzers have a 12 month warranty Ultrasonic Transducers have a one time replacement warranty Normal wear items and consumables excluded from any warranty coverage include but are not limited to filters fuses light bulbs lubricants gaskets and seals cast urethane fixture components laser flashlamps laser beam delivery optics and lasing gases The forgoing warranty is the sole and exclusive warranty and is made in lieu of all other warranties express implied or statutory including without limitation any warranties of merchantability fitness for a particular purpose descrip tion quali
85. kane horn an improperly assembled stack or a stack component that is worn or amaged can produce vibrational characteristics outside these specifications Pre test Checklist 1 68 Make sure that the correct booster and horn specified for the application are installed in the thruster Check the press Ultra Com and generator for proper ground ing Check the ultrasound cable connections on the generator Ultra Com and thruster for proper seating and security Verify that the horn is not under load in contact with a fixture or part Section 7 System Test Stack Test continued Acoustic Stack Test 1 Turn the generator s AC POWER switch ON 2 Perform a test by manually holding the spring loaded OP ERATE STOP TEST O S T selector switch in the TEST posi tion Compare the generator s indications with TABLE 7 1 below 3 Release the selector switch and it will go back to the STOP position ITEM BAD GOOD Light glows or flickers Reading of 5 15 Reading over 15 Vibration at Vibration No vibration observed Horn apparent Table 7 1 Test Procedure Indications If the first three steps of the test were completed successfully the stack is operational Proceed to Step 4 on the next page If the displays show other results there may be a problem with the stack NOTE If the ultrasound signal should stop due to an overload con dition the meter will indicate 0 and the OVERLOA
86. ly System User s Manual Pressure Transducer continued e The other set of limits is used to monitor the air pressure when the ultrasound is turned on This feature can be used as an indicator when checking for a trigger or load cell malfunction A more precise method to monitor trigger force is to use a load cell Calibration The pressure transducer does not require any on site calibration Load Cell A load cell force transducer is a device that measures force The load cell converts mechanical force into an electrical signal The load cell monitors the force applied to the part It sends a signal to the Ultra Com to indicate when the mechanical pres sure is equal to the programmed Trigger Force The trigger is the point at which the ultrasound is turned on The Trigger Force parameter can be viewed from the Utilities menu with the Ultra Com Choose USER PARAMETERS then choose TRIGGER FORCE The values for this parameter are in pounds or Newtons A force versus time graph can be generated if a printer is con nected to the Ultra Com Load Cell Calibration The load cell is calibrated at the factory It does not require any on site calibration 44 SECTION 5 Stack Fixture Setup e This section outlines steps needed to remove and assemble an acoustic stack It also discusses fixture installation Dukane Corporation This page intentionally left blank Dukane Corporation Section 5 Stack Fixture S
87. mooth and clean Look for surfaces that are uneven concave convex have stress cracks chips or gouges Any of these irregularities will affect the operation of the stack and could cause further damage Refer to Section 9 Maintenance for steps to take in cleaning or smoothing the mating surfaces If the components have no damage continue with the fol lowing steps NOTE A pitted surface or one that has a buildup of old grease and dirt will interfere with the transfer of energy from one com ponent fo another 1 Remove any foreign matter from the threaded stud and the mating hole 2 Put a thin coat of high pressure grease A small packet is supplied with the system on one of the mating surfaces If high pressure grease is not available then use a thin coat of petroleum jelly NOTE Do not apply grease or lubricant to the stud or to its corre sponding mating hole 3 Thread the components together and tighten them Figure 5 6 by applying torque as follows 250 inch pounds 20 8 foot pounds or 28 2 Newton meters Figure 5 5 Assembling Stack Components CAUTION Do not overtighten Overtightening compo nents can cause stress cracks stud loosening or unexplained power supply overloading Continued 50 Section 5 Stack Fixture Setup Stack Assembly continued Mounting Studs Thread the mounting stud into the input end of the horn or the input end of the booster Tighten with
88. nalen e a tege 116 Section 12 Specifications Regulatory Agency Compliance cccccecccsseseeseeseeseeseeseeseeseeseeseeseeseeseeseeneens 117 System Standard Components EE 118 Systemi REQ MEIER gereest EE eK EEEE AVRO E EEES ee 119 Compressed EE 119 STEE 119 el driest ust eka Tce Sa imc eas tel Tse tia Se as oiler tab iste 119 Eege 119 Press Thruster Dimensions scicnessticcdarqacenesnaenarosdtamanibiadeagadeenesntentitedesumendarsd 120 Operating EIERE eege 121 Identification Duer 122 Table of Contents Table of Contents List of Figures NWN OMANADKRWON WBN HADRON DONAGDKRWN RON NV ARRAAAAAAAATARR EEE OOENHNHNHNYYYT TSS Example of 120 V Grounded 3 Prong Receptacle ccccccccccssesessseseeees 8 Example of 120 V Ground Adapter Hookup c cccccsseseeetseseescsseeeseseens 9 Example of 30A E EE 9 Typical Equipment Grounding Arrangement 10 BEER 12 Pr ss Ree 13 Adjusting the Column Clamps i cs ancescssass acatesceteesasasanasnaracesesaenseicrsedecsnonen 14 Press Right Side View sasiersasanraeirucadineriaatanarandedbataniavanranintentninatdnlashanstinnss 14 Press System Cable Connections ccccccccsscscesecsceseesecseeseesecseeseeseeseesees 16 Thruster Air Inlet Detail sicsccnessscczsonatecscescnsicadiescedesietahsdndanondenewticctnatelesauaas 18 Mounting Hagen eet Eeer 21 Thruster System Cable Connections ccccccccccceseeseeseeseeseeseeecseeseeseeseeneens 22 Base Flange Template
89. nd Horn Stud Torque ccccccccccsssssesecsseseesecseseeesecsesseeseeseeeesees 87 10 1 Equipment Requirements for Primary Weld Characteristics e00 92 12 1 Ultra 15 kHz Systems Standard Components c ccccccecsessesseseeseeseens 118 12 2 Component Dimensions and Weight 119 12 3 Miscellaneous Dimensions ssiie lt ccocescaveccssdawsssanenstercatarcssateotsmmiaonvend 121 xiii Ultra 15 kHz Assembly System User s Manual This page intentionally left blank xiv SECTION 1 Introduction and Safety e This section introduces the User s Manual and the equipment and also deals with safety considerations Dukane Corporation This page intentionally left blank Dukane Corporation Section 1 Introduction and Safety Before Operating Equipment Before you operate the equipment please follow the recom mendations given here Read this Manual First Before operating the equipment read this User s Manual to get familiar with the Ultra Assembly System Read the Supplementary Ultra Com Manual Because the Ultra Com High Power process controller is an integral part of your plastics assembly system please read the User s Manual Dukane Part No 403 393C before operating the system The Ultra Com manual is a companion to this User s Manual and it supplements information provided here By reading both manuals you will have gained basic under standing of equipment operation This will be helpful in
90. ng Overview Process Troubleshooting This first part of this troubleshooting section provides infor mation to help identify causes and to recommend solutions for problems you may have during e Welding e Inserting e Staking or e Continuous Welding The Process Troubleshooting material on Pages 93 107 has these three elements e Problem e Probable Cause and e Solution Equipment Troubleshooting Beginning on Page 108 the second part of this section gives information focused on equipment troubleshooting Continued 91 Ultra 15 kHz Assembly System User s Manual Troubleshooting Overview continued Process Troubleshooting Primary Weld Characteristics Dukane Corporation s Ultra Systems support those primary weld characteristics for which they have been configured Solutions of fered here may or may not apply to your particular welding system Primary weld characteristics such as Time Distance Absolute Distance Energy and Peak Power are used to control the weld ing process Each characteristic needs certain system components to support it Table 10 1 shows each characteristic with correspond ing equipment requirements Characteristic Equiment Requirements Ultra Com with a time function Ultra Com with a distance measurement function Distance distance module and a press or thruster equip ped with a linear encoder Ultra Com with a distance measurement function distance module and a
91. nicssenksicraniitinditeanaia seetecubioutsechoasannnierniosiiea i iaa 84 Torque EE 87 QV eene Eeer 87 Stack Assembly Torque Values is vo cxsacdscoadewatexessisiasduinesedsche ds nneasasedeniedeenanees 87 Booster and Horn Stud Torque Values ccccccccsscsscscesscseesceseeseeseeseesteatenes 87 Press Thruster Maintenance cccccccssccsecssscscessesscesscsscesecsseseecseseesessesecessessens 88 Daily Nin E EE 88 Six Month Periodic Maintenance cccccsccssessecsscesecseeescessesecesecssesseeseeeees 88 Ultra 15 kHz Assembly System User s Manual Table of Contents Section 10 Troubleshooting Ee 91 reegelen ebteeetetre Ate Ee 91 Equipment Troubleshooting ccccccccsscssessesecsecscesecseescesecseescesecsseseesecstesees 91 Process Troubleshooting ergeet 92 Primary Weld Chorocheriettcs 92 EE 93 LE EE 100 el EE 103 Continuous Welding EE 106 Equipment Troubleshooting cccccccccsccssesecseeseesecseesecsecseesecsecsessecsecseeseeseeseens 108 Section 11 Dukane Contacts and Warranty Contacting Dukane Crelo eegne 113 EE 113 Try Our Website EH 113 Contacts in the Ultrasonics Divisionisisssssisacansoncastedsontianiidsatansviannnsancavantiveeas 113 Ultrasonics Division E mail Addresses ccccccccsccscesecseeseeseeseessesecseeseeseees 114 Ultrasonics Division Phone Numbers sssssssseseiiessessissrsisissrrrrsrsrsrrnenn 114 Dukane Corporation Warranty USA Canada Mexico sec cece e Ee eEeE 115 Internatio
92. ns Section 2 Installation explains setup of the press thruster and shows cable connections for a typical system Section 3 Controls and Indicators introduces the control devices on the press thruster and press base Section 4 Press Options provides detailed information re garding the installation and operation of the linear encoder electronic pressure regulator pressure transducer and load cell Section 5 Stack Fixture Setup gives information about removing and installing the stack assembly Procedures for stack component disassembly and assembly are covered also Section 1 Introduction and Safety Organization Before Welding continued Basics of Operation Sections 6 8 Section 6 4000 Watt Generator provides information on installation the front panel controls rear panel connec tions and basic operation of the generator Section 7 System Test provides the testing methods used to ensure that the press system is functioning prop erly before normal operations start Section 8 System Operation provides a start up check list start up and shut down procedures and things to consider when making changes to the system Supporting Information Sections 9 12 Section 9 Maintenance provides information on main taining the stack components and the press thruster Section 10 Troubleshooting provides a list of the more common problems that may occur in the various ultrasonic processes It also provides suggested corrective
93. nting studs Tape a clean sheet of 400 grit or finer emery cloth to a clean smooth flat surface such as a piece of plate glass so the grit side is up Hold the stack component with one hand as shown in n Figure 9 6 This view shows the thumb covering one of the three spanner wrench holes j Without applying any downward pressure carefully stroke E k m the part IN ONE DIRECTION across the emery cloth The GH vy component s weight alone will be enough as the part is rg p 3 s moved Complete a second stroke across the cloth just d S like the first one Figure 9 6 Manual Resurfacing CAUTION Use extreme care to keep the part level when moving it across the emery cloth Do not tilt it An uneven mating surface could leave the welding system inoperative Keep the element s surface flat against the emery cloth and turn it 120 one third of a complete rotation so the thumb covers the next spanner wrench hole Again move the part twice across the emery cloth as outlined in Step 6 Give the part a final one third turn and repeat the two strokes described in Step 6 CAUTION It is important to perform only 2 strokes each time the component is rotated 120 Perform ing more or fewer strokes affects whether the surface remains flat If the surface loses its perpendicularity in relationship to the component s centering axis the weld ing system may become inoperative 85 Ultra 15 kHz Assembly Sy
94. of the thruster casting using those screws 3 Put the stationary encoder head on top of the aluminum plate so its top and bottom holes line up with matching holes in the plate Temporarily attach the encoder head with two 6 32 x 3 4 pan head screws and washers Screws will be tightened later during alignment 4 Secure the encoder cable to the black bracket using two nylon cable clamps two 10 32 lock washers and two 10 32 nuts Loosen or remove the presss support panel Gf sup plied and feed the cable and connector through the notch in the thruster casting Use edge guard to protect the cable from any sharp edges on the press support sheet metal AO Top of Stroke Black Bracket Switch Bracket Qu Qu e Thruster able Casting Clamp 2 L en E e Encoder Cable Figure 4 2 Linear Encoder Mounting Detail Section 4 Press Options Installing Linear Encoder Kit continued 5 Remove the encoder head and allow it to hang free Attach the new scale mounting plate to the casting using the screws saved when the standard thruster side panel was removed Use Loctite or a comparable adhesive on the screw threads 6 Again attach the encoder head to its aluminum plate Remove the screw that holds the stationary encoder head to the movable encoder scale Carefully slide the encoder scale so its top and bottom holes match with holes in the scale mounting plate Use two 8 Scale Mounting 32 x
95. om Sales ussales dukcorp com Support Service amp Parts usservice dukcorp com Technical Writing ustechwriting dukcorp com Tooling Beem We St hw er a eee ear ustooling dukcorp com Training EE ustraining dukcorp com Ultrasonics Division Phone Numbers Application Support 630 797 4930 For applications and or process technology questions Engineering 630 797 4950 For engineering of standard and customized systems Food Processing 630 797 4920 or 4938 For information about using ultrasonics in food processing International 430 797 4915 For questions about international locations support etc Marketing 630 797 4906 For product literature and trade show information Metal Welding 630 797 4953 For information about any aspect of metal welding Sales 630 797 4918 Although your local Dukane representative is the main source of Dukane product and order information you may want to see jue ces is Soe ine ee E A contact the Sales Department i 24 hour Emergency Service i Service amp Parts 630 762 4987 I Effective May 10 2004 7 For a service related problem with your equipment l l 630 797 4987 i Technical Writing 630 797 4907 Cee mm mm ee ee ee mm mm mm d For information and comments about user sg manual content Tooling Support 630 797 4930 For information about tooling horns and fixturing Training Hotline 630 797 4904 We offer a curriculum of educational p
96. ood Prototype Renshape 460 Renwood tools employ are only warranted for 200 part cycles reusable content and therefore remain the property e All other prototype tooling is warranted as of Dukane described in each specific proposal All Dukane warranties commence on the date of the original shipment of the equipment or tooling and duration is based upon a single shift per day five day per week operation The warranty period on rentals of new equipment that are converted to a purchase are deemed to have commenced on the initial date of rental These warranties are limited to equipment and tooling operated and maintained per Dukane s written instructions and used under normal operating conditions These warranties do not include normal wear or normal wear items and do not cover damage attributable to misuse improper installation faulty repair unauthorized alteration or modification neglect or accident Misuse includes operation of equipment with tooling that is not qualified for the equipment or properly installed on the equipment The warranty on all Dukane equipment and tooling purchased and installed in North America is a parts and labor warranty only Equip ment installed outside of North America regardless of where it was purchased is covered by Dukane s International Warranty Policy In all cases when on site service is required Travel amp Living T amp L expenses will be billed at cost Warranty service labor including tr
97. or Ultra Com High Power 43x350 NOTE The High Power Ultra Com unit features an extended power range input capable of measuring the higher Thruster includes Top of Stroke Switch Dual Pressure Regulators and Limit Switches 43A215 Operation Control Cable 200 417 power levels of the 15 kHz Thruster Control Cable 200 418 system The standard High Power High P Ult d j aedi e a 11073996 optional components it then 43A216 becomes a 43C350 138 528 43D350 or a 43E350 Aluminum booster w 3 4 16 threads on oth ends Optional Components Linear Optical Encoder 438 846 Electronic Pressure Regulator Contact Force Transducer Dukane Pressure Transducer I Included Component O Optional Component Available Table 12 1 Standard amp Optional Components for Ultra 15 kHz Systems 118 Section 12 Specifications System Requirements Compressed Air The thruster requires 80 100 psi of clean dry air NO Maximum available clamp pressure is 175 lb 100 psi with a Compr essed air must be standard 1 5 inch diameter 38 1 mm air cylinder delivered at a higher pressure than the expected Electrical output pressure and ina range of 80 100 psi Ultra Com 120 VAC 50 60 Hz 0 5 A Press Thruster 24 vdc 2 amps obtained from the Ultra Com Ultra 4000 Generator 240 VAC 50 60 Hz single phase 30 A 3 wire 2 pole grounded outlet with locking type NEMA L6 30R receptacle Generator will meet 4
98. or statutory including without limitation any warranties of merchantability fitness for a particular purpose descrip tion quality productiveness or any other warranty The remedy set forth in this warranty policy is the sole and exclusive remedy of Purchaser and in no event shall Dukane be liable for any compensatory consequential special punitive or contingent damages or for damages arising from any delay in performance by Dukane under this warranty 116 SECTION 12 Specifications Dukane Corporation This page intentionally left blank Dukane Corporation Section 12 Specifications Specifications Regulatory Agency Compliance The Ultra Com complies with the following requirements e the limits for FCC measurement procedure MP 5 Methods of Measurement of Radio Noise Emissions from ISM Equip ment pursuant to FCC Title 47 Part 18 for Ultrasonic Equipment CAUTION DO NOT make any modifications to the Ultra Com to the generator to the press thruster or to associated cables because the changes may result in violating one or more regula tions under which the equipment is manufactured 117 Ultra 15 kHz Assembly System User s Manual Systems Standard Components The table below lists the standard and optional components available for both the basic press system and the thruster system tem Systems SCH eee Description Hesel Contact Dukane for Model art No Numbers g 15kHz 1544000 enerat
99. ormation offered here is a general guide to thruster installation If installing the thruster by itself make some decisions about your own setup factors Then use the steps outlined below as a guide in mounting the thruster Setup Factors Height Adjustment Mounting a thruster on a rigid stationary support structure means the thruster itself cannot move Therefore after the thruster is installed its height cannot be adjusted NOTE In its fully extended position the thruster slide assembly will have moved approximiately 6 75 inches about 170 mm from its retracted position TIP A shorter distance to Space Considerations travel stroke between the retracted If the thruster height cannot be adjusted position the thruster so horn tip and the parts that the distance from the tip of the retracted horn to the top of in the fixture during the assembly part in the fixture is less than 6 75 inches Exten operation gives two sion of the thruster slide is a maximum of about 6 75 inches or advantages about 170 mm If the distance is greater the horn will be unable e A thruster that is to reach the part to be welded more stable than one fully In addition be certain there is enough space for placing and extended when removing parts applying pressure to the parts and e A shorter duty cycle for a greater production rate 20 Section 2 Installation Mounting the Thruster 1 Plac
100. ow the bottom column clamp Press System Basic Cable Connections Ground the System Make sure the system is properly grounded CAUTION Is the system properly grounded Before proceeding make sure you have followed the instructions of Section 1 relating to electrical grounding Continued Ultra 15 kHz Assembly System User s Manual m y 12 conductor cable mm Part No 200 418 Part No 200 1064 move EECH ULTRACOM IDUKANE CORPORATION ST CHARLES IL 60174 MADE IN USA THRUSTER STROKE ENCODER J12 120 VOLT Coaxial RG11A U Part No 200 1289 US 123456 50 60 HZ ULTRASMUND TO THRIBTER U S PATENT 4 277 710 A POWER MU GROUNDEL DUKANE CORP ST CHARLES IL U S GENERATOR 9Sreel SN MODEL 1544000 MADE IN USA 80 100 psi Air Supply DISCONNI 240 VAC 50 60 HZ 30A COVER O 5 O 2 E S g N T 3 o 5 atlas Sf wn Zu e e FO 2 v ZP wen E CO D E Dil Ww E 5 I 2 E T 0O 0O E l 1 y of i I gt I l l i li I l 1 y Q I Pi l A KN __ Le Li L J35 M Base I 8 conductor cable Interface ny Part No 200 1064 16 WARNING OUTLET POWERCORD BEFORE REMOVING OPERATIONAL CONTROL AUTO INPUT J9 OPERATIONAL CONTROL OPERATIONAL CONTROL TO THRUSTER TO GENERATOR J7 J6 0000000000000 000000000000 RS 232 SERIAL PORT DEC J3 J8 WARNING REMOVE ALL POWER
101. p adjustable in 001 025 mm increments Dual Pressure allows for an increased clamp force im proving melt during the weld cycle or greater pressure in the Hold portion of the cycle to strengthen the weld Calibrated Dynamic Trigger system with LED indicator starts the ultrasonic signal at a precise user selectable force Pre trigger and End of Weld lower limit switches are standard and adjustable in 001 025 mm increments Top of Stroke limit switch for automated applications Ergonomic Base and cycle activation switches reduce operator fatigue optional opti touch cycle activation switches are available Status Indicators in base for POWER IN CYCLE and ABORT clearly communicate system operating status Twist Release EMERGENCY OFF switch on the press base meets international safety standards Advanced Programmer keyboard and monitor pro vide an option for more efficient programming Ultra 15 kHz Assembly System User s Manual Health and Safety Recommendations Please observe these health and safety recommendations for safe efficient and injury free operation of your equipment NOTE These recommendations apply to the welding system System in this manual refers to a complete group of components associated with the welding of parts also known as an ultrasonic assembly system A typical Ultra System consists of the Ultra Com ultra sonic process controller a generator a press with thruster sw
102. ping the System Normal Conditions The press stops when the programmed cycle ends A programmed cycle can have one step or multiple steps Emergency Conditions Manual System Press the red PUSH FOR EMERGENCY OFF gt o a switch palm but ton on the press Left base plate Activation 8 Switch See Figure 8 1 Black Four things hap pen when the switch is pressed Se Right Activation Switch Black Press Status LED Display PUSH FOR EMERGENCY OFF e the ultrasound Figure 8 1 Press Base Switches Switch Red signal is turned off immediately e electrical power to the press is removed e a firmware emergency stop sequence is begun and e the word ABORT appears in the Press Status Display As long as the PUSH FOR EMERGENCY OFF switch is pushed in these conditions are active Twist and pull the PUSH FOR EMERGENCY OFF button to allow the press to reactivate Automated System An automated system has external controls supplied by the customer that will stop the cycle automatically Those controls are connected to the rear of the Ultra Com at the AUTO INPUT connector J9 79 Ultra 15 kHz Assembly System User s Manual Making Changes to the System Your 15 kHz assembly system is versatile but before making changes to your system or setup refer to the appropriate docu mentation Figure 8 2 indicates the primary reference documents for the four major subsystems CAUTION Before connecting o
103. pressure and counterclockwise to decrease air pressure 3 When the air gauge displays the desired welding pres sure Pressure 1 is set Pressure Select Switch WELD PRESSURE HOLD PRESSURE This switch is used to select either the Weld Pressure Pres sure 1 regulator or the Hold Pressure Pressure 2 regulator This can be done to set the pressures and to montior them Mechanical Stop Adjustment Knob To move the stop and also the indicator flag turn the Mechanical Stop Adjust knob counterclockwise to lower it and clockwise to raise it This provides a way to stop the slide e ata particular depth of travel relative to the fixture or e to prevent the horn from contacting the fixture when there is no part present 6 Pressure 2 Adjustment Knob 30 Pressure 2 is the pressure inside the air cylinder used during the Hold portion of the weld cycle The adjustment knob connects to a second air pressure regulator To set Pressure 2 1 Press and hold the Pressure Select Switch button to HOLD PRESSURE 2 Watch the PRESSURE gauge and turn the knob clockwise to increase pressure turn it counterclockwise to decrease pressure 3 When the air gauge shows the desired Hold pressure Pressure 2 is set Release the Pressure Select Switch Section 3 Controls and Indicators When welding with dual pressure both regulators are active though at different times in the weld cycle Pres sure 1 regulator is active as the slide
104. r s Manual Additional Grounding Grounding lugs have been provided on the Ultra Com gen erator press base and thruster See Figure 1 4 to meet any additional grounding requirements that may arise Use 18 AWG ground wire for the ground connection between the press thruster the Ultra Com and the generator RFI Filter Considerations Ground Connection on back of thruster Use this when the In addition to the safety considerations above proper ground thruster Ae nok used ing at the generator power cord is essential for the effective with a press support operation of the RFI Radio Frequency Interference filter in package every Dukane generator The filter prevents line noise from entering the control circuitry of the ultrasonic equipment as well as blocking ultrasonic RFI from the power Press Base line Ground l Connection Ultra Com To 120 VAC Power Generator To 240 VAC Power CC To Earth Ground a grounded metal pipe or a grounding electrode Figure 1 4 Typical Equipment Grounding Arrangement SECTION 2 Installation e This section deals with basic installation locating and cabling the equipment Dukane Corporation This page intentionally left blank Dukane Corporation Section 2 Installation Before Unpacking Before unpacking your equipment WARNING Cartons and their contents are heavy Use mechanical means to move the cartons Lifting or carrying them manually could r
105. r cord grounding prong or alter the plug in any way Extension Cord If an extension cord is needed use a three wire cord that s in good condition The cord should be large enough to do the job safely It too must be plugged into a grounded receptacle Do not use a two wire extension cord with this product Section 1 Introduction and Safety 120 Volt Ground Adapter If it is impossible to change the wall receptacle to an approved grounding type and where local codes permit you may use an adapter to connect the three prong grounding plug to the two prong receptacle See Figure 1 2 e 1 Power cord w 3 prong plug 2 Adapter assembly 3 Wall Plate 4 Receptacle 5 Cold water pipe metal 6 Ground clamp 7 Mounting screw 8 Green ground lead 9 14 AWG 1 63mm ol ground wire Figure 1 2 Example of Proper 120 V Ground Adapter Hookup CAUTION The green pigtail on the adapter MUST BE CONNECTED TO GROUND If the receptacle is grounded the pigtail may be connected to it If the receptacle is not grounded connect a separate 14 AWG 1 63mm dia ground wire from the receptacle to the nearest effectively grounded metal pipe or equivalent grounding elec trode 30A Generator Plug The 15 kHz system generator power cord uses the twist lock type of plug shown in Figure 1 3 Make sure its receptacle is grounded properly Figure 1 3 Example of 30A Plug Ultra 15 kHz Assembly System Use
106. r disconnecting any of the system cables Turn off electrical power to the Ultra Com and to the generator and remove AC power cords from their outlets system will be affected by the change want to make 2 Customer Supplied Auxiliaries Press Generator Thruster Ultra Com Ultra Ultra Manufacturer 15 kHz 15 kHz Documentation System System User s Manual User s Manual P N 403 542 P N 403 542 Ultra Com User s Manual P N 403 393C Figure 8 2 Primary Reference Documents for Subsystems 80 SECTION 9 Maintenance e In this section maintenance for the major system components is outlined Dukane Corporation This page intentionally left blank Dukane Corporation Section 9 Maintenance Overview Maintenance information is organized under these headings e Stack Maintenance e Reconditioning Stack Components NOTE e Torque Values and e Press Thruster Maintenance See Section 6 for genera tor maintenance and see the Ultra Com User s Manual for that unit s Stack Maintenance a E ments Overview It is essential that the mating surfaces of all stack components transducer booster and horn are flat and smooth When the surfaces of the components are joined and tightened there must be no air gap between them If a gap of any kind remains no matter how small Mating Surfaces m mmm there will be a Mating Su
107. rasound turns on during each operating sequence the Auto Trac monitors stack motion on a cycle by cycle basis ad justing the ultrasound signal to an optimal level Because the Auto Trac continuously monitors each operating sequence it compensates for vibrational changes that occur during repeated operations due to heating of the stack compo nents It also compensates for aging of the piezoelectric crystals in the transducer and for horn wear The Auto Trac feature excels in environments hostile to reliable operation such as high stress continuous duty applications or high duty cycles in bursts With this ability to automatically deter mine the optimal setting for a stack during each operation the Auto Trac feature permits the use of one generator with multiple sequence fired stacks In such a situation the Auto Trac compen sates for the unique vibrational characteristics of each stack due to differences in aging loading temperature and to the many differences in horn configurations 67 Ultra 15 kHz Assembly System User s Manual Operational Stack Test Before beginning to operate the system for a full production run verify that the stack s vibrational characteristics fall within the Auto Trac s range To do this complete the Pre test Checklist and the Acoustic Stack Test explained below NOTE All Dukane stack components are manufactured to specifications within the generator s Auto Trac range A non Du
108. re 2 2 Then carefully slide the press system onto the benchtop Alternatively hook the press support on the lifting eye bolt and use a me chanical hoist to lift the unit into place Lifting Eye Bolt Benchtop aa Pallet Lift Figure 2 2 Press Placement Press without Base When the press and thruster have been configured without a base secure the base flange to a stationary rigid and level supporting structure To fasten the flange to the structure Dukane Corporation recommends using socket head cap screws M12 1 75 with a minimum length of 40 mm Engage the cap screws a minimum of 1 inch 25 4 mm full thread into the supporting structure Depending upon the structure s thickness and material longer screws and or additional hardware may be required Flange Template Provided A full scale template of the base flange is provided as Page 25 of this section Use it to position and drill holes in the supporting structure 13 Ultra 15 kHz Assembly System User s Manual D OS Press System Thruster Height Adjustment Kc 4 Thruster height on the column is adjustable by using the two S column clamps together with the height adjustment wheel and the six Allen Cocking screws shown in Figure 2 4 yu WARNING a Keep hands away from the horn and Figure 2 3a Loosening fixture when loosening the column clamps the Column Clamps When the clamps are loosened the thruster and acoustic stack could drop toward the
109. ressure the power or increase the amplitude Solution If using a power control increase the power Use a more powerful generator Increase the hole diameter if possible Use a smaller insert Support the part directly under the boss Install a metal post directly under the part being inserted Increase the down speed 101 Ultra 15 kHz Assembly System User s Manual Insertion Problem Plastic flows over the top of the insert Probable Cause Solution The weld time is too long Decrease the primary weld characteristic The insert is being driven too deep Reset the bottom stop There is too much interference Increase the hole diameter if possible between the hole and the insert Use smaller inserts Problem Melted plastic fills the hole Applies to internally threaded inserts Probable Cause Solution The insert is too long or the hole is Use a shorter insert or too shallow make the hole deeper There is too much interference Increase the hole diameter between the hole and the insert Use smaller inserts The insert is being driven too deep Reset the bottom stop Decrease the primary weld characteristic 102 Section 10 Troubleshooting Staking Problem A ragged or irregularly shaped stake head is formed Probable Cause Solution The staking cavity is too large Change to a smaller cavity in the horn The volume of plastic in the stud is Increase the stud height diameter insufficient
110. rfaces loss in power output and efficiency In some cases the union of the mating surfaces could be so poor as to prevent a stack from start ing That would happen because excessive power draw occurred as a result of the bad surface contact Figure 9 1 Location of Stack Mating Surfaces Continued 8 Ultra 15 kHz Assembly System User s Manual Inspecting the Stack Look at the mating surfaces to see where the shiny burnished areas are These areas show where the surfaces have been in Hole for contact and indicate that the surfaces themselves are either SE flat or uneven Ci Surfaces with Even Contact A flat surface has made even contact and will be uniformly Burnished burnished across its entire contact area Area Figure 9 2 illustrates that type of contact Figure 9 2 Burnished Area Indicates Flat Mating Surfaces Surfaces with Uneven Contact A surface that is not completely flat makes uneven contact and will be burnished in only part of its contact area Figure 9 3 shows what a surface would look like if only the e inner area had been making contact because that is where burnishing has taken place The outer area has no marks at Burnished er ete Area all indicating there has been no contact there Figure 9 3 Burnished Area Indicates Crowning Uneven Mating Surfaces As shown in Figure 9 3 the burnished area appears only around the mounting stud area and not at the edges This is evidence T
111. rograms 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 114 Section 11 Dukane Corporation Contacts and Warranty DUKANE CORPORATION NORTH AMERICAN WARRANTY POLICY Subject to the terms limitations and exclusions set forth below Dukane Corporation IAS Division Dukane warrants to the original Pur chaser unless otherwise expressly agreed to in writing by Dukane that all equipment and tooling designed and built by Dukane will be free from defects in material or workmanship Normal wear items are not covered by this warranty Warranty duration shall be defined as documented herein and in conjunction with any exceptions or exclusions in the accompanying Dukane quotation to the Purchaser Equipment Type Equipment Warranty Duration Other Comments Custom Systems 12 months on all Dukane designed and built content Dukane standard product included in custom systems that is not part of our standard product are covered by the applicable product warranty manufacturer OEM warranty is applicable optics are warranted for only 30 days Ultrasonic Welder 36 months See WARRANTY EXCLUSIONS OR EXCEPTIONS below Vibration Welder 24 months All Production 12 months one time replacement 6 month none Tooling one time replacement for carbide tipped horns Prototype Tooling e All tooling made from Renshape 460 Renw
112. rol potentiometer hereafter referred to as a pot If the pot has never been adjusted it should be in the 3 o clock 9 o clock position as shown in Figure 7 2 Figure 7 2 Range Control Potentiometer Slot in Home Position Oe 4 72 Generator Auto Trac Control Pot Turn the generator s AC POWER switch ON Manually hold the spring loaded O S T OPERATE STOP TEST selector switch in the TEST position If the ultrasound signal remains on go to Step 6 If the ultrasound signal stops the meter s needle will drop to zero and the OVERLOAD light will glow Release the switch so that it moves to the STOP position and go to Step 5 Use a flat blade screwdriver to turn the control pot about 1 8 of a turn in either direction Repeat Step 4 Section 7 System Test Auto Trac Range Adjustment continued NOTE Each time you return to Step 5 turn the pot another 1 8 turn in the same direction it was turned at first The pot has a mechanical stop just short of 180 degrees from the home po sition in both directions If the stop is met in one direction and the ultrasound signal will not stay on return the pot to the home position Then repeat Steps 4 and 5 turning the pot the other way If the signal will not stay on after followng the above steps do not run the horn until it is evaluated and the situa tion resolved Discuss the details with Dukane personnel The horn may need to
113. rs Dampen any damaged area if possible Reduce the amplitude by changing to a lower gain booster Decrease the weld time Increase the amplitude Increase the gauge pressure Check the molding conditions Check the part design Reduce the amplitude 95 Ultra 15 kHz Assembly System User s Manual Problem Underwelding occurs Probable Cause Insufficient energy is being transmitted to the part Energy is being absorbed into the fixture Problem Uneven welding occurs Probable Cause Warped part s The energy director varies in height Horn fixture and the part are not properly aligned with each other Wall flexure is occurring The knockout pin location is in the joint area There is insufficient support in the fixture 96 Welding Solution Increase the gauge pressure Increase the weld time primary weld charac teristic Change to a higher gain booster to increase the amplitude Use a more powerful assembly system Change the type of fixture being used Solution Check part dimensions Check the molding conditions Use a higher trigger pressure Use a higher hold pressure Redesign the energy director to ensure uni form height Use an interrupted energy director Make sure the thruster is perpendicular Check the part dimensions Add ribs to the part Modify the fixture to prevent outward flexure Redesign the part so the knockout pin is not in the joint area
114. rt dimensions Check the molding dimensions There are cavity to cavity variations Check the part dimensions and tolerances Check for cavity wear Check the molding conditions 98 Section 10 Troubleshooting Welding Problem Welding process is not in control inconsistent weld results on a part to part basis continued Probable Cause Solution Part dimensions vary due to mold Perform a Statistical study to see if a pat cavity variations tern develops with certain cavity combina tions The resin contains regrind or degraded Consult with the molder plastic Check the molding conditions Reduce the percentage of regrind Improve the quality of the regrind Fluctuations in the AC line voltage Upgrade to a generator with line supplied to the generator regulation Fluctuations in the air line pressure Upgrade to a system with electronic pressure regulation Add a surge tank with a check valve to the air line Raise the compressor output pressure The plastic s filler content is too high Reduce the percentage of filler in the plastic Check the processing conditions Change the type of filler G e from short to long glass fibers The horn doesn t fit the part correctly Check the part dimensions Check for cavity to cavity variations Obtain a new horn The weld cycle is too long Reduce the weld cycle time by increasing the amplitude or pressure Change the dynamic trigger force There is misalignment between Check for
115. s when on site service is required Travel amp Living T amp L expenses will be billed at cost Warranty service labor including travel time at the customer s site is provided on a Monday through Friday excluding holidays 7 a m to 7 p m basis Any warranty service requested outside of these hours is available on a charge basis equal to 150 of Dukane s prevailing rate for technical service work Any equipment or tooling that proves to be defective in material or workmanship during the stated warranty period will be repaired or replaced at the sole discretion of Dukane Corporation when Dukane is promptly notified in writing During the warranty period defective equipment components or tooling that are returned properly packed with all transportation charges prepaid will be repaired or replaced and returned to the end user without charge Shipments of warranty parts will be via standard non expedited delivery service Expedited shipment requests are subject to freight charges to the Purchaser Computers PLCs CRTs LCDs touch screens and keyboards separate and or incorporated as an integral part of a system will carry a one 1 year warranty from the date of shipment when used under normal operating conditions and not subjected to misuse abuse or neglect For all other equipment components or parts included in equipment or systems from Dukane but not manufactured by Dukane or its affiliates this warranty shall be limited in time and e
116. signal sent by the Ultra Com and converts it to the programmed air pressure The pressure value settings Pressure 1 P1 and Pressure 2 P2 are stored in the Process Setup under Pressure in the Ultra Com P1 and P2 are set in pounds per square inch PSD or BARS To monitor Pressure 1 and Pressure 2 values use the CHECK PRESSURE parameter contained in the Utilities menu under User Parameters on the Ultra Com The Ultra Com uses a pressure transducer to measure the I P output pressures Calibration The I P transducer installed in this thruster press does not require on site calibration The unit is equipped with self correcting closed loop circuitry Pressure Transducer The pressure transducer P I transducer performs the same function as the air gauge on the press The P I transducer converts the air pressure P to an electrical signal current 1 It then sends the signal to the Ultra Com The Ultra Com displays this signal as pressure Two sets of upper and lower limits can be monitored with the pressure transducer e One set of limits is used to monitor the air pressure before a cycle starts Using the bad parts limits the unit will not begin a cycle if the air pressure is outside the pressure window that has been set This set of limits is used to ensure that air pressure from the input line has not dropped below the pressure required for an acceptable weld force Continued 43 Ultra 15 kHz Assemb
117. stem User s Manual Resurfacing Components continued 9 Reexamine the mating surfaces and repeat Steps 6 8 until the corrosion has been removed Typically this takes no more than three complete rotations of the component 10 Mounting studs need to be reinserted but before that is done get proper thread engagement by e inspecting and cleaning the stud e cleaning the threaded hole with a cloth and e threading the stud into the hole and tightening it to the torque specifications shown in Table 9 1 on the next page NOTE Threads may deform if the studs are overtightened Removing a stud that has been overtightened could damage the threads in the horn If this should happen retap the horn threads and replace the stud with a new one 11 Reassemble the stack and install it using the procedure shown in Section 5 12 Complete the Operational Stack Test shown in Section 7 86 Section 9 Maintenance Torque Values Overview Apply torque values from the three categories listed below when reassembling stack components e Stack assembly values below e Booster and horn stud values Table 9 1 e Tip torque values Table 9 2 CAUTION Do not overtighten stack components Overtightening may cause studs to loosen causing the generator to go into an OVERLOAD condition Stack Assembly Torque Value A 15 kHz acoustic stack consists of a transducer a booster and a horn Use the following torque
118. t 6 month none Tooling one time replacement for carbide tipped horns Prototype Tooling e All tooling made from Renshape 460 Renwood Prototype Renshape 460 Renwood tools employ are only warranted for 200 part cycles reusable content and therefore remain the property e All other prototype tooling is warranted as of Dukane described in each specific proposal All Dukane warranties commence on the date of the original shipment of the equipment or tooling and duration is based upon a single shift per day five day per week operation The warranty period on rentals of new equipment that are converted to a purchase are deemed to have commenced on the initial date of rental These warranties are limited to equipment and tooling operated and maintained per Dukane s written instructions and used under normal operating conditions These warranties do not include normal wear or normal wear items and do not cover damage attributable to misuse improper installation faulty repair unauthorized alteration or modification neglect or accident Misuse includes operation of equipment with tooling that is not qualified for the equipment or properly installed on the equipment The warranty on all Dukane equipment and tooling purchased and installed in North America is a parts and labor warranty only Equip ment installed outside of North America regardless of where it was purchased is covered by Dukane s International Warranty Policy In all case
119. t start continued Ultrasound cable is loose not connected or not conducting Press thruster contact leaf not making proper contact with transducer s contact button Problem Press thruster does not move down Loose power cord s or not plugged in to the receptacle Cables not connected or loose Down speed valve adjusted for no air flow Mechanical Stop adjusted for no travel Make sure cable is connected and snug May need to replace it Clean any dirt or corrosion from contact leaf and contact button Check that there is proper alignment of contact leaf with transducer contact button Tighten the power cord s and make sure it is plugged in to the receptacle Connect and or tighten the cables See Cable Connections in Section 2 Adjust down speed valve for proper air flow Adjust Mechanical Stop knob counterclockwise CAUTION Turn OFF electrical power before connecting or disconnecting cables from any device Equipment damage may occur AC power switch es on the Ultra Com and or generator are in the OFF position Make sure AC power switches are switched ON If using push button activation switches to start cycle Activation switch cables not connected properly Activation switches are defective Activation switches not held closed for the correct amount of time Activation switches held closed preventing next cycle from starting Activation switches are not depressed at the sam
120. ture into which the assembly parts are placed and welded is required Press Thruster Similarities and Differences Both presses and thrusters include the following e a housing for the stack assembly e a pneumatic system for raising and lowering the stack and for applying pressure to the part e gauges switches and controls to regulate stack movement to control the stack clamping pressure on the part and to start and stop the ultrasound signal A press support package is included with a press making it self supporting by providing a rigid support frame and machine base In its standard configuration a thruster does not include a sup port package and must be mounted to a rigid support of some kind The support package is available as a thruster option Usually a thruster is used as a part of an automated system where it is mounted within a special configuration Section 1 Introduction and Safety Key Features of the Press Thruster Ultra rigid Square Support Column with rack and pinion height adjustment and up to 10 of radial align ment capability Heavy Duty Precision Slide assembly with 1 25 4 mm diameter steel rods and sealed Thomson ball bush ings preloaded for reliable frictionless operation Height Adjustment Handwheel is supplied and it can be specified for mounting on either side of the press Gas Strut counterbalence for easy height adjustment Stroke of 6 75 171 mm with mechanical bottom sto
121. ty productiveness or any other warranty The remedy set forth in this warranty policy is the sole and exclusive remedy of Purchaser and in no event shall Dukane be liable for any compensatory consequential special punitive or contingent damages or for damages arising from any delay in performance by Dukane under this warranty 115 Ultra 15 kHz Assembly System User s Manual DUKANE CORPORATION INTERNATIONAL WARRANTY POLICY Subject to the terms limitations and exclusions set forth below Dukane Corporation IAS Division Dukane warrants to the original Pur chaser unless otherwise expressly agreed to in writing by Dukane that all equipment and tooling designed and built by Dukane will be free from defects in material or workmanship Normal wear items are not covered by this warranty Warranty duration shall be defined as documented herein and in conjunction with any exceptions or exclusions in the accompanying Dukane quotation to the Purchaser Equipment Type Equipment Warranty Duration Other Comments Custom Systems 12 months on all Dukane designed and built content Dukane standard product included in custom systems that is not part of our standard product are covered by the applicable product warranty manufacturer OEM warranty is applicable optics are warranted for only 30 days Ultrasonic Welder 12 months See WARRANTY EXCLUSIONS OR EXCEPTIONS below Vibration Welder 12 months All Production 12 months one time replacemen
122. value when assembling the stack e 250 inch pounds e 20 8 foot pounds e 28 2 Newton meters Booster and Horn Stud Torque Values Use the torque values shown in Table 9 1 when installing studs into either a booster or horn to be used in a 15 kHz stack Stud Thread Torque hee Table 9 1 Booster and Horn Stud Torque 87 Ultra 15 kHz Assembly System User s Manual Press Thruster Maintenance NOTE Several factors determine how often the equipment needs attention The material being welded duty cycle and the manufacturing environment are primary factors in deciding how frequently inspections and maintenance should occur l CAUTION Daily Inspection Air lockout valve must 1 Check the entire unit for oil and dirt accumulation and wipe any away 2 Inspect the air filter bowl and filter element on the rear of the press Clean the filter bowl and clean or replace the filter element when needed be closed and secured with padlock before servicing this equipment See Page 36 3 Inspect wires and cables for signs of wear Reroute them if necessary to eliminate the problem Six Month Periodic Maintenance WARNING 1 Disconnect the Ultra Com and generator AC power cords Hee from the AC receptacles extend when Remove the left and right press housing covers air lockout is activated Make sure all socket head cap screws are tight Keep hands away from Check the air cylinder mounting to make sure it
123. xtent to the warranty given to Dukane by the OEM EQUIPMENT WARRANTY EXCLUSIONS OR EXCEPTIONS When specified in our quotation a limited warranty may apply to certain components of the equipment and or for certain types of applications of the equipment including those noted below Q This warranty is void if the ultrasonic welder and or tooling i e horn s and fixture s are used for applications requiring metal to metal contact when the ultrasonic exposure period weld cycle exceeds 250 milliseconds Q Ultrasonic Equipment and tooling used in continuous duty cycle modes such as but not limited to continuous cut and seal and food processing are warranted for 2000 hours or 12 months from shipment whichever occurs first Q Any ultrasonic horn or tool quoted and sold as Experimental is not warranted Q This warranty does not cover failures of equipment and components attributable to improper cooling or overheating of the transducer Q Ultrasonic Horn Analyzers have a 12 month warranty Q Ultrasonic Transducers have a one time replacement warranty Q Normal wear items and consumables excluded from any warranty coverage include but are not limited to filters fuses light bulbs lubricants gaskets and seals cast urethane fixture components laser flashlamps laser beam delivery optics and lasing gases The forgoing warranty is the sole and exclusive warranty and is made in lieu of all other warranties express implied
124. y screen At the back of the base is a cable connector for an interface between the Ultra Com and the base front panel Base Plate i Left Activation Switch Black Press Status LED Display Right Activation Switch PUSH FOR Black EMERGENCY OFF Switch Red Figure 3 6 Press Ergonomic Base Base Plate The base plate is bolted to the top of the ergonomic base It contains drilled and tapped holes that line up with leveling screws in the fixtures This allows for easy fixture leveling and alignment with the horn For details on the alignment and leveling of the fixture see Fixture Installation Pages 54 56 Emergency OFF Switch The PUSH FOR EMERGENCY OFF switch applies 24 vdc power to the thruster press If the switch is pushed in the Ultra Com and the generator begin the following procedure e Turns off the ultrasound signal immediately e Removes the electrical power from the press and e Initiates a software abort sequence 37 Ultra 15 kHz Assembly System User s Manual Activation Switches To initiate a weld cycle both the left and right activation switches must be pushed on within 350 milliseconds ms of each other and held closed for at least 25 ms This is a mandated safety requirement Press Status Display The display shows one of three press status conditions e READY When the PUSH FOR EMERGENCY OFF switch is twisted and then pulled out the green READY status light indi
125. y closed contact of the emergency stop switch Failure to connect an emergency stop switch will disable the Dukane thruster assembly Customer Emergency Stop Switch Ultra Com Ultra Com Input Normally Closed Device Normally Open Power to Thruster 200 707 Cable NOTE IfJ5 connections utilize the abort inputs on Pin 6 and Pin 9 then the normally open contacts connected to Pin 7 of J8 are not required Figure 10 1 Ultra Com Input for Emergency Stop Switch 110 Section 10 Troubleshooting Problem Generator shut down due to overload Troubleshooting Checklist Are cables properly connected Make sure equipment is properly connected Are cables damaged Replace cables Are connector pins bent Straighten pins Are there any short circuits Find source of short circuit and repair Is acoustic stack visibly damaged and is it Perform the Operational Stack Test outlined in assembled properly Section 7 111 Ultra 15 kHz Assembly System User s Manual This page intentionally left blank 112 SECTION 11 Dukane Corporation Contacts and Warranty Dukane Corporation This page intentionally left blank Dukane Corporation Section 11 Dukane Corporation Contacts and Warranty Contacting Dukane Corporation When contacting Dukane especially if calling about a service related problem be prepared to give this information e DPC model number firmware version serial number and line

Ultrasonics

Contents

Download Pdf Manuals

Related Search

Related Contents