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Intelligent Assembly Solutions
Dual Servo Spin Welder
User’s Manual
DUKANE Part No. 403–570-01
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949
Dukane
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Dual Servo Spin Welder User’s Manual Copyright © 2009 Dukane Intelligent Assembly Solutions 2900 Dukane Drive St. Charles, IL 60174 USA Notice of Rights: All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical, photocopying, recording, or by any information storage and retrieval system, without written permission from Dukane Corporation. Notice of L
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Revision History Revision Revision Number Summary Date - 00 Original release. 10/24/2008 - 01 Menu language choices added; Revised Upper Tool Vacuum paragraphs 09/25/2009 Page iii Dukane Manual Part No. 403-570-01
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Dual Servo Spin Welder User’s Manual This page intentionally left blank Page iv Dukane Manual Part No. 403-570-01
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Dukane Dual Servo Spin Welder Contents Section 1 – Introduction 1 Section 2 – Safety Considerations 7 Section 3 – Unpacking and Setup 13 Section 4 – Display and Controls 21 Section 5 – Touch Screen Menus 27 Section 6 – Machine Operation 49 Section 7 – Optimizing Performance 57 Section 8 – Welder Data Export Software 65 Section 9 – Troubleshooting 71 Section 10 – Maintenance 81 Section 11 – Contacting Dukane 85 Section 12 – Specifications 89 Appendix A – Connector Pinouts 95 Appendix B – Toolin
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Dual Servo Spin Welder User’s Manual This page intentionally left blank Page vi Dukane Manual Part No. 403-570-01
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Section 1 - Introduction SECTION 1 Introduction Important User Information . . . . . . . . . . . . . .3 . . . . . . Read the Manual First . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . Notes and Tips . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . Caution and Warnings . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . Drawings and Tables . . . . . . . . . . . . . . . . . . . .3 . . . . . . . . . Dual Servo Spin Welder Overview . . . . . . . . . . . 4 .
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Section 1 - Introduction Important User Information Read This Manual First Before operating the Dual Servo Spin Welder, read this User’s Manual to become familiar with the system. This will ensure correct and safe operation. The manual is organized to allow you to learn how to safely operate this system. The examples given are chosen for their simplicity to illustrate basic setup procedures. Notes and Tips Throughout this manual we use NOTES to provide information that is important for th
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Dual Servo Spin Welder User’s Manual Dual Servo Spin Welder Overview The Dual Servo Spin Welder excels at frictional welding of assemblies and parts which require accurate angular orientation and collapse distance. The parts can be any shape and only the weld joint must be circular. The welder uses two electric servos: a servo motor for spinning the tool, and a servo actuator for moving the machine head up and down. Both servos have high- resolution encoders, enabling accurate process con
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Section 1 - Introduction • Fixture throat depth is a generous 8”. Key Dual Servo Spin • Vertical servo actuator operation with adjustable Welder Features 5” (127 mm) stroke assures quiet operation and is environmentally safe. • Color touch–screen display uses Color Active Ma- trix Thin–Film Transistors (TFT) for high contrast • Industry-standard logic controller and motor and wide viewing angle even under high ambient– controller means replacement parts are readily lighting conditions. The
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Section 2 - Safety Considerations SECTION 2 Safety Considerations Health and Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Plastics Health Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Run Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 General Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section 2 - Safety Considerations Health and Safety Tips Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your welder. In this manual, the term welder and/or dual servo spin welder both refer to the Dual Servo Spin Welder. Proper Installation - Do not operate the Dual Servo IMPORTANT Spin Welder until after the electrical system is properly Always wear a face installed. shield when operating the No Unauthorized Modifications - Do
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Dual Servo Spin Welder User’s Manual Plastics Health Notice Before using any Dukane welding system, be sure you are familiar with OSHA regulations from the U.S. Department of Labor about the particular type of plastic(s) you are using. When plastic materials are being processed, some of them may emit fumes and/or vapors that could be hazardous (e.g. PVC – Polyvinyl Chloride can emit chlorine gas under certain processing conditions). Make sure you use proper ventilation whenever these plas
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Section 2 - Safety Considerations Electrical Safety 240V AC Power Receptacle The power cord used on the Dual Servo Spin Welder has a two–blade, grounding type plug designed for 240 VAC at 20 Amps. It is designed to be plugged into a 240 VAC, 20 Amp NEMA type 6–20R receptacle as GND shown in Figure 2–1. Do not alter the plug or receptacle in any way. G Grounding It is important for operator safety that the receptacle grounding wire be installed properly and securely attached to an effecti
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Section 2 - Safety Considerations SECTION 3 Unpacking and Setup Unpacking Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Packing List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Work Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Secure to Work Bench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Benc
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