Intelligent Assembly Solutions MICROLOGIC CONTROLLER SPIN WELDER SVB031 – 3 HP SVB051 – 5 HP User’s Manual Dukane Part No. 403 - 547- 03 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797-4949 ISO 9001:2008 Dukane products are manufactured in ISO registered facilities. www.dukane.
Spin Welder User’s Manual Copyright © 2011 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.
Revision History Revision Number Revision History Date – 00 Original release 2001-Sept-11 – 01 Corrected Fig 11-3 Side View Dimensions 2002-Feb-14 – 02 Clarify Counterbalance Regulator description on page 41. 2004-Sept-30 Elaborate counterbalance adjustment on page 52. Added warning regarding excessive counterbalance force setting on page 55. New Division and 24–Hour Service Phone Numbers. New Consolidated Domestic and Intn'l Warranty.
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Table of Contents Table of Contents Section 1 – Introduction............................................................ 1 Important Information.............................................................................. 3 Read This Manual First..................................................................................... 3 Notes and Tips.................................................................................................. 3 Cautions and Warnings........................................
Spin Welder User’s Manual Section 5 – Theory of Operation............................................ 25 Spin Welding Process............................................................................... 27 Material Considerations........................................................................... 28 Control Parameters.................................................................................. 28 Axial Pressure...................................................................................
Table of Contents Hold Time........................................................................................................ 49 Weld by Time.................................................................................................. 49 Weld by Distance............................................................................................ 50 Tooling Capacity....................................................................................... 50 Upper Hub.................................
Spin Welder User’s Manual Section 8 – Maintenance......................................................... 65 User Interface Panel................................................................................. 67 Cleaning.......................................................................................................... 67 Display............................................................................................................. 67 Control Keys..............................................
Table of Contents Section 11 – Specifications...................................................... 83 Energy Requirements............................................................................... 85 Pneumatic....................................................................................................... 85 AC Power........................................................................................................ 85 Operating Environment....................................................
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Section 1 – Introduction Section 1 Introduction • Important Information • Manual Organization • Key Features Important User Information..........................3 Read This Manual First................................... 3 Notes and Tips................................................ 3 Caution and Warnings................................... 3 Drawings and Tables...................................... 3 Manual Organization.....................................4 Spin Welder Key Features.....................
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Section 1 – Introduction Important User Information Read This Manual First Before operating the 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 a spin–welding system. The examples given are chosen for their simplicity to illustrate basic setup procedure.
Spin Welder User’s Manual Manual Organization Section 1 – Introduction gives a general explanation of the Dukane Spin Welder. Section 2 – Unpacking and Major Components gives unpacking instructions and identifies major Spin Welder components. Section 3 – Safety discusses safety considerations and regulations. Section 4 – Installation describes the setup sequence and external connections necessary for operation.
Section 1 – Introduction Spin Welder Key Features • Computer Controlled Motor with digital RPM setting. DC Braking or optional Dynamic Braking stops the motor quickly. • Column–Mounted direct drive 3 or 5 HP motor for solid, reliable welding operation. • Digital Timer for Weld Time and Hold Time gives precise control of the Spin Welding process. • Keypad Programmer with backlit 2–line LCD Display for operator convenience and ease of setup.
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Section 2 – Unpacking Section 2 Unpacking • Unpacking System • Packing List • System Requirements • Major Components Unpacking System.......................................... 9 Packing List.....................................................9 System Requirements...................................10 Physical Space............................................... 10 Electrical........................................................ 10 Pneumatic.....................................................
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Section 2 – Unpacking Unpacking System The Spin Welder is normally packed in a corrugated carton resting on a wooden shipping pallet. To unpack the Spin Welder follow these steps. 1. Remove the straps from the carton. 2. Open the top of the carton. Carefully remove any packing materials, cables and documentation. 3. Cut the tape at the bottom corners and unfold the flaps. 4. Remove the corrugated carton, but leave the Spin Welder on the pallet. 5.
Spin Welder User’s Manual System Requirements Physical Space Allow sufficient area on either side of the Spin Welder to accommodate current and future parts and fixtures. Also be aware that under extreme spin welding conditions, small droplets of molten plastic may be ejected by the spinning upper part. Electrical The Spin Welder requires a 240VAC – 3 phase outlet rated at 20 Amps. Both the 3HP and 5HP model use the same power cord and plug.
Section 2 – Unpacking 1 Lifting Ring 2 Compressed Air Inlet 3 Top–Of–Stroke Connector 4 Base Interface Connector (J8) 5 Air Exhaust Diffuser 6 Spin Welder Serial Number 7 Spin Welder Model Number 8 Counterbalance Regulator 9 AC Power To Press 10 Upper Dovetail Lock 11 Main AC Disconnect and Fuse Enclosure 12 AC Power Switch & Lockout 13 AC Enclosure Lockout 14 Lower Dovetail Lock 15 Press Height Adjustment Crank 16 AC Power Cord 240VAC 3–Phase 17 Base Serial Number 18 Base Interface Connector (J3
Spin Welder User’s Manual User Interface 20 Display & Keypad Pressure Regulator Gauge 21 Pressure Regulator 22 Adjustment Down Speed Adjustment 23 Motor Speed Control 24 Front Access Panel 25 Upper Press Housing 26 Bottom Stop Indicator Flags 27 Lower Motor Housing 28 Tooling Hub 29 Height Adj. Rack Gear 30 Height Adj. Gas Spring 31 Bottom Stop Adjustment 32 Bottom Stop Adj.
Section 2 – Unpacking Section 3 Safety • Safety Regulations • Electrical Safety • Mechanical Safety • Pneumatic Safety Safety Regulations....................................... 15 Plastics Health Notice................................... 15 Palm Switches............................................... 15 General Safety.........................................15 Electrical Safety............................................16 AC Power...................................................... 16 Grounding.......
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Section 3 – Safety Safety Regulations Plastics Health Notice Before using any Dukane plastic welding system, make sure you are familiar with applicable regulations regarding the particular type(s) of plastic 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 vapors that could be hazardous (e.g. PVC – Polyvinyl Chloride can emit chlorine gas under certain processing conditions).
Spin Welder User’s Manual Follow the installation instructions to ensure the Spin Welder is properly installed. Do not operate the Spin Welder until after it has been properly and securely installed. Electrical Safety AC Power For safety and reliability, the power cords on the Dukane Spin Welder have a grounded Twist–Lock NEMA configuration plug. This should be connected to a NEMA L15–20R configuration receptacle (see Figure 2–2).
Section 3 – Safety If a fuse has blown, determine the cause and repair the defect before replacing the fuse. Replace the fuses only with fuses of the same type and rating. Grounding It is important for operator safety that the receptacle grounding wire be installed properly and securely attached to an effectively grounded rod. The function of the ground wire is to keep the Spin Welder base and housing at earth potential.
Spin Welder User’s Manual Compressed air can develop a considerable amount of force. This force is large enough to inflict serious injury if one places their hand or other limb under the tool head. The Spin Welder uses a 3–inch (76–mm) diameter air cylinder which converts the air pressure to mechanical movement and has a force multiplication factor of seven. This means that at the full 100 psi (6.9 bar), the air cylinder is capable of exerting 700 pounds (318 kg) of force.
Section Section 4 – Installation 3 – Safety Section 4 Installation • Secure to Work Table • Tooling Attachment • Compressed Air • Control Cable • AC Power Connection Work Area......................................................21 Secure to Work Table......................................21 Bench Capacity............................................... 21. Leveling.......................................................... 21 Mounting Holes..............................................
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Section 4 – Installation Work Area Allow sufficient area on either side of the Spin Welder for handling material, work pieces and fixtures. Provide ample room so that the movement of an operator or helper does not interfere with the work of another. Also be aware that under extreme conditions, small droplets of molten plastic may be spun off from the upper part. Securing to Work Table Bench Capacity The Spin Welder weighs approximately 500 lbs. (225 kg).
Spin Welder User’s Manual detailed measurements of the fixture mounting holes in the platen. Compressed Air The Spin Welder requires a clean, dry supply of compressed air at a nominal pressure if 100 psi (6.9 bar). The air supply should be capable of delivering 1 SCFM and at least 80 psi (5.5 bar) and not greater than 110 psi (7.6 bar). The air is attached to the rear of the press using a standard 3/8” NPT fitting. The location is shown in Figure 4–3.
Section 4 – Installation The Base Interface to Press cable (Part No. 200– 1064) is a supplied part and is included with the Spin Welder (see Table 2–1). The cable is connected between J8 on the press and J35 on Base Interface connector. This connection is illustrated in Figure 4–4. Both J8 and J35 are 14–contact female connectors with 7 active contacts. The control cable carries the operate and emergency stop signals from the palm operate and abort switches on the base.
Spin Welder User’s Manual switch enclosure are three fuses for the 240 VAC three–phase power rated at 20 Amps. The power switch and fuses are identical on both the 3 HP and 5 HP models. The AC power switch has a provision to lock the handle in the OFF position during any maintenance or servicing. The cover can also be locked to prevent unauthorized access.
Section 5Section – Theory 4 –ofInstallation Operation Section 5 Theory of Operation • Spin Welding Process • Material Considerations • Control Parameters • Initial Settings • Part Size Spin Welding Process......................................27 Material Considerations..................................27 Control Parameters.........................................28 Axial Pressure.................................................. 28 Surface Velocity (RPM).................................... 29 Weld Time...
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Section 5 – Theory of Operation Spin Welding Process Dukane Manual Part Number 403-547-03 on iti e III IV V ol H d Ti m St dy ea St II el M tin g Tr a at e ns s tin tic le ea rP ar lH na W ea tio I ic Fr The spin welding process is divided into 5 distinct phases as shown in Figure 5–1. In Phase I, the rotational friction generates heat. Frictional heating is intensified with both axial pressure and joint surface velocity.
Spin Welder User’s Manual Material Considerations Materials that can be friction (i.e. vibration) welded can also be joined with by spin welding. The semicrystalline thermoplastics are more readily joined using spin welding than ultrasonics. Using compatible polymers, spin welding is capable of making reliable hermetic seals. Far–field welding is easier with spin welding than with ultrasonic welding. Additional parts can be entrapped between the upper and lower pieces during spin welding.
Section 5 – Theory of Operation areas require more pressure. Higher pressure not only increase the weld penetration depth, it also increases the penetration velocity. Mass reduction – a measure of the amount of wear particles and flash – is not significantly affected by increased pressure, especially at high rotation speeds. A slower surface velocity (i.e. small diameter weld joints) requires higher pressure.
Spin Welder User’s Manual penetration has been achieved, we want to stop the rotation as quickly as possible. Too long of a deceleration time will allow the polymer to solidify and subsequently shear reducing the weld strength. Higher axial pressure may help stop the rotation sooner on large diameter parts. Hold Time During Phase V, a holding time allows the plastic to solidify before removing pressure from the joint.
Section 5 – Theory of Operation RPM (Surface Velocity) Maximum weld strength occurs at an optimum pressure and speed. Higher rotation speeds decrease the weld initiation time, but to a lesser extent than axial pressure. This means that you will typically need to make larger percentage changes in motor speed to see a noticeable difference in the weld properties than you would in axial pressure. The basic expression commonly seen is: 600 = 25 00 R 41 PM .7 M RP 00 0 15 25. = N N 35 N = 00 R PM 58.
Spin Welder User’s Manual 120 inch/sec (3 m/sec) have been used for parts with thin wall sections. Figure 5–2 is a plot of surface velocity (v) as a function of weld joint diameter (D) for five different RPM settings (N). You can use this graph to estimate the surface velocity (vertical axis), that various RPM settings will yield for a given part diameter (horizontal axis). Note that we have converted all units to inches/second for consistency.
Section 5 – Theory of Operation The generalization of RPM being a noncritical parameter applies only to motor drives. An inertial drive utilizes a flywheel’s kinetic energy which is a function of the square of its rotational velocity. Inertial drive units adjust the energy delivered by adjusting the flywheel’s speed and are therefore more sensitive to a change in rotational velocity. Weld Time Weld times are very application dependent but typically less than a second.
Spin Welder User’s Manual rating of 3500 RPM, while the 5 HP model has a maximum speed of 1750 RPM. The joint diameter range given in Table 5–1 is a very general guide. The overlap between the two models is large enough, and the variability in applications diverse so that only very general recommendations can be made. Please contact the Dukane Applications Laboratory (see Section 10) for a recommendation concerning your specific application. Model Minimum Diameter Maximum Diameter 3 HP 1.
Section 5 – Theory of Operation Section 6 Control Functions • AC Power Switch • Operate & Emergency Off • Pneumatic Controls • Process Controller • Motor Speed Control • Height Adjustment • Bottom Stop Switch AC Power.......................................................37 AC Switch....................................................... 37 AC Fuses......................................................... 37 Operate Controls............................................38 Palm Switches......................
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Section 6 – Control Functions AC Power AC Switch The main power switch turns the AC power off and on. The power switch enclosure also contains three fuses. The enclosure cover can be locked but still permit operation of the power switch. The power switch handle can also be locked out which effectively locks the enclosure lid. Figure 6–1 shows the outside of the AC power switch enclosure and the AC power switch in both the OFF (lower) and ON (upper) position.
Spin Welder User’s Manual 20 Amp Fuses (3) Figure 6–2 AC Power Enclosure Showing the Three Fuses Operate Controls Palm Switches The dual operate palm switches are located at either side of the base near the front. These safety switches comply with OSHA safety regulations and require simultaneous activation to start the spin welder. The switches must be held until the Start–Of–Weld optical switch is triggered (see Start–Of–Weld in Section 7). The palm switches are shown in Figure 6–3.
Section 6 – Control Functions Emergency OFF The Abort/Emergency OFF switch is located at the front of the base (see Figure 6–3). When the red palm switch is pushed in, it will stop the spin welder regardless of where it is in the cycle. When the Emergency OFF switch is pushed in, the following conditions are present: • The motor and press are disengaged. • The activation palm buttons are deactivated. • The air is allowed to bleed out of the downstroke air cylinder.
Spin Welder User’s Manual palm switches activate the spin welder, the display also indicates IN CYCLE in green. These indicators are shown in Figure 6–4. Pneumatic Controls Air Pressure Regulator The air pressure regulator is located on the front panel of the Spin Welder and is shown in Figure 6–5. The pressure regulator knob is a ten–turn control. About five turns are required to change the setting from 0 to 100 psi (6.9 bar). Turning the knob clockwise increases the pressure.
Section 6 – Control Functions Down Speed Control This control determines the downward velocity of the Spin Welder tool hub when the palm switches are activated. The Down speed control is located below the regulator adjustment knob and is also shown in Figure 6–5. It is a ten–turn valve that adjusts the flow of the air exhausted from the air cylinder during the downstroke. Clockwise rotation reduces the flow which decreases the down speed.
Spin Welder User’s Manual The keypad uses a sealed membrane with a tactile feedback. The keypad and the display are both illustrated in Figure 6–5. Number Keys The ten number keys are white with black letters. They are arranged telephone style and located on the right side of the keypad. Function Keys The two function keys are blue with white letters. They are located in the upper left side of the keypad and are labeled F1 and F2. They are used to display any application screen assigned to the key.
Section 6 – Control Functions Motor Speed Control The motor speed is controlled by the digital switch shown in Figure 6–5. This switch has three decades of control and is used to set the motor RPM as a percentage of the full rated motor speed. The rated motor speed is nominally 3500 RPM for the 3 HP model and 1750 RPM for the 5 HP model. Mechanical Controls NOTE The maximum motor speed setting is 999 which corresponds to 99.9% ( 3HP = 3496 RPM and 5HP = 1748 RPM).
Spin Welder User’s Manual raises the press. Clockwise rotation of the crank lowers the press. The dovetail locking levers must be loosened before the press height is adjusted. Dovetail Locks The dovetail locking levers lock the height adjustment in place. They must be loosened (counterclockwise) before the press height is adjusted, and tightened (clockwise) once the desired height is reached. The dovetail locks are also shown in Figure 6–7.
Section 6 – Control Functions determines the vertical stroke. The vertical scale has ten divisions per inch and a range of seven inches. The scale is positioned the same way you would place a ruler against the scale with 0.0” at the bottom and 7.0” at the top. One rotation of the knob moves the flag 0.0556” (1.41mm). Counterclockwise rotation raises the flag to the top of the scale which lengthens the stroke. Clockwise rotation lowers the flag to the bottom of the scale and reduces the stroke.
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Section Section 76 –– Operational Control Functions Setup Section 7 Operational Setup • Terminology • Tooling Capacity • Setup Checklist • Bottom Stop Adjustment • Pneumatic Adjustments • Motor Speed Control • Operating Menus Terminology....................................................49 Tooling Capacity.............................................50 Setup Checklist...............................................51 Press Height Adjustment.................................52 Bottom Stop Adjustment.........
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Section 7 – Operational Setup Terminology Pre–Spin There are two possible methods of starting the spin welding process. The first is to spin the motor up to the desired RPM, then bring the upper part into contact with the lower part in the fixture and apply pressure. This is called pre–spin and is the most common spin welding process. NOTE Refer back to Section 5 – Theory of Operation for further discussion of the terms listed here.
Spin Welder User’s Manual Weld by Distance The weld cycle is determined by the bottom stop setting. The End–Of–Weld optical switch stops the process 0.005” above the actual setting to compensate for the system momentum. Tooling Capacity Upper Hub The upper hub can safely accommodate a maximum tool nest diameter of 12 inches (305mm) which allows for a clearance of 0.22 inches (5.6mm) in the back. This is shown in Figure 7–1. Lower Fixture The platen surface is 410mm wide (16.14”) by 347mm deep (13.
Section 7 – Operational Setup the bottom stop adjustment. The maximum stroke is 7” (178mm). This gives the lowest achievable height above the platen of 2.19” (55.6mm). The stroke range you set determines the space you have to load and unload the parts. Air Lockout 100 psi Air J8 Optional Pre–Filter Setup Checklist 1. Attach Tooling Make sure the upper tool nest is securely fastened to the tooling hub. Also attach the lower tooling fixture at this time. 2.
Spin Welder User’s Manual welder. You may also be required to install an air lockout as mentioned in Section 3 under Pneumatic Safety. If you have an air lockout, flip it to the ON position at this time. 6. Turn Power ON Flip the AC power switch handle up to the ON position. The status display should now indicate ABORT in red as shown in Figure 7–3. 7.
Section 7 – Operational Setup Turning the crank clockwise lowers the tooling hub. Place the parts to be welded in the upper tool nest and in the lower fixture. Adjust the hand crank to raise or lower the tool hub to allow sufficient room for safely loading and unloading the parts. Stroke Adjustment CAUTION The bottom stop should turn without too much effort. If the knob is difficult to turn, check that the bottom stop lock on the side is loosened (CCW).
Spin Welder User’s Manual Press the Emergency OFF button again. If you adjusted the bottom stop for more stroke than needed, turn the bottom stop knob clockwise to reduce the stroke (lower the flag) until it backs up against the mechanical limit. Repeat this process until you have achieved the desired stroke and bottom stop settings. Start–Of–Weld The Start–Of–Weld trigger occurs 0.50” (12.7mm) above the bottom stop setting.
Section 7 – Operational Setup Exhaust Diffuser Compressed Air In Pressure Gauge 3–inch Air Cylinder Main Valve Quick Exhaust Valve Front Panel Regulator Counterbalance Regulator Pilot Valve Air Downspeed Adjustment Figure 7–6 Pneumatic System Schematic Counterbalance Regulator The counterbalance regulator on the rear of the press (see Figure 6–6) adjusts the amount of upward pressure applied to the air cylinder between weld cycles.
Spin Welder User’s Manual Down Speed Adjustment The down speed adjustment on the front of the press (see Figure 6–5) adjusts the flow of air leaving the air cylinder during the downward stroke only. The restoring pressure during the upward stroke is not affected. The knob has numeric graduations ranging from 0 to 9 and controls a ten–turn flow valve with a one–way bypass. There are also two small windows to view a color–coded internal shaft. The shaft has eight colored bands.
Section 7 – Operational Setup cal, so the chart is more than adequate for setting the speed control. For example, a setting of 500 (50.0%) results in a motor speed of 875 RPM for the 5 HP and 1750 RPM for the 3 HP motor. The maximum setting is 999 (99.9%). At less than maximum speed, the variable frequency drive maintains a fairly constant HP output from the motor. This means that the torque increases as RPM decreases.
Spin Welder User’s Manual 6. The next screen displayed gives three options for a menu selection. You can return to this screen at any time by pressing the MENU key. 1=RUN 2=SETUP 3=MODIFY Operating Menus SETUP Press the numeric 2 key to switch the processor to its setup mode. The display then instructs you to push the Emergency OFF button to begin setup. Push the Emergency OFF button in. PUSH E STOP TO BEGIN SETUP The display now instructs you to set the bottom stop.
Section 7 – Operational Setup SETUP Menu MENU 1=RUN 2=SETUP 3=MODIFY 2 PUSH E STOP TO BEGIN SETUP Push Emergency OFF Button In SET BOTTOM STOP 1=BYPASS 1 Turn Counterbalance Regulator CCW To Allow Motor To Drop Down To Limit Stop STOP SET 1=PRE LOAD 2=PRE SPIN NOTE A flashing black box (on the second line to the right of the current data) in the display prompts you to enter the data for the specified parameter.
Spin Welder User’s Manual it is preferable to begin with the Weld by Time mode. After you have some experience with your parts and the correct parameters, you may wish to experiment with the Weld by Distance mode. RUN Menu Once the necessary parameters have been entered, twist the Emergency OFF button clockwise and out. Select the RUN menu by pressing 1. Now simultaneously press both palm switches to start operation. The RUN menu flowchart is shown in Figure 7–9.
Section 7 – Operational Setup MODIFY Menu To modify the parameter values, press the MENU key, then 3 to enter the MODIFY menu. The flowchart for MODIFY is shown in Figure 7–10. MODIFY Menu MENU 1=RUN 2=SETUP 3=MODIFY 3 RESET COUNTER? 1=YES 2=NO 1 2 Counter is reset to zero Counter is not reset Checks Which Mode Was Selected in the SETUP Menu PRE–LOAD Was Selected in SETUP Menu PRE–SPIN Was Selected in SETUP Menu Check If PART PICKUP Was Selected in SETUP Menu Part Pickup = YES SET PRE LOAD TIME .
Spin Welder User’s Manual Input Parameters PART PICKUP An option available for the Pre-Spin mode only. If selected, the tool hub lowers to pick up the upper portion of the part from the fixture, then rises to the top. The lower portion of the part remains in the fixture. The tool hub then begins spinning as it is lowers to begin the weld cycle. PICKUP TIME This is the amount of time that the tool hub spends in the lowered position to pick up the part.
Section 7 – Operational Setup PREV and NEXT Keys PREV Key PREV In the Setup menu, the Previous key recalls the data value entered previous to the current one displayed. This key does not work in Modify menu. NEXT Key NEXT The Next key skips the currently displayed value and steps to the next input parameter in either the Setup or Modify menu.
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Section Section 7 – Operational 8 – Maintenance Setup Section 8 Maintenance • User Interface Panel • AC Power Cord & Plug • Weekly Maintenance • Monthly Maintenance • Annual Maintenance User Interface Panel........................................67 Cleaning......................................................... 67 Display............................................................ 67 Keypad........................................................... 67 AC Power Cord......................................
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Section 8 – Maintenance User Interface Panel Cleaning Do not use any solvents or abrasive cleaners on the display window. Using a soft cloth or clean sponge, clean the display with a mild soap or detergent. Dry the display with a chamois or moist cellulose sponge to avoid water spots. Do not spray or apply a cleaner directly to the interface panel. Remove grease or fresh paint splashes before they dry by rubbing lightly with isopropyl alcohol.
Spin Welder User’s Manual Weekly Maintenance Pre–Filter If you have installed a pre–filter in the compressed air line, check the filter once a week and clean if necessary. Exhaust Diffuser Exhaust Diffuser The exhaust diffuser is porous, sintered metal filter. It acts similar to a metallic sponge, and is designed to trap solid particles in gas streams. Its location is shown in Figure 8–1. A darkened diffuser indicates contaminated compressed air is being exhausted from the system.
Section 8 – Maintenance Annual Maintenance Gas Spring Check the external gas spring (see Figure 8–3) for sufficient counterbalance force by turning the hand crank to move the head all the way up and down. Make sure to first unlock the two dovetail locking levers. The gas spring counterbalances the entire upper motor and press assembly up to the maximum height, which is adjusted by the hand crank.
Spin Welder User’s Manual Lubricate Slides Lubricate the dovetail slides with Mobil Vactra #2 or equivalent. Do not use grease. There are four fittings, two on each side. Three are clearly visible and one is hidden behind the Dukane name plate of the upper gas spring support bracket. Cut out an access hole to gain access to this grease fitting (see Figure 8–4). The lower fitting is shown in Figure 8–3. The two fittings on the opposite side are visible in Figure 6–7.
Section Section 9 –8Troubleshooting – Maintenance Section 9 Troubleshooting • Welding Process • Welder Troubleshooting • User Interface Welding Process..............................................73 Material Choice.............................................. 73 Parameter Effects............................................ 73 Welder Troubleshooting..................................74 Pneumatics..................................................... 74 Mechanical...........................................
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Section 9 – Troubleshooting Welding Process Material Choices A family of thermoplastics is usually compatible with its own type and sometimes with other types. Characteristics to consider are the melting point and coefficient of linear expansion. Even members of the same family may cause problems due to differences in the manufacturing process. For example, an extruded Polyethylene (PE) piece may not weld as well to an injection molded PE piece as it would to another extruded PE piece.
Spin Welder User’s Manual Welder Troubleshooting Pneumatics The air cylinder requires a clean, dry supply of compressed air at 100 psi (6.9 bar). If you have an air lockout device, make sure it is turned on. If you have a pre–filter, make sure it is clean and functioning properly. Mechanical The part fixture should be securely mounted perpendicular to, and centered under the spin axis. Electrical Power WARNING Always turn the AC power OFF before opening the AC switch enclosure.
Section 9 – Troubleshooting A complete block diagram of the electrical components is shown in Figure 9–1. The base interface cable supplies power to the status display and passes the operate and abort signals to the Micrologic Controller. A more detailed schematic is shown in Appendix B.
Spin Welder User’s Manual AC Motor Controller The motor controller is located behind the removable front panel on the right hand side. The front of the controller contains two indicator LEDs to aid in troubleshooting. The controller is shown in Figure 9–2. The lower green READY indicator LED illuminates when the DC bus is charged and the drive is ready to run. The upper red FAULT indicator LED illuminates when a drive fault condition exists.
Section 9 – Troubleshooting TEST FUNCTIONS Menu MODE *LIMITED ACCESS* CODE: Any Code Works Until Access Code is Set 1 Valid Code Access Permitted 1 Reset 2 Comm 3 Spec 4 Other 5 Eight Tests plus Reset Press Enter Key to Initiate Test Press NEXT or PREV Key to Select Test Select Reset to Exit TEST Menu 4 1Code 2Scal 3Sim 5Ex 4Test 4 Diagnostic Tests Display PREV A Diagnostic Tests Reset Diagnostic Tests Display PREV All Pixels Are Turned On Diagnostic Tests Core ROM PREV Diagnostic Tests Sy
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Section Section 10 –9Contacting – Troubleshooting Dukane Section 10 Contacting Dukane • Dukane Support • Website • FAX • Telephone Numbers Identify Equipment..........................................81 Our Website...................................................81 Mailing Address..............................................81 Phone Number................................................
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Section 10 – Contacting Dukane Contacting Dukane Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • Model number, line voltage and serial number. • Alarm messages from the touch screen display. • Problem description and steps taken to resolve it. Many problems can be solved over the telephone, so it is best to call from a telephone located near the equipment.
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Section Section 10 – Contacting 11 – Specifications Dukane Section 11 Specifications • Energy Requirements • Operating Environment • Dimensions • Model & Serial Numbers Energy Requirements......................................85 Pneumatic....................................................... 85 AC Power....................................................... 85 Operating Enviornment...................................85 Dimensions.....................................................
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Section 11 – Specifications Energy Requirements Pneumatic The compressed air supply must be clean and dry. The acceptable pressure range is 80 psi to 110 psi (5.5 bar to 7.6 bar). If the air line contains moisture or oil, install a pre–filter before the Spin Welder air inlet. AC Power The electrical power requirements are 200 to 240 VAC, 3–phase, 60 Hz at 20 AMPS. 3–phase Input Current 3 HP: 12 Amps (2.2kW) 5 HP: 18 Amps (3.7kW) The spin welder uses three identical AC fuses.
Spin Welder User’s Manual Dimensions 12.25 (311) 13.94 (354) 55.88 (1419) inches (millimeters) 6.38 (162) 20.94** (532) MAX 16.50 (419) 21.50 (546) ** 26.94 (684) WITH SPECIAL FACTORY CONFIGURATION 7.63 (194) inches (millimeters) 3.90 18.58 (472) Figure 11–2 Front View and Dimensions Page 86 6.25 (158) 13.66 (347) 8.50 (216) 27.
Section 11 – Specifications 0.50 (12.7) DIA. HOLES 18.58 (472) 0.50 RADIUS 2 PLACES 16.50 (419) inches (millimeters) 8.25 (209.6) (336.6) M10 X 1.5 2B TAP THRU EQUALLY SPACED AND LOCATED AT TRUE POSITION WITHIN .015 DIA ON (2) TWO BOLT CIRCLES 8 PLACES 14.00 (355.6) 7.61 (193.3) 7.00 inch BOLT CIRCLE 125.0 mm BOLT CIRCLE 12.38 12.00 inch BOLT CIRCLE 24.84 (631 1.52/(38.6) 1.50/(38.1) 2.00/(50.8) 2.25 TYP. M12 X 1.75 6H TAP THRU 5 PLACES 2.63 TYP. (66.
Spin Welder User’s Manual Base Model and Serial Number The base is Dukane model number 438–749. The serial number tag is located on the rear of the base above the Base Interface connector as shown in Figure 11–6.
Section 11 – Specifications Appendix A List of Figures List of Tables Dukane Corporation • Dukane Manual Part Number 403-547-03 • Ultrasonics Division Page 89
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Appendix A - List of Figures and Tables List of Figures Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 240VAC L15-20 Plug......................................................................... 10 240VAC L15-20 Receptacle............................................................... 10 Major Components Rear View with Callouts...................................... 11 Major Components Front View with Callouts.................................... 12 Figure 3-1 AC Power Enclosure, Switch and Lockouts.........
Spin Welder User’s Manual Figure 9-1 Figure 9-2 Figure 9-3 Block Diagram of Electrical Components........................................... 75 Motor Controller LEDs....................................................................... 76 TEST Function Flowchart.................................................................... 77 Figure 11-1 Figure 11-2 Figure 11-3 Figure 11-4 Figure 11-5 Figure 11-6 FLNR 250V/20AMP SLO–BLO Fuse.....................................................
Appendix Appendix A - List B -ofElectrical Figures and Schematic Tables Appendix B Electrical Schematic Dukane Corporation • Dukane Manual Part Number 403-547-03 • Ultrasonics Division Page 93
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Dukane Manual Part Number 403-547-03 N.
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Index Index A ABORT Status.................................................................................................. 39 AC Fuses...............................................................................................37-38, 87 AC Lockout...................................................................................................... 16 AC Power Cord............................................................................................... 67 AC Power Indicator.......................
Spin Welder User’s Manual E Electrical Block Diagram................................................................................ 75 Electrical Schematic........................................................................................ 95 Emergency OFF Switch............................................................................. 38, 52 eMail Address................................................................................................. 81 End–Of–Weld.................................
Index M Maintenance Schedule..............................................................................67-70 Maximum Time Limit Setting......................................................................... 62 Mechanical Safety.......................................................................................... 17 Melting Transition Phase............................................................................... 27 Menu Hierarchy................................................................
Spin Welder User’s Manual R Regulator, Counterbalance.......................................................... 41, 52, 55, 68 Regulator, Pressure................................................................................... 40, 52 RPM Conversion Chart.................................................................................. 57 RUN Menu Flowchart..................................................................................... 60 S Safety....................................................
Dukane ISO ISO CERTIFICATION Dukane chose to become ISO 9001:2008 certified in order to demonstrate to our customers our continuing commitment to being a quality vendor. By passing its audit, Dukane can assure you that we have in place a well-defined and systematic approach to quality design, manufacturing, delivery and service. This certificate reinforces Dukane's status as a quality vendor of technology and products.
Please refer to our website at: www.dukane.com/us/sales/intsales.htm to locate your local representative. Spin Welder User's Manual Part No. 403 - 547 - 03 www.dukane.com/us Printed in the United States of America Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St.
