Dukane Ultrasonic Welder Model 220 /943A220)with DPC-IV 3300 Watt Generator Convertor and Booster Included 220 Press Thruster Features •Narrow 4.5" (114mm) profile for close center-to-center distances in multi-head and automation installations •Rugged construction using the highest quality components provides superior performance, precision, and reliability •Compact, single-rail linear ball slide assembly system offers accurate positioning, stable movement, and friction-free resistance •Dual pressure increases clamp force to improve melt during the weld cycle, or to provide tighter assembly during the hold cycle •Optional hydraulic slow speed available for precise, repeatable control of horn travel during the weld cycle •7" (178mm) stroke with mechanical bottom stop adjustable in .001" (.025mm) increments •Top-of-stroke limit switch for automation application •All controls are accessible from the front for convenient set-up and operation •Easy to use front panel position indicators with universal icons instantly show settings of position and bottom stop, and optional slow speed, pre-trigger, and end-of-weld switch •Internally mounted optional linear encoder saves space in multi-head and automated installations •Remote pneumatics availability offers increased flexibility in system integration •OSHA-required lockout for air supply is standard •Ergonomic base and cycle activation switches reduce operator fatigue •Status indicators in base for Power, In Cycle, and Abort clearly communicate system conditions •Twist-release emergency stop switch meets international safety standards •Press/thruster design provides system flexibility and upgradeability, reducing equipment investment DPC-IV Generator Features The DPC IV and IV Plus are the most technologically advanced models in a line of process controllers offered by Dukane Corporation and used with Dukane ultrasonic welding systems. A selection of DPC models helps meet different needs. For instance, one model can be a reliable power source for welding applications. Another model can function with a single, hand-held ultrasonic probe, while another model can be linked to a larger, stationary press, and another model might be networked with a group of DPCs to control an extensive array of ultrasonic systems. The fully integrated process controller provides essential control and monitoring features for ultrasonic welding operations. Its modular design provides tailor-made flexibility in meeting a wide variety of process requirements in one, space-saving unit. The advanced programming capabilities of the DPC improve the welding process. Process characteristics and equipment settings are made so that parts are joined precisely and consistently. The DPC is capable of being a one-point source for data collection and display. When the DPC is coupled with the Man-Machine Interface (MMI) (not included), a visual display and data entry device, real-time process information and characteristic graphs are more easily viewed using the MMI touch screen. The DPC and MMI are a powerful pair making process control easier and more efficient. Key Features • Modular Design makes upgrades and retrofits easy when application requirements change. • Weld Process Control is accomplished using the primary controls of time, distance, absolute distance, energy, and peak power. Enabling secondary controls adds an even greater level of precision in process control. Two sets of limits for as many as 25 process characteristics can be made. Weld cycles can then be monitored to detect parts whose process characteristics are outside the preset limits. • Progressive Pressure for holding and welding are available in combination with the Dukane thruster that incorporates dual pressure capability. • Interface Versatility means there is the front panel display and the ability to integrate the DPC with automation equipment, printer, computer, additional DPCs, and Dukane’s MMI. • Automatic Setup Change is used when parts require more than one assembly operation and more than one set of process parameters. • Pulse Width Modulation is Dukane’s patented circuitry giving the DPC power supply the ability to efficiently change the voltage sent to the transducer. • Auto-Trac Tuning automatically tracks the resonant frequency of the acoustic stack (horn booster, transducer), and adjusts the generator output frequency to match it.* • Line Voltage Regulation automatically maintains constant amplitude regardless of line voltage deviation.* • Load Regulation provides constant amplitude automatically regardless of load (power draw).* • Power Factor Correction with this feature, electrical power consumption for the DPC will be reduced by approximately 25%. Manual Index of Features in the DPC-IV Generator: Section 3 The Control PanelOverview..........................................................................................................19 Control Panel Layout..........................................................................................19 DPC Display and Keypad..............................................................................20 Display...................................................................................................20 Display Lines Explained............................................................................20 Keypad...................................................................................................21 Generator Status Panel..................................................................................22 Generator Control...................................................................................22 System Status..........................................................................................22 System Power Output...............................................................................23 AC Power....................................................................................................23 Start-up.............................................................................................................24 Stopping the Weld Cycle....................................................................................25 Normal Conditions.......................................................................................25 Emergency Conditions...................................................................................25 The Main Menu.................................................................................................26 From the Main Menu: An Example......................................................................28 Selecting and Changing Parameters...............................................................29 Selecting Parameters................................................................................29 Changing Numerical Parameters..............................................................30 Changing Other Parameters.....................................................................31 Exiting the Menu or Parameter List............................................................32 Section 4 Network – Naming the DPC Name Each DPC................................................................................................33 When Naming is Needed..............................................................................33 When Naming is Optional............................................................................33 Naming Procedure........................................................................................33 DPC ID..............................................................................................................35 Status...........................................................................................................35 Connect.......................................................................................................36 Section 5 Hardware Setup Overview..........................................................................................................37 Before Start-up..................................................................................................38 International.................................................................................................38 Language................................................................................................38 Units.......................................................................................................39 Date Format............................................................................................39 Time and Date..............................................................................................40 Set Time..................................................................................................40 Set Date..................................................................................................40 Ports............................................................................................................41 Destination..............................................................................................42 Output Device.........................................................................................42 Output Mode...........................................................................................44 Baud Rate...............................................................................................45 Protocol..................................................................................................46 Xon/Xoff...........................................................................................46 RTS/CTS............................................................................................46 Lines per Page.........................................................................................47 LF After CR..............................................................................................47 Limit Indicators........................................................................................47 Calibration...................................................................................................48 When Calibration is Enabled....................................................................48 How to Enable Calibration.......................................................................48 During Normal Operation..................................................................................49 User I/O......................................................................................................49 Outputs...................................................................................................50 Up Valve on Abort...................................................................................50 End of Weld............................................................................................51 Ground Detect.........................................................................................51 Fixture Installation....................................................................................52 Status Outputs.........................................................................................53 Define Ready As......................................................................................53 Define Suspect As....................................................................................55 Buzzer Status..........................................................................................55 Advanced I/O..............................................................................................56 Kinechek......................................................................................................57 Generator....................................................................................................58 Defaults..................................................................................................58 Settings...................................................................................................56 Phase................................................................................................59 Softstart.............................................................................................59 Frequency..........................................................................................60 Pulse Width.......................................................................................60 Section 6 Security Overview..........................................................................................................61 Security Coverage..............................................................................................62 Enabling Security...............................................................................................63 Changed Your Mind? ...................................................................................63 Disabling Security..............................................................................................63 Normal Use.......................................................................................................65 Access.........................................................................................................65 Changes......................................................................................................65 Password Forgotten?..........................................................................................66 Section 7 Process Setup – Process Control Overview..........................................................................................................67 Process Setup Organization...........................................................................67 Process Control..................................................................................................68 Initiate Mode.....................................................................................................69 Manual .......................................................................................................69 Probe Method.........................................................................................69 All Other Trigger Methods........................................................................69 Latch on Bad Part....................................................................................70 Auto............................................................................................................71 Trigger..............................................................................................................72 Trigger Type.................................................................................................72 Maintained.............................................................................................72 Momentary.............................................................................................73 Force......................................................................................................74 Velocity...................................................................................................74 Trigger Method.............................................................................................75 Trigger Method 1: Normal Trigger............................................................75 Trigger Method 2: Delay by Time..............................................................76 Trigger Method 3: Delay by Distance........................................................76 Trigger Method 4: Delay till Auto-In..........................................................77 Trigger Method 5: Pre-trigger by Distance.................................................78 Trigger Method 6: Probe..........................................................................80 Weld Method.....................................................................................................81 Single Pressure.............................................................................................81 Dual Pressure...............................................................................................81 Continuous...................................................................................................82 Entering Report Interval............................................................................82 Control Parameters – Single and Dual Pressure Welding..................................83 Time.......................................................................................................83 Distance..................................................................................................83 Absolute Distance....................................................................................84 Energy....................................................................................................84 Peak Power.............................................................................................85 Scrub................................................................................................................86 Hold Method.....................................................................................................87 Time............................................................................................................87 Distance.......................................................................................................88 Auto............................................................................................................88 Disable........................................................................................................88 Afterburst..........................................................................................................89 Pressure............................................................................................................90 Local............................................................................................................90 Pressure Profiling Instructions for the DPC........................................................93 Amplitude.........................................................................................................95 Local............................................................................................................95 Section 8 Process Setup – Process Limits Overview..........................................................................................................97 Available Process Characteristics.........................................................................97 Process Characteristics Defined......................................................................98 Bad Part Limits............................................................................................100 Disabled...............................................................................................101 Display.................................................................................................101 Window...............................................................................................101 Secondary Control.................................................................................102 Suspect Part Limits.......................................................................................103 Disable.................................................................................................103 Enable..................................................................................................103 Section 9 Process Setup – Utilities Overview........................................................................................................105 Setup Utilities...................................................................................................105 Select Setup................................................................................................105 Verify Setup Choice...............................................................................106 Copy a Setup.............................................................................................106 Erase Setups...............................................................................................107 Current Setup........................................................................................107 All Setups..............................................................................................107 Print Setup..................................................................................................107 Part Count.......................................................................................................108 Reset Part Count.........................................................................................108 Preset Part Count........................................................................................108 Count Bad Part...........................................................................................108 Part Sampling..................................................................................................109 Lot Size......................................................................................................109 Sample Size...............................................................................................109 Exclude......................................................................................................109 Store..........................................................................................................110 User Parameters...............................................................................................110 Job ID........................................................................................................110 Horn..........................................................................................................111 Booster......................................................................................................111 Fixture.......................................................................................................111 Power Utilities..................................................................................................111 Power Averaging........................................................................................111 High and Low Options................................................................................112 Section 10 Process Setup – Sequencing Overview........................................................................................................113 Selecting Sequence Settings..............................................................................115 Disable......................................................................................................115 Enable.......................................................................................................115 Remote.......................................................................................................115 When Sequencing Is Enabled............................................................................116 Segment Length..........................................................................................116 Reset Sequence...........................................................................................116 Define Part As............................................................................................116 Preset Segment...........................................................................................117 Preset Cycles..............................................................................................117 Sequence Definition....................................................................................118 Section 11 Operate Overview........................................................................................................119 View Parameters..............................................................................................120 Print Headers...................................................................................................121 Print Part Data.................................................................................................122 Graphing…………………………………………………………………………………………..123
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