Dukane 220C User Manual

Section 1 – Introduction Dukane Part No. 403–556–03 Page iModel 22020kHz Press/ThrusterModel 34030/40kHz Press/Thruster04 05 06 07 08 09 10 11 12

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Section 10 – Contacting Dukane & WarrantyDukane Part No. 403–556–03 Page 93Replacement Parts ListDescription Part #Air cylinder 1-1/2” dia. x 7”

Model 220/340 Press User's Manual Page 94 Dukane Part No. 403–556–03DUKANE CORPORATION NORTH AMERICAN WARRANTY POLICYSubject to

Section 10 – Contacting Dukane & WarrantyDukane Part No. 403–556–03 Page 95Subject to the terms, limitations and exclusions set forth below, Duka

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Section 10 – Contacting Dukane & WarrantyDukane Part No. 403–556–03 Page 97SECTION 11Dukane Corporation • • Ultrasonics DivisionSpecifications•

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Section 11 – SpecificationsDukane Part No. 403–556–03 Page 99Frequency RegulationsThe ultrasonic system and the equipment installation describe

Model 220/340 Press User's Manual Page 100 Dukane Part No. 403–556–03System RequirementsPneumatic Power RequirementsThe 220/340 Thruster require

Section 11 – SpecificationsDukane Part No. 403–556–03 Page 101Figure 1-1 Model 220/340 Press Specications4.48(114)1.88(48)OF HORN& PRESSCL18.58

Section 1 – Introduction Dukane Part No. 403–556–03 Page 3This symbol warns you of any hazard or unsafe practice that could result in per-sonal in

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Section 11 – SpecificationsDukane Part No. 403–556–03 Page 103SECTION 12Dukane Corporation • • Ultrasonics DivisionDiagrams• This section contains

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Section 12 – DiagramsDukane Part No. 403–556–03 Page 1051615141312111098765432116151413121110987654321MLKJHGFEDCBAMLKJHGFEDAAAREF FILE:FILENAME:NEXT

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Section 12 – DiagramsDukane Part No. 403–556–03 Page 107INCHES PNEUMATIC DIAGRAM- 43A260 43B260 43A2

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Section 12 – DiagramsDukane Part No. 403–556–03 Page 109 400-21024 5 7 8 9 1011AINCHES SJOBLO NWPFR B8712 4-24-95 1 1 03 400-2092 43A220

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Section 12 – DiagramsDukane Part No. 403–556–03 Page 111SECTION 13Dukane Corporation • • Ultrasonics DivisionGlossary of Terms• This section provi

Model 220/340 Press User's Manual Page 4 Dukane Part No. 403–556–03• When ultrasonic plastic assembly equipment is used with automatic material

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Section 13 – Glossary of TermsDukane Part No. 403–556–03Page 113Amorphous Plastic A thermoplastic which has a random molecular structure (e.g

Model 220/340 Press User's Manual Page 114 Dukane Part No. 403–556–03Fixture A device used to align and support the parts to be assembled.

Section 13 – Glossary of TermsDukane Part No. 403–556–03Page 115Mold Release A substance added to plastics so that parts are easily removed from the

Model 220/340 Press User's Manual Page 116 Dukane Part No. 403–556–03Spot Welding An ultrasonic assembly method where two thermoplastic compone

Section 13 – Glossary of TermsDukane Part No. 403–556–03Page 117SECTION 14Dukane Corporation • • Ultrasonics DivisionIndex• This section provides

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Section 14 – IndexDukane Part No. 403–556–03Page 119AABORT Status Display, Press ... 27Abort Switch ...

Model 220/340 Press User's Manual Page 120 Dukane Part No. 403–556–03Disassembly, Stack ... 44Display, Sta

Section 14 – IndexDukane Part No. 403–556–03Page 121IN CYCLE Status Display, Press ... 27INPUT TEST Display, DPC ...

Section 1 – Introduction Dukane Part No. 403–556–03 Page 5Special Health Notice – PlasticsCertain plastic materials, when being processed, may emi

Model 220/340 Press User's Manual Page 122 Dukane Part No. 403–556–03Pressure, Press Clamping ... 100Pre-Trigger Cont

Section 14 – IndexDukane Part No. 403–556–03Page 123Trigger Method ... 38Troubleshooting ...

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Section 1 – Introduction Dukane Part No. 403–556–03 Page 125Dukane ISOISO CERTIFICATIONDukane chose to become ISO 9001:2000 certi-fied in order to

Model 220/340 Press User's Manual Page 126 Dukane Part No. 403–556–03Part No. 403–556–03Dukane Intelligent Assembly Solutions • 2900 Dukane Driv

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Section 1 – Introduction Dukane Part No. 403–556–03 Page 7Dukane Corporation • • Ultrasonics DivisionSECTION 2 Installation• This section exp

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Section 2 – Installation Dukane Part No. 403–556–03 Page 9Installing the Press SystemThe press system consists of a thruster, ergonomic base and s

Model 220/340 Press User's Manual Page 10 Dukane Part No. 403–556–03The placement of the press system should be by mechanical means.To place th

Section 2 – Installation Dukane Part No. 403–556–03 Page 11WashersMounting Bolts *Rigid MountingDistance from horn to work surface should be less t

Model 220/340 Press User's Manual Page ii Dukane Part No. 403–556–03Printed in the United States of America.Dukane Part Number: 403–556–03Duka

Model 220/340 Press User's Manual Page 12 Dukane Part No. 403–556–03Cable ConnectionsPress SystemThe press is not equipped with its own source o

Section 2 – Installation Dukane Part No. 403–556–03 Page 13• Ergonomic Base (J35) - Connects the base controls and display to the Press Base Port

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Section 2 – Installation Dukane Part No. 403–556–03 Page 157.75 inches(196.85 mm)FRONT2.625 inches(66.675 mm)2.625 inches(66.675 mm)2.25 inches(57.

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Section 2 – Installation Dukane Part No. 403–556–03 Page 17Dukane Corporation • • Ultrasonics DivisionSECTION 3Control Description• This sectio

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Section 3 – Control DescriptionDukane Part No. 403–556–03Page 19OverviewThis section describes the controls, indicators and features for the manual an

Model 220/340 Press User's Manual Page 20 Dukane Part No. 403–556–03Manual ControlsRefer to Figure 3-1 for the location of the controls.Down Sp

Section 3 – Control DescriptionDukane Part No. 403–556–03Page 21205467832104321098765MECH STOPDOWN SPEEDWELDPRESSUREHOLDPRESSUREMECH STOP STROKE / SLO

Section 1 – Introduction Dukane Part No. 403–556–03 Page iiiRevision History Revision Revision Number History Date –00 220 Press Manual

Model 220/340 Press User's Manual Page 22 Dukane Part No. 403–556–03Pressure 2 RegulatorIn applications where welding with dual pressure is requ

Section 3 – Control DescriptionDukane Part No. 403–556–03Page 23IndicatorsPressure GaugeThe pressure gauge shows the amount of air pressure applied t

Model 220/340 Press User's Manual Page 24 Dukane Part No. 403–556–03Refer to Figure 3-2 for the location of the controls.The EPR (Electronic Pr

Section 3 – Control DescriptionDukane Part No. 403–556–03Page 2520MECH STOPDOWN SPEEDMECH STOP STROKE / SLOWSPD50403020106070809010034215670DOWNCM0123

Model 220/340 Press User's Manual Page 26 Dukane Part No. 403–556–03Ergonomic BaseThe ergonomic base, shown in Figure 3-3, consists of a base p

Section 3 – Control DescriptionDukane Part No. 403–556–03Page 27Base Status Display The function of the display is to indicate one of three status c

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Section 3 – Control DescriptionDukane Part No. 403–556–03Page 29SECTION 4Press Options• This section provides detailed information regarding the i

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Section 4 – Press OptionsDukane Part No. 403–556–03Page 31OverviewThis section provides detailed information for the common options for press/thruster

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Model 220/340 Press User's Manual Page 32 Dukane Part No. 403–556–03Hydraulic Speed ControlSLOW SPEED Control and Indicator FlagsThe thruster ha

Section 4 – Press OptionsDukane Part No. 403–556–03Page 33The hydraulic cylinder is mounted in a clamping block. The block is threaded onto a long

Model 220/340 Press User's Manual Page 34 Dukane Part No. 403–556–03Installing the Distance EncoderPurposeTo install and calibrate the distance

Section 4 – Press OptionsDukane Part No. 403–556–03Page 354. Connect the cable to the DPC connector J-401 (Thruster Stroke Encoder).5. Repl

Model 220/340 Press User's Manual Page 36 Dukane Part No. 403–556–036. Perform the following procedure to test the encoder for the proper setti

Section 4 – Press OptionsDukane Part No. 403–556–03Page 37Electronic Press ControlsThe electronic press controls consist of the following thr

Model 220/340 Press User's Manual Page 38 Dukane Part No. 403–556–03 This set of limits is used to ensure that air pressure from the input li

Section 4 – Press OptionsDukane Part No. 403–556–03Page 39SECTION 5Stack/Fixture Setup• This section provides detailed informa-tion regarding the pr

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Section 5 – Stack/Fixture SetupDukane Part No. 403–556–03Page 41OverviewA Dukane press/thruster and a DPC (Dynamic Process Controller) generat

Section 1 – Introduction Dukane Part No. 403–556–03 Page vTable of ContentsSection 1 – IntroductionAbout This Manual ...

Model 220/340 Press User's Manual Page 42 Dukane Part No. 403–556–03Stack DescriptionThe stack shown in Figure 5-1 consists of three components

Section 5 – Stack/Fixture SetupDukane Part No. 403–556–03Page 43Changing Stack ComponentsStack RemovalBefore removing the stack, perform the following

Model 220/340 Press User's Manual Page 44 Dukane Part No. 403–556–03Stack DisassemblyTo separate the stack component carefully follow the

Section 5 – Stack/Fixture SetupDukane Part No. 403–556–03Page 45Stack AssemblyBefore assembling a stack, inspect all of the components for

Model 220/340 Press User's Manual Page 46 Dukane Part No. 403–556–03Installing a Detachable TipIf the horn has a detachable tip, do the followi

Section 5 – Stack/Fixture SetupDukane Part No. 403–556–03Page 47FixtureHold Down BoltsFixtureHoles for 3–HoleMounting Fixture(12" x 14")Fixt

Model 220/340 Press User's Manual Page 48 Dukane Part No. 403–556–03Note: The xture should be at on the base. If the xture is eq

Section 5 – Stack/Fixture SetupDukane Part No. 403–556–03Page 495. Tighten the hold-down cap screws by turning them clockwise until a rm resistance

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Section 5 – Stack/Fixture SetupDukane Part No. 403–556–03Page 51SECTION 6Systems Test• This section provides the testing methods used to ensure

Model 220/340 Press User's Manual Page vi Dukane Part No. 403–556–03Section 4 – Press OptionsOverview ...

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Section 6 – Systems TestDukane Part No. 403–556–03Page 53OverviewA Dynamic Process Controller (DPC) must be operating and connected to the press/thrus

Model 220/340 Press User's Manual Page 54 Dukane Part No. 403–556–03Operational Test of the Acoustic StackThe following test procedure is s

Section 6 – Systems TestDukane Part No. 403–556–03Page 553. Press the DPC TEST button: , and hold it until the display of Figure 6-2 appears o

Model 220/340 Press User's Manual Page 56 Dukane Part No. 403–556–035. Turn the DPC off. Check the stack for proper assembly, damaged

Section 6 – Systems TestDukane Part No. 403–556–03Page 57Yellow RedProcedure for Cycling the System1. Check that you have correctly performed the fol

Model 220/340 Press User's Manual Page 58 Dukane Part No. 403–556–032. Check the quality of an assembled part for the following:a. Strength of

Section 6 – Systems TestDukane Part No. 403–556–03Page 59SECTION 7Dukane Corporation • • Ultrasonics DivisionStack Maintenance• This section prov

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Section 7 – Stack MaintenanceDukane Part No. 403–556–03Page 61Inspection of the Acoustic Stack ComponentsIt is essential that the mating faces between

Section 1 – Introduction Dukane Part No. 403–556–03 Page viiSection 6 – Systems TestOverview ...

Model 220/340 Press User's Manual Page 62 Dukane Part No. 403–556–03Reconditioning Stack ComponentsNote: The operating efciency of the

Section 7 – Stack MaintenanceDukane Part No. 403–556–03Page 638. Rotate the part the remaining 120° and repeat. Be certain to perform the same numb

Model 220/340 Press User's Manual Page 64 Dukane Part No. 403–556–03• For horn and booster studs, refer to Table 7-1.• For detachable tips on

Section 7 – Stack MaintenanceDukane Part No. 403–556–03Page 65SECTION 8Dukane Corporation • • Ultrasonics DivisionTroubleshooting• This section pro

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Section 8 – TroubleshootingDukane Part No. 403–556–03 Page 67ApplicationsThe Troubleshooting section of this manual contains a listing of problems

Model 220/340 Press User's Manual Page 68 Dukane Part No. 403–556–03The generator/digital timer should be any of Dukane’s 20 kHz generators con

Section 8 – TroubleshootingDukane Part No. 403–556–03 Page 69Welding_________________________________________________________________________________

Model 220/340 Press User's Manual Page 70 Dukane Part No. 403–556–03Welding_____________________________________________________________________

Section 8 – TroubleshootingDukane Part No. 403–556–03 Page 71Welding_________________________________________________________________________________

Model 220/340 Press User's Manual Page viii Dukane Part No. 403–556–03Section 12 – DiagramsElectrical Schematic ...

Model 220/340 Press User's Manual Page 72 Dukane Part No. 403–556–03Welding_____________________________________________________________________

Section 8 – TroubleshootingDukane Part No. 403–556–03 Page 73Welding_________________________________________________________________________________

Model 220/340 Press User's Manual Page 74 Dukane Part No. 403–556–03Welding_____________________________________________________________________

Section 8 – TroubleshootingDukane Part No. 403–556–03 Page 75Welding_________________________________________________________________________________

Model 220/340 Press User's Manual Page 76 Dukane Part No. 403–556–03Insertion___________________________________________________________________

Section 8 – TroubleshootingDukane Part No. 403–556–03 Page 77Insertion_______________________________________________________________________________

Model 220/340 Press User's Manual Page 78 Dukane Part No. 403–556–03Insertion___________________________________________________________________

Section 8 – TroubleshootingDukane Part No. 403–556–03 Page 79________________________________________________________________________________________

Model 220/340 Press User's Manual Page 80 Dukane Part No. 403–556–03Staking_____________________________________________________________________

Section 8 – TroubleshootingDukane Part No. 403–556–03 Page 81Staking_________________________________________________________________________________

Section 1 – Introduction Dukane Part No. 403–556–03 Page 1• This section gives a general introduc-tion to the press, and deals with safety consid

Model 220/340 Press User's Manual Page 82 Dukane Part No. 403–556–03Continous Welding __________________________________________________________

Section 8 – TroubleshootingDukane Part No. 403–556–03 Page 83Continous Welding ______________________________________________________________________

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Section 8 – TroubleshootingDukane Part No. 403–556–03 Page 85SECTION 9Dukane Corporation • • Ultrasonics DivisionService/Maintenance • This secti

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Section 9 – Service/MaintenanceDukane Part No. 403–556–03 Page 87Six Month Periodic Maintenance1. Disconnect the generator AC power cord from the AC

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Section 9 – Service/MaintenanceDukane Part No. 403–556–03 Page 89SECTION 10Dukane Corporation • • Ultrasonics DivisionContact Dukane/Warranty• Thi

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Section 10 – Contacting Dukane & WarrantyDukane Part No. 403–556–03 Page 91Contacting DukaneIdentify EquipmentWhen contacting Dukane about a serv