Intelligent Assembly Solutions - Dukane · Dynamic Processor ControllerTM DPC III User’s Manual...

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InitateMode

Scrub

Manual

Auto

Maintained

Momentary

Enter Trigger Delay Time (sec)

Enter Trigger Delay Distance (in/mm) / Enter Max. Delay Time (sec)

Enter Probe Delay Time (sec)

Enter Pre-Trig Distance (in/mm)

Disabled

Enabled Enter Scrub Time (sec)

TriggerMethod

Probe Delay

Normal Trigger

Probe Mode

Delay Trigger by Distance

Delay Trigger by Time

DelayTrigger Till Auto In

Pre-trigger by Dist

WeldMethod

Enter Time (sec)

Enter Distance (in/mm) / Enter Max. Weld Time (sec)

Enter Absolute Distance (in/mm) / Enter Max. Weld Time (sec)

Enter Peak Power (watts) / Enter Max. Weld Time (sec)

Enter Energy (joules) / Enter Max. Weld Time (sec)

Enter Time (sec)





Enter Time (sec)


Enter Absolute Distance (in./mm) / Enter Max. Weld Time (sec)

Enter Peak Power (watts) / Enter Max. Weld Time (sec )

Enter Reporting Interval (sec)


Pressure 1

Pressure 2

Time

Peak Power

Abs Distance

Distance

Energy

Time

Peak Power

Abs Distance

Distance P1

Energy

Time

Peak Power

Abs Distance

Distance P2

Energy

Dual Pressure

Single Pressure

Continuous

AfterburstDisabled

Enabled

HoldMethod

Hold by Time Enter Hold Time (sec)

Enter Hold Distance (in/mm) / Enter Max. Hold Time (sec)Hold by Dist

Trigger

Pre-trigger

Enable Hold

Disable Hold

Delay Enter Delay Time (sec)

Enter Duration (sec)Duration

Start Weld At

www.dukane.com/us

Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797–4900 • FAX (630)

Dukane Part No. 403–541–04User’s Manual

Intelligent Assembly SolutionsIntelligent Assembly Solutions

Dynamic Process Controller

DPC™ III

ISO 9001:2000 Dukane products are manufactured in ISO registered facilities

Dynamic Processor ControllerTM DPC III User’s Manual

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Printed in the United States of America.

Dukane Part Number: 403–541–04

Dukane ultrasonic equipment is manufactured under one or more of the followingU.S. Patents:3,780,926 3,825,481 4,131,505 4,277,710 5,798,599 and 5,880,580.

DataMyte is a registered trademark of DataMyte Corporation.Epson is a registered trademark of Epson Corporation.HyperTerminal is a registered trademark of Microsoft Corporation.IBM is a registered trademark of International Business Machines Corporation.Intel is a registered trademark of Intel Corporation.Kinechek is a registered trademark of Deschner Corporation.Lotus and 1-2-3 are registered trademarks of Lotus Development Corporation.Microsoft, and Excel are registered trademarks of Microsoft Corporation.Sherwood is a registered trademark of Inkel Technology, Inc.Windows 95, Windows 98, Windows 2000, Windows XP and Windows NT

are trademarks of Microsoft Corporation.

Copyright © 2000—2004 Dukane Corporation

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, elec-tronic, mechanical, photocopying, recording, or by any information storage and retrieval system, without written permission from Dukane Corporation.

Notice of Liability:The information contained is this manual is distributed on an “As is” basis, without warranty. While every precaution has been taken in the preparation of this manual, Dukane Corporation shall not have any liability to any person or entity with respect to any liability, loss, or damaged caused or alleged to be caused directly or indirectly by the instruc-tions contained in this manual, or by the hardware products described herein.


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Revision History

Revision Revision Number History Date ––– Original release. 2000-Apr-12

–01 Incorporate Addendum 1 (Amplitude Control standard feature) 2002–Jun–06 Incorporate Addendum 2 (Jumper Block for Hand Probe) Update Generator Model Number in Table 12–1 Update Interpreting the DPC Model No. in Figure 12–2

–02 Revise Hand Probe instructions on pages 19, 52, 53 & 60 2002-Oct-23 Corrections to Top–Of–Stroke connector pinout diagram (Figure A–8) on page A–XVII in Appendix A.

–03 Remove all references to obsolete DDeX commands. 2004-Jan-16 Remove references to obsolete Remote Setup Commands. Remove references to discontinued Force Transducer/Load Cell. Remove references to discontinued Electronic Pressure Regulator. Remove references to discontinued Pressure Transducer. ModifyIndexandTOCtoreflectdeletionsandpagenumberchanges. UpdatemenuflowchartsinAppendixD(PreviouslyAppendixF) toreflectchanges. AddnewfunctionstoCommunications–>OutputMode

–04 UpdateTable2—1,PackingContentstoreflectRev–4manual. 2004-Nov-15 UpdateTable2–3toreflectnewpartnumbers. Table2–2and2–3nowindicateCable200–740onlysupplied withAdvancedProgrammeroption. TerminalsuppliedwithAdvancedProgrammeroptionhasdifferent DPCconnections.Replaceddiagramsonpages17,18and144. Replaceinstructionsforenteringsetupmodetoconfiguremonitor and connecting printers in Section 13, pages 141–145. AddTableC–4whichprovidedescriptionsof CSVtagnumbers. Figure A–1 (I/O Jumper Location) restored. Figure became corrupted in revision –03. Newconsolidatedwarrantyand24–HourServicenumber. UpdatecertificationtoISO9001:2000. UpdateIndextoreflectnewinformationandchangedpagenumbers.

Update Dukane Contacts Page. 2010-July-8 Update Regulatory Agency Compliance Statement. UpdateDukanewebsiteaddress.

DPC–III User’s Manual

Dynamic Processor ControllerTM DPC III Plus User’s Manual

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Table of Contents

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TableofContentsSection1IntroductionandSafety

BeforeOperatingEquipment................................................................................ 1ReadthisManualFirst.................................................................................... 1WatchforSpecialParagraphs........................................................................ 1

AboutthisManual............................................................................................... 2Contents........................................................................................................ 2Organization................................................................................................. 2

DPCOverview.................................................................................................... 4KeyFeatures....................................................................................................... 4HealthandSafetyRecommendations.................................................................... 6

SpecialHealthNotice–Plastics....................................................................... 7ElectricalSafetyGroundingInstructions........................................................... 7

120VoltGroundAdapter......................................................................... 8InternationalGrounding............................................................................ 9AdditionalGrounding.............................................................................. 9

RFIFilterConsiderations................................................................................ 9

Section2InstallationUnpacking........................................................................................................ 11DPCPlacement................................................................................................. 11

Benchtop.................................................................................................... 11Rack-mounted.............................................................................................. 12

RearPanelLayout............................................................................................. 13GroundtheSystem............................................................................................ 15ConnecttheCables........................................................................................... 15

TheAdvancedProgrammer.......................................................................... 17Overview............................................................................................... 17Connections........................................................................................... 17

HandProbeConnections.............................................................................. 19ComputerConnections................................................................................. 19GroundDetectFeatureConnections............................................................... 20RecheckConnections.................................................................................... 20ConnectElectricalPower.............................................................................. 20


vi

Overview......................................................................................................... 21FrontPanelLayout............................................................................................. 21

FrontPanelDisplayandKeypadOverview.................................................... 22Display.................................................................................................. 22Keypad.................................................................................................. 22

KeypadDetails............................................................................................ 23TheCancelKey...................................................................................... 23TheEnterKey......................................................................................... 24TheDownArrowKey.............................................................................. 25TheUpArrowKey.................................................................................. 25TheLeftArrowKey................................................................................. 26TheRightArrowKey............................................................................... 26ModeSelectionKeyswitch....................................................................... 27

GeneratorStatusPanel................................................................................. 28GeneratorControl.................................................................................. 28SystemStatus......................................................................................... 29SystemPowerOutput.............................................................................. 30

ACPower................................................................................................... 30TheAdvancedProgrammerKeyboard................................................................ 31

FunctionKeys.............................................................................................. 31ProgrammingaFunctionKey........................................................................ 32RemovingaFunctionKey’sProgram.............................................................. 32MiscellaneousKeyFunctions......................................................................... 33BlockingAccesstoSETUPMode.................................................................... 34

Section4Start-upOverview......................................................................................................... 35Start-upwithoutAdvancedProgrammer............................................................. 35Start-upwithAdvancedProgrammer.................................................................. 36StoppingtheWeldCycle................................................................................... 38

NormalConditions...................................................................................... 38EmergencyConditions.................................................................................. 38

TableofContentsSection3Controls

Table of Contents

vii

Section5MenuOrientationOverview......................................................................................................... 39

TermstoKnow............................................................................................. 40MenuItem.............................................................................................. 40Page...................................................................................................... 40Menu..................................................................................................... 40

EntryFields................................................................................................. 41NumericEntryField................................................................................ 41ListEntryField........................................................................................ 41TextEntryField....................................................................................... 42

NavigatinginSETUPMode.......................................................................... 43HowtoNavigate......................................................................................... 44

UsingtheFrontPanelControls................................................................. 44UsingtheAdvancedProgrammer............................................................. 46

NavigatinginOPERATEMode...................................................................... 48

TableofContents

Section6SetupMode,ProcessControlPageOverview......................................................................................................... 49ProcessControlPage......................................................................................... 50

StartingDisplays.......................................................................................... 51InitiateMode.................................................................................................... 52

Manual....................................................................................................... 52ProbeMethod........................................................................................ 52AllOtherTriggerMethods....................................................................... 52

Auto........................................................................................................... 53TriggerMethod................................................................................................. 54

TriggerType................................................................................................ 54Maintained............................................................................................ 54Momentary............................................................................................ 55Force..................................................................................................... 55TriggerMethod1:NormalTrigger........................................................... 56TriggerMethod2:DelaybyTime............................................................. 56TriggerMethod3:DelaybyDistance........................................................ 57TriggerMethod4:DelaytillAuto-In......................................................... 57TriggerMethod5:Pre-triggerbyDistance................................................ 59TriggerMethod6:Probe......................................................................... 60


viii

TableofContents

Section8SetupMode,CommunicationsPage

TableofContentsSection6SetupMode,ProcessControlPage,continued

WeldMethod.................................................................................................... 61SinglePressure............................................................................................ 61DualPressure.............................................................................................. 61Continuous.................................................................................................. 62

EnteringReportInterval........................................................................... 62ControlParameters–SingleandDualPressureWelding................................. 63

Time...................................................................................................... 63Distance................................................................................................. 63AbsoluteDistance................................................................................... 64Energy................................................................................................... 64PeakPower............................................................................................ 64MaximumWeldTime.............................................................................. 64

Scrub............................................................................................................... 65HoldMethod.................................................................................................... 66

Disable....................................................................................................... 66HoldMethodChoices................................................................................... 66

HoldbyTime.......................................................................................... 66HoldbyDistance.................................................................................... 66

Afterburst......................................................................................................... 67SecondaryControls........................................................................................... 68

Section7SetupMode,ProcessLimitsPageOverview......................................................................................................... 69AvailableProcessCharacteristics........................................................................ 71ProcessCharacteristicsDefined.......................................................................... 71BadLimits......................................................................................................... 75

BadLimitsStatusField.................................................................................. 76Disabled................................................................................................ 76Display.................................................................................................. 76Window................................................................................................ 76

SuspectLimits.................................................................................................... 77SuspectLimitsStatusField............................................................................. 78

Disabled................................................................................................ 78Enabled................................................................................................. 78

EnablingProcessLimits...................................................................................... 79SecondaryControl............................................................................................ 80

NotAllCharacteristicsHaveSecondaryControl............................................. 80

Overview......................................................................................................... 81ConfigureSerialPort......................................................................................... 82

OutputDevice.............................................................................................. 83DeviceTypes.......................................................................................... 84

OutputMode............................................................................................... 85BaudRate................................................................................................... 85Protocol...................................................................................................... 86

Xon/Xoff................................................................................................ 86RTS/CTS................................................................................................ 86

LFAfterCR.................................................................................................. 87LimitIndicators............................................................................................ 87TimeTag..................................................................................................... 88

UserI/O.......................................................................................................... 88Outputs....................................................................................................... 88EndofWeld/GroundDetect......................................................................... 89StatusOutputs............................................................................................. 90DefineJ801-5As......................................................................................... 90

GoodPart.............................................................................................. 90InDwell................................................................................................. 90InCycle................................................................................................. 91SonicsOn.............................................................................................. 91

Table of Contents

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TableofContents

Section8SetupMode,CommunicationsPage

TableofContentsSection6SetupMode,ProcessControlPage,continued

WeldMethod.................................................................................................... 61SinglePressure............................................................................................ 61DualPressure.............................................................................................. 61Continuous.................................................................................................. 62

EnteringReportInterval........................................................................... 62ControlParameters–SingleandDualPressureWelding................................. 63

Time...................................................................................................... 63Distance................................................................................................. 63AbsoluteDistance................................................................................... 64Energy................................................................................................... 64PeakPower............................................................................................ 64MaximumWeldTime.............................................................................. 64

Scrub............................................................................................................... 65HoldMethod.................................................................................................... 66

Disable....................................................................................................... 66HoldMethodChoices................................................................................... 66

HoldbyTime.......................................................................................... 66HoldbyDistance.................................................................................... 66

Afterburst......................................................................................................... 67SecondaryControls........................................................................................... 68

Section7SetupMode,ProcessLimitsPageOverview......................................................................................................... 69AvailableProcessCharacteristics........................................................................ 71ProcessCharacteristicsDefined.......................................................................... 71BadLimits......................................................................................................... 75

BadLimitsStatusField.................................................................................. 76Disabled................................................................................................ 76Display.................................................................................................. 76Window................................................................................................ 76

SuspectLimits.................................................................................................... 77SuspectLimitsStatusField............................................................................. 78

Disabled................................................................................................ 78Enabled................................................................................................. 78

EnablingProcessLimits...................................................................................... 79SecondaryControl............................................................................................ 80

NotAllCharacteristicsHaveSecondaryControl............................................. 80

Overview......................................................................................................... 81ConfigureSerialPort......................................................................................... 82

OutputDevice.............................................................................................. 83DeviceTypes.......................................................................................... 84

OutputMode............................................................................................... 85BaudRate................................................................................................... 85Protocol...................................................................................................... 86

Xon/Xoff................................................................................................ 86RTS/CTS................................................................................................ 86

LFAfterCR.................................................................................................. 87LimitIndicators............................................................................................ 87TimeTag..................................................................................................... 88

UserI/O.......................................................................................................... 88Outputs....................................................................................................... 88EndofWeld/GroundDetect......................................................................... 89StatusOutputs............................................................................................. 90DefineJ801-5As......................................................................................... 90

GoodPart.............................................................................................. 90InDwell................................................................................................. 90InCycle................................................................................................. 91SonicsOn.............................................................................................. 91


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TableofContentsSection9SetupMode,UtilitiesPage,continued

EncoderUtilities.............................................................................................. 106EncoderUnits............................................................................................ 106EncoderPosition........................................................................................ 106

Reset/PresetPartCount................................................................................... 107ResetPartCount........................................................................................ 107PresetPartCount....................................................................................... 107

UserParameters.............................................................................................. 107JobNumber.............................................................................................. 107Horn......................................................................................................... 108Booster..................................................................................................... 108Fixture...................................................................................................... 108Pressure1................................................................................................. 108Pressure2................................................................................................. 108TriggerForce............................................................................................. 109

PowerUtilities(EnergySystemsOnly)............................................................... 110PowerAverage.......................................................................................... 110Power....................................................................................................... 110

Section8SetupMode,CommunicationsPage,continued

TableofContents

DefineJ801-6As......................................................................................... 91Ready.................................................................................................... 91GoodPart,InCycle,andSonicsOn......................................................... 91

BuzzerStatus............................................................................................... 92AdvancedProgrammer...................................................................................... 93

Status.......................................................................................................... 93BaudRate................................................................................................... 93

PartSampling................................................................................................... 94ConsecutiveMemory............................................................................... 94SampleMemory..................................................................................... 94

LotSizeandSampleSize................................................................................... 94LotSize....................................................................................................... 94SampleSize................................................................................................ 95Exclude....................................................................................................... 96Store........................................................................................................... 96

Graphing......................................................................................................... 97LeftandRightAxis....................................................................................... 97StartAt....................................................................................................... 97StopAt....................................................................................................... 97SelectingTime,Power,andDistanceScales.................................................... 98

Section9SetupMode,UtilitiesPageOverview......................................................................................................... 99SetupUtilities.................................................................................................. 100

SelectNewSetup....................................................................................... 100CopyaSetup............................................................................................ 101EraseSetups.............................................................................................. 101

EraseCurrentSetup.............................................................................. 102EraseAllSetups.................................................................................... 102

PrintSetup................................................................................................. 102PrintSetup-Text.................................................................................... 102PrintSetup-Hex................................................................................... 104

TimeandDateUtilities..................................................................................... 105SetDate.................................................................................................... 105SetTime.................................................................................................... 105CheckDate............................................................................................... 105CheckTime............................................................................................... 105DateFormat.............................................................................................. 105

Section10SetupMode,SequencingPageOverview....................................................................................................... 111WhatisaSequence?....................................................................................... 112ExampleSequence.......................................................................................... 113Sequencing.................................................................................................... 114

Disabled................................................................................................... 114Enabled.................................................................................................... 114

SegmentLength.................................................................................... 114ResetSequence..................................................................................... 114DefinePartAs...................................................................................... 115

Cycle.............................................................................................. 115Sequence........................................................................................ 115

PresetSegment..................................................................................... 115PresetCycles........................................................................................ 115

Sequence....................................................................................................... 116SelectSegment.......................................................................................... 116SelectSetup............................................................................................... 116

FunctionKeysandSequencing......................................................................... 117

Table of Contents

xi

TableofContentsSection9SetupMode,UtilitiesPage,continued

EncoderUtilities.............................................................................................. 106EncoderUnits............................................................................................ 106EncoderPosition........................................................................................ 106

Reset/PresetPartCount................................................................................... 107ResetPartCount........................................................................................ 107PresetPartCount....................................................................................... 107

UserParameters.............................................................................................. 107JobNumber.............................................................................................. 107Horn......................................................................................................... 108Booster..................................................................................................... 108Fixture...................................................................................................... 108Pressure1................................................................................................. 108Pressure2................................................................................................. 108TriggerForce............................................................................................. 109

PowerUtilities(EnergySystemsOnly)............................................................... 110PowerAverage.......................................................................................... 110Power....................................................................................................... 110

Section8SetupMode,CommunicationsPage,continued

TableofContents

DefineJ801-6As......................................................................................... 91Ready.................................................................................................... 91GoodPart,InCycle,andSonicsOn......................................................... 91

BuzzerStatus............................................................................................... 92AdvancedProgrammer...................................................................................... 93

Status.......................................................................................................... 93BaudRate................................................................................................... 93

PartSampling................................................................................................... 94ConsecutiveMemory............................................................................... 94SampleMemory..................................................................................... 94

LotSizeandSampleSize................................................................................... 94LotSize....................................................................................................... 94SampleSize................................................................................................ 95Exclude....................................................................................................... 96Store........................................................................................................... 96

Graphing......................................................................................................... 97LeftandRightAxis....................................................................................... 97StartAt....................................................................................................... 97StopAt....................................................................................................... 97SelectingTime,Power,andDistanceScales.................................................... 98

Section9SetupMode,UtilitiesPageOverview......................................................................................................... 99SetupUtilities.................................................................................................. 100

SelectNewSetup....................................................................................... 100CopyaSetup............................................................................................ 101EraseSetups.............................................................................................. 101

EraseCurrentSetup.............................................................................. 102EraseAllSetups.................................................................................... 102

PrintSetup................................................................................................. 102PrintSetup-Text.................................................................................... 102PrintSetup-Hex................................................................................... 104

TimeandDateUtilities..................................................................................... 105SetDate.................................................................................................... 105SetTime.................................................................................................... 105CheckDate............................................................................................... 105CheckTime............................................................................................... 105DateFormat.............................................................................................. 105

Section10SetupMode,SequencingPageOverview....................................................................................................... 111WhatisaSequence?....................................................................................... 112ExampleSequence.......................................................................................... 113Sequencing.................................................................................................... 114

Disabled................................................................................................... 114Enabled.................................................................................................... 114

SegmentLength.................................................................................... 114ResetSequence..................................................................................... 114DefinePartAs...................................................................................... 115

Cycle.............................................................................................. 115Sequence........................................................................................ 115

PresetSegment..................................................................................... 115PresetCycles........................................................................................ 115

Sequence....................................................................................................... 116SelectSegment.......................................................................................... 116SelectSetup............................................................................................... 116

FunctionKeysandSequencing......................................................................... 117


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Section13CareandTroubleshootingCare.............................................................................................................. 131

Environment.............................................................................................. 131FrontPanel................................................................................................ 131

Cleaning.............................................................................................. 131ReplaceableParts...................................................................................... 132

Troubleshooting.............................................................................................. 133DPCIIIErrorandWarningMessages................................................................ 134

LatchedError/WarningMessages............................................................... 134UnlatchedError/WarningMessages........................................................... 134

ErrorMessages............................................................................................... 135WarningMessages......................................................................................... 140AdvancedProgrammerReset........................................................................... 141

ResettingtheAdvancedProgrammer........................................................... 141ResettingtheMonitor............................................................................ 141SelectingaPrinterPort.......................................................................... 143PrintingtheAdvancedProgrammerScreen............................................. 145

VerifyingModuleOperation............................................................................ 146DistanceModule........................................................................................ 146EnergyModule.......................................................................................... 147ElectronicPressureRegulatorandthePressureTransducer............................. 147

CheckingtheOperationofInputs..................................................................... 148ControlInputs............................................................................................ 148

Auto-In................................................................................................ 148CycleStop............................................................................................ 149TriggerSwitch...................................................................................... 149EndofWeld/GroundDetect.................................................................. 149ActivationSwitches–SS1andSS2........................................................ 149

EffectsofI/OandSystemErrorsonProcessFlow.............................................. 150AnUninterruptedCycle.............................................................................. 150TheCycleTerminatesDuringDownstroke..................................................... 151PrematureWeldTermination....................................................................... 152

Miscellaneous................................................................................................. 154TheDPCWon’tCycle................................................................................. 154NoUltrasound........................................................................................... 155

Section11OperateMode,OperatePageOverview....................................................................................................... 119OperatePagewithFrontPanel......................................................................... 120

SelecttheOperateMode............................................................................ 120ReviewingProcessCharacteristics................................................................ 120AccessingOperateFunctions...................................................................... 120

OperatePagewithAdvancedProgrammer....................................................... 121SelecttheOperateMode............................................................................ 121ReviewingProcessCharacteristics................................................................ 121AccessingOperateFunctions...................................................................... 121

OperateFunctions........................................................................................... 122FunctionKeys............................................................................................ 122PrintPartMemory...................................................................................... 122PrintHeaders............................................................................................. 122DisplayPartMemory................................................................................. 123PrintGraph............................................................................................... 123

TEXT.................................................................................................... 123RawData............................................................................................. 124

ResetSequence.......................................................................................... 125

Section12SpecificationsRegulatoryAgencyCompliance....................................................................... 127Dimensions..................................................................................................... 128PowerSupplyElectricalSourceRequirements.................................................... 129GeneratorModels........................................................................................... 129OperatingEnvironment................................................................................... 129InterpretingtheDPCModelNumber................................................................. 130

TableofContents TableofContents

Table of Contents

xiii

Section13CareandTroubleshootingCare.............................................................................................................. 131

Environment.............................................................................................. 131FrontPanel................................................................................................ 131

Cleaning.............................................................................................. 131ReplaceableParts...................................................................................... 132

Troubleshooting.............................................................................................. 133DPCIIIErrorandWarningMessages................................................................ 134

LatchedError/WarningMessages............................................................... 134UnlatchedError/WarningMessages........................................................... 134

ErrorMessages............................................................................................... 135WarningMessages......................................................................................... 140AdvancedProgrammerReset........................................................................... 141

ResettingtheAdvancedProgrammer........................................................... 141ResettingtheMonitor............................................................................ 141SelectingaPrinterPort.......................................................................... 143PrintingtheAdvancedProgrammerScreen............................................. 145

VerifyingModuleOperation............................................................................ 146DistanceModule........................................................................................ 146EnergyModule.......................................................................................... 147ElectronicPressureRegulatorandthePressureTransducer............................. 147

CheckingtheOperationofInputs..................................................................... 148ControlInputs............................................................................................ 148

Auto-In................................................................................................ 148CycleStop............................................................................................ 149TriggerSwitch...................................................................................... 149EndofWeld/GroundDetect.................................................................. 149ActivationSwitches–SS1andSS2........................................................ 149

EffectsofI/OandSystemErrorsonProcessFlow.............................................. 150AnUninterruptedCycle.............................................................................. 150TheCycleTerminatesDuringDownstroke..................................................... 151PrematureWeldTermination....................................................................... 152

Miscellaneous................................................................................................. 154TheDPCWon’tCycle................................................................................. 154NoUltrasound........................................................................................... 155

Section11OperateMode,OperatePageOverview....................................................................................................... 119OperatePagewithFrontPanel......................................................................... 120

SelecttheOperateMode............................................................................ 120ReviewingProcessCharacteristics................................................................ 120AccessingOperateFunctions...................................................................... 120

OperatePagewithAdvancedProgrammer....................................................... 121SelecttheOperateMode............................................................................ 121ReviewingProcessCharacteristics................................................................ 121AccessingOperateFunctions...................................................................... 121

OperateFunctions........................................................................................... 122FunctionKeys............................................................................................ 122PrintPartMemory...................................................................................... 122PrintHeaders............................................................................................. 122DisplayPartMemory................................................................................. 123PrintGraph............................................................................................... 123

TEXT.................................................................................................... 123RawData............................................................................................. 124

ResetSequence.......................................................................................... 125

Section12SpecificationsRegulatoryAgencyCompliance....................................................................... 127Dimensions..................................................................................................... 128PowerSupplyElectricalSourceRequirements.................................................... 129GeneratorModels........................................................................................... 129OperatingEnvironment................................................................................... 129InterpretingtheDPCModelNumber................................................................. 130

TableofContents TableofContents


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Figures 1-1 Exampleof120V,Grounded,3-ProngReceptacle.........................................7 1-2 Exampleof220V,Grounded,3-ProngReceptacle.........................................7 1-3 Exampleof120VGroundAdapterHookup..................................................8 1-4 ExampleofInternational220/240VGrounding............................................9 1-5 TypicalEquipmentGroundingArrangement...................................................9 2-1 PlacingaBenchtopDPC.............................................................................11 2-2 Rack-mountedDPCUsingBracketKit...........................................................12 2-3 DPCRearPanel........................................................................................13 2-4 DPCCablingConnections...........................................................................16 2-5 AdvancedProgrammertoDPCIIIConnection...............................................17 2-6 AdvancedProgrammerSerialPrinterConnection.........................................18 2-7 KeyboardConnectorandPowerSwitchonAdvancedProgrammer..............18 2-8 ProbeCabling...........................................................................................19 2-9 GroundDetectFixtureInstallation................................................................20 3-1 FrontPanelLayout......................................................................................21 3-2 KeypadFunctions......................................................................................22 3-3 FrontPanelKeyswitch.................................................................................27 3-4 GeneratorStatusPanel...............................................................................28 3-5 GeneratorControlKeys..............................................................................28 3-6 SystemStatusDisplay.................................................................................29 3-7 NormalOperationIndicators......................................................................30 3-8 WarningIndicators....................................................................................30 3-9 ACPowerSwitch.......................................................................................303-10 AdvancedProgrammerKeyboard..............................................................313-11 AdvancedProgrammerSpecialPurposeKeys..............................................334-1 RightSideViewAdvancedProgrammer......................................................36 4-2 DisplaysatStart-up....................................................................................37 5-1 DPCIIIMenuOrganization.........................................................................39 5-2 NavigatinginSETUPMode........................................................................43 5-3 FrontPanelKeyFunctions...........................................................................44 5-4 NavigatingwiththeFrontPanel..................................................................45 5-5 AdvancedProgrammerSpecialPurposeKeys..............................................46 5-6 NavigatingontheAdvancedProgrammerDisplay.......................................47 5-7 NavigatinginOPERATEMode....................................................................48 6-1 SETUPModePages....................................................................................49 6-2 ProcessControlPageMenu........................................................................50 6-3 AdvancedProgrammerProcessControlDisplay...........................................51 6-4 FrontPanelProcessControlDisplay.............................................................51 6-5 DukaneWeldCycleComponents................................................................58

TableofContentsTableofContentsSection14DukaneCorporationContactsandWarranty

ContactingDukaneCorporation....................................................................... 157LocalSupport................................................................................................. 157

TryOurWebsite........................................................................................ 157ContactsintheUltrasonicsDivision............................................................. 157UltrasonicsDivisionE-mailAddresses.......................................................... 158UltrasonicsDivisionPhoneNumbers............................................................ 158

DukaneCorporationWarrantyUSA,Canada,Mexico............................................................................... 159International.............................................................................................. 160

Section15AppendicesAppendixA – Input/OutputInterfaceBoardAppendixB – ConnectorPinoutDescriptionsAppendixC – ExternalSerialDeviceSupportAppendixD – ReferenceGuidetoDPCIIIMenuStructure

Index

Table of Contents

xv

Figures 1-1 Exampleof120V,Grounded,3-ProngReceptacle.........................................7 1-2 Exampleof220V,Grounded,3-ProngReceptacle.........................................7 1-3 Exampleof120VGroundAdapterHookup..................................................8 1-4 ExampleofInternational220/240VGrounding............................................9 1-5 TypicalEquipmentGroundingArrangement...................................................9 2-1 PlacingaBenchtopDPC.............................................................................11 2-2 Rack-mountedDPCUsingBracketKit...........................................................12 2-3 DPCRearPanel........................................................................................13 2-4 DPCCablingConnections...........................................................................16 2-5 AdvancedProgrammertoDPCIIIConnection...............................................17 2-6 AdvancedProgrammerSerialPrinterConnection.........................................18 2-7 KeyboardConnectorandPowerSwitchonAdvancedProgrammer..............18 2-8 ProbeCabling...........................................................................................19 2-9 GroundDetectFixtureInstallation................................................................20 3-1 FrontPanelLayout......................................................................................21 3-2 KeypadFunctions......................................................................................22 3-3 FrontPanelKeyswitch.................................................................................27 3-4 GeneratorStatusPanel...............................................................................28 3-5 GeneratorControlKeys..............................................................................28 3-6 SystemStatusDisplay.................................................................................29 3-7 NormalOperationIndicators......................................................................30 3-8 WarningIndicators....................................................................................30 3-9 ACPowerSwitch.......................................................................................303-10 AdvancedProgrammerKeyboard..............................................................313-11 AdvancedProgrammerSpecialPurposeKeys..............................................334-1 RightSideViewAdvancedProgrammer......................................................36 4-2 DisplaysatStart-up....................................................................................37 5-1 DPCIIIMenuOrganization.........................................................................39 5-2 NavigatinginSETUPMode........................................................................43 5-3 FrontPanelKeyFunctions...........................................................................44 5-4 NavigatingwiththeFrontPanel..................................................................45 5-5 AdvancedProgrammerSpecialPurposeKeys..............................................46 5-6 NavigatingontheAdvancedProgrammerDisplay.......................................47 5-7 NavigatinginOPERATEMode....................................................................48 6-1 SETUPModePages....................................................................................49 6-2 ProcessControlPageMenu........................................................................50 6-3 AdvancedProgrammerProcessControlDisplay...........................................51 6-4 FrontPanelProcessControlDisplay.............................................................51 6-5 DukaneWeldCycleComponents................................................................58

TableofContentsTableofContentsSection14DukaneCorporationContactsandWarranty

ContactingDukaneCorporation....................................................................... 157LocalSupport................................................................................................. 157

TryOurWebsite........................................................................................ 157ContactsintheUltrasonicsDivision............................................................. 157UltrasonicsDivisionE-mailAddresses.......................................................... 158UltrasonicsDivisionPhoneNumbers............................................................ 158

DukaneCorporationWarrantyUSA,Canada,Mexico............................................................................... 159International.............................................................................................. 160

Section15AppendicesAppendixA – Input/OutputInterfaceBoardAppendixB – ConnectorPinoutDescriptionsAppendixC – ExternalSerialDeviceSupportAppendixD – ReferenceGuidetoDPCIIIMenuStructure

Index


xvi

A-1 I/OJumperBlockLocation...................................................................... A-VI A-2 DPCIIIInputConfiguration1................................................................. A-VIII A-3 DPCIIIInputConfiguration2................................................................... A-IX A-4 DPCIIIOutputConfiguration1.................................................................. A-X A-5 DPCIIIOutputConfiguration2................................................................. A-XI A-6 DPCIIIOutputConfiguration3.................................................................A-XII A-7 DPCIIIInputforEmergencyStopSwitch..................................................A-XIII A-8 PLCInputforThrusterTop-of-StrokeSwitch.............................................. A-XIV C-1 DCEtoDTESerialConnections.................................................................C-III C-2 ParallelandSerialInterfaceConnectors.................................................... C-IV C-3 ASCIIOutputFormat............................................................................... C-VI C-4 1-2-3OutputFormat.............................................................................. C-VII C-5 CSVOutputformat................................................................................C-VIII C-6 ZontecOutputFormat............................................................................. C-IX

TableofContentsFigures–Appendices

7-1 ProcessLimitsPageMenu..........................................................................69 7-2 ProcessLimitsPageDisplayedontheAdvancedProgrammer.......................70 7-3 LowerandUpperLimits,DownstrokeDistance............................................72 8-1 CommunicationsPageMenu.....................................................................81 8-2 TheCommunicationsPageasDisplayedontheAdvancedProgrammer..........81 9-1 UtilitiesPageMenu...................................................................................99 9-2 TheUtilitiesPageasDisplayedontheAdvancedProgrammer......................99 9-3 ExampleofaPrintedSetup......................................................................103 9-4 LimitsOveraNormalDistribution............................................................104 10-1 SequencingPageMenu...........................................................................111 10-2 TheSequencingPageasDisplayedontheAdvancedProgrammer.............111 10-3 WhatisaSequence?..............................................................................112 10-4 ExampleSequence.................................................................................113 11-1 OperatePageMenu...............................................................................119 11-2 TheOperatePageasDisplayedontheAdvancedProgrammer..................119 11-3 ADistanceandPowervs.TimeGraph.....................................................123 11-4 RawDataGraphExample.......................................................................124 12-1 Dimensions............................................................................................128 12-2 InterpretingtheDPCModelNumber........................................................130 13-1 StatusLineLocationonAdvancedProgrammerDisplay.............................134 13-2 InitialSetupMenu...................................................................................141 13-3 SetupMenuAfterPRNTSCRNKeyPressed...............................................141 13-4 LocationofCONTROL,PRNTSCRN,SCROLLLOCKandCURSORKeys.........142 13-5 DEFAULTTERMINALSelected....................................................................142 13-6 ENTERKeyPressed.................................................................................142 13-7 SAVEALLY/NMessage.........................................................................143 13-8 PASSMessageinUpperRightHandCorner.............................................143 13-9 SERIALPrinterPortSelected.....................................................................143 13-10 PARALLELPrinterPortSelected.................................................................143 13-11 AdvancedProgrammerPortLocations......................................................144 13-12 DataFromanUninterruptedCycle...........................................................150 13-13 CycleTerminatedbyI/ODuringDownstroke............................................151 13-14 CycleTerminatedbyHighBadLimitDuringDownstroke............................151 13-15 CycleTerminatedDuetoPre-triggerOvertravel.........................................151 13-16 WeldTerminationDuetoEndofWeld/GroundDetect...............................152 13-17 WeldTerminationDuetoTriggerLost.......................................................152 13-18 WeldSegmentTerminatedbyaSecondaryControl...................................153 13-19 WeldSegmentTerminatedbyaBadPartLimit..........................................153

TableofContentsFigures,continued

Table of Contents

xvii

A-1 I/OJumperBlockLocation...................................................................... A-VI A-2 DPCIIIInputConfiguration1................................................................. A-VIII A-3 DPCIIIInputConfiguration2................................................................... A-IX A-4 DPCIIIOutputConfiguration1.................................................................. A-X A-5 DPCIIIOutputConfiguration2................................................................. A-XI A-6 DPCIIIOutputConfiguration3.................................................................A-XII A-7 DPCIIIInputforEmergencyStopSwitch..................................................A-XIII A-8 PLCInputforThrusterTop-of-StrokeSwitch.............................................. A-XIV C-1 DCEtoDTESerialConnections.................................................................C-III C-2 ParallelandSerialInterfaceConnectors.................................................... C-IV C-3 ASCIIOutputFormat............................................................................... C-VI C-4 1-2-3OutputFormat.............................................................................. C-VII C-5 CSVOutputformat................................................................................C-VIII C-6 ZontecOutputFormat............................................................................. C-IX

TableofContentsFigures–Appendices

7-1 ProcessLimitsPageMenu..........................................................................69 7-2 ProcessLimitsPageDisplayedontheAdvancedProgrammer.......................70 7-3 LowerandUpperLimits,DownstrokeDistance............................................72 8-1 CommunicationsPageMenu.....................................................................81 8-2 TheCommunicationsPageasDisplayedontheAdvancedProgrammer..........81 9-1 UtilitiesPageMenu...................................................................................99 9-2 TheUtilitiesPageasDisplayedontheAdvancedProgrammer......................99 9-3 ExampleofaPrintedSetup......................................................................103 9-4 LimitsOveraNormalDistribution............................................................104 10-1 SequencingPageMenu...........................................................................111 10-2 TheSequencingPageasDisplayedontheAdvancedProgrammer.............111 10-3 WhatisaSequence?..............................................................................112 10-4 ExampleSequence.................................................................................113 11-1 OperatePageMenu...............................................................................119 11-2 TheOperatePageasDisplayedontheAdvancedProgrammer..................119 11-3 ADistanceandPowervs.TimeGraph.....................................................123 11-4 RawDataGraphExample.......................................................................124 12-1 Dimensions............................................................................................128 12-2 InterpretingtheDPCModelNumber........................................................130 13-1 StatusLineLocationonAdvancedProgrammerDisplay.............................134 13-2 InitialSetupMenu...................................................................................141 13-3 SetupMenuAfterPRNTSCRNKeyPressed...............................................141 13-4 LocationofCONTROL,PRNTSCRN,SCROLLLOCKandCURSORKeys.........142 13-5 DEFAULTTERMINALSelected....................................................................142 13-6 ENTERKeyPressed.................................................................................142 13-7 SAVEALLY/NMessage.........................................................................143 13-8 PASSMessageinUpperRightHandCorner.............................................143 13-9 SERIALPrinterPortSelected.....................................................................143 13-10 PARALLELPrinterPortSelected.................................................................143 13-11 AdvancedProgrammerPortLocations......................................................144 13-12 DataFromanUninterruptedCycle...........................................................150 13-13 CycleTerminatedbyI/ODuringDownstroke............................................151 13-14 CycleTerminatedbyHighBadLimitDuringDownstroke............................151 13-15 CycleTerminatedDuetoPre-triggerOvertravel.........................................151 13-16 WeldTerminationDuetoEndofWeld/GroundDetect...............................152 13-17 WeldTerminationDuetoTriggerLost.......................................................152 13-18 WeldSegmentTerminatedbyaSecondaryControl...................................153 13-19 WeldSegmentTerminatedbyaBadPartLimit..........................................153

TableofContentsFigures,continued


xviii

Tables 2-1 ContentsofDPCShippingContainer...........................................................11 2-2 RearPanelConnectionPoints/Ports.............................................................14 2-3 DPCCables...............................................................................................16 6-1 InitiateModeSummary..............................................................................53 8-1 DeviceTypeAllowedOperations.................................................................83 8-2 LimitIndicatorSymbolsandTheirMeaning..................................................8712-1 GeneratorModels....................................................................................129Appendices A-1 Signals:J801........................................................................................... A-I B-1 J901ThrusterCableConnections...............................................................B-1 B-2 J902PressBaseCableConnections............................................................ B-II C-1 DCE/DTESignalswithPinNumbers...........................................................C-II C-2 PrinterControlCodes...............................................................................C-V C-3 PrinterPitchperCharactersPrinted...........................................................C-V C-4 CSV/LKITagDescriptionandTagNumber...............................................C-VIII

TableofContents

SECTION 1

Introduction and Safety

• This section gives a general introduction to the DPC III, and dealswithsafetyconsiderations.

Dukane Corporation



Section 1 Introduction and Safety

�

Before Operating EquipmentBeforeyouoperatetheequipment,pleasefollowtherecommendationsgivenhere.

Read this Manual FirstBefore operating the Dynamic Process ControllerTM (DPC) III, read this User’sManualtobecomefamiliarwiththeDPC.

Watch for Special ParagraphsWatchforthesespecialkindsof paragraphsinthismanual:

NOTE

Note statements highlight procedures or provide information.

CAUTION

Caution statements identify conditions or practices that could result in damage to the equipment or other property.

WARNING

Warning statements point out conditions or practices that could result in personal injury or loss of life.

Dynamic Processor ControllerTM DPC IIIUser’s Manual

�

About this ManualContentsThismanual: • explains the installation and setup necessary for the Dukane

DPC III process controller, • provides basic programming information to achieve precise

ultrasonicwelding, • gives process control information about advanced program-

ming techniques, • contains details to monitor process data, and • providesequipmentspecificationsandtroubleshootinginfor-

mation.

OrganizationBefore Welding: Sections 1–5

Section 1 Introduction and Safety gives a general explanation of the DPC, and covers safety considerations.

Section 2 InstallationexplainsDPCsetupandshowscableconnec-tions for a typical system.

Section 3 Controls introduces Front Panel and Advanced Program-mercomponentsandfunctions,andthebasicsof movingwithinthemenus.

Section 4 Start-up explains the start-up procedure using the Front PanelandtheAdvancedProgrammer.Stoppingtheweldcycleisalsocovered.

Section 5 Menu Orientation givesanoverviewof howthemenuisorganized and provides basics on navigating through the menu.

Basics of Process Control: Section 6Section 6 Setup Mode, Process Control Page describes the set-tingsthathavetobeconsideredandmadebeforeweldingcanbegin.


�

Organization, continued

.

Beyond the Basics of Process Control: Sections 7-10Section 7 Setup Mode, Process Limits Page describes process characteristicsandshowshowtoestablishlimitstodefinebadandsuspect parts.

Section 8 Setup Mode, Communications Page explainshowtocommunicatewithexternaldevicesincludingsetupinformationallow-ing part sampling and graphing.

Section 9 Setup Mode, Utilities Page gives information on using the setup management tools and diagnostic features this menu pro-vides. Section 10 Setup Mode, Sequencing Page describeshowtheDPCcanbeusedforjobsthatneedmultipleweldsinasinglesetup.

Section 11 Operate Mode, Operate Page describeswaystoaccom-plish real-time monitoring of the process control functions.

Section 12 Specifications isasummaryof theDPCpowerandspacerequirements.

Section 13 Care and Troubleshooting describes equipment care and provideselementarydiagnosticinformationincludingerrorandwarn-ing messages.

Section 14 Contacting Dukane gives information on support from theDukaneUltrasonicsfactoryteam,andprovideswarrantyinforma-tion.

Section 15 Appendices contain technical reference data.

The Index has page references for terms the manual uses.

Monitoring the Welding Process: Section 11

Supporting Information: Sections 12 -16


�

DPC OverviewThe DPC III is one of Dukane Corporation’s most technologically ad-vancedprocesscontrollersusedwithDukaneultrasonicweldingsystems.

This fully integrated process controller provides essential control and monitoringfeaturesforultrasonicweldingoperations.Itsmodularde-signprovidestailor-madeflexibilityinmeetingawidevarietyof processrequirements in one, space-saving unit.

A selection of DPC models helps meet different needs. For instance, the DPCIisareliablepowersourceforweldingapplications.TheDPCIIcanfunctionwithasingle,hand-heldultrasonicprobe,whileourDPCIIIcanbelinkedtoalarger,stationarypress,andtheDPCIVmightbenetworkedwithagroupofDPCstocontrolanextensivearrayofultrasonicsystems.

The advanced programming capabilities of the DPC III and IV improve the weldingprocess.Processcharacteristicsandequipmentsettingsaremadesothat parts are joined precisely and consistently.

The DPC III and IV provide a one-point source for data collection anddisplay.WhentheDPCIIIiscoupledwiththeoptionalAdvancedProgrammer,it’smucheasiertoprogramandviewprocessparameters.Thatmeansprocesscontrolcanbemanagedmoreefficiently.

Key Features• Modular Designmakesupgradesandretrofitseasywhenappli-

cation requirements change.

• Weld Process Control is accomplished using the primary con-trolsof time,distance,energy,andpeakpower.Enablingsecond-ary controls means any combination of these factors can be used to achieve a greater level of process control precision.

Twosetsoflimitsforasmanyas25processcharacteristicscanbemade.Weldcyclescanthenbemonitoredtodetectpartswhoseprocess characteristics are outside the preset limits.


�

amplitude regardless of line voltage deviation.*

• Load Regulation provides constant amplitude automatically regardlessof load(powerdraw).*

• Power Factor Correction (optional) means that the DPC wouldbecapableof reducingitselectricalpowerconsump-tion by approximately 25%.

• Worldwide Auto-Ranging Universal Voltage Input means thattheDPCwilloperateanywhereintheworld.Nomanualpoweradjustmentsareneeded.

* Within specified ranges.

• Progressive PressureforholdingandweldingareavailableincombinationwiththeDukanethrusterthatincorporatesdual pressure capability.

• Interface Versatility means that in addition to the DPC’s ownfrontpaneldisplay,itcanconnectwiththeAdvancedProgrammer display, automation equipment, printer, and computer.TheDPCwillalsooutputdataforadedicatedstatistical process control (SPC) system.

• Automatic Setup Changeisusedwhenpartsrequiremorethan one assembly operation and more than one set of pro-cess parameters.

• Pulse Width Modulation is Dukane’s patented circuitry giv-ingtheDPCpowersupplytheabilitytoefficientlychangethevoltage sent to the transducer.

• Auto-Trac Tuning automatically tracks the resonant fre-quency of the acoustic stack (horn, booster, transducer), and adjusts the generator output frequency to match it.*

• Line Voltage Regulation automatically maintains constant

Key Features, continued


�

NOTE

These recommendations apply to the welding system, that is, the DPC, and the other components associated with join-ing plastic and/or metal parts ultrasonically.

Proper Installation - Operate system components only after they are properly installed.

No Unauthorized Modifications - Do not modify your system in any wayunlessauthorizedtodosobyDukaneCorporation.Unauthorizedmodificationscouldcauseequipmentdamageand/orinjurytotheopera-tor.Inaddition,unauthorizedmodificationswillvoidequipmentwar-ranty.

Keep the Cover On - Do not remove any equipment cover unless di-rected to do so by Dukane Corporation.

Grounded Electrical Power -Operatethisequipmentonlywithagrounded electrical connection. (See Electrical Safety Grounding Instructions on the next page.)

Comply with Regulations - You may be required to add accessories to bringthesystemintocompliancewithapplicableOSHAregulationsformachine guarding and noise exposure.

CAUTION Parts being joined ultrasonically some-times vibrate at audible frequencies. Wear ear protectors to reduce annoy-ing or uncomfortable sounds. In addi-

tion, ultrasound baffles, sound enclosures, or ma-terials that absorb sound may be located to sur-round the system.

Health and Safety RecommendationsPleaseobservethesehealthandsafetyrecommendationsforsafe,effi-cient, and injury-free operation of your equipment.

“System” in this manual refers to a complete group of components associ-atedwiththeweldingofplasticormetalparts,alsoknownasanultrasonicassembly system. A typical system consists of a generator and/or ultrasonic processcontroller,athrusterorpress,switches,controls,cables,transducer,booster,horn,andfixture.


�

Special Health Notice – PlasticsBeforeusinganyDukaneultrasonicsystem,becomefamiliarwithOSHA regulations from the U.S. Department of Labor about the particular type of plastic(s) you are using.

When plastic materials are being processed, they may emit fumes and/or gases that could be hazardous.

Makesurethereisproperventilationwhenevertheseplasticsareprocessed.

Electrical Safety Grounding InstructionsForsafety,thepowercordsusedonallDukaneproductshaveathree-prong, grounding-type plug.

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 Na-tional Electric Code and any local codes and ordi-nances that apply. See Figures 1-1 and 1-2.

If there is any question about the grounding of your receptacle, have it checked by a qualified electrician.

Do not cut off the power 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.

Approved 2 pole, 3 wire grounding receptacle BRYANT No. 5261 or equivalent to NEMA 5-15R OR 5-20R

Figure1-1 Example of ��0 V, Grounded, 3-Prong Receptacle

Approved 2 pole, 3 wire grounding receptacle HUBBELL No. 5652 or equivalent to NEMA 6-15R OR 6-20R

Figure1-2 Example of ��0 V, Grounded, 3-Prong Receptacle

CAUTION

CAUTION


�

120 Volt Ground AdapterIf itisimpossibletochangethewallreceptacletoanapprovedground-ing-type,andwherelocalcodespermit,youmayuseanadaptertocon-nectthethree-pronggroundingplugtothetwo-prongreceptacle.(See Figure1-3.)

CAUTION

The ground lead on the adapter MUST BE CONNECTED TO GROUND. Do not connect to gas pipes because that may present a hazardous condi-tion.

If the receptacle is grounded, the earth ground lead marked as 8 in Figure 1-3, may be connected to it.

If the receptacle is not grounded, connect a separate 14 AWG (1.63mm =0.064’’dia.)groundwirefromthereceptacletothenearesteffectivelygroundedmetalpipe(coldwaterpipe)orequivalentgroundingelectrode.

1

2

4

3

5

6

7

8

9

1 - Power cord w/ 3 - prong plug2 - Adapter assembly3 - Wall Plate4 - Receptacle5 - Cold water pipe (metal)6 - Ground clamp7 - Mounting screw8 - Earth Ground Lead9 - 14 AWG (1.63 mm ø) Ground wire

Figure1-3Example of 120 V Ground Adapter Hookup


�

International GroundingThepowercablenormallyprovidedforinternationaluseiscompatiblewithmanypoweroutlets.(RefertoFigure1-4.)However,if yourappli-cationrequiresanothertypeof cable,checkwiththelocalDukaneproductsrepresentative,andfollowlocalregulationsconcerningproperwiringandgrounding.

Additional GroundingGrounding lugs have been provided on the DPC, base, and thruster (See Figure1-5). You should connect a separate 14 AWG groundwiretoaneffectivelygroundedmetalpipe.Thiswillminimize any external electrical interference from leaking into the controlcircuitryandwillnotcompromisethesafetyof thepowerground.

RFI Filter Considerations In addition to the safety considerations above, proper grounding atthegeneratorpowercordisessentialfortheeffectiveoperation of the RFI (Radio Frequency Interfer-ence)filterineveryDukanegenerator.Thefilterpreventslinenoisefromenteringthe control circuitry of the ultrasonic equipment,aswellasblockingultra-sonicRFIfromthepowerline.

Figure1-5 Typical Equipment Grounding Arrangement

Figure1-4 Example of Internation-al 220/240V Grounding

GroundingContacts

TypicalOutlet

ProvidedCable

DPC Ground Connection

To “earth ground”, a metal pipe or grounding elec-trode.

Thruster Ground Connection (Used when the thruster is not used with a press support

Base GroundConnection


�0


SECTION 2

Installation• Thissectiondealswithbasicinstallation:locatingand

cabling the .

Dukane Corporation



Section � Installation

��

UnpackingCarefully open the shipping container, and make sure it has theitemsshowninTable2-1.

Quantity Item Part Number1 DPC III **

1 DPC III User’s

Manual

403-541-04

AC power cord and cables as specified. See your packing

list. Compare with Table 2-3.

Table2-1 Contents of DPC Shipping Container

** See Section 12, Specifications, for an explanation of the DPC part number.

DPC PlacementPlacementof theDPCdependsonwhattypeitis,bench-top or rack-mounted.

Benchtop PlacetheDPCneartheultrasonicpressonaflatsurfacewithitsfrontpaneleasilyaccessible.Makecertaintheplacementandcablingdonotinterferewithpressopera-tion.

Allow5inches(13cm)attherearof theDPCforcableclearance.Allow6inches(15cm)of spaceoneithersideof the DPC for air circulation. Refer toFigure2-1.

Figure2-1 Placing a Benchtop DPC Continued

2200

STATUS

FAULT

ON LINE

INPUT TEST

OVERTEMP

OVERLOAD

OFF LINE

0 20 40 60 80 100PERCENTAGE OF AVAILABLE POWER

SYSTEM POWER OUTPUT

ONLINE

TESTOFFLINE

Allow space, 5 inches (12 cm) for cables

Allow space for ventilation,

4 inches (10 cm) on each side.

Dynamic Process Controller DPC III

CANCEL ENTER

SETUP

OPERATE

TM

NOTEQuestions or problems? Call your sales representa-tive or the Sales Depart-ment at Dukane Corpo -ration Headquarters for most concerns. If reporting damage, contact the car-rier 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 �� for contact information.


��

Figure2-2showstheuseof abracketkitinmountingaDPCtoa19-inchequipment rack. (Contact Ultrasonic Sales at Dukane, and ask for the kit as Part Number US-1155.) The DPC illustrated has the standard, angled front panel of impact-resistant ABS plastic.

Figure2-2 Rack-mounted DPC Using Bracket Kit

DPC Placement, continued

Rack-mounted22

00 STATUS

FAULT

ON LINE

INPUT TEST

OVERTEMP

OVERLOAD

OFF LINE


SYSTEM POWER OUTPUT

ONLINE TEST OFF

LINE

Allow 5 inches (12 cm) of space behind the DPC for cables.

Approximate17.35 inches (44 cm)

19 inches (48 cm)

Dynamic Process Controller DPC IIITM

CANCELENTER OPERATE

SETUP

Removeanyobstructionsthatwouldpreventthefree

flowofairaroundtheDPC.

CAUTION

DonotinstalltheDPCinasealedenclo-sure.Insuchaninstallation,heatwouldbuildupinsidetheenclosure,andcoulddamagetheequipment.Ifanenclosure

isneeded,besuretoprovideforadequateventi-lationsoanyheatbuildupwouldbeeliminated.

CAUTION


��

Rear Panel Layout Familiarizeyourself withtheconnectionpointsforpowerandground, and all communication ports on the DPC rear panel; see Figure2-3belowandTable2-2, on the next page.

NOTE

See Appendix B, ConnectorPinoutDescriptions, for Press Cable (Port J901), and Press Base Cable (Port J902) .

Figure2-3 DPC Rear Panel

Continued

WARNINGPOWER LINE MUST BEGROUNDED AT OUTLET

– WARNING! –

POWER LINE MUST BEGROUNDED AT OUTLET.

REMOVE ALL POWER BEFOREREMOVING COVER OR CONNECTING

OR DISCONNECTING CABLES.

J1

ULTRASOUNDOUTPUT

LINEARENCODER

J901THRUSTER

J902BASE

J801I/O

J802AUTOSTOP

J3SERIALPORT

RS-232DCE

40%MIN

100%MAX

60% 80%

ULTRASOUNDAMPLITUDE

DUKANE CORPST. CHARLES, IL 60174MADE IN USA

SERIAL NUMBER US 123456

O

I

IEC ACInput

Ground

Activation Switch Port

Auxiliary Input/Output Port

(Press Interface Port)

AC BreakerSwitch

(Customer Automation)

(Customer Signal)

(Distance Encoder Port)

AmplitudeControl


��

Table2-2 Rear Panel Connection Points/Ports

Connection Point/Port

Panel label(Alternate Designation)

Function

Ground (Electrical Ground) Connection point to establish electrical ground.

IEC AC Input (AC Power Source Input) Receptacle accepts all approved AC power cords.

J1 ULTRASOUND OUTPUT High voltage ultrasound output to press, thruster, or probe system.

J901 THRUSTER(Press Interface Board)

Control for pressure regulator and air valves.

J902 BASE(Activation Switch Port)

Connects cycle activation switches and the press base display to the DPC.

J401 TO LINEAR ENCODER(Distance Encoder)

Connection to the optical linear distance en-coder (mounted on the side of the press).

J3 SERIAL PORTRS-232

DCE

Connects the DPC to printers or data pro-cessing systems.

J801 I/O(Auxiliary Input/Output Port)

Gives access to equipment (Automation Input, Ground Detect) and/or functions (Bad Part Output, Good Part Output, Suspect Part Output, Ready Output) not already provided through other connections.

J802 AUTO STOP Customer supplied signal.


��

CAUTIONThe power cord is equipped with a three-prong, gounded-type plug for your safety. Whenever a two-slot re-ceptacle is encountered, we strongly

recommend that it is replaced with a prop-erly grounded three-lead receptacle. Have a qualified electrician do the replacement in ac-cordance with the National Elecrical Code and local codes and ordinances.

DO NOT cut off the power cord grounding prong or alter the plug in any way.

Ground the SystemMake sure the system is properly grounded.

Is the system properly grounded? Before proceeding, make sure you have fol-lowed the instructions of Section 1 relat-ing to electrical grounding.

Connect the Cables

Make sure electrical power is off before connecting or disconnecting cables to the DPC. Put both the front panel ON/OFF

switch and the rear panel AC breaker switch in the OFF position whenever cables are connected to or disconnected from the DPC.

Complete the cable connections for your system usingFigures2-4 through 2-8 and Table2-3 as guides.Thepowercableisthelastonetobeconnected,butdonotturnonthepowertotheDPCasyet.

Systems may or may not have cables as shown. Com-pare your equipment order with the cables that were

NOTE

CAUTION

CAUTION

Continued


��

Figure2-4 DPC Cabling Connections

Table2-3DPC Cables

Rear Panel Connections, continued

DPC III - Rear View

J1

I

O

To Earth Ground

PowerCord

To Press Base Ground

Customer AutomationEquipment

Customer AutomationEquipment

J401

ULTRASONICAMPLITUDE

5

5

3

J902

J901

4

7

4

1

3

J801

J802

2

2

J3

Connect to Printer,Advanced Programmeror Computer 6

Cable No.

Part No. Cable TypeLength

(m)From DPC To

1 200-479 Coaxial 2.4 J1 J1 on Thruster

2 200-1203 15-Pin Sub-D 3.0 J801Input/Output

cable

3 200-1124 9-Pin Sub-D 3.0 J902J35 on Press

Base

4 200-1104 36-Pin #M 2.4 J901 J7 on Thruster

5 625-14 12-Pin 3.0 J401 Linear Encoder

6 200-1127 25-Pin Sub-DC 3.0 J3Serial connec-tor on printer or

processor

7

200-1276-202 AC (120V) 2

IEC ACInput

3-prong ACreceptacle

200-1276-201 AC (240V) 2

200-1276-203AC

ContinentalEurope

2


��

The Advanced Programmer (Part No. 438–641)

Figure2-5 Advanced Programmer to DPC III Connection

Connections1. DPC III to Advanced Programmer Connect the serial adaptor cable from J3 on the DPC III to the SES

1–EIA connector on the terminal. See Figure2-5.

2. Keyboard Connections Connectthekeyboardcabletothesideof theterminalasshownin

Figure2-7.

3. Power Connection Connecttheadvancedprogrammerpowercordtoasuitable120

VAC grounded outlet.

OverviewThe DPC can be easily programmed using the keyboard for data entry. Themonitorprovidesaway toviewfull screensof processcontrolinformation.Byallowingtheoperatortohavequickaccesstoprogram-ming and information, the Advanced Programmer is a valuable process controltool.TheoptionalAdvancedProgrammerconsistsof:• 14”videodisplayemulatorterminalwithtwoserialandoneparal-

lel port.• 120VACpowercordforterminal• ASCII Keyboard and connecting cable• Serial port cable to connect DPC III generator to Advanced Pro-

grammerterminal(DukaneP/N200–740)


– WARNING! –




J1

ULTRASOUNDOUTPUT

TOLINEAR

ENCODER

J401

J901THRUSTER

J902BASE

J801I/O

J802AUTOSTOP

J3SERIALPORT

RS-232DCE

40%MIN

100%MAX

60% 80%

ULTRASOUNDAMPLITUDE



O

I

Cable – Dukane Part No. 200–740

Advanced Programmer MonitorSES 1–EIA

Port J3 Serial Port25–Pin Sub–DDPC III Generator

CAUTIONDo not use a two wire extension cord with

the monitor. Fol-low the electrical grounding guide-lines found on Pages 6-7.


��

Figure2-7 Keyboard Connector and Power Switch on Advanced Progammer


– WARNING! –




J1

ULTRASOUNDOUTPUT

TOLINEAR

ENCODER

J401

J901THRUSTER

J902BASE

J801I/O

J802AUTOSTOP

J3SERIALPORT

RS-232DCE

40%MIN

100%MAX

60% 80%

ULTRASOUNDAMPLITUDE



O

I

Serial Printer

2nd Serial Cable – Dukane Part No. 200–740


SES 1–EIASES 2–AUX

25–PinSub–D

25–PinSub–DDPC III Generator

The Advanced Programmer is factory configured with the serial printer port enabled. To reset the monitor or re–enable the serial port, refer to Section 13, pages 141–144.

(one supplied with Advanced Programmer)

CAUTIONMake sure the moni-tor power is off when

connecting or dis-connecting the keyboard. If the power is on, the keyboard or the Advanced Pro-grammer could be damaged.

KeyboardConnector

PowerSwitch

Figure2-6 Advanced Programmer Serial Printer Connection


��

Hand Probe System ConnectionsAprobesystemrequirestwoconnectionstotheDPC–TheAuxiliaryInput/Output(PortJ801),andUltrasoundOutput,(PortJ1)asshownin Figure2-8below.Inaddition,ajumperblock(DukanePartNo.200-1293) is required on J902 to replace the normally closed contact from theEmergencyOFF(ABORT)switchonthepressbase.

Computer ConnectionsSee Appendix C for these connections.

J1

J801J902

J802

J3

J401

200–1248

200–1293

The hand probe works only in AUTO mode – refer to pages 53 and 60.

NOTE

NOTE

The Advanced Programmer is factory configured to use the serial printer port. Remember, that serial printers are supported and parallel printers may work if they support the printer codes listed in Appendix C, page V. However, Dukane does not guarantee that all parallel printers which support the listed printer codes will work. To use the parallel port, it must be enabled. Follow the procedure in Section 13 on pages 141–143. Remember, only one of the output ports, serial (preferred) or parallel

Figure2-8Probe Cabling


�0

Ground Detect Feature ConnectionsIf a DPC system has the ground detect feature, complete the press installa-tionstepstoisolatethefixtureasshownbelowbeforerecheckingthecon-nectionsandbeforeconnectingelectricalpower.

Recheck ConnectionsRecheckallconnections,andwhentheyareallsecure,youarereadytoconnectelectricalpower.

Connect Electrical PowerAsafinalstepinthecablingprocess,connecttheelectricalpowerfromtheACpowersourcespecifiedforyourDPC.SeeSpecifications, Section 12, Table12-1.

Figure2-4showstheACpowercableidentifiedasCable7.

Figure2-9 Ground Detect Fixture Installation

Base Plate

Fixturefrom the DPC, a�+ 5 VDC signal.

Ground detect wireScrew

3

2

1

2

The horn is ground and acts � as a switch closure when it � touches the fixture.

� Horn

With all electrical power to the�system turned off, connect cable P/N 200-1203 to the�J801 connector on the DPC rear panel. Connect the cable's�green (ground) wire to the fixture. The ground signal is sent �to the cable's Pin 15.�

Use plastic insulating washers�with the bolts used to fasten�the fixture to the base plate.�Center the washers and bolts so�the bolts will not touch the insides�of the fixture holes.

Install a plastic insulator�between the fixture�and the base plate.

SECTION 3

Controls• Functions of the controls on the DPC III Front Panel,

Rear Panel and the Advanced Programmer are explained.

Dukane Corporation



Section � Controls

��

Figure3-1b Front Panel Layout

Front Panel LayoutThe DPCFrontPanelisarrangedintothreesectionsshownbelowinFigure3-1b:

• DPC Display and Keypad,

• Generator Status Panel, and

• ACPower.

Rear Panel ControlThe rear panel has an amplitude adjustment knob for controlling the ultrasound output level. The amplitude may be manually adjusted from40%to100%.Theadjustmentshaftissecuredwithashaft–lockbushing that is vibration and shock resistant to prevent unintentional changes.ThecontrolisshownbelowinFigure3–1a.

GeneratorStatus Panel

AC Power

GreenPower On LED

2200

STATUS

FAULT

ON LINE

INPUT TEST

OVERTEMP

OVERLOAD

OFF LINE

ONLINE TEST OFF

LINE


SYSTEM POWER OUTPUT


OPERATECANCEL

SETUP

ENTER

S01 PROCESS CONTROL

DPC™ III

DPC Display and Keypad

Figure3-1a Rear Panel Amplitude Control


TOLINEAR

ENCODER

J401

40%MIN

100%MAX

60% 80%

ULTRASOUNDAMPLITUDE

O

I

AmplitudeControl


��

Keypad

Thesix-keykeypadisusedtoaccessdata,andtosetupandmodifyweldprocess parameters. The operator can scroll through the various menus, makechangesintheoperatingparameters,andselectspecificoperationsto be monitored.

Front Panel Display and Keypad OverviewDisplay The LCD display has one line displaying as many as 32 alphanumeric characters.Thedisplayallowstheoperatortoselectand/ormodifyallprocessparameters.Inaddition,allerrormessagesandpromptswillap-pear here.

IntheOperatemode,allopenprocesslimitsof thelastweldwillappearhere.

Figure3-2 Keypad Functions

2200

STATUS

FAULT

ON LINE

INPUT TEST

OVERTEMP

OVERLOAD

OFF LINE

ONLINE TEST OFF

LINE


SYSTEM POWER OUTPUT


OPERATECANCEL

SETUP

ENTER

S01 PROCESS CONTROL

DPC™ III

Press to cancel an operation or amistaken entry.When moving through the menus, itacts as a "back" key to move fromthe current item back to a more general one.

Press to select and enter process and system parameters into setupmemory.When moving through menus,it acts as a "forward" key to move from the current item ahead to amore specific one.

ENTER

CANCELLeft and Right Arrows

Two functions:1. When entering a number, move cursor left or right to the digit to be changed.2. In Operate mode: Each active process parameter of the last weld can be viewed on the display by pressing either the left or right arrow key.

Up and Down ArrowsTwo functions:1. Move up or down in a list to select an item.2. When entering a number, the keys increase or decrease the number indicated by the cursor.


��

Continued

Keypad DetailsThe CANCEL Key

The CANCELkey performs three functions depending on the system mode, SETUPor OPERATE:

• Menu Navigation,• Canceling an Erroneous Entry, or• Canceling a Print or Display Operation

Menu Navigation

In the SETUP mode, on any page, pressing CANCELhas the effect of movingfromalowerlevelmenuitemtoahigherlevelmenuitem.For example, if INITIATEMODE is displayed on the front panel, press-ing CANCELchanges the display to PROCESSCONTROL.

Theonlyexceptiontothisiswhenanentryhasbeenchanged,butnot entered. A description of pressing CANCELin this case is ex-plainedbelow.

Canceling an Erroneous Entry

If anerrorismadewhenenteringanewvaluefortheFrontPaneldisplay, pressing the CANCELkey removes the erroneous entry, and replacesitwiththeoldvalue.PressingtheCANCELkey again moves from the current menu item to the previous menu item.

Canceling a Print or Display Operation

When sending information to the printer or displaying data from previouswelds,pressingtheCANCELkey cancels the print or display operation.

CANCEL


��

The ENTER Key

The ENTERkeyperformstwofunctions:• Menu Navigation, and• Setup Selection Entry

Menu Navigation

Pressing the ENTERkeyallowsyoutomovefromahigherlevelmenuitemtoalowerlevelitem.Forexample,if thedisplayisatINITIATEMODE, pressing ENTERcauses the Front Panel display to change from INITIATEMODE to SELECTINITIATEMODE. When changing pages, the ENTERkey operatesdifferentlydependingonwhethertheAdvancedProgrammerisconnected to the system.

WiththeAdvancedProgrammerconnected,whenENTERis pressed the pagedisplaywillchangefromPROCESSCONTROL to COMMUNICATIONS. Thisallowsallpagestobedisplayedinquicksuccessionwithaminimumnumber of keystrokes. To access the menu items of a particular page, press the ENTERkeytwice.

Without the Advanced Programmer in the system, pages are changed withtheFrontPanelkeypad.PresstheENTERkey only once to change from page to page.

Setup Selection Entry

To input an item that has been selected, press the ENTERkeywhenthatentry is complete. The ENTER key must be pressed before the DPC III ac-cepts the entry into memory.

ENTER

NOTEREMINDER - The ENTER key must be pressed to save an item to the program memory.


��

The Down Arrow Key

TheDownArrowkeyisusedtochooseSETUP menu items and to change entry values. When choosing from a list of items, pressing the DownArrowkeywillchoosethenextitem.

Whenenteringanumber,presstheDownArrowkey,andthedigitatthecursorlocationwillbereducedbyone.

Whenmodifyingatextfield,suchasJobIDorHornNumber,press-ingtheDownArrowkeyatthecursorlocationchangestheletterinreverse alphabetical order.

If the key is held longer than 0.5 second, automatic changes occur each 0.25 second.

TheUpArrowkeyisusedmuchliketheDownArrowkeyasex-plained above. It is used to choose SETUP menu items and to change entry values. When choosing from a list of items, pressing the Up Arrowkeywillchoosethenextitem.

Whenenteringanumber,presstheUpArrowkey,andthedigitatthecursorlocationwillbeincreasedbyone.

Whenmodifyingatextfield,suchasJobIDorHornNumber,press-ingtheUpArrowkeyatthecursorlocationchangestheletterinalphabetical order.

If the key is held longer than 0.5 second, automatic changes occur each 0.25 second.

The Up Arrow Key


��

The Left Arrow Key

In SETUPmode,theLeftArrowkeyhasonlyonefunction.Pressthekeyto move the cursor to the left, to the next character. When the cursor can nolongermoveleft,thenexttimetheLeftArrowkeyispressed,thecur-sorwill“wraparound”andappearattheendof theentryfield.

In OPERATEmode,pressingtheLeftArrowkeyallowstheoperatortoscrollthroughtheactiveprocesscharacteristicsof thelastweld.

If theLeftArrowkeyisheldlongerthan0.5second,thecursorautomati-cally moves one place to the left every 0.25 second.

The Right Arrow Key

In SETUPmode,theRightArrowkeyhasonlyonefunction.Pressthekeyto move the cursor to the right, to the next character. When the cursor cannolongermovetotheright,thenexttimetheRightArrowkeyispressed,thecursorwill“wraparound”andappearatthebeginningof theentryfield.

In OPERATEmode,pressingtheRightArrowkeyallowstheoperatortoscrollthroughtheactiveprocesscharacteristicsof thelastweld.

If theRightArrowkeyisheldlongerthan0.5second,thecursorauto-matically moves one place to the right every 0.25 second.


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Mode Selection Keyswitch

Themodeselectionkeyswitchhastwopositions:

SETUP and OPERATE.

UsingtheKey - The key must be used to change from one mode to another. ThekeycanberemovedwhenintheOPERATEposition only. In this wayaccesstotheSETUP function can be limited to authorized person-nel.

SETUP - Welding cannot take place in this position. The Front Panel displayshowstheletterSfollowedbythecurrentsetupnumber.Move through the Setup menu in this position.

OPERATE-Weldingtakesplacewheninthisposition.TheFrontPaneldisplayshowstheletterOfollowedbythesetupnumberthatwillbeusedforthenextcycle.MovethroughtheOperatemenuinthis position.

Figure3-3 Front Panel Keyswitch

2200

STATUS

FAULT

ON LINE

INPUT TEST

OVERTEMP

OVERLOAD

OFF LINE

ONLINE TEST OFF

LINE


SYSTEM POWER OUTPUT


OPERATECANCEL

SETUP

ENTER

DPC™ III

Mode Selection KeyswitchSETUP• Key is needed to activate this mode.• Key cannot be removed.OPERATE• Key is needed to activate this mode.• Key can be removed.


��

2017

STATUS

FAULT

ON LINE

INPUT TEST

OVERTEMP

OVERLOAD

OFF LINE

ON �LINE TEST OFF �

LINE

0 20 40 60 80 100PERCENTAGEOFAVAILABLEPOWER

SYSTEMPOWEROUTPUT

�Dynamic Process Controller16 Bit Micro �

TM

�

OPERATECANCEL

SETUP

ENTER

DPC III

�

GeneratorControl

SystemStatus

SystemPowerOutput

Generator ControlGenerator Control has three keys, shown in Figure3-5.

ONLINE Key – Pressing this key makes the generator operational so it can produce the ultrasound signals.

TEST Key – After ONLINEhasbeenpressed,whentheTEST key is pressed, the generator activates and produces an ultrasound signal. The DPC displayshowsthepowerof theacousticstackbeingtested.Atthesametime, the SYSTEMPOWEROUTPUTdisplayshowsgeneratoroutputinper-cent.

OFFLINE Key – Press this key to make the generator no longer opera-tional. This prevents production of ultrasound signals.

Generator Status PanelThe GeneratorStatusPanelhasthreesections:• Generator Control, • System Status,and•SystemPowerOutput.

Figure3-4 Generator Status Panel

Figure3-5 Generator Control

ON�LINE TEST OFF�

LINE


��

OVERTEMP – Thisindicatorlightsif inputoroutputpowermodulesoverheat.Thegeneratorthenautomaticallyshutsdown.Itresetswhenitreaches75°C.

OVERLOAD –Thisindicatorlightswheneitherof thefollowingcondi-tionsoccurs:

•Aninstantaneousoverloadcausedbyamismatchbetweentheultra-sound signal and the vibrational characteristics of the acoustic stack (transducer, booster and horn).

•Excesspowerbeyondthegeneratorpowerratingisbeingdrawnfromthe generator.

The ultrasound signal is shut down when an overload occurs.

The red warning indicator in the SYSTEMPOWEROUTPUT section of the panel lights just prior to an average over-load indication. See Figure3-8.

NOTE

System StatusThe STATUSdisplayshowsthestatusof sixconditions.If acondition’sstatus is “active”, the name of the condition is lighted in the System Status Display.InFigure3-6, ONLINEis active.Theconditionsareexplainedbelow.

ONLINEandOFFLINE – One or the other of these generator con-ditionscanbeactiveatonce.Thecorrespondingwordsshowingtheactive status are lit in the System Status Display.

Figure3-6 System Status Display

STATUS

FAULTON LINE

INPUT TESTOVERTEMP

OVERLOADOFF LINE

INPUTTEST – Thisindicatorflashesduringthepower-uptestsequence.Itwillalsolightif afaultoccursontheinputmodulecircuit.

FAULT – Thisindicatorlightswhenout-of-tolerancevoltagefluctua-tionsoccurthatarerelatedtooneof thefollowing:

• AC line voltage.

•AninternalDCpowersupply(+5VDC;-12VDC;+12VDC;or,+24VDC).

•Thepowerfactorcircuitsand/orthe360VDCbus.

Continued


�0

�

2017

STATUS

FAULT

ON LINE

INPUT TEST

OVERTEMP

OVERLOAD

OFF LINE

ON�LINE TEST OFF�

LINE

0 20 40 60 80 100PERCENTAGEOFAVAILABLEPOWER

SYSTEMPOWEROUTPUT

�Dynamic Process Controller16 Bit Micro �

TM

�

OPERATECANCEL

SETUP

ENTER

DPC III

ON

OFF

GreenPowerOnLED

ACPowerSwitch

Pushthe"I"endoftheswitchtoturnpoweron.

Pushthe"0"endoftheswitchtoturnpoweroff.

AC PowerTheACpowersectionhas:

• AnON/OFFswitchforACelectricalpower.

• AgreenLEDindicatorthatlightswhenpowerhasbeenswitched“on”.

NOTE

The ON/OFF switch is also a circuit breaker that pro-vides overload protection for the DPC. This switch works together with a similar AC breaker switch on the rear panel.

System Power OutputThe three colorSYSTEMPOWEROUTPUT display indicates the percentage of ultrasonicpowerbeingdrawnbytheload.

• GREEN indicates normal operation. If the rear–panel amplitude con-trolissettolessthan100%,thepowermeterwillreflectthereducedamplitude signal.

Figure3-7showsthegroupof “normal”indicators.

•YELLOWwarnsthatapotentialoverloadconditionexists.

•REDwarnsthatanoverloadconditionexists.

Figure3-8showswhichindicatorswarnof overloadconditions.

Green

Yellow Red

0 20 40 60 80 100

SYSTEM POWER OUTPUT

PERCENTAGE OF AVAILABLE POWER

Figure3-8 Warning Indicators

Figure3-7 Normal Operation Indicators

60 80 100

WER OUTPUT

ABLE POWER60 80 100

WER OUTPUT

ABLE POWER

Figure3-9 AC Power Switch

Makesureelec-tricalpowerisoffbeforeconnect-ingordisconnect-

ingcablestotheDPC.PutboththefrontpanelON/OFFswitchandtherearpanelACbreakerswitchintheOFFposi-tionwhenevercablesareconnectedtoordiscon-nectedfromtheDPC.

CAUTION


��

The Advanced Programmer KeyboardThe Advanced Programmer custom keyboard and its monitor sim-plify process control by giving the operator a tool to more quickly programandmonitortheweldingprocess

Figure3-10 Advanced Programmer Keyboard

Function KeysTheactivefunctionkeysareF1throughF9.Thesecanbedefinedbytheoperatortoperformthingsthatwouldbeusedmostfrequently.Useof thekeyscanreducetheneedtoswitchbackandforthfromSETUPto OPERATE.

For your convenience the F10keyhasbeendefinedasSELECTNEWSETUP. F10 cannot be deleted or reprogrammed, and it functions in both SETUPand OPERATEmodes.

Continued

Sherwood

Esc

Enter

Shift Shift

Ctrl AltAltFn

BackSpace

PgUp

PgDn

End

Home

Del

ScrollLock

NumLock

CapsLock

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10Prt ScSysRq

ProgrammableFunctionKeysF1-F9

NOTE

Refer to the Sherwood (monitor) User’s Manual for ad-ditional information about the abilities of the Advanced Programmer.


��

Function Keys, continued

Programming a Function Key

NOTEProgramming the function keys can only be done in SETUP mode.

Toprogramafunctionkey:

1. Highlightthenumber,list,ortextentryfieldyouwanttoprogram.

2. Press and hold the SHIFTkey.

3. Press the function key (F1 through F9) to be programmed .

4. Oneof twomessageswillbedisplayed: KEYPROGRAMMED, or

KEYDEFINED-OKTOOVERWRITE?

5. If thekeyisalreadydefined,youcaneither: • Abort the programming process by selecting NO, or •OverwritethepreviousprogrammingbyselectingYES.

Removing a Function Key’s Program

To remove the programming from a function key, the Advanced Pro-grammer display must be in the OPERATEmode. The procedure is similar toprogrammingafunctionkey:

1. Press and hold the SHIFT key.

2. Press the function key to be changed.

3. Amessageappearsaskingtheoperatortoconfirmwhetherthefunc-tion key’s program is to be deleted.

4. Theoperatorcaneither: •AbortthedeleteprocedurebyansweringNO, or •Deletethefunctionkey’sprogrambyansweringYES.


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Enter

Shift

Alt

BackSpace

PgUp

PgDn

End

Home

Del

ScrollLock

NumLock

CapsLock

Miscellaneous Key Functions

In SETUP:Allowsquickmovementfrompage to page.An Example: If WELDMETHOD is selected and the HOME key is pressed, the next item toappearwillbePROCESSCONTROL.That isthemenupageonwhichWELDMETHOD appears.

UpandDownArrowsTwofunctions:1.Moveupordowninalisttoselectan item.2. When entering a number, the keys increase or decrease the digit indi-cated by the cursor.

PageUp,PageDownSelectbetweenSETUP and OPERATE modes.

LeftandRightArrowsTwofunctions:1. Move cursor left or right to a digit that needs to be changed.2. In OPERATEmode:Eachactiveprocessparam-eterof thelastweldcanbeviewedbypressingeithertheleftorrightarrow.

Home

DeletePress to cancel an operation or a mistaken entry.When moving through the menus, it acts as a “back” key moving from the current entry to a more general one.

Figure3-11 Advanced Programmer Special Purpose Keys

EnterPress to select and enter process and system parameters into setup memory. When moving through themenus,itactsasa“forward”key moving from the current item toamorespecificone.


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Blocking Access to SETUP Mode

Access to the SETUPmodefunctionsisblockedwhentheFrontPanelkeyisremovedfromthekeyswitchwhiletheunitisinOPERATEmode. (See Page27.)

If theunithastheAdvancedProgrammerhowever,thekeyboardPgUp and PgDnkeyscanbeusedtoswitchbetweenmodeseventhoughthefrontpanelkeyswitchislockedintheOPERATEposition. To block access to the SETUPmode in this case, disconnect the keyboard from the moni-tor, and store the keyboard securely.

SECTION 4

Start-up• Start-up sequences are explained.

Dukane Corporation


��


Section 4 Start-up

��

Start-up without Advanced Programmer1. PushtheDPCIIIrearpanelACbreakerswitchtoON. 2. Push the ONLINE generator control key on the front

panel. 3. PushthefrontpanelACpowerswitchtoON.

WhentheDPCisturnedon:• Three quick tones from the buzzer are heard.• INPUTTESTflashes(red)brieflyasthepower-uptestisrun.• Thegreen“on”LEDindicatorintheACpowersectionlights.

Next,fourseparatedisplaysappearinrapidsequence:

•

•

•

•

Thefinalmessagedisplayedinthestart-upsequencedependsonwhichmodewasselectedbytheModeSelectionKeyswitch:SETUP or OPERATE.

If SETUPwasselected,themessagewillbe:

If OPERATEwasselected,themessagewillbe:

Overview

DPCIIIWELDINGSYSTEM

SOFTWAREVERSIONv.1.xxxx

S01-PROCESSCONTROL

ON�LINE

AC Breaker Switch

OFF

ON

O01-PARTCOUNT

SetupNumber

Completeinstallation(Section2),andbecomefamiliarwiththecontrols (Section 3) before start-up. Section 4 describes the start-up sequence–firstforsystemswithnoAdvancedProgrammer,andthenforsystemswithit.

NOTEThe setup number to the left of the menu item begins with the letter “S” for SETUP, or with “O” for OPERATE.

COPYRIGHTDUKANECORPORATION1989-2000

ALLRIGHTSRESERVED


��

Start-up with Advanced Programmer

I

O

Power Switch

Figure4-1 Right Side ViewAdvanced Programmer

If your system has an Advanced Programmer, the DPC III sends an “are you there” command to the Advanced Programmer every twotothreeseconds.WhentheAdvancedProgrammerrespondsforthefirsttime,orafterithasbeendisconnectedforoverfiveseconds, communications are established automatically. To turn on theAdvancedProgrammer:

1. Turn on the DPC III as outlined on the previous page.

2. TurnthePowerSwitchlocatedonthelowerrightsideof thebase from the 0 (OFF) position to the I (ON) position. See Figure4-1.

3. TheAdvancedProgrammerbeepstwiceaftersystemchecksand initialization.

4. The Advanced Programmer screen displays an “OK” message mo-mentarily before displaying either the SETUPor OPERATEscreen.

Front Panel and Advanced Programmer display content depends onthepositionof theModeSelectionKeyswitch.Figure4-2on the nextpageillustratesthedisplayswhenthekeyswitchisineithertheSETUPor OPERATEposition at start-up.

Section 4 Start-up

��

Figure4-2Displays at Start-up

Keyswitch in OPERATE Position

Keyswitch in SETUP Position

OPERATE

SETUP

DPC III

PROCESSCONTROL

INITIATEMODEMANUAL

TRIGGERMETHODMAINTAINEDTRIGGERNORMAL

AFTERBURSTDISABLED

OFF

OFFOFFOFF

OFFOFF

WELDDISTANCEP1WELDENERGYP1PEAKPOWERP1ABSOLUTEDISTANCETOTALCYCLETIMETOTALSTROKE

DPCIIISetup#1:Insert#2 v1.xxxx

1.PROCESSCONTROL2.PROCESSLIMITS3.COMMUNICATIONS

4.UTILITIES5.SEQUENCING

(c)1989-99DukaneCorp.

WELDMETHODSINGLEPRESSURE

SCRUBDISABLED

HOLDMETHODENABLEDTIME0.000

TIME0.000

S01:PROCESSCONTROL

Advanced Programmer Display

Front Panel Display


1.FUNCTIONKEYS2.PRINTCONSECUTIVEMEMORY3.PRINTSAMPLEMEMORY

4.PRINTHEADERS5.DISPLAYCONSECUTIVEMEMORY6.DISPLAYSAMPLEMEMORY

7.PRINTGRAPH8.RESETSEQUENCE

PARTCOUNT

DOWNSTROKETIME

TRIGDELAYTIME

WELDTIMEPRESSURE1

WELDDISTPRESSURE1

TOTALCYCLETIME

TIME

HIBADLIMHISUSLIMLOSUSLIMLOBADLIM

0.00600.00550.00450.0040 0.800

Front Panel Display

Advanced Programmer Display

001:PARTCOUNT0

SECONDARYCONTROLS

�

OPERATE

SETUP

DPC III


��

Stopping the Weld CycleNormal ConditionsThecyclestopswhentheprogrammedcycleends.

Emergency ConditionsManual SystemPress the red, PUSHFOREMERGENCYOFFswitchonthepressbaseplate.

Automated SystemCustomer-supplied external controls provide the means to stop the cycle for an automated system.An auxiliary cable connects these external controls to the DPC at con-nector J902. See Figure2-4, Page 16.

SECTION 5

Menu Orientation• This section provides orientation to menu organization

and to the basics of navigating through the menus.

Dukane Corporation



Section 5 Menu Orientation

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DPC III Menu Organization

OPERATE

SETUP

• PRINT SAMPLE MEMORY

• UTILITIESSetup UtilitiesTime and Date UtilitiesEncoder UtilitiesReset/Preset Part CountUser ParametersPower Utilities

• PROCESS CONTROLInitiate ModeTrigger MethodWeld MethodScrubHold MethodAfterburstSecondary Controls

• PROCESS LIMITSBad LimitsSuspect Limits

• FUNCTION KEYS

FUNCTIONAL MODES

• PRINT CONSECUTIVE MEMORY

• SEQUENCINGSequencingSequence

• COMMUNICATIONSConfigure Serial PortUser IOAdvanced ProgrammerPart SamplingGraphing

• PRINT HEADERS • DISPLAY CONSECUTIVE MEMORY • DISPLAY SAMPLE MEMORY

• PRINT GRAPH • RESET SEQUENCE

Figure5-1 DPC III Menu Organization

Overview

Both Front Panel and Advanced Programmer control are considered. Figure5-1illustrateshowthemenuisorganizedunderthetwomainfunctional modes, SETUP and OPERATE.

This section of the user’s manual provides orientation to the DPC III menu by providing;• TermstoKnow,and• Instructiononnavigatingthroughthemenu–firstinSETUP

mode and then in OPERATEmode.


�0

Terms to Know

Menu ItemEachwordorphraseappearingontheFrontPaneldisplayorontheAd-vanced Programmer display is a menu item. The single-line Front Panel displayshowsmenuitemsoneatatime,whilethefull-screenAdvancedProgrammerdisplayshowsmanymenuitemsatonce.

NOTEThese terms apply to the way the DPC III program has been put together. Knowing what these terms mean will help in understanding how to move through the program.

NOTEThe menu item currently selected on the Advanced Pro-grammer display is highlighted in reverse video.

PageA page is a collection of menu items grouped under a main topic. For instance,SETUPmodeisorganizedintothesefivepages: • Process Control • Process Limits • Communications • Utilities, and • Sequencing.

MenuThemenuistheDPC’sinterfacebetweentheoperatorandtheprogramthatactuallycompletestheworktobeaccomplished.Themenuismadeup of all the menu items.


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Entry FieldsEntryfieldsaremenuitemsthatallowtheoperatortoinputormodifyparameters.Youwillencounterthreetypes:• Numeric• List, and• Text

Numeric Entry Field

Thistypeof entryfieldrequiresnumericvaluestobeentered.Ex-amplesof numericentryfields:

• ENTERWELDTIME,

• ENTERSAMPLESIZE, and

• ENTERPARTCOUNT.

AdvancedProgrammer - Numbers can be entered using the Ad-vanced Programmer’s keyboard number keys and the decimal point key. This is direct parameter entry.Anotherwayof enteringnumbersiswiththeedit mode. A number can be edited by pressing any non-nu-meric key on the keyboard. The current setting is displayed and can

List Entry Field

FrontPanelDisplay- With the Front Panel, using edit mode is the onlywaytomakenumericentries.

This type of entry requires selecting a parameter from a list of choices. Select by using the Advanced Programmer’s numeric keys or byscrollingthroughthelistusingtheUpandDownArrowkeysof the Front Panel or Advanced Programmer. Examplesof listentryfields:

• SELECTINITIATEMODE–MANUAL/AUTO

• SELECTSCRUB–DISABLE/ENABLE

• SELECTBUZZERSTATUS–ON/OFF

Continued

Terms to Know, continued


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Text Entry Field

This type of entry requires entering strings of text. Text entry is done as wasnumericentrywiththeexceptionthatupperandlowercaseletters(AtoZ)andpunctuationmarkscanbeused(aswellasnumbers).Examplesof textentryfields:

• JOBID, and

• BOOSTER(description).

NOTEReview what the keys’ functions are by referring to Section3-Controls.

Terms to Know, continued


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SETUP






Figure5-2 Navigating in SETUP Mode

Navigating in SETUP Mode

Figure5-2illustratesatypical“flow”whennavigatingthroughtheSETUPportionof themenu.StartingwiththePROCESSCONTROL page and end-ingwiththeSEQUENCINGpage, the gray line indicates that each menu itemislinkedtotheonethatfollows(orprecedes)it.

Continued


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How to NavigateUsing the Front Panel Controls

Navigating in SETUP Mode, continued

Figure5-3 Front Panel Key Functions

Areviewof FrontPanelkeyfunctionsisshownbelowsoyoucanapplythat understanding to navigating through the menu as explained on the followingpage.

2200

STATUS

FAULT

ON LINE

INPUT TEST

OVERTEMP

OVERLOAD

OFF LINE

ONLINE TEST OFF

LINE


SYSTEM POWER OUTPUT


OPERATECANCEL

SETUP

ENTER

S01 PROCESS CONTROL

DPC™ III

Press to cancel an operation or amistaken entry.When moving through the menus, itacts as a "back" key to move fromthe current item back to a more general one.

Press to select and enter process and system parameters into setupmemory.When moving through menus,it acts as a "forward" key to move from the current item ahead to amore specific one.

ENTER

CANCELLeft and Right Arrows

Two functions:1. When entering a number, move cursor left or right to the digit to be changed.2. In Operate mode: Each active process parameter of the last weld can be viewed on the display by pressing either the left or right arrow key.

Up and Down ArrowsTwo functions:1. Move up or down in a list to select an item.2. When entering a number, the keys increase or decrease the number indicated by the cursor.


��

Selectfromlistofchoiceswitharrowkeys.

TosetFORCE.

Tomovecursor.

TouchingtheCANCELkeymovesthedisplay“back”tothelastmenuitem.Inthisexample,itwouldbetoTRIGGERTYPE.

Navigating in SETUP Mode, continued

SO1SELECTINITIATEMODEAUTO

SO1TRIGGERMETHOD

SO1TRIGGERTYPE

SO1TRIGGERFORCE

ENTER

SO1PROCESSCONTROL

SO1INITIATEMODE

ENTER

MANUAL

ENTER

FORCEMAINTAINED

MOMENTARY

ENTER

ENTER

10

CANCEL

Ingeneral,theactionsshownusingtheENTER, CANCEL,andarrowkeys in this example apply to navigating any part of the menu in SETUP mode.

StartingdisplayinSETUPmode.

Figure5-4 Navigating with the Front Panel

Thefigurebelowillustratestheconceptsof navigatingfromPROCESSCONTROL to TRIGGERFORCE using the Front Panel.

In addition to the starting PROCESSCONTROLdisplay,fivemoredis-playswillbeencountered.Thesedisplaysandthekeysusedtomovetothemareshownbelow.

NavigatingwiththeAdvancedProgrammerisdescribednext.

Setup(S)Number(01)


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Using the Advanced Programmer

Figure5-5 Advanced Programmer Special Purpose Keys

Thefigurebelowhighlightsthefunctionsof thekeystypicallyusedtonavigatewiththeAdvancedProgrammerkeyboard.

Enter

Shift

Alt

BackSpace

PgUp

PgDn

End

Home

Del

ScrollLock

NumLock

CapsLock

In SETUP:Allowsquickmovementfrompage to page.An Example: If WELDMETHOD is select-ed and the HOME key is pressed, the next itemtoappearwillbePROCESSCONTROL. ThatisthemenupageonwhichWELDMETHOD appears.

UpandDownArrowsTwofunctions:1.Moveupordowninalisttoselect an item.2. When entering a number, the keys increase or decrease the digit indicated by the cursor.

PageUp,PageDownSelectbetweenSETUP and OPERATE modes.

LeftandRightArrowsTwofunctions:1. Move cursor left or right to a digit that needs to be changed.2. In OPERATEmode:Eachactiveprocessparameterof thelastweldcanbeviewedbypressingeithertheleftorrightarrow.

DeletePress to cancel an operation or a mistaken entry.When moving through the menus, it acts as a “back” key moving from the current entry to a more general one.

EnterPress to select and enter pro-cess and system parameters into setup memory. When moving through the menus, it acts as a “forward”keymovingfromthecurrentitemtoamorespecificone.

Home


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TheFigurebelowillustratesthePROCESSCONTROL Page. Circled numbers1-5correspondtothenumberedstepsbelowdescribinghowtonavigatefromPROCESSCONTROL to TRIGGERFORCE.In general, the actions described in this example apply to navigating any part of the menu in SETUPmode.ComparethisprocesswithFrontPanel navigation described on Pages 44 and 45.

PROCESSCONTROL

INITIATEMODEMANUAL

TRIGGERMETHODFORCE10TRIGGERNORMAL

AFTERBURSTDISABLED

SECONDARYCONTROLS

OFF

OFFOFFOFF

OFFOFF







SCRUBDISABLED


TIME0.000

Highlightindicatescurrentselection.

The5PagesinSETUPMode

1

3

4 5

2

1 Press ENTERto move toINITIATEMODE.

2 Press to move to the right for mode selection.

3

Figure5-6 Navigating on the Advanced Programmer Display

Use the keys to select MANUAL.

4 Press ENTERto move toTRIGGERMETHOD.

5

Use the keys to select FORCE.

Press tomovetotherightwherepressureischosen.

Usethekeystochoosetwodigitsforthepressure.

Navigating with the Advanced Programmer, continued


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Navigating in OPERATE Mode

Navigating techniques learned for the SETUPmodewillfunctionaswellingetting around in the OPERATEmode. DPC Front Panel keys and the Ad-vanced Programmer keys function for OPERATE as they did for SETUP. Menu itemsarelinkedintheorderindicatedbythegraylineinthefigurebelow.

Specificreferencestoeachof themenuitemscanbefoundinSection 11, Operate Mode.

Quick Review of Key FunctionsReviewthekeyfunctionsbyreferringtoFigure5-3 for Front Panel keys and toFigure5-5 for Advanced Programmer keys.

Figure5-7 Navigating in OPERATE Mode

OPERATE

•PRINT SAMPLE MEMORy•FUNCTION KEyS •PRINT CONSECUTIVE MEMORy

•PRINT GRAPH •RESET SEQUENCE

•PRINT HEADERS •DISPLAy CONSECUTIVE MEMORy •DISPLAy SAMPLE MEMORy

SECTION 6

Setup Mode, Process Control Page• This section outlines the settings that have to be consideredandmadebeforeultrasonicweldingcan begin.

Dukane Corporation



Section 6 Setup Mode, Process Control Page

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SETUP






Figure6-1 SETUP Mode Pages

OverviewThefigurebelowillustratestheSETUPmodemenuanditsfivepages:Process Control; Process Limits; Communications; Utilities; and, Sequencing.Section 6 provides basic information about using the Process Con-trolPage.Sections7-10dealwitheachof thefourotherpages:Pro-cess Limits, Communications, Utilities, and Sequencing respectively.

Continued

NOTEReview how to select SETUP mode by referring to Pages 27 and 33.


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Process Control PageThesevenprimarymenuitemsof theProcessControlPageareshowninFigure6-2. The items are organized and displayed in the order they have inausualweldcycle.ThatmeansthatInitiateModeisconsideredfirst,and Secondary Controls considered last. These are the basics the operator mustconsiderbeforestartingtoweldparts.

SETUP

•PROCESS CONTROLInitiateModeTriggerMethodWeldMethodScrubHoldMethodAfterburstSecondaryControls

Figure6-2 Process Control Page Menu

At start-up (in SETUPmode) Front Panel and Advanced Programmer dis-playswillappearasshownonthenextpage.


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PROCESSCONTROL

INITIATEMODEMANUAL

TRIGGERMETHODMAINTAINEDTRIGGERNORMAL

AFTERBURSTDISABLED

SECONDARYCONTROLS

OFF

OFFOFFOFF

OFFOFF







SCRUBDISABLED


TIME0.000

StatusLineS01-PROCESSCONTROL

Figure6-3 Advanced Programmer Process Control Display

Figure6-4 Front Panel Process Control Display

ThefiguresbelowapproximatehowthedisplaysappearwhenstartingoutwiththeProcessControlPage.

Starting Displays

Continued

NOTETo review how to use the Front Panel and Advanced Programmer keys to navigate through the menu, refer to Section3,Controls.


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Initiate ModeInitiateModecontrolshowacycleisstarted.Thecyclebe-ginsinoneof twomodes:ManualorAuto.

ManualTrigger MethodsWith each trigger methods, the cycle is started by depressing bothactivationswitches(ActivationSwitch1andActivationSwitch2)within0.5secondof eachother.Depresstheactivationswitchescontinuouslyuntilthetriggerswitchonthepresshasclosedoruntiltheultrasonicsignalisapplied.Otherwise,the cycle is terminated, and the error message E13:SS(s)RELEASEDBEFORETRIG is displayed on the Front Panel display and on the Advanced Pro-grammer display status line. See Figure6-3on the previous page.

SETUP

•PROCESSCONTROLInitiate ModeTriggerMethodWeldMethodScrubHoldMethodAfterburstSecondaryControls


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Table6-1 Initate Mode Summary

AutoWith Auto Mode, the cycle is begun by providing a closedcontactbetweenPins8and2of theJ801con-nector. Apply the Auto Input signal for a minimum of 50 milliseconds to ensure that the cycle has been started.

Mode Input Duration

Auto J801 50 msec minimum

Manual J801

Until trigger or

ultrasound signal is

activated.


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Thefirstchoicetobemadeiswhattypeof triggeryouneed.Trig-gertypedefineswhetherthesignalthattriggerstheapplicationof anultrasonicsignalis:MaintainedorMomentary.

Trigger Type

Trigger Method “Trigger”definesthetypeof eventthatturnsontheultra-soundsignal.Thiseventcanbe:

• acontactclosurefromthetriggerswitchinthepressor• an absolute encoder position as in the case of pre-trigger-

ing.

TriggerMethoddefinesthebehaviorof thesystemasitrelatesto trigger.

SETUP


Maintained

A maintained trigger means that the trigger signal is active for the entire Weld portion of the cycle. The signal comes from the pressure switchonthepress. If thesignalislostwhiletheultrasonicsignalison,thecycleisterminat-ed,andoneof twoerrormessagesisdisplayedontheFrontPanelandontheAdvancedProgrammermonitor:

E12:TRIGGERLOSTWITHIN100msappearswhentheultrasonicsignalislostwithinthefirst100milliseconds.

E11:TRIGGERLOSTWHILESONICSON is displayed if the signal is lost after the ultrasonic signal has been on for at least 100ms.


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TIPHere are some reasons the triggerswitchmaybelost:The application may need a light trigger setting and lowpressurecausingthepress inertia at the start of thedownstroketoclosethetriggerswitch.Anotherreason:Involvesuse of Kinechek (hydraulic speed control). If the mate-rial melts at a rate faster than the horn descends, pressure is lost at the face of the horn, and the trig-gerswitchcanopen.

Momentary

With a momentarytrigger,thetriggerswitchisignoredafteritclosesonce.If thetriggerswitchopensduringtheweldportionof thecycle,theweldcontinuesnormally.Noerrormessageisgenerated.

Be certain that the application of the ultrasonic signal is due to contact with the part, and not due to anything else. This can be determined by setting

downstroke limits for distance and time.

Use extreme caution when using the Momentary trigger type. Open-ing the trigger switch will NOT ter-

minate the weld cycle. Guard the horn/fixture “pinch point” to prevent hands, or fingers from being crushed by the vibrating horn.

Continued

CAUTION

CAUTION

Once a trigger type has been selected, a trigger method can be chosen fromthisgroupof sixmethods:

• Normal Trigger • Delay Trigger by Time • Delay Trigger by Distance • Delay Trigger till Auto-In, • Pre-trigger by Distance, and • Probe Mode.


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Trigger Method, continued

Trigger Method 1: Normal Trigger

Theultrasoundsignalisappliedwhenthetriggerswitchinthepresscloses or the force read from the force transducer reaches its preset limit (the force built up after the horn contacts the part).

Trigger Method 2: Delay by Time

Thismethoddelaysthestartoftheultrasoundsignalbyaspecifiedtime.Otherwise,thismethodisthesameas“NormalTrigger”.

Entering Trigger Delay by Time

Enter trigger delay time in seconds from 0 to 99.999 in increments of 1 millisecond.

NOTEThe force needed to close the trigger switch can be adjust-ed by rotating the trigger adjustment knob on the thruster. In systems equipped with a force transducer, adjust the force by increasing or decreasing the force level with the Front Panel or with the Advanced Programmer when FORCE is the trigger type.

TIPDelaying the trigger causes the ultrasonic signal to bedelayeduntilaspecificevent occurs. The delay allowsadditionalpressurebuild up on the part. In this wayresilientcompoundssuch as O-rings, and gaskets canbecollapsed.Likewise,warpedpartscanbeflat-tened before the ultrasonic signal is turned on.


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Trigger Method 3: Delay by Distance (Systems with Distance Encoder Only)

Thismethoddelaysthestartoftheultrasoundsignalbyaspecifieddis-tancebeyondthenormaltriggerpoint.Otherwise,thismethodisthesame as “Normal Trigger”.

Tocontinuetheweldcycleevenif thedelaydistanceisnotmet,aMAXIMUMDELAYTIME value must also be entered.

EnteringTriggerDelaybyDistanceandMaxTime

Enter trigger delay distance in inches from 0 to 9.9999 in increments of 0.0001 inch. (Distance can also be entered in millimeters from 0 to 99.999 mm in increments of 0.001 mm.)

Next, enter MAXTIME in seconds from 0 to 99.999 in increments of 1 millisecond.

Trigger Method 4: Delay till Auto-In

This method delays the start of the ultrasound signal until an Auto-In input (an external signal from customer equipment) is received. Delay till Auto-In can be

used to synchronize the application of ultrasound in a multi-headed applica-tion. During this delay the INDWELL signal on Pin 5 of the J801 connector is asserted(if InDwellhasbeen enabled).

TIP

Delay till Auto-In is in addition to the auto-initiate signal that may have been used.

NOTE

NOTE

Although a press pre-trigger flag could be used, the pur-pose of the Delay till Auto-In feature would be defeated.


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With Delay till Auto-In as the trigger method, there are two auto-in signals: the first starts the cycle (Cycle Initiate) and the second starts the ultrasound signal. If the Initiate Mode is set to AUTO, take care to avoid confusion between these

auto-in signals. For Delay till Auto-In to work, end the Auto-In (Cycle Initiate) signal before the trigger switch is activated. Otherwise, there will be no de-lay when the trigger switch activates, and the ultrasound signal will start too soon.

CAUTION

WeldCycleTimeLine

Cyc

leIn

itiat

e

Read

yO

utPre

-trigg

er**

Hold

WeldDelayt

illAuto

-In

Trigg

er

** Pre-trigger cannot be used if Delay till Auto-In is chosen as the trigger method.Auto-In 1 Auto-In 2

Top

-of-S

troke

(Hom

e)

�

Figure6-5 Dukane Weld Cycle Components


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Trigger Method 5: Pre-trigger by Distance (Systems with Distance Encoder Only)

Pre-triggeringisdefinedasturningontheultrasoundsignalbeforethehorncontactsthepart.Inthiswaythehornreachesfullampli-tude before part contact is made.Theultrasoundsignalisturnedonatauser-defineddistance.Thisis measured from the reference mark (zero) of the distance encoder mounted on the press.

NOTE

The maximum travel of the press from the pre-trigger point (without closing the trigger switch or reaching the specified force level) is 0.75 inch (19.05 mm). Exceed-ing this distance results in an E10:PRETRIGGER>0.75inABOVEPART error message, and the cycle terminates.

Insertion,swaging,andstaking can make good use of the Pre-trigger by Dis-tancemethodbyallowingplastic to melt immediately upon horn contact.Pre-triggering can also help to run large, complex horns if overload conditions occur on start-up (if no mechani-cal/electrical faults are foundwithinthesystem). Presslimitswitchescanbe used to pre-trigger the ultrasound signal above the part.

Start Weld At

Whenpre-triggeringbydistance,thehorncontactsthepartwiththeultrasound signal turned on. From the time the horn contacts the parttoclosureof thetriggerswitch,weldingistakingplace.Thismayresultininconsistentweldtimesandwelddistances.

Inothercases,suchaswhenworkingwithsmallparts,insufficientpressuremaykeepthetriggerswitchfromclosingorpreventtheforce transducer from reaching its programmed force level.

Toavoidthesesituationswhenpre-triggering,theusermaychoosetostarttheweldatthepre-triggerpointoratthetriggerpoint.

If thestartof weldisatthepre-triggerpoint,thenallweldparame-terswillbereferencedfromthatpoint.If thestartof weldisdefinedasthetriggerpoint,thenallweldparametersrelatetothepointatwhichthetriggerisclosed.

TIP


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Trigger Method 6: Probe

ProbemethodisdesignedforusewithaDukanehand-heldprobeorcustom designed probe system.

If this method is used as the trigger, only single pressure and continu-ousweldingmodesareallowed;dualpressureweldingisdisabled.Inaddition:

• All press functions are disabled.•Alldistancerelatedprocessmethodswilldefauttotime.• All distance process characteristics are disabled.

Entering Probe Delay Time

This option is available to give the probe a time delay before the ultra-sound signal is started.

Hand probe works only in AUTO mode and requires a jumper block. AUTO mode is described on page 53.

NOTE


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Weld Method

Continued

ProcessControlmenudescriptioncontinueswiththeWeldMethod submenu.WeldMethoddefineswhentheultrasoundsignalistermi-nated after it has been triggered.Therearethreemethodsof welding: • Single Pressure, • Dual Pressure, and • ContinuousChoosingonemethodautomaticallydeactivatestheothertwo.

Single PressureSingle Pressure** (designated as P1) is a preset pressure applied to the partduringtheweldprocess.Thepressurecontinuesuntilthecon-trol parameter (Time, Distance, Absolute Distance, Energy, or Peak Power)specifiedundertheWeldMethodmenuitemisreached.

SETUP

•PROCESSCONTROLInitiateMode

TriggerMethod

Weld MethodScrubHoldMethodAfterburstSecondaryControls

Dual PressureWhenDualPressure**ischosen,twoseparatepressuresareappliedtothepart(P1andP2)whiletheultrasoundsignalison.Whenthecontrol parameter is reached for P1, the pressure changes to Pressure 2.TheweldcontinuesuntilthecontrolparameterforP2isreached(or a process characteristic moves outside its process limits). Control parametersforP2arethesameasthoseusedforP1,howeverthelimitssetfortheparametersarespecifictoeachpressure.

** Pressure is measured in pounds per square inch (psi) or in kPascals (kPa). The range is 0–100 psi or 0–690 kPa.


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ContinuousContinuousweldingisusedwhentheparttobeweldedmovescontinu-ously under the horn. Films and fabrics are examples of product types thatrequirecontinuouswelding.

Unlikesingleordualpressurewelding,thismethodhasnocontrolparametertoendthecycle.Withcontinuouswelding,thecycleisendedwhentheinitiatingsignalisremoved.Theamountof materialtobepro-cessed determines cycle length.

Graphing functions are not available in Continuous mode.

Thereportintervalisauser-definedperiodoftimethattellstheDPCwhento output process data (to the output device, or to the Advanced Program-mer).Thisallowsarecordoftheprocesstobeproducedthatcanbeusedas process documentation or input to an SPC (statistical process control) softwarepackageforanalysis.Theminimumintervalisonesecond.

With the exception of TOTALCYCLETIME, all process param-eters are reset after each report interval.

Entering Report Interval

NOTEThe Report Interval usually will not correspond to actual weld time. In fact, the Report Interval time should always be less than actual weld time to produce valid interval data.

NOTE

NOTE

TIPProcess limits are also reported and analyzed from the beginning of each interval.


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Control Parameters – Single and Dual Pressure WeldingTime

Welding by time means that the DPC III applies the ultrasound signal for auser-specifiedperiod.Therangeisfrom0to99.999secondswitha.001second increment.

Distance (For Systems with Distance Encoder Only)

Welding by distance means that the DPC applies the ultrasound signal untilthepresstravelsauser-defineddistancefromthetriggerpoint.Therangeisfrom0to9.9999inches(0to99.999mm)witha0.0001inch (0.001 mm) increment. A secondary control characteristic, MAXWELDTIME, must also be set to shut off the ultrasound signal if the thrustercannotreachthespecifieddistance.

NOTE

MAX WELD TIME is a secondary characteristic of Distance, Absolute Distance, Energy and Peak Power. The time forces the weld portion of the cycle to stop even if the specified control parameter is not met.


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Absolute Distance (For Systems with Distance Encoder Only)

NOTE

Downstroke Distance = Distance the horn travels until the ultrasound trigger point is reached. Where pre-triggering is used, it is the distance the horn travels until the pre-trig-ger point is reached (and not the contact point of the part being welded).Weld Distance = Distance the horn moves during the appli-cation of ultrasound to create the weld.Hold Distance = Distance the horn moves during the hold or “cooling” portion of the weld cycle.Absolute Distance = Downstroke Distance + Weld Distance.

Welding by absolute distance means the DPC turns off the ultrasound signalafterthehorntravelsauser-defineddistancefromthedistanceencoderreferencemark.(Thisisindependentof whenthehorntouchestheparttobewelded.)AbsoluteDistanceterminatestheultrasoundsignalatthespecifieddis-tanceabovetheworkpiece.

Energy (For Systems with Energy Module Only)

WithEnergyastheselectedweldcontrolparameter,thesystemweldsuntilthegeneratordeliversaspecifiedlevelofenergytothetransducerwhilethehornisincontactwiththepart.Energy, measured in joules, has a range of 0 to 99999.9, and has a 0.1 joule resolution.

Peak Power (For Systems with Energy Module Only)

WithPeakPowerastheselectedweldcontrolparameter,thesystemweldsuntilthegeneratordeliversaspecifiedlevelof powertothetransducer.PeakPower,measuredinwatts,hasa1wattresolution.PeakPowerrangeisdependentongeneratoroutput.

Maximum Weld TimeInallweldmethods,withtheexceptionof time,theoperatorisrequiredtoenteramaximumweldtime.Thistimeforcestheendof theWeldpor-tionof theweldcycleevenif thespecifiedcontrolparameterisnotmet.


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SETUP

•PROCESSCONTROLInitiateModeTriggerMethodWeldMethodScrubHoldMethodAfterburstSecondaryControls

ScrubScrubisanextensionof theweldtimegeneratedwhentheweldportion of the cycle is ended by the ground detect input.

Typically this is used in cutting applications. Often the horn cuts through the material at a single point. This activates the ground detectandendstheweldportionof thecycle.Theremaybeanincompletecuthowever.

Scrubtimeallowsthecuttobecompletedbykeepingtheultra-sound signal on for a maximum of 100 milliseconds.

Tousethisfeature,itmustfirstbeenabled.Secondly,atimewillbeentered.

In addition, the End of Weld and Ground Detect menu selection (ENDOFWELD/GNDDET) must be enabled. Look for that item on the Communications page under the I/O heading.

NOTE

Scrub time is not reported, and it is not included in either the Weld or Hold portions of the weld cycle.


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SETUP

•PROCESSCONTROLInitiateModeTriggerMethodWeldMethodScrubHold MethodAfterburstSecondaryControls

Hold MethodTheHoldMethoddeterminesinwhatwaypressureonthe part is held after the ultrasound signal has ended. First, enable Hold Method; then proceed to select either Hold by Time or Hold by Distance.

Hold Method ChoicesHoldingallowsthemoltenthermoplasticmaterialtosolidify(underpressure)beforethepressheadretracts.HoldMethodchoicesare:

• Hold by Time, or

• Hold by Distance.

Choose a hold time, and enter it.

Hold by Time

TheDPCwillkeeppressureonthepartforthetimespecifiedaftertheultrasound signal is ended.

Hold by Distance (For Systems with Distance Encoders Only)

DisableWhen DISABLEis selected, Hold Time and Distance are not avail-able.Therefore,holdingwillnotoccurinthiscycle.

In multi-head applications, Hold by Time can be usedinconjunctionwitha secondary control on Total Cycle Time to force all heads to retract from a part at the same time.

TIP

Holding by distance involves keeping pressure on the part until a specifieddistancefromthestartof Holdisreached.

Aswiththeweldmethods,topreventthepressfromstayingonthepartindefinitelyif theholddistanceisnotreached,aMAXHOLDTIME mustbeenteredwiththisoption.


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SETUP

•PROCESSCONTROLInitiateModeTriggerMethodWeldMethodScrubHoldMethodAfterburstSecondaryControls

AfterburstIn some applications the horn can stick to the part being weldedastheheadof thepressretracts.Afterburstpreventsthis by sending a short burst of ultrasound on the upstroke.

The Afterburst feature can be turned off by choosing DISABLE, or it can be turned on by choosing ENABLE.

WhenAfterburstisenabled,thetwovaluesthatdefineit,DelayandDuration times, are entered.

Delay is the time from the start of the upstroke until the start of the afterburst.

Duration is the length of time the afterburst ultrasound signal is on.

NOTE

Both of the times – Delay and Duration – must each be greater than 50 milliseconds.


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SETUP

•PROCESSCONTROLInitiateModeTriggerMethodWeldMethodScrubHoldMethodAfterburstSecondary Controls

Secondary Controls

A secondary control is activated by selecting ONat the de-sired secondary control. Next, a value is entered specifying the upper limit of the selected parameter. During the cycle, if that parameter is met or exceeded during the Weld portion of the cycle, the Weld portion of the cycle terminates.

NOTE

If Dual Pressure welding is being used, and a Pressure 1 secondary control is reached, control is transferred to the Pressure 2 segment of the cycle. Otherwise, control is trans-ferred to the Hold portion of the cycle, if that is enabled, or to upstroke.

Secondary Controls provide a secondary method for ending theWeldportionof theweldcycleinadditiontotheprimarycontrolmethodspecifiedunderWELDMETHOD.Thisallowstheoperatortocontroltheweldeitherbytheprimarycontrolmethod or by one or more secondary controls.

SECTION 7

Setup Mode, Process Limits Page• This section describes process characteristics and showshowtoestablishlimitsforthem.

Dukane Corporation



Section 7 Setup Mode, Process Limits Page

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SETUP

•PROCESS LIMITSBadLimitsSuspectLimits

OverviewAstheweldcycleprogresses,time,distance,powerandenergyinformationiscompiledforeachportionof theweldcycle.Thesemeasurements or process characteristics, form a record of the process for each part. Records analysis can establish parts limits that can be used to determine if the current process is “in control.” The DPC can report the process characteristics as Bad or Suspect. The characteristics canalsobedisplayedorprintedwithoutevaluation.Thereare22processlimitsthatcanbeenabled.Processlimitavailabilityhoweverdepends on the current DPC setup.

Limits are set using either statistical methods or physical system constraints. Statistical methods can be applied to pre-production partsthatwereevaluatedforphysicalcharacteristicsof quality(suchas strength and appearance). Results of this evaluation are correlated to the process characteristics. Limits for the characteristics related to part quality are calculated. Other limits are determined by the system itself. For instance, TOTALCYCLETIME limits may be established to end the cycle before an index table moves. DOWNSTROKEDISTANCE may be set to detect a misload or incomplete assembly.

Figure7-1 Process Limits Page Menu


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Figure7-2 Process Limits Page Displayed on the Advanced Programmer

DPC III Setup # 1:Insert #2 v1.xxxx

1. PROCESS CONTROL2. PROCESS LIMITS3. COMMUNICATIONS

4. UTILITIES5. SEQUENCING

© 1989—2004 Dukane Corp.

DOWNSTROKE TIMEDOWNSTROKE DISTWELD TIME P1WELD DISTANCE P1WELD ENERGY P1PEAK POWER P1ABSOLUTE DISTANCEHOLD TIMEHOLD DISTANCETOTAL CYCLE TIMETOTAL STROKE

CHARACTERISTICS BAD PART LIMITS SUSPECT PART LIMITS STATUS HI LIM LO LIM STATUS HI LIM LO LIMDISPLAYDISPLAYWINDOWWINDOWDISPLAYDISABLEDDISABLEDDISABLEDDISABLEDWINDOWDISPLAY

1.0000.0010

0.5000.0000

1.000

DISABLEDDISABLEDDISABLEDDISABLEDDISABLEDENABLEDDISABLEDDISABLEDDISABLEDDISABLEDDISABLED

350 250

PROCESS LIMITS


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Continued

Available Process CharacteristicsNOTE

Of the available process characteristics, the ones that apply to a particular part depend on the current DPC setup for

Hereisalistof theavailableprocesscharacteristicsfollowedbybrief descriptions of each.

Process Characteristics DefinedDownstroke Time–Thisisthetimefromthestartof theweldcycle(closingof theAutoInputormanualactivationswitches)tothetriggerpoint.Triggerpointiseithertheclosingof thetriggerswitchorthepre-trigger point if STARTWELDATisdefinedasPRE-TRIGGER.DownstrokeTimeisavailableinalltriggermodesexceptProbe.

Downstroke Distance (Distance Encoder Systems Only) – This is the distancebetweenthedistanceencoderreferencemarkandthetriggerpoint. This limit is available in all trigger modes except for the Probe mode.

1.DownstrokeTime

2.DownstrokeDistance

3. Trigger Delay Time

4. Trigger Delay Distance

5. Weld Time P1

6. Weld Distance P1

7.WeldEnergyP1

8.PeakPowerP1

9. Weld Time P2

10. Weld Distance P2

11. Weld Energy P2

12.PeakPowerP2

13. Absolute Distance

14. Total Weld Time

15. Total Weld Distance

16. Total Weld Energy

17.HoldTime

18. Hold Distance

19. Total Cycle Time

20. Total Stroke


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Encoder Head

Lower LimitUpper Limit

Direction of travel;distances increase.

Part in Process

Linear Encoder ScaleProcess Characteristics Defined, continued

Figure7-3 Lower and Upper Limits, Downstroke Distance

Figure7-3showstherelationshipbetweenlowerandupperlimitsonDownstrokeDistance.Becausedistanceincreasesasthepressheadtrav-elstowardthepartinprocess,thelowerlimitisphysicallyabove the upper limit.

Trigger Delay Time –Theultrasoundsignalcanbedelayedbyaspecifiedamountoftimeafterthetriggerswitchhasclosed.Itisavailablewhendelay-ing the trigger by time, distance, or till Auto-In.

Trigger Delay Distance (Distance Encoder Systems Only) – The ul-trasoundsignalcanbedelayeduntilthepresstravelsaspecificdistancebeyondthetriggerpoint.Itisavailablewhendelayingthetriggerbytime,distance, or till Auto-In.

Weld Time P1 – This is the length of time the ultrasound is applied to thepartwhilePressure1(P1)isappliedtothepart.

Weld Distance P1 (Distance Encoder Systems Only) – This is the distancethepresstravelswhiletheultrasoundsignalisappliedtothepartunder Pressure 1.

Weld Energy P1 (Energy Systems Only) – This is the amount of energy drawnfromthegeneratorwhiletheultrasoundsignalisappliedtothepart under Pressure 1.


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Peak Power P1 (Energy Systems Only) – This is the highest in-stantaneouspowerdeliveredtothetransducerduringthePressure1portionof theweldcycle.

Weld Time P2 – This is the length of time the ultrasound is applied tothepartwhilePressure2(P2)isappliedtothepart.

Weld Distance P2 (Distance Encoder Systems Only) – This is the distancethepresstravelswhiletheultrasoundsignalisappliedtothepart under Pressure 2.

Weld Energy P2 (Energy Systems Only) – This is the amount of energydrawnfromthegeneratorwhiletheultrasoundsignalisap-plied to the part under Pressure 2.

Peak Power P2 (Energy Systems Only) – This is the highest in-stantaneouspowerdeliveredtothetransducerduringthePressure2portionof theweldcycle.

Absolute Distance (Distance Encoder Systems Only) – This is the user-defineddistancethehorntravelsfromthedistanceencoderref-erencemark(regardlessof whenthehorncontactsthepart).

Total Weld Time–Thisisavailablewhendualpressureweldingisselected.Itisthetotalof P1andP2weldtimes.

Total Weld Distance (Distance Encoder Systems Only) – This is availablewhendualpressureweldingisselected.Itisthetotalof P1andP2welddistances.

Total Weld Energy (EnergySystemsOnly)–Thisisavailablewhendualpressureweldingisselected.Itisthesumof thePressure1andPressure2weldenergies.

Continued


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Hold Time – This is the time the horn maintains pressure on the part aftertheultrasoundsignalhasstopped,andwhilePressure2isappliedtothe part.

NOTE

This characteristic is available when the Hold Method setup item on the Process Control Page is Enabled, and Hold by

Process Characteristics Defined, continued

Hold Distance (Distance Encoder Systems Only) – This is the distance thepresstravelswhilemaintainingPressure2onthepartaftertheultra-sound signal has stopped.

Total Cycle Time – This is the time from Cycle Initiate through the Hold portion of the cycle. (See Figure6-5, Page 58.) The start of the cycle isdefinedasthepointtheautoinputsignalbeginsorwhenmanualacti-vationswitchesareclosed.Theendof thecycleisdefinedasthepointthe head retracts from the part.

Total Stroke (Distance Encoder Systems Only) – This is the absolute press position as measured from the distance encoder reference mark. It is active during the entire cycle.

NOTEThis characteristic is available when the Hold Method setup item on the Process Control Page is enabled and Hold by Distance is selected.


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Bad LimitsBad limits are used to establish boundaries thatdefineunacceptableresultsforpartsbeingprocessed. If a “bad” limit is either not met or isexceeded,theweldcycleisterminatedimmedi-ately,andtheoperatorisnotifiedintheseways:

• FrontPanel:Thecharacteristicthatcausedthecycletoendisdisplayedfortwoseconds.If theupperlimitwasexceeded,thenumericalvalueisprecededbytwo“greaterthan”(>>)symbols.If thelowerlimitwasnotmet,two“lessthan”(<<)symbols precede the numerical value.

• AdvancedProgrammer:AllactivewindowsareshownonthetwoOperatePagesof thedisplay.If theupperlimitwasex-ceeded,thenumericalvalueisprecededbytwo“greaterthan”(>>)symbols.If thelowerlimitwasnotmet,two“lessthan”(<<)symbolsprecedethenumericalvalue.

• The DPC III’s Bad Part output, J801 Pin 3 is activated. This outputcanbedefinedasMaintainedorPulsed.

• Two100millisecondtonesaregeneratedif thebuzzerhasbeenset to ON.

SETUP

• PROCESS LIMITS

Bad LimitsSuspect Limits


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Bad Limits Status FieldTherearethreeavailableselectionsfortheBadLimitsstatusfield:Disabled,Display,andWindow.

Disabled

When a process characteristic is disabled, it is not evaluated as a limit and is not displayed unless it is selected as a suspect limit. DISABLEDis the default selection.

Display

The DISPLAYselectionallowsthecharacteristictobedisplayedontheFront Panel and on the Advanced Programmer displays. DISPLAYalso enables a characteristic to be sent to an output device (such as a printer or a computer).

Window

The Bad Limits WINDOWchoiceassignsupperandlowerlimitstoachar-acteristic. The upper limit is tested continuously during the segment in whichthecharacteristicisactive.Thelowerlimitistestedonlyattheendof the active segment.

Forexample,whenintheWeldportionof thecycle,theupperlimitonWeld Distance is tested from the start to the end of the Weld segment. ThelowerlimitonWeldDistanceistestedonlyattheendof theWeldsegment. Figure7-2showsWeldTimeP1setasawindow.

IfacharacteristicisenabledasaWindowand as a Secondary Control, the upper bad limit is not available on the Process Limits Page.

A secondary control is designed to pass control of the process to the next segmentoftheweldcyclewithoutevaluatingthepartbasedontheenabledcharacteristic.Therefore,placinganupperbadlimitwouldbeinconsistentgiventhewaysecondarycontrolsaredesigned.

Attempting to access the upper limit results in a W00:MAXLIMITCON-TROLPARAMETERwarningmessagedisplayedontheFrontPanelandAdvanced Programmer displays. Figure7-2showstheTotalCycleTimecharacteristicsetupasbothawindowandasasecondarycontrol.


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If azerovalueisspecifiedasanupperlimit,thelimitcheckingisdisabled and the limit behaves as a Display. If a value for the upper limitthatislessthanthelowerlimitisentered,aW01:MAXLIMIT<MINLIMITwarningmessageisdisplayedontheFrontPanelandontheAdvanced Programmer.

Window, continued

Suspect LimitsSuspectlimitsdetectout-of-limitconditionswithoutendingtheweldcycle.Theselimitsareusefulwhenprocesscharacteristicsfallwithinthe“grayarea”betweengoodandbad.Byusingsuspectlimits,good,bad,andsuspectpartscanbesorted.Thisallowsthesuspect parts to be hand inspected. Suspect limits also can be used as a form of pre-control in applications wherestatisticalprocesscontrolmethodsarebeingapplied.To notify the user that a suspect limit has been exceeded, or not reached,thefollowingeventsoccur:

• On the Front Panel display, suspect limits are preceded by a single “greaterthan”(>)symbolindicatingtheupperlimitwasexceed-ed.Asingle“lessthan”(<)symbolindicatesthelowerlimitwasnot reached.

• TheAdvancedProgrammerdisplaysallactivewindowsonthetwo

Operate Pages of the display. Out-of-limit characteristics are pre-cededbyone“greaterthan”(>)symbolindicatingtheupperlimitwasexceeded.Asingle“lessthan”(<)symbolindicatesthelowerlimitwasnotreached.

• The DPC III’s Suspect Part output, J801 Pin 4 is activated. This outputcanbedefinedasMaintainedorPulsed.

• One 100 millisecond tone is generated if the buzzer is set to ON.

Continued

SETUP

• PROCESS LIMITSBad Limits

Suspect Limits


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Suspect Limits Status FieldTherearetwoavailableselectionsfortheSuspectLimitsstatusfield:Disabled or Enabled.

Disabled

If a suspect limit is disabled, it is not evaluated as a Suspect limit.

Enabled

Enablingasuspectlimitallowstheentryof upperandlowerSuspectlimits for the selected process characteristic. Suspect limits are tested at theendof thecycle.Thereforetheyhavenoeffectontheflowof theweldingprocess.AswithBadLimits,settingtheupperlimittozeroisthe same as specifying the limit as Display only. No evaluation of the limit is performed. Entering a value for the upper limit that is less that thelowerlimitresultsinaW01:MAXLIMIT<MINLIMITwarningmessagedisplayed on the Front Panel and on the Advanced Programmer.


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Enabling Process LimitsNOTE

The status field controls the behavior of the character-istic both as a process limit and as a displayable pa-rameter. If either status field is not set to DISABLED, the characteristic is displayed on both the Front Panel and Advanced Programmer displays. It is also sent to the output device.

Enable process limits by starting on the Process Limits Page. Then do thefollowing:

1. Press the ENTERkey.

2. PresstheUporDownArrowkeystochoosebetweenBadLimitsand Suspect Limits. With the Advanced Programmer keyboard, the “1” and “2” number keys can also be used to make the choice.


4. PresstheUporDownArrowkeystoselectaprocesscharacteris-tic.


6. PresstheUporDownArrowkeys(orthe“1”,“2”,“3”numberkeys on the Advanced Programmer keyboard) to choose the Bad LimitsorSuspectLimitsstatusfieldselections.

7. PresstheENTERkey.

8. Repeatsteps4–7foreachprocesscharacteristicdesired.


�0

Secondary ControlSecondarycontrolsprovideadditionalwaystoendtheWeldportionof acycletogetherwiththeprimarycontrolmethodspecified.Thismeanscontrolof theweldprocesscanbeaccomplishedeitherbytheprimarycontrol or by one or more secondary controls.

Not All Characteristics Have Secondary ControlSecondarycontrolscanbeselectedforthefollowingprocesscharacteristics:

Weld Energy P1 PeakPowerP1 Weld Energy P2 PeakPowerP2 Absolute Distance Total Weld Time Total Weld Distance Total Weld Energy Total Cycle Time Total Stroke

EXAMPLE

If youareusingdualpressurewelding,andaP1secondarycontrollimitisreached,controlistransferredtotheP2portionof thecycle.Otherwise,control is transferred to the Hold portion of the cycle (if it is enabled) or to the Upstroke portion of the cycle.

SECTION 8

Setup Mode, Communications Page• ThissectiondescribeshowtheDPCIIIcanbesetuptocommunicatewithexternaldevices.

Dukane Corporation



Section 8 Setup Mode, Communications Page

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Overview

Figure8-1 Communications Page Menu

•COMMUNICATIONSConfigureSerialPortUserIOAdvancedProgrammerPartSamplingGraphing

SETUPTheCommunicationsPagehasthefivemenuitemsthatareshowninFigure8-1.

In using the menu items, the operator encounters all of the selectionsthatenabletheDPCIIItocommunicatewithex-ternaldevices.Theseinclude:theAdvancedProgrammer;serialdevices such as printers, computers, and data collectors; and, automated machines using discrete and serial I/O.

The Communications Page also has the setup information that allowspartsamplingandgraphingof processparameters.

Figure8-2belowshowshowtheCommunicationsPageappearson the Advanced Programmer display.

Figure8-2 The Communications Page as Displayed on the Advanced Programmer





COMMUNICATIONS

OUTPUT DEVICEOUTPUT MODEBAUD RATEPROTOCOLLF AFTER CRLIMIT INDICATORSTIME TAG

OUTPUTSUP VALVE ON ABORTEND OF WELD/GND DETSTATUS OUTPUTSDEFINE J602-5 ASDEFINE J602-6 ASBUZZER STATUS

STATUS BAUD RATE

LOT SIZESAMPLE SIZEEXCLUDESTORE

LEFT AXISRIGHT AXISSTART ATSTOP ATTIME SCALEPOWER SCALEDISTANCE SCALE

EPSON-FXALL

9600XON/XOFF

YESDISABLEDDISABLED

ACTIVE HIOFF

DISABLEDMAINTAINEDGOOD PART

READYON

ENABLED9600

00

NONENONE

POWERDISTANCE

WELDEND OF WELDAUTO RANGEAUTO RANGEAUTO RANGE

CONFIGURE SERIAL PORT

I/O

ADVANCED PROGRAMMER

PART SAMPLING

GRAPHING


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Configure Serial PortThe DPC III has a serial port that enables bi-directional serialcommunicationswithexternaldevices.Thesedevicescanbedefinedinoneof twoways:

Either

1. When an Advanced Programmer is connected to the DPC III, all serial port setup selections apply to the Aux (Auxiliary) port of the Advanced Programmer.

Or,

2. When no Advanced Programmer is connected and the external de-vice is connected directly to the DPC’s RS-232 serial connector (Port J3),allserialportsetupselectionsmadewiththeDPCIIIapplytothis port.

Figure8-2onthepreviouspageshowsthattherearesevenmenuitemstoconsider:• Output Device,• Output Mode,• Baud Rate,• Protocol,• LF After CR,• Limit Indicators, and• Time Tag.These items are discussed on Pages 83-88.

•COMMUNICATIONSConfigure Serial PortUserIOAdvancedProgrammerPartSamplingGraphing

SETUP


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Output DeviceOUTPUTDEVICEdefineswhattypeof deviceisconnectedtotheDPC.This controls both the output data format and the operations that are available.

TheDPCIIIsupportsfourprintertypesdirectly.Theyare:EpsonFX-85; IBM ProXL; IBM ProX24 (a subset of IBM ProXL); and, Okidata 182/183. Other printers are supported through printer emulation modes.

Appendix B - External Serial Device Support has a detailed description of the output formats and printer emulation modes supported by the DPC III. Table8-1illustrateswhichoperationsareavailableforeachdevice type.

TIP

Table8-1 Device Type Allowed Operations

Twodevicesthatcom-municatewitheachother must have the same data frame format and the same baud rate.Data Frame – This refers to the format of the individual characters that are transmitted and received by the serial devices. The frame is definedintermsofthenumber of data bits, the number of stop bits, and the parity of the data frame.DPC III Data Frame Format:8databits;1stop bit; no parity.Baud Rate – This is the speedatwhichbitsaretransmitted and received. The higher the baud rate, the more information that can be exchanged in a given time.

Continued

DevicePart Data

HeadersSetup(Text)

Setup(Hex)

GraphGraph(Data)

Epson FX-85 X X X X X X

IBM Pro XL X X X X X X

IBM Pro X24 X X X X X X

Okidata 182/183

X X X X X X

ASCII X X X X X

1-2-3 X X

Tagged CSV X

Zontec X

DataMyte X


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Device TypesOf the 10 device types, four are types of printers that are directly sup-portedbytheDPCIII:• Epson FX-85,• IBM ProXL,• IBM ProX24, and• Okidata 182/183.Each (of the four) device type supports printers that use its correspond-ing control set.

ASCII – This device type is used to connect a computer or printer that is notdirectlysupportedbytheDPCIII.Nodevice-specificcontrolcodesare transmitted.

1-2-3–Thisdevicetypespecifiesacommadelimitedoutputformaten-abling data to be output to a computer in a format that can be imported into a spreadsheet.

Tagged CSV – The Tagged CSV (Comma Separated Value) device type allowscommunicationwithcertainSPCpackages.Eachcharacteristicoutputisidentifiedwithatagvalueandseparatedbyacomma.

Zontec–ThisdevicetypeallowscommunicationbetweentheDPCIIIand the Zontec Advanced Series SPC packages. The part data output for-matconformstotheZontecASCII-2DeviceInterfacespecification.

DataMyte–ThisdevicetypeenablestheDPCIIItocommunicatewithDataMyte data collectors. This device type adds one decimal place to powermeasurements.

Output Device, continued

NOTE

If Epson FX-�� is chosen as the de-vice type, Epson has two current printer models: LQ��0 and LQ�0�0 that are be compatible with that device type. The printers are avail-able from Epson distributors. Each requires a serial interface card.


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Output ModeOUTPUTMODEselectionsspecifywhichpartsaresenttotheoutputdevice.Theselectionsare:All –Allpartsaresenttotheoutputdeviceimmediatelyfollowingtheweldcycle.None – No parts are sent to the output device. Part data is stored in both consecutive and samplememoriesandisavailablefordownloadingfrom the Operate Page. This selection can be used to increase system performancewhenoperatinginveryhigh-volumeapplications.Sample – All part data stored in the sample memory are sent to the output device.Good – All Good parts are sent to the output device.Bad – All Bad parts are sent to the output device.Suspect – All Suspect parts are sent to the output device.Bad and Suspect – All Bad and Suspect parts are sent to the output device.Good and Bad - All Good and Bad parts are sent to the output device.Good and Suspect - All Good and Suspect parts are sent to the output device.

Baud RateBaud rate is the serial port output speed in bits per second.

NOTE

Baud rate settings on both the sending unit (DPC III) and the receiving unit (computer, printer) must be the same for communication between the devices to work properly.

Choose a baud rate appropriate for your output device.

Continued


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ProtocolProtocol refers to the programming rules established to ensure reliable communicationsbetweendevices.Inmanycases,therateatwhichadevice can transmit information to the second device exceeds the second device’s ability to process it.Wheninformationissenttoaprinter,therateatwhichtheprinterre-ceives and processes the information is much faster than its ability to print it.Eventually,theprinterwouldrunoutofstorage,orbufferspace.Thismeansthatanyexcessdatawouldbelost.The printer and the DPC III can provide acceptable transmission rate informationtoeachothertoregulatetheflowof databetweenthem.

ThetwomethodsusedbytheDPCIIItocontrolthisinformationflowrateareXon/Xoff andRTS/CTSasexplainedbelow:

Xon/XoffXon/Xoff isasoftwareprotocolregulatingtheflowof informationbetweentwodevicesbysendinganXoff character(13H,^S)tostoptheflowof informationandanXoncharacter(11H,^Q)toresumetheflowof information.

RTS/CTSRTS/CTSisahardwareprotocolthatusestwosignals(RTSandCTS)toregulatetheflowof informationbetweendevices.RequesttoSend(RTS)istransmittedwhenadevicehasinformationtosendtoaseconddevice.TheseconddeviceacknowledgestheRTSbysendingaCleartoSend(CTS)signalwhenitcansafelyacceptinforma-tion. If the second device’s capacity to accept information has been ex-ceeded, the CTS line is turned off until information can again be safely sent.

Configure Serial Port, continued


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LF After CREachlineof outputendswithacarriage return(<CR>).Somedevicesautomatically insert a line feed(<LF>)toadvancethepaper,whileothers do not. The LFAFTERCRfunctionallowsyoutoinsertalinefeed at the end on an output string.

Select YESif youwantdataprintedoneveryline.

Select NOif youwantdataprintedoneveryotherline.

Limit IndicatorsLimit indicators are characters that appear in front of displayed or printedpartdatatoindicatewhetherthedatahasreachedorexceed-edanupperorlowerlimit.The“greaterthan”sign(>)indicatesthatanupperlimithasbeenexceeded.The“lessthan”sign(<)indicatesthatalowerlimithasnotbeenreached(orinotherwords,hasbeenexceeded in a negative direction).

WhenaSuspectlimitisexceeded,onesign(either<or>)appearsinfront of the out-of-limit characteristic. When a Bad limit is exceeded, twosigns(either>>or<<)appearinfrontof theout-of-limitchar-acteristic. Table8-2summarizes the limit indicators. Limit indicators alwaysappearonboththeFrontPanelandAdvancedProgrammerdisplays.

Select DISABLE if the limit indicator characters may confuse a pro-gram running an SPC or data collection application. Select ENABLE to allowuseof thelimitindicators.

Table8-2 Limit Indicator Symbols and Their Meaning


Symbol Meaning

<< Lower Bad limit not reached

< Lower Suspect limit not reached

> Upper Suspec limit exceeded

>> Upper Bad limit exceeded


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Time TagTIMETAGallowseachpartrecordtobetimestamped.Thetime at the end of each cycle is added to the part record. TIMETAG can be either DISABLEDto turn off the feature or ENABLEDto turn it on.

TheDPCIIIhasaflexiblediscreteinput/outputstruc-turethatallowstheDPCIIItointerfacewithautomatedmachineryandPLC’sinanumberof configurations.TheI/Omenuallowstheoperatortocustomizethepolar-ity and behavior of the discrete I/O to suit the needs of specificapplications.

OutputsThisselectiondefinesthepolarityof theoutputsignalwhentheoutputissetorreset.

OUTPUTSselectsbetweenthefollowing:

ACTIVEHIreferstoasignalthatishigh,oron,whentheoutput is active. When the output is not active, the signal is low,oroff.

ACTIVELOreferstoasignalthatislow,oroff,whentheoutput is active. When the output is not active, the signal is high, or on.

Theoutputsaffectedare:

• Bad Part Output,

• Suspect Part Output,

•J801-5(GoodPartOutput,InDwell,InCycle,Sonics

On), and

• J801-6 (Ready, Good Part Output, In Cycle, Sonics On).

User I/O •COMMUNICATIONS

ConfigureSerialPort

User IOAdvancedProgrammerPartSamplingGraphing

SETUP



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UseActiveLowhenapositiveacknowledgmentof anoutputisneeded.

EXAMPLEConsiderasituationwheretheBadPartoutputisroutedtoaPLCthatcontrols a gate. The gate routes reject (Bad) parts to a reject part bin andshutsdowntheprocessiftwo“rejects”occurinarow.WithActiveHioutputs,abrokenwireorafailedoutputwouldpreventtherejectpartgatefromoperatingandwouldcauseBadpartstomixwithGoodparts.If,however,ActiveLooutputswereselectedandasystemfaultoccurred,thesignalwouldbelost,andthePLCwouldconsiderallpartsBad.Aftertwobadparts,thePLCwouldshutdowntheprocessandoutput an alarm. After determining that the DPC III produced Good parts, maintenance personnel could conduct tests to identify and correct the fault.

SwitchingtheOUTPUTS item from ACTIVEHI to AC-TIVELO, or vice versa, causes the above outputs to reset.

End of Weld/Ground DetectThis ENDOFWELDmenuitemdetermineswhethertheEndof Weld/Ground Detect inputs are recognized or ignored. Selecting DISABLEDmeanssignalswillbeignored.Selecting ENABLEDmeansthesignalswillberecognized.

TheEndof WeldinputisfromtheEndof WeldpresslimitflagandisusedtoendtheWeldportionof theweldcyclebasedontheposi-tionof thepresshead.Theflagcanbemanuallyraisedorloweredonthepresstoendtheweldatanabsolutedistance.

NOTE

This feature is generally not used with a press or thruster that has a distance encoder.

The Ground Detect input is located at the DPC III rear panel on Pin 15 of the J801 Auxiliary connector. Ground Detect is used in con-junctionwithScrub.RefertotheProcess Control Page for more infor-mation about Scrub.

Continued


�0

Status OutputsThisfeatureallowsaselectionof eitherMaintainedorPulsedpartstatusoutputs.Partstatusoutputsare:BadPartOut,SuspectPartOut,andGoodPartOut.MAINTAINED means that the outputs stay active until the start of the next weldcycle.PULSED means that outputs are active for 100 ms before being reset.

Define J801-5 AsPin5outputof theJ801Auxiliaryconnectorcanberedefinedasanyof thefollowing:

• Good Part,

• InDwell,

• In Cycle, or

• Sonics On.

Good PartTheGoodPartoutputisassertedwheneveraGoodpartismade.ItcanbeusedwiththeBadpartandSuspectpartoutputstodeterminepart status.

In DwellTheInDwelloutputisactivewhenevertheDPCIIIisinadelaypor-tionof theweldcycle.Delaysinclude:

• Trigger Delay by Time,

• Trigger Delay by Distance,

• Trigger Delay till Auto-In,

• Hold by Time, and

• Hold by Distance.

InDwellcanbeusedtodeterminewhereinthecurrentcyclethepro-cess is or it can be used to synchronize multiple DPC III’s in a multi-head application.

User I/O, continued


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In CycleInCycleissetwhentheDPCIIIgoesintoaweldcycleandisresetatthe start of the Upstroke portion of the cycle.

Sonics OnSonicsOnoutputissetwhentheDPCIIIturnsontheultrasoundsignal. This is not a confirmation from the generator that the signal has fired. UsethePeakPowerprocesslimitstoverifygeneratoroperation.

Define J801-6 AsPin6outputof theJ801Auxiliaryconnectorcanberedefinedasanyof thefollowing:

• Ready,

• Good Part,

• In Cycle, and

• Sonics On.

ReadyReadyoutputissetwhenevertheDPCIIIisreadytogointothenext cycle. This means that the initiating signal from the last cycle has been cleared and that no inhibiting conditions exist. Inhibiting condi-tionsaredefinedas:• Cycle Start Input Active,• End of Weld Active,• Eitheroneorbothof theactivationswitchesActive,or• Auto Input Active from the last cycle.

If any inhibiting conditions exist, an error message appears on Front Panel and Advanced Programmer displays.

Good Part, In Cycle, and Sonics OnThe Good Part, In Cycle, and Sonics On outputs are identical to the DefineJ801-5menuitemdescribedabove.

Continued

NOTE

The Ready signal is not the same as the Top-of-Stroke position. See Page ��, Figure6-5.


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Buzzer StatusUse BUZZERSTATUS to turn the DPC internal buzzer on or off.

ON

Thebuzzerwillsoundforeveryprocesscondition(suchaswhenaBador Suspect part limit has been exceeded).

OFFThebuzzerwillnotsoundforanyprocesscondition(suchaswhena

Bad or Suspect part limit has been exceeded).(ItwillsounditsnormaltonesduringtheDPCIIIstart-upsequencehowever.)

User I/O, continued


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•COMMUNICATIONSConfigureSerialPort

UserIO

Advanced ProgrammerPartSamplingGraphing

SETUPAdvanced ProgrammerThe Advanced Programmer menu controls the Advanced ProgrammerstatusandthebaudratebetweentheDPCIII and the Programmer.

StatusSTATUSnotifiestheDPCIIIwhethertheAdvancedProgrammerisconnectedtotheDPCIIIserialport,J507.If theoperatorknowsthattheAdvancedProgrammerwillnotbeconnected, set STATUSto DISABLED.

Baud RateThisistherateof informationflowbetwentheDPCIIIandthatAdvanced Programmer measured in bits per second.

NOTE

Baud rates for both the DPC III and the Advanced Pro-grammer must be the same for the units to communicate properly.


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Part SamplingTherearetwokindsof partstoragememoryintheDPCIII:Consecutive memory and Sample memory.

Consecutive MemoryThistypeof memorystoreseachpartrecordafteraweldiscomplet-ed.Thecapacityis512characteristics.Todeterminehowmanycom-plete parts can be stored, divide the number of characteristics plus the part count into 512.

EXAMPLEIf fiveprocesscharacteristicsarebeingdisplayed(includingthepartcount characteristic), then the number of parts that can be stored in consecutive memory is 102. If capacity has been reached and a part is welded,theoldestpartinmemoryiserasedbeforethenewpartrecordisadded.

Sample MemorySamplememoryhastwicethecapacityof Consecutivememoryallowingforstorageof 1,024characteristics.UnlikeConsecutivememory,whichstores every part, Sample memory can be customized by the user.

Lot Size and Sample SizeThesemenuitemscontrolwhichpartsarestoredinSamplememory.

Lot SizeThis is the number of parts in a group, or lot, to be sampled (for accep-tance or rejection).

•COMMUNICATIONSConfigureSerialPortUserIOAdvancedProgrammer

Part SamplingGraphing

SETUP


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Sample Size

This is the number of parts from the lot to be sampled.

If the Lot Size is set at 100 and the Sample Size is set at 5, then the followingpartswouldbestoredinSamplememory:

96,97,98,99,100 196,197,198,199,200 296,297,298,299,300 etc. . .

Samplingallowsqualityassurancepersonneltoautomaticallysamplepart data over a period of time so that the data can be collected once rather than several times per shift.

NOTE

If either LotSize or SampleSize is set to zero, or they are set to the same number, all parts are sampled automati-cally. Sample memory contains consecutive part records.

Part Sampling, continued

Continued


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ThisitemallowstheoperatortofilteroutunwantedpartdatafromSamplememory.Excludeoptionsare:• None,• Bad,• Suspect, and• Bad and Suspect.

EXAMPLECustomersneedpartdatafurnishedwithdeliveredpartsforqualitycontrolpurposes. If the DPC III is set to detect Bad or Suspect parts, and those parts are removed from the shipped parts, then the Bad and Suspect part datashouldberemovedfromtheshippingdataaswell.EXCLUDEallowsthe operator to do that.

NOTE

Parts excluded are notcounted by the lot counter. There-fore, excluded parts will change the part numbering se-quence as described under LotSize and SampleSize.

StoreSTORE is the opposite of EXCLUDE.ThisallowstheoperatortoincludeBadorSuspectpartsinSamplememoryalongwiththesampleparts.This might be used to gather data on Bad or Suspect parts for analysis.

Storing parts has no effect on the lot counter.

Choices for STOREare the same as they are for EXCLUDE.

Part Sampling, continued

Exclude


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GraphingTheDPCIIIcanstore,inreal-time,power,distance,force and pressure measurements each millisecond and can provide graphical output at the end of each cycle. This information can be used to document/analyze your pro-cess. Graph informaton can be presented in print (using the printer types available to the DPC III). Graphical information canalsobepresentedasacommadelimitedtableof rawdatathatcanbedownloadedtoacomputerordatacollectiondeviceforanalysisanddisplay.

There are several menu items the operator can use to control the collecton and display of graphical data.

Left and Right AxisEntries made for the left and right axes control the type of graph to be dis-played and also the labeling of the vertical axes.

NOTE

By selecting different data types for the left and right vertical axes, a combination graph (i.e. Power and Distance vs. Time) can be produced.

Start AtSTARTATdefineswhenduringtheweldcycletheDPCIIIstartstocollectgraph data. By choosing different STARTAT entries, the DPC III data collec-tionislimitedtothepartof thecyclethathasbeendefined.SelectionsforSTARTATinclude:• Weld,• Trigger, and• Cycle Start.

Stop AtSTOPATdetermineswhentheDPCIIIstopscollectinggraphdata.Com-binedwithSTARTAT,theoperatorcandefinearangeinthecycleduringwhichgraphdataiscollected.STOPATselections:• End of Cycle, or• End of Hold.

•COMMUNICATIONSConfigureSerialPortUserIOAdvancedProgrammer

PartSampling

Graphing

SETUP

Continued


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As the DPC III prepares to print a graph, the scale for each graph parameter is calculated based on that parameter’s maximum value. This is refered to as Auto Ranging. When the graphs are printed, the change in scale caused by Auto Rangingcanmakecomparisonof graphsdifficult.Toalleviatethisproblem,Time,Distance,andPowergraphshaveuser-select-ablescales.Selectingafixedscaleensuresthatgraphsappearconsistentfromcycle to cycle.

NOTE

Power and Distance scales can be changed between multiple graphs of the same part, but the Time scale cannot be changed.

Selecting Time, Power, and Distance Scales Graphing, continued

SECTION 9

Setup Mode, Utilities Page• ThissectiondescribeshowtheUtilitiesmenu

item can be used for setup management and for diagnostic tools..

Dukane Corporation



Section 9 Setup Mode, Utilities Page

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SETUP


Overview

Figure9-1 Utilities Page Menu

TheUtilitiesPagehasthesixmenuitemsshowninFigure9-1. With these menu items, the operator can use system utilities as setup management tools, for encoder setup, and as diagnostic tools.Userparametersarealsoincludedthatallowtheoperatortoattach a unique name to each setup. In addition, names or descrip-tions of external system components (horn, booster, etc.) can be given.Whenasetupanditscomponentsareidentifiedintheseways,referencesareprovidedforlaterrecall.

Figure9-2belowshowshowtheUtilitiesPageappearsontheAd-vanced Programmer display.

Figure9-2 The Utilities Page as Displayed on the Advanced Programmer


1. PROCESS CONTROL

2. PROCESS LIMITS

3. COMMUNICATIONS

4. UTILITIES

5. SEQUENCING


UTILITIES

SELECT SETUP

COPY A SETUP

ERASE SETUP

PRINT SETUP

ENCODER UNITS

RESET PART COUNT

PRESET PART COUNT

JOB ID

HORN

BOOSTER

FIXTURE

POWER AVERAGE

POWER

ENGLISH

INSERT #2

DX-1133

2 to 1

NONE

EIGHT

SETUP UTILITIES

I/O

RESET/PRESET PART COUNT

USER PARAMETERS

POWER UTILITIES

TIME AND DATE UTILITIES

SET DATE

SET TIME

CHECK DATE

CHECK TIME

ENCODER POSITION

DATE FORMAT MM-DD-YY

PRESSURE 1 30.0

PRESSURE 2 45.0

CHECK PRESSURE

TRIGGER FORCE


�00

SETUP

•UTILITIESSetup UtilitiesTimeandDateUtilitiesEncoderUtilitiesReset/PresetPartCountUserParametersPowerUtilities

Setup UtilitiesSetupUtilitiesenabletheoperatorto:

•SelectNewSetup,

• Copy a Setup,

• Erase Setups, or

• Print Setup.

Select New SetupThe SELECTNEWSETUPmenuitemcanbeused:•tochooseanewsetup,or• to choose a setup in memory that needs changing.

Toaccessthismenufeature:Front Panel Display

• Use the Front Panel keypad.Thecurrentsetupnumberandthejobidentificationaredisplayed.AnewsetupischosenbypressingtheUporDownArrowkeysontheFrontPanelkeypaduntilthedesiredsetupnumberisshown.

Advanced Programmer

• Use the Advanced Programmer keyboard, or• Use the F10 function key. It is the only key that can be used in either

SetuporOperatemodeandhasbeendefinedasSelect New Setup. Thekeycannotberedefined.FormoreinformationonFunctionKeys, see Section 3.

When SELECTSETUPischosen,theentryareaonthedisplayshowsaselec-tionnumberfollowedbyasetupnumberandtheJobID.

NOTE

The Job ID is entered in the USER PARAMETERS section of the Utilities Page.

Anewsetupischosenbypressingthekeyboardnumberkeycorrespond-ingtothedesiredsetup(1-8).TheoperatorcanalsousetheUporDownArrowkeystoscrolltothedesiredsetup.


�0�

NOTE

With both the Front Panel and Advanced Programmer, the ENTER key selects the new setup, and the DELETE key cancels any selection made.

Copy a SetupUsing this selection data from one setup is copied into the current setup.

When COPYASETUPis selected, enter the setup number of the setup to be copied. When the ENTERkey is pressed to the DPC III asks for confirmationbydisplayinganOKTOOVERWRITE?message.

If YESischosen,thespecifiedsetupwillbecopiedintothecurrentsetup. Selecting NOor pressing the DELETEkey cancels the operation.

Erase Setups

When ERASESETUP is chosen, the operator can erase the current setup or erase all setups. Once setups have been removed from memory, they must be reentered to be restored. The menu choices are explained on the next page.

Setup Utilities, continued

Continued

It is a good idea to make a printed copy of all setups as a way of back-ing up what’s in the DPC III memory. Once the deletion process begins, it cannot be stopped.

CAUTION


�0�

Erase Current SetupErasing the current setup removes all setup information for the current setup.If thisitemisselected,theDPCIIIpromptstheoperatorwithOKTOERASESETUP?beforeproceedingwiththeoperation.Toerasethesetup, select YES. To cancel, select NOor press DELETE.

Erase All SetupsErasing all setups removes all setup parameters in all setups. If this item isselected,theDPCIIIpromptstheoperatorwiththemessage:OKTOERASEMEMORY?. If YESis selected, all setups are erased from memory. (This operation can take from 1 to 20 seconds.) To cancel the operation, choose NOor press DELETE.

Print SetupUse this menu item to print a setup selection to a printer or to a com-puterfile.If thisselectionischosen,theoperatormaychooseeitherTEXT or HEX.

Print Setup - TextThisselectionallowsprintingof asetuptoaprinter(forbackuppur-poses).

NOTE

Printing a setup in this mode can only be done when the OUTPUT DEVICE has been set to one of the four printer types (Epson FX-85, etc.) or to ASCII. Trying to print in any other way results in the appearance of a warning, W02:INVALIDOUTPUTDEVICE on the Front Panel display and on the status line of the Advanced Programmer display.

Figure9-3showsanexampleof asetupprintedbyaprinter.

Erase Setups, continued


�0�

----------------------------------------------------------------------------------------------------------------- SETUP 2: LOWER LIM ITS UPPER LIMITS PROCESS LIMITS PROCESS SEQUENCE BAD SUSPECT BAD ------------------------- ------- ---------------- ------- ---------------- 1.250 1.450 2.4000 2.4500 NORMAL TRIGGER WELD BY TIME 1.200 275 HOLD BY TIME 1.000

TOTAL CYCLE TIME TOTAL STROKE

--------------------------------------PEAK POWER 395

--------------------------------------OUTPUT DEVICEOUTPUT MODEBAUD RATEPROTOCOLLF AFTER CRLIMIT INDICATORSTIME TAG

- IBM PRO XL- ALL- 9600- X0N/X0FF- YES- ENABLED- ENABLED

--------------------------------------JOB IDHORNBOOSTERFIXTUREPRESSURE 1PRESSURE 2TRIGGER FORCE

SECONDARY CONTROLS

USER PARAMETERSCOMMUNICATIONS

- Setup 2- --- 20.0- 35.0- 2.25

ADVANCED PROGRAMMER ENCODER UTILITIES--------------------------------------

--------------------------------------

--------------------------------------

--------------------------------------

BAUD RATESTATUS

- 9600- ENABLED

ENCODER UNITS - ENGLISH

I/O GRAPHING


- ACTIVE HI- OFF- DISABLED- MAINTAINED- GOOD PART- READY- ON


- POWER- DISTANCE- WELD- END OF HOLD- 0.050 SEC- AUTO RANGE- AUTO RANGE

PART SAMPLING MISCELLANEOUS


- 100- 5- NONE- NONE

POWER AVERAGEDATE FORMATINITIATE MODETRIGGER METHOD

- EIGHT- MM-DD-YY- AUTO- MAINTAINED

SEQUENCING

SEQUENCINGSEGMENT LENGTHRESET SEQUENCEDEFINE PART AS

- DISABLED- 0- BAD- CYCLE

---------------------------------------------------------------------------------------------------Time: 12:58:24 © 1989—2004 Dukane CorpDate: 10-20-99 v1.xxxx

-------------------------------------- --------------------------------------

--------------------------------------

DOWNSTROKE TIME DOWNSTROKE DIST

WELD TIME P1PEAK POWER

Figure9-3 Example of a Printed Setup


�0�

Figure9-3showstheProcessControl/ProcessLimitssectionof thesetup. To the left, underPROCESSSEQUENCE, the entire sequence of operations for the current setup is listed. To the extreme right, under PROCESSLIMITS, all process limits are listed for each process control seg-ment. Limits are listed in the order they are evaluated and listed on the Advanced Programmer display and output device. The center section containstheupperandlowerBadandSuspectlimitsforallopenprocesslimits.Theyareshowninincreasingorderfromlefttoright.

Figure9-4showsthelimitsoveranormaldistribution.DownstrokeTimeis an example of a Bad limit; Weld Time P1 is an example of a limit definedasDisplayonly;andPeakPowerP1isanexampleof alimitthatshowsaprocesslimitdefinedasaBadlimitandisalsodefinedasaSec-ondary Control. (Notice that there is no upper limit.)

Print Setup - HexWhen HEX is chosen, the current setup is sent to the output device in Intel®hexadecimalformat.Thisformatwillallowthesetuptobestoredinacomputerfileandlaterdownloaded(totheDPCIII).Inanauto-matedenvironment,setupscanbedownloadedtomatchtheneedsof production.Bydownloadingsetups,thesetupcapacityof theDPCIIIisunlimited.

SETUP2:PROCESSSEQUENCE

NORMALTRIGGERWELDBYTIME 1.200

1.250

275

2.4000 2.45001.450

LOWERLIMITS UPPERLIMITS PROCESSLIMITS

DOWNSTROKETIMEDOWNSTROKEDIST

WELDTIMEP1PEAKPOWERP1

Bad BadGoodSuspect Suspect

BAD BADSUSPECT

Figure9-4 Limits Over a Normal Distribution

Print Setup, continued


�0�

SETUP

•UTILITIESSetupUtilitiesTime and Date UtilitiesEncoderUtilitiesReset/PresetPartCountUserParametersPowerUtilities

Time and Date UtilitiesThe DPC III has a real-time clock/calendar. With this fea-turetheoperatorcan:

• Set the time and date, and•Determinewhethertheclock/calendarisfunctioning

properly.Wheninproduction,theutilityallowsthepartdatatobetime-tagged.Inthiswayapartislinkedtoaspecifictimeanddate.

Set DateThecalendarportionof thereal-timeclock/calendarissetwiththismenuitem.DateformatisbasedonwhatischosenintheDATEFOR-MATmenuitemexplainedbelow.

Set TimeThe internal clock can be set using this menu item. Set the clock in 24-hourformat:Hours(HH),Minutes(MM),andSeconds(SS).

Check DateWiththismenuitemthecurrentdateisdisplayed.Thedisplayfieldisupdatedeachsecond,withthecurrentdate.

Check TimeWith this menu item, the current time of the real-time clock is displayed.Thisdisplayfieldisupdatedonceeachsecondwiththecur-rent time.

Date FormatWiththismenuitemtheoperatorchooseshowthedatewillbedis-playedusingoneof thefollowingformats:• MM–DD–YY (Month–Day–Year),• DD–MM–YY, or• YY–MM–DD.


�0�

Encoder Utilities monitor the distance encoder’s current position. The utilities also are used to select encoder units of measure.

Encoder UnitsEncoder units can be displayed in English (default) units (inches witharesolutionof 0.0001inch)orinmetricunits(millimeterswitharesolutionof 0.001millimeter).

Encoder PositionWhen ENCODERPOSITION is chosen, the current position of the encoder is displayed.

NOTE

Encoder units can either be positive or negative.

Withthismenuitem,theoperatorcan:•checkwhethertheencoderisworkingproperly,or• determine the distance from the encoder reference mark to the top of a parttobewelded.

Theencoderreferencemarkisalwaysenabled in this mode. If your press has a seven-inch stroke, it is possible to cross a second ref-erence at the bottom of the thruster stroke. This is not a problem during production since the reference mark is disabledwheneitherthefirstrefer-encehasbeencrossedorwhentheultrasoundsignalisapplied.

Encoder Utilities (Distance Systems Only)

SETUP

•UTILITIESSetupUtilitiesTimeandDateUtilitiesEncoder UtilitiesReset/PresetPartCountUserParametersPowerUtilities


�0�

SETUP

•UTILITIESSetupUtilitiesTimeandDateUtilitiesEncoderUtilitiesReset/Preset Part CountUserParametersPowerUtilities

SETUP

•UTILITIESSetupUtilitiesTimeandDateUtilitiesEncoderUtilitiesReset/PresetPartCountUser ParametersPowerUtilities

Reset/Preset Part CountWith this utility the operator can modify the part count.

Reset Part CountSelecting this menu item sets the part count to zero (0). This also sets the Sample counter to zero (0).

Preset Part CountThe operator enters a number for the part count (maximum of 999,999). Preset Part Count has no effect on the Sample counter.

User ParametersThis menu item gives the operator a place to enter notes that identify partsandconditionsassociatedwithaparticularsetup.Informationaboutthesesevenparameterscanbeentered:

• Job Number,

• Horn,

• Booster,

• Fixture,

• Pressure 1,

• Pressure 2, and

• Trigger Force.

Job NumberThisisa10-characterfieldinwhichtheoperatorcanenteranameornumbertoidentifythejoborpartthatisassociatedwiththecurrentsetup.Thejobidentificationappearsatthetopof eachAdvancedPro-grammer Setup page (Process Control Page, Process Limits Page, etc.) next to the setup number.

Whenchoosinganewsetup,thejobidentificationisdisplayedwiththesetup number in the Advanced Programmer entry area and on the Front Panel display.

Continued


�0�

HornThis10-characterfieldallowstheoperatortoenterthehornnumber or description.

BoosterThe10-characterBoosterfieldcanbeusedtoenteraboosternumberoritsgainratio(2:1forinstance).

FixtureThis10-characterfieldletstheoperatorenteranumberorde-scriptionof thefixture.

Pressure 1EntertheairpressuresettingforPressure1whichisusedforDownstrokeandsinglepressurewelding.

Pressure 2Enter the air pressure setting for Pressure 2. Pressure 2 is used duringthePressure2portionof adualpressureweldingappli-cationandduringtheHoldportionof theweldcycle.

Trigger ForceThe TRIGGERFORCEsettingprovidesanentryfieldtorecordthetrigger force. Enter the numeric setting that is on the thruster’s triggerswitch.

User Parameters, contin-


�0�

SETUP

•UTILITIESSetupUtilitiesTimeandDateUtilitiesEncoderUtilitiesReset/PresetPartCountUserParametersPower Utilities

MenuitemsassociatedwithPowerUtilitiesallowtheoperatortodisplaythepresent,instantaneousultrasoundpoweroutputlevel as measured by the DPC III energy module. This menualsoallowsforselectionof asamplingratewhenmeasuringthepoweroutput.

Power AverageSome applications, such as inserting and cutting gener-ate“noise”intheultrasonicsignalwhichcausesextremefluctuationsinthepowermeasurement.Althoughtheseextremes do not affect system operation, they do limit the usefulnessof powermeasurementforcontrolandmonitoring.

Poweraveragingisusedto“filter”thepowermeasurement,limitingtheamountof fluctuation,andprovidingfora“smooth”powervs.timecurve.

Thefilteringisperformedbyamovingaverage. POWERAVERAGE selec-tions are EIGHT, FOUR, TWO, and DISABLED(one). These values represent thenumberof measurementsthatareaveragedtogetthepresentpowermeasurement.

EXAMPLE

Whentheaverageissettoeight,thelasteightpowermeasurementsareaveragedtogetthelatestpowerlevel.Anewpowermeasurementistakeneverymillisecondreplacingtheoldestof thelasteightpowermeasure-ments.

PowerThe POWERselectionisusedtodisplaythecurrentpowerlevel.Thiscouldbeused:•todetermineif theenergy/powersubsystemof theDPCIIIisopera-

tional, and •todetermineif thegenerator/stacksubsystemisoperatingwithinnor-

mal limits.

Power Utilities (Energy Systems Only)


��0


SECTION 10

Setup Mode, Sequencing Page• ThissectiondescribeshowtheDPCIIIcanbeusedforjobsthatrequiremultipleweldsinasingle setup.

Dukane Corporation



Section 10 Setup Mode, Sequencing Page

��

SETUP

• UTILITIES • SEQUENCINGSequencingSequence

Overview

Figure10-1 Sequencing Page

Figure10-2 The Sequencing Page as Displayed on the Advanced Programmer





SEQUENCING

SEGMENT LENGTH 3RESET SEQUENCE DISABLEDDEFINE PART AS CYCLEPRESET SEGMENTPRESET CYCLES

SEQUENCING DISABLED

SEQUENCE DEFINITIONSEGMENT SETUP CYCLES1. 1:Insert #2 12. 2:Insert #3 23. 3:Insert #4 3

Thefinalgroupof menuitemsintheSetupmodeinvolvestheSequencing Page. Sequencing is typically used for operations wherepartsmustbestakedorinsertedandneedmorethanoneprocessing step or more than one set of process parameters.

To use sequencing, the operations performed on a part must be grouped according to a setup number. Once the setup param-eters have been established for each group, determine the order inwhichthegroupsaretobeprocessed.Thisorderof opera-tionsdeterminestheorderof thesegmentsinthesequencedefini-tion.

Figure10-2showstheSequencingPageasitappearsontheAd-vanced Programmer display.


��

Figure10-3givesagraphicrepresentationof asequence.Thefigureshowsthatasequenceisapro-cess that has from 1 to 8 seg-ments and that each of those segments can have from 0 to 255 cycles.

What is a Sequence?

Figure10-3 What is a Sequence?

Segments:

From 1 to 8

2

1

3

4

5

8

Cycles per Segment:

From 0 to 255

01

23

45

67

89

255

Sequence


��

Example SequenceOurexamplesequencewouldappearontheSequencePageas:

In our example, the sequence has three segments. In Segment 1, Setup 3 is used to process four Type 1 inserts. The DPC III then changessetupsandgoestoSegment2,Setup1inwhichtwoType2inserts are processed.

Finally,theDPCswitchestoSegment3andSetup2thatprocessestwoType1inserts.Atthispointthesequenceisresetandanotherpart can be processed. Figure10-4illustrateshowthesequencemightbe implemented on an X-Y table.

SEQUENCEDEFINITIONSEGMENT SETUP CYCLES1. 3:Insert#1 42. 1:Insert#2 23. 2:Insert#1 2

Figure10-4 Example Sequence

Start PointStop Point

Setup 03, Cycle 1 Setup 03, Cycle 2

Setup 02Cycle 1

Setup 01Cycle 2

Setup 01Cycle 1

Setup 02Cycle 2

Setup 03, Cycle 3Setup 03, Cycle 4


��

SETUP


SequencingAfter SEQUENCINGis chosen, the operator selects fromalistof three“states”:Disabled,Enabled,orRemote.

DisabledSelect DISABLEDto turn off the sequencing feature.

EnabledWhen ENABLEDisselected,asequencecanbespecified.Agroupof fivesequencingparametersispresented:

• Segment Length,• Reset Sequence,•DefinePartAs,• Preset Segment, and• Preset Cycles.

Segment LengthSetthenumberof segmentsinthesequencebychoosinganumber:1through 8.

NOTE

If the segment length is changed with the Advanced Pro-grammer, the Sequence Definition menu item will be changed respectively.

Reset SequenceThismenuitemallowsthesequencetoresetautomaticallywhenaselect-edeventoccurs.Theseeventsare:BAD – Bad part detected.SUSPECT – Suspect part detected.ABORT – System abort occurs.DISABLED is selected to prevent an automatic sequence reset.

NOTE

A sequence can be reset manually from the Operate Page using the Advanced Programmer keyboard or the Front Panel keypad.


��

Define Part AsThismenuitemcontrolshowthesystemtreatsthepartcounter.

Cycle

The part counter is incremented every time the system cycles. Use this settingwhentheweldingprocessiscompletedinasinglecycle.

Sequence

Thepartcounterincrementsaftereverysequence.Usethissettingwhenweldingapartneedsmorethanonetypeof setup.

Preset SegmentTheoperatorcanprogramthesequencetostartwithacertainsegment(segment pointer) by using PRESETSEGMENT.Thisallowsresettingorpresettingasequenceincaseswhereaprocessproblemrequiresthatanoperation or group of operations needs repeating.

Preset CyclesTheoperatorcanprogramthesequencetostartwithaspecificcycle(cycle pointer) by using PRESETCYCLES. Thisallowstheresettingorpresettingof asequenceincaseswhereaprocess problem requires that an operation or group of operations be repeated.

NOTE

As with any entry field, Preset Segment can be defined as a function key.

Sequencing Enabled, continued

A single part number can be associated with a mul-tiple-operation assembly. All data generated for an entire assembly will have the same part number.

NOTE


��

SETUP


Sequence (Definition)ThechoicespresentedwiththeSEQUENCEmenu item allowtheoperatortodefinethesequence.

Select SegmentSelectanindividualsegmentforsetupormodification.Use theUpandDownArrowkeystomakethatselection.See the Example Sequence in Figure10-4, on Page 113.

Select SetupThisfielddetermineshowmanycyclestoperformfortheselectedseg-ment.Whenthenumberisreached,theDPCIIIswitchestothenextsegment. At the last segment, the DPC III resets the segment pointer to thefirstsegment.


��

Functionkeysaredefinedintermsof andavailableforaparticularprocesssetup.Thatisimportanttorememberwhenplayingbackafunctionkeyfromthe Operate Page.

NOTE

The current Operate setup appears on the Front Panel display.

DuringSequencingorRemoteSetupSwitching,theDPCIIIchangestheOp-erate setups. Take care to make sure that the function key set desired matches the set for the current Operate setup.

Function Keys and Sequencing


��


SECTION 11

Operate Mode, Operate Page• Thissectiondescribeswaystomonitorthe

process functions.

Dukane Corporation



Section �� Operate Mode, Operate Page

��

Overview

Figure11-2 The Operate Page as Displayed on the Advanced Programmer

WiththeOperatePagetheoperatorcan:• Replay or delete the function keys,• Print Consecutive and Sample memory,• Print headers,• Display Consecutive and Sample memory,• Print a graph, and • Reset the sequence counter.Figure11-1 illustrates the Operate Page menu.

InthefigurebelowtheOperatePageisillustratedasitmightlookonthe Advanced Programmer display.

Figure11-1 Operate Page Menu

1. FUNCTION KEYS2. PRINT CONSECUTIVE MEMORY3. PRINT SAMPLE MEMORY

4. PRINT HEADERS5. DISPLAY CONSECUTIVE MEMORY


PART DOWNSTROKECOUNT TIME

6. DISPLAY SAMPLE MEMORY

7. PRINT GRAPH 8. RESET SEQUENCE

HI BAD LIMHI SUS LIMLO SUS LIMLO BAD LIM

123456789

10

0.5250.5300.5300.5300.5300.5300.5300.5300.5300.530

TRIG DELAYTIME

WELD TIMEPRESSURE 1

WELD DISTPRESURE 1

TOTAL CYCLETIME

TIME

0.2500.2500.2500.2500.2500.2500.2500.2500.2500.250

0.0750.0750.0750.0750.0750.0750.0750.0750.0750.075

<0.00430.00500.00510.00510.00510.00500.00510.0051

>>0.00610.0050

0.8500.8550.8550.8550.8550.8550.8550.8550.8550.855

12:08:53S12:09:1212:09:1512:09:2012:09:2612:09:2912:09:3212:09:3712:09:41B12:09:46

0.00600.00550.00450.0040 0.800

OPERATE

• PRINT SAMPLE MEMORY• FUNCTION KEYS • PRINT CONSECUTIVE MEMORY

• PRINT HEADERS • DISPLAY CONSECUTIVE MEMORY • DISPLAY SAMPLE MEMORY

• PRINT GRAPH • RESET SEQUENCE


��0

Select the Operate ModeTurnthekeyswitchtotheOPERATEposition.Aweldcyclecanonlybestartedwiththeswitchinthisposition.Thekeycanberemovedwhenitisin the OPERATEposition.

Reviewing Process CharacteristicsAllprocesscharacteristicsfromtheweldcyclejustcompletedcanbere-viewedusingtheLeftandRightArrowkeysontheFrontPanelkeypad.

Parts processed previously cannot be displayed, although they can be downloadedtoaprinterorcomputerusingtherearpanelJ3serialportconnector.

Accessing Operate FunctionsPresstheUporDownArrowkeysontheFrontPanelkeypadtoscrollthrough the menu items.

Operate Page with Front Panel

To prevent access to the SETUP mode, and when the key-switch has been turned to OPERATE, remove the key.

NOTE


��

Select the Operate ModePresseitherthePageUporPageDownkeyonthekeyboard.

NOTE

If there are more than �� process characteristics active for the current process, the Operate Page will display on two screens. The first screen will provide information for as many as 11 characteristics. The second screen will have information for the remaining characteristics.

NOTE

Switching the Front Panel keyswitch from SETUP to OPERATE changes the Advanced Programmer mode accordingly.

Reviewing Process CharacteristicsThe Advanced Programmer can display more information at a glance thantheFrontPaneldisplay(withitsone-linedisplay).Inaddition,whentheDisplayConsecutive/SampleMemorycommandsareused,parthistorycanbereviewedaswell.

Accessing Operate FunctionsOperatefunctionscanbeselectedusingtheUpandDownArrowkeyson the Advanced Programmer keyboard. Operate functions can also be chosen by pressing the number key corresponding to the menu item linked to each function.

EXAMPLETo print headers, press the “4” key on the Advanced Programmer keyboard.

Operate Page with Advanced Programmer

Continued


��

Operate FunctionsFunction KeysFunctionkeyscanbereplayedinseveralways:•withtheAdvancedProgrammerfunctionkeys(F1throughF10),or•withtheUp/DownArrowkeysof theFrontPanelorAdvancedPro-

grammer.Function keys can be used to change process parameters during the “trial anderror”processof setup,andtheycanallowtheoperatorlimitedac-cess in making setup changes to the system.

NOTE

Each setup has its own set of nine function keys. If multiple setups are to be used, define the keys for each setup.

Remember: F10 is permanently defined as, SelectNewSetup.

For more information about Function Keys, see Section 3, Controls, Pages 31-32.

Print Part MemoryEither Consecutive or Sample part memory can be sent to an output device giving a hard copy record of part memories.

When either PRINTCONSECUTIVEMEMORY or PRINTSAMPLEMEMORY is accessed,themessage:PARTSTODOWNLOAD is displayed. The number of available parts is displayed in parentheses (xx) to the left of the entry field.Enterthenumberof partstobedownloaded.To cancel the print operation, press the DELETEkey.

Print Headers“Headers”referstothewordsthatappearatthetopsof columnsontheAdvanced Programmer display. They identify the columns of process characteristicsappearingbelowthem.Havingtheheadersprintedhelpstoidentifywhathasbeenrecorded.


��

Display Part MemoryDisplay part memory is an Advanced Programmer function. When either DISPLAYCONSECUTIVEMEMORY or DISPLAYSAMPLEMEMORY is accessed,thenumberof partstobedisplayedisenteredattheprompt:PARTSTODISPLAY(xx)xxx. The number of available parts is displayed inparenthesesattheleftof theentryfield.If thenumberof partsisgreaterthanten,onlytenpartswilldisplayatatime.Toseemoreparts,press any key on the Advanced Programmer keyboard. To cancel the display operation, press the DELETEkey.

Print GraphWith this function, a graph or graph data can be sent to an output de-vice. When PRINTGRAPH is chosen, choices are TEXT and RAWDATA.

TEXTWhen TEXT is chosen, a graph is printed to the output device according to the settings made in the Graphing section of the Communications Page. If no informaton has been collected by the system, the error mes-sage E14:NOGRAPHDATAAVAILABLE is displayed on the status line of the Advanced Programmer. The error is displayed on the Front Panel displayif thekeyswitchisintheOPERATEposition.Graph axes are labeled in real units and not simply as percentages. See Figure11-3foranexampleof agraphshowingDistanceandPowervs.Time.

ContinuedFigure11-3 A Distance and Power vs. Time Graph

250 Watts

125

0

0.250 sec0.1250

0.0100

0.0050

0.0000 in


��

Print Graph, continued

Raw DataThe RAWDATAselectionsendsgraphdatainatabularformatwhena graphical device (such as a printer) is not attached to the DPC III. Thismeansthattime,distance,velocity,power,pressure,andforcedata can be sent to a computer for analysis (using spreadsheet soft-ware)orforarchivalpurposes.Allprocessparametersaresentregardlessof systemconfiguration.If a particular option is not installed in the system, a data column willdisplayzeroes.Amaximumof 255linesof outputisgenerated.Figure11-4showsanexampleof rawdataoutput.

0.056,0.058,0.060,0.0620.064,0.066,0.068,0.070,0.072,0.074,

271,312,360,424,479,531,576,620,667,728,

2.0090,2.0097,2.0103,2.0109,2.0118,2.0126,2.0135,2.0148,2.0158,2.0169,

0.00010.00020.00010.00020.00020.00020.00020.00030.00020.0003

Time (ms) Distance (in/mm)

Velocity (in/s; mm/s)Power (w)

Figure11-4Raw Data Graph Example


��

Reset SequenceThismenuselectionallowstheoperatortomanuallyresetasequenceincase a system error or Bad part limit is exceeded. Before the sequence is reset,theoperatorispromptedbythesystemwhethertheresetshouldbe carried out. The message OKTORESETSEQUENCE is displayed. Then a YES/NO choice is made.Choosing NOcancels the operation to reset the sequence.Choosing YESresets the system to the beginning of a sequence.

NOTE

Presetting a sequence can be done by defining one func-tion key as PRESETSEGMENT and another function key as PRESETCYCLES.


��


SECTION 12

Specifications• This section has a regulatory agency compliance

statement, dimensions, operating requirements, and an explanation of the model number..

Dukane Corporation



Section 12 Specifications

��

Regulatory Agency Compliance

FCCThe equipment complies with the following Fed-eral Communications Commission regulations.• The limits for FCC measurement procedure

MP-5, “Methods of Measurement of Radio Noise Emissions from ISM Equipment”, pur-suant to FCC Title 47 Part 18 for Ultrasonic Equipment.

CE MarkingThis mark on your equipment certifies that it meets the requirements of the EU (European Union) concerning interference causing equip-ment regulations. CE stands for Conformité Eu-ropeéne (European Conformity). The equipment complies with the following CE requirements.• The EMC Directive 2004/108/EC for Heavy

Industrial — EN 61000-6-4: 2001

EN 55011: 2003 EN 61000-6-2: 2001 EN61000–4–2

EN61000–4–3 EN61000–4–4 EN61000–4–5 EN61000–4–6 EN61000–4–8 EN61000–4–11

• The Low Voltage Directive 2006/95/EC.

• The Machinery Directive 2006/42/EC. EN 60204: 2006

Safety of Machinery - Electrical Equipment of Machines Part 1: Gen-eral Requirements.

CAUTION

DO NOT make any modifications to the DPC or associated ca-bles as the changes may result in violating one or more regula-tions under which this equipment is manu-factured.


��

Dimensions Refer to Table12-1onthenextpagefortheinputpowerrequiredbyyour DPC generator model.

Figure12-1Dimensions

18.42468 17.26

439

INCHESMILLIMETERS

23.75604

1.6041

3.8297

12.35314

1.6943

ALLOW 5" (125mm)BEHIND DPC FOR CABLING

OPT

ION

AL

RAC

K M

OU

NTI

NG

ALLOW OPEN AREAFOR COOLING AIR

BOTH SIDES

5.17132

5.59142

18.38467

19.00488

5.59142

Section 12 Specifications

��

Generator Models

Table12-1 Generator Models

Power Supply Electrical Source Requirements

Operating EnvironmentOperatetheDPCwithintheseguidelines:

Temperature: 40 - 100° F (5 - 38° C)Pressure: AmbientAir Particulates: Keep the DPC dry. Minimize exposure to moisture, dust, dirt, smoke and mold.

2050

2120

2170

2220

3150

4035

4070

4100

5015

701070 kHz

50 kHz

40 kHz

30 kHz

20 kHz

FrequencyDPC–3

Generator ModelPeak Power

Rating (Watts) Nominal Input Power Requirements

500

1200

1700

2200

1500

350

700

1000

150

100

95–130V 50/60 Hz @ 8 Amps

95–130V 50/60 Hz @ 15 Amps

95–130V 50/60 Hz @ 6 Amps

95–130V 50/60 Hz @ 12 Amps

95–130V 50/60 Hz @ 15 Amps

95–130V 50/60 Hz @ 6 Amps

95–130V 50/60 Hz @ 6 Amps

190–260V 50/60 Hz @ 4 Amps

190–260V 50/60 Hz @ 4 Amps

190–260V 50/60 Hz @ 8 Amps

190–260V 50/60 Hz @ 4 Amps

190–260V 50/60 Hz @ 4 Amps

190–260V 50/60 Hz @ 8 Amps

190–260V 50/60 Hz @ 8 Amps

190–260V 50/60 Hz @ 12 Amps

190–260V 50/60 Hz @ 12 Amps

190–260V 50/60 Hz @ 15 Amps


��0

Interpreting the DPC Model Number

NOTE

Figure12-2 is designed to help you determine which elements your DPC has. It is not meant to suggest that every combination of these elements is possible. Look on the DPC rear panel for the model number.

Figure12-2 Interpreting the DPC Model Number

2220-HN4-PC3 Generator Controller

FREQUENCY 2 = 20 kHz 3 = 30 kHz 4 = 40 kHz 5 = 50 kHz 7 = 70 kHz

RATED POWER

015 = 150 w 035 = 350 w 050 = 500 w 070 = 700 w 100 = 1000 w 120 = 1200 w 170 = 1700 w

INPUT POWERMODULE L = Low power module H = High power module

N = Non-power Factor

TRANSDUCERS 2 = 2 ceramics 4 = 4 ceramics

PRESS P = Press Control Board P1 = Press Option Board

010 = 1 0 0 w

C = Time, Distance & EnergyD = Time & DistanceE = Time & EnergyT = Time Only

3 = Level 3

220 = 2200 w

SECTION 13

Care and Troubleshooting• This section has information about care of the

DPC III controller, and it describes error and warningmessages.

Dukane Corporation



Section 13 Care and Troubleshooting

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CareEnvironmentProlongthelifeof yourDPCIIIintheseways:

• HandletheDPCwithcare.Itisasensitiveelectronicdevice,andshouldbetreatedaccordingly.Itisnotdesignedtowithstandhighimpactblowsof anykind.

• Do not expose the DPC to moisture. Keep the unit dry.

• Minimize the DPC’s exposure to, dust, dirt, smoke, and the ex-tremesof temperature.Allarefactorswhichcanshortencompo-nent life.

• Keepfingersclean.Becausetheywillbetouchingthekeypad,andcancarrydirt,grease,etc.,fingersshouldbeascleanaspossible.

Front PanelThe operator controls on the Front Panel (keypad, generator control keysandACpowerswitch)respondtoagentlebutfirmtouch.Neveruse a sharply pointed object to touch any of these controls.

CAUTION

PLEASE, do not use any sharply point-ed object to touch any part of the DPC front panel!

CleaningWhen cleaning the DPC, put a small amount of computer cleaner on asoftcloth,andgentlywipetheclothandcleaneroverthesurfacetobecleaned.Donotapply(sprayorotherwise)anycleanerdirectlytothe DPC.

NOTE

Handle your Advanced Programmer display and keyboard with the same care outlined here for the DPC.


��

Replaceable PartsThe DPC III is a self-contained device and has no parts that are replaceable by the end user.

When parts need replacing, contact Dukane Corporation.See Section 14 for contact information.


��

Problem PossibleSolutionFront Panel display image disappears.Panel goes dark.

1. Check to see that the DPC’s green, LED powerlightison.

2. If the light is not on, tighten all cable connec-tions. Then, make certain the DPC rear panel ACbreakerswitchandtheFrontPanelpowerswitcharebothintheON position.

NOTE

Contact Dukane Corporation for servicing. (See Section 14.) The DPC and Advanced Programmer are serviceable only by Dukane personnel. Unauthorized attempts to service either unit will void any warranty.

Troubleshooting

Theultrasoundsignalwillshutdownduringanoverload condition. If overloading continues, analysisof applicationandhardwaremaybeneeded.Contact Dukane Corporation. See Section 14 for contact information.

SystemStatusDisplayshowsOVERLOAD condition.

Unitpower-upsequencestops,andSystemStatusDisplay INPUTTESTisflashing.

Theself testroutineforinputpowercompat-ibilitywiththeDPChasfoundaproblem.Thepower-upsequencewillnotcontinueuntiltheproblem is resolved. Recheck line voltage and DPC system requirements.Anotherpossibility:afaultmayhaveoccurredonthe DPC’s input module circuit.


��

ErrormessagesandwarningsaredisplayedontheFrontPanelandAdvanced Programmer displays. The Advanced Programmer has a “Status Line” of reverse video at the bottom of each page that con-tainsacopyrightnotice.Allerrorandwarningmessagesappearinthisline. See Figure13-1 for the location of the status line. Each time an errororwarningmessageappearsonthestatusline,anaudibletoneisgenerated from the Advanced Programmer.Therearetwokindsof errorandwarningmessages:latched and un-latched.Explanationsof bothtypesfollow.

Latched Error/Warning MessagesLatchederrorandwarningmessagesappearonthedisplaydeviceuntilakey is pressed or the next cycle has been initiated.

Unlatched Error/Warning MessagesUnlatchederrorandwarningmessagesappearonthedisplayforthreeseconds and then clear themselves.

DPC III Error and Warning Messages

Figure13-1 Status Line Location on Advanced Programmer Display





COMMUNICATIONS

OUTPUT DEVICEOUTPUT MODEBAUD RATEPROTOCOLLF AFTER CRLIMIT INDICATORSTIME TAG


STATUS BAUD RATE



EPSON-FXALL

9600XON/XOFF

YESDISABLEDDISABLED

ACTIVE HIOFF

DISABLEDMAINTAINEDGOOD PART

READYON

ENABLED9600

00

NONENONE

POWERDISTANCE

WELDEND OF WELDAUTO RANGEAUTO RANGEAUTO RANGE

CONFIGURE SERIAL PORT

I/O

ADVANCED PROGRAMMER

PART SAMPLING

GRAPHING

Status Line


��

Error messages appear on the Front Panel display and on the Ad-vanced Programmer display status line. Error messages remain on the displays until cleared by removing the condition that caused them (e.g., a system abort) or by pressing an Advanced Programmer or Front Panel key. Errors 04 – 09, I/O Active at Cycle Start, appear for three seconds and then disappear for three seconds. Each time the error message appears, it is accompanied by an audible tone from the Advanced Programmer.

E00:EEPROMWRITEVERIFYERROR(This is a latched error.)

TheEEPROMWriteVerifyerroroccurswhenanattempttowriteto the EEPROM (Electrically Erasable Programmable Read-Only Memory) fails. The EEPROM contains the setup information for the DPC III. If updates to the setup memory fail, unintended operation of the DPC may result.

If the E00:EEPROM WRITE VERIFY ER-ROR appears on the Front Panel dis-play or the Advanced Programmer status line, contact the Dukane Ultra-

sonics Service Department immediately.

E01:CYCLEABORTED(This is a latched error.)

The Cycle Aborted error message apears on the Advanced Program-merstatuslinewhiletheDPCAbortinputisasserted.OntheFrontPanel,theCycleAbortederrorisdisplayedonlywhenthekeyswitchis in the OPERATEposition.Thisallowsthesystemtobeprogrammedin the SETUPmode even though the system is aborted and cannot be placed in cycle. Note that the 24VDC to the press head is removed whentheAbortswitchsuppliedwiththesafetyswitchesispressed.With an automated system, the UPVALVEONABORT menu item on the Communications Page may be set to ONduring an abort. This prevents heavy horns from pulling the press head into the path of movingtablesandfixtures.The24VDCsupplytothepressshouldnotbeswitchedthroughtheAbortswitchinthiscase.RefertoAp-pendix A – I/O for details on controlling the 24VDC to the press.

Error Messages

CAUTION

Continued


��

Cycle Aborted, continued

E02:ENCODERERROR(Distancesystemsonly)Theencodersignalisalow-levelquadratureoutputthatdetectschanging position and direction of travel. If one or more of the quadratureinputsisweakorlost,anencodererrorsignalissenttotheDPCIII.EncodererrorhasnoeffectontheDPCcycle.Itwillnotterminateoraltertheflowof theprocess.Itmayhaveaneffecton the distance measurements and therefore should be addressed as quicklyaspossible.Encodererrorsmaybearesultof thefollowingsituations:

• Incorrect encoder alignmentThegapbetweentheencoderreadheadandtheencoderscaleshouldbesetat0.039inch(1mm).Thismeasurementshouldbetakenwithfeelergaugeswhenthereadheadisatboththetopandthebottomof theencoderscale.Theallowabletoleranceasspecifiedbythemanufactureris±0.005inchyieldinganallowablerangeof 0.034inchto 0.044 inch.

• Damaged encoder cableBecausetheencodersignalsareof alowlevel,damagetothecable,such as a cut or splice, can cause interruption or corruption of the signals from the encoder. If the cable is damaged, contact the Du-kane Ultrasonics Service Department for a replacement.

E03:SERIALPORTTIME-OUTERRORASerialPortTime-outerroroccurswhentheDPCIIIcannotcom-municatetotheoutputdevice.Inserialcommunications,theflowof information to a terminal device sometimes occurs at a faster rate than the ability of the terminal device to process it. This causes data to back up in the terminal device. When the terminal device is full, it commands the DPC to stop sending data. If the terminal device does notsenda“go”or“resume”commandwithin30seconds,aSerialPortTime-outerroroccurs.TheDPCwillcontinuetoattempttosend data to the terminal device after the time-out.Topreventtime-outfromoccurring,trythefollowing:• Limit the amount of data output to the serial port. Determinewhichprocesscharacteristicsareactuallyrequiredto

gaugeyourprocessqualityandwhicharenot.Usesamplingtooutput only those parts that are of interest.

(This is a latched error.)


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• Keep the printer stocked with paper. If the printer runs out of paper, it acts as if it is off-line.

E04:SS1ACTIVEATCYCLESTART(This is an unlatched error.)

ThiserrormessageisactiveonlywhentheInitiateModeselectiononthe Process Control Page is set to MANUAL. It informs you that the ActivationSwitch1isdepressedatthestartof thecycle.Tocleartheerror,releaseActivationSwitch1.TheActivationSwitch1inputcanbetestedbyholdingtheswitchdownforfiveseconds.Aslongastheswitchcontactismade,theerrormessagewillbedisplayedforthreeseconds and removed from the display for three seconds.

E05:SS2ACTIVEATCYCLESTART(This is an unlatched error.)

TheSS2ActiveatCycleStarterrormessageisactiveonlywhentheInitiate Mode selection on the Process Control Page is set to Manual. ItinformsyouthattheActivationSwitch2isdepressedatthestartofthecycle.Tocleartheerror,releaseActivationSwitch2.TheActiva-tionSwitch2inputcanbetestedbyholdingtheswitchdownforfiveseconds.Aslongastheswitchcontactismade,theerrormessagewillbedisplayedforthreesecondsandremovedfromthedisplayforthree seconds.

• Get a faster terminal device. If youcannotcutdownonthenumberof characteristicsreport-

ed,youmaywishtoinvestinahigherspeedterminaldevice(e.g.,a printer or data collector).

• Do not leave a printer off-line. To perform form and line feeds, many printers require that the

printer be taken off-line, meaning that the printer can neither pro-cessnorprintdata.However,whileoff-line,theprintercontinuestoreceivedata.Eventually,theprinterbufferwillfillandtheDPCwilltime-out.Afteranextendedperiodof time,partdatamaybelost.Unlessthereisaspecificreason(e.g.,settingprinterspecifi-cations),alwaysmakesuretheprinterison-line.

Serial Port Time Out Error, continued


��

E08:TRIGGERATCYCLESTART(This is an unlatched error.)

Ifthepresstriggerswitchisclosedorthepresspre-triggerflagisactiveatthestartofthecycle,thesystemwillnotgointocycleandtheE08:TRIGGERATCYCLESTART error message is displayed. To remove this error,eitherlowerthepre-triggerflagtoanacceptablelevelorincreasethetriggerpressurebyturningthetriggerswitchknobcounter-clock-wisetoahighernumber.

E09:CYCLESTOPATCYCLESTART(This is an unlatched error.)

ThiserrorisgeneratedwhentheCycleStopinputisactiveatthestartof a cycle. This signal must be removed before a cycle can be success-fully initiated.

E10:PRE-TRIG>0.75inABOVEPART(This is a latched error.)

For operator safety, the pre-trigger travel distance prior to closing the pressureswitchorreachingthedesiredtriggerforceislimitedto0.75inch.If thedistanceof 0.75inchisexceeded,thecycleimmediatelyterminates, and the error messageE10:PRE-TRIG>0.75inABOVEPART is displayed. In this situation, it is desirable to increase the pre-trigger distance.

E11:TRIGGERLOSTWHILESONICSONWith a momentary trigger type, the loss of the trigger signal termi-natestheweldandresultsintheaboveerrormessagebeingdisplayed.Thismaybeduetoalossof horn/partcontactpressurewhenusingtheKinechekhydraulicspeedcontrol.Solutionstothiserrorwouldbetoincreasethetriggerpressure,increasetheKinechekspeed,orswitchthe trigger type from Momentary to Maintained.

(This is a latched error.)

E06:AUTOACTIVEATCYCLESTARTTheAutoActiveatCycleStarterrormessageisactiveonlywhentheIniti-ate Mode selection on the Process Control Page is set to AUTO. It is the resultof anactiveAutoinputatpower-onoranAutoinputthathasnotbeen removed from the last cycle.

E07:EOWACTIVEATCYCLESTART(This is an unlatched error.)

If the End of Weld/Ground Detect input is enabled at the start of a cycle, then this error message is displayed. This may be due to the posi-tioningof theEndof Weldlimitswitchonthepressoranincorrectlyinstalled Ground Detect input. The cause of this error must be removed before the system can go into cycle.


��

E12:TRIGGER LOST WITHIN 100ms

Thiserrormessageindicatesthatthetriggerwasmadeandlostwithin100msof cycleinitiation.Thisusuallymeansthatthetriggerswitchclosedatthetopof thepressstrokeduetotheinitialinertiaof thepressslide.AswitherrorE11,thecycleisterminatedimme-diately.Topreventthiserror,increasethetriggerswitchsetting.Itisalso recommended in the case of light triggering to place a limit on DownstrokeDistancetoguaranteethatthehornisinanacceptablerangewhenthetriggerswitchcloses.

E13:SS(s)RELEASEDBEFORETRIG(This is a latched error.)

WheninManualmodeandoperatingthesystemwithactivationswitches,itisrequiredthattheactivationswitchesbehelduntilthetriggerswitchcloses.Thisappliesforalltriggertypesincludingpre-trigger.If theoperatorreleasestheactivationswitchesbeforethetriggerswitchcloses,thecycleterminatesimmediately.

E14:NOGRAPHDATAAVAILABLE (This is a latched error.)

Thiserrormessageisdisplayedwheneveryouattempttoprintagraph and no graph data is currently available. Graph data is avail-ableaftertheDPCentersthatportionof thecycleasspecifiedbytheSTARTAT and STOPAT menu selections in the Graphing section of the Communications Page.


��0

Warning MessagesWarning messages are displayed on the Front Panel display and on theAdvancedProgammerstatusline.Eachtimeawarningmessageappears, it is accompanied by an audible tone from the Advanced Programmer.

W00:MAXLIMITCONTROLPARAMETER

Thiswarningmessageisdisplayedwheneverentrytoacharacteris-tic’s maximum Bad limit is prevented due to the characteristic being definedasaSecondaryControl.

W01:MAXLIMIT<MINLIMIT(Thisisanunlatchedwarning.)Thiswarningmessageisdisplayedwheneveryouareenteringcharacteristic limits on the Process Limits Page and the maximum limityouaretryingtosetislessthanthelowlimit.Thissituationisundesirablebecausethecharacteristicwillalwaysbeout-of-limit.Itis the operator’s responsibility to correct this situation.

W02:INVALIDOUTPUTDEVICE(Thisisalatchedwarning.)Anytimeinformationisdownloadedtoanoutputdevice,theDPCIII checks to see if the output device can support the data type. If thedatatypeisnotsupportedfortheoutputdevice,thewarningmessage W02:INVALIDOUTPUTDEVICE is displayed. For example, if the output device is set to 1-2-3 and graph printing is attempted, theDPCwillnotprintthegraph.The1-2-3outputdeviceiswrittento generate a unique data format for importing data into a spread-sheet computer program. The spreadsheet input function cannot recognize the printer control codes that are used to print graphic information.

(Thisisanunlatchedwarning.)


��

TheDPCIIIisdesignedtoworkwiththeAdvancedProgrammerfromitsdefaultstate.If thereisanyquestionastowhethertheAdvancedPro-grammerissetupinawaythatwouldpreventoperationwiththeDPC,followtheresetproceduredescribedbelowandonthefollowingpages.

Please note that when entering the Ad-vanced Programmer Setup Directory, no settings other than those described here should be modified unless it is done under the direct supervision of qualified Dukane personnel.

Advanced Programmer Reset

CAUTION

Resetting the Advanced Programmer1. Depress and hold the CONTROL key, then press the SCROLL LOCK

key.ReleasethekeysandtheSetupmenuwillappearasshowninFigure13-2.

2. Press the PRINT SCN keyandanewmenuwillappearasshowninFigure13-3. See Figure13-4 for the location of the CONTROL, SCROLL LOCK and PRINT SCN keys.

Figure13-2 Initial Setup Menu Figure13-3 Setup Menu After PRINT SCRN Key Pressed


��

Figure13-5 DEFAULT TERMINAL Selected Figure13-6 ENTER Key Pressed

Figure13-4 Location of CONTROL, PRINT SCRN, SCROLL LOCK and CURSOR

3. Use the cursor keys to select the menu item DEFAULT TERMI-NAL. ItwillbeishighlightedasshowninFigure13-5.

4. Press the ENTER key and a message saying WAIT followed byDONE willappearasshowninFigure13-6.

5. Depress and hold the CONTROL key, then press the SCROLL LOCK key. Release the keys and the message SAVE ALL? Y/N appears asshowninFigure13-7.

6. Press the Y key to save all changes. After the screen goes blank, turn thepoweroff andbackon.AmessagesayingPASS willappearasintheupperrighthandcornerof thescreenasshowninFigure13-8.


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Figure13-7 SAVE ALL Y/N Message

Selecting a Printer Port7. Afterdefaultingtheterminalfollowingsteps1through6,repeatstep1.

8. Using the cursor keys, select the menu item HOST/PRINTER = EIA/NONE asshowninFigure13-9 for a serial printer.

9. Using the cursor keys, select the menu item HOST/PRINTER = EIA/PARA asshowninFigure13-10 for a parallel printer.

Figure13-8 PASS Message In Upper Right Hand Corner

Figure13-9 SERIAL Printer Port Selected. Figure13-10 PARALLEL Printer Port Selected.


�� Figure13-11 Advanced Programmer Port Locations

Printing the Advanced Programmer Screen1. Connect a printer to the appropriate port on the rear panel of the

Advanced Programmer monitor. A serial printer connection is showninFigure2-6.Bothserialandparallelconnectionsareshownin Figure13-11.Theprintershouldautomaticallyprintouteachnewweldcycledisplayedonthescreen.

2. To print the current monitor screen image, press and hold the CONTROL(Ctrl) key.

3. While holding the CONTROL key, press the letter “P” key.

4. If you are having problems, make sure –

A. Cable connections are correct (see Figure 13–11).

B. The keyboard is connected to the terminal.

C. The DPC, monitor and printer are all turned on.

D. The connections are secure.

The Advanced Programmer is factory configured to use the se-rial printer port. Remember, that serial printers are supported and parallel printers may work if they support the printer codes listed on Page C–V of this manual. However, Dukane does not guarantee that all parallel printers which support the listed printer codes will work. To use the parallel port, it must be enabled using the procedure outlined. It has been found that it is best to default the terminal (Steps 1–6) before changing the output port in Steps 7–9. Only one of the output ports, serial (preferred) or parallel can be enabled at a time.


– WARNING! –




J1

ULTRASOUNDOUTPUT

TOLINEAR

ENCODER

J401

J901THRUSTER

J902BASE

J801I/O

J802AUTOSTOP

J3SERIALPORT

RS-232DCE

40%MIN

100%MAX

60% 80%

ULTRASOUNDAMPLITUDE



O

I

Sherwood Monitor(Discontinued)

Serial Printer

(Supplied when Advanced Interface Option is ordered)




Parallel Printer

Boundless Monitor(New Model)

SES 1–EIA

KeyboardCable

ACPowerCord

PAR

SES 2–AUX

25–Pin Sub–D

25–PinSub–D

36–PinCentronics(Typically)

DPC III Generator

Use either the SES 2–AUX or the PAR monitor port, but not both.

To use the parallel port, you must enable the PAR port in the monitor setup menu. The monitors are con-figured to use the serial printer port. Remember, that serial printers are supported and parallel printers may work if they support the print-er codes listed on Page C–V of the DPC III User’s Manual. However, Du-kane does not guarantee that all parallel printers which support listed printer codes will work. To use the parallel port, it must be enabled using the procedure outlined at left. It has been found that it is best to reset the terminal before changing the output port.


��Figure13-11 Advanced Programmer Port Locations

Printing the Advanced Programmer Screen1. Connect a printer to the appropriate port on the rear panel of the

Advanced Programmer monitor. A serial printer connection is showninFigure2-6.Bothserialandparallelconnectionsareshownin Figure13-11.Theprintershouldautomaticallyprintouteachnewweldcycledisplayedonthescreen.

2. To print the current monitor screen image, press and hold the CONTROL(Ctrl) key.

3. While holding the CONTROL key, press the letter “P” key.

4. If you are having problems, make sure –

A. Cable connections are correct (see Figure 13–11).

B. The keyboard is connected to the terminal.

C. The DPC, monitor and printer are all turned on.

D. The connections are secure.

The Advanced Programmer is factory configured to use the se-rial printer port. Remember, that serial printers are supported and parallel printers may work if they support the printer codes listed on Page C–V of this manual. However, Dukane does not guarantee that all parallel printers which support the listed printer codes will work. To use the parallel port, it must be enabled using the procedure outlined. It has been found that it is best to default the terminal (Steps 1–6) before changing the output port in Steps 7–9. Only one of the output ports, serial (preferred) or parallel can be enabled at a time.


– WARNING! –




J1

ULTRASOUNDOUTPUT

TOLINEAR

ENCODER

J401

J901THRUSTER

J902BASE

J801I/O

J802AUTOSTOP

J3SERIALPORT

RS-232DCE

40%MIN

100%MAX

60% 80%

ULTRASOUNDAMPLITUDE



O

I

Sherwood Monitor(Discontinued)

Serial Printer

(Supplied when Advanced Interface Option is ordered)




Parallel Printer

Boundless Monitor(New Model)

SES 1–EIA

KeyboardCable

ACPowerCord

PAR

SES 2–AUX

25–Pin Sub–D

25–PinSub–D

36–PinCentronics(Typically)

DPC III Generator

Use either the SES 2–AUX or the PAR monitor port, but not both.

To use the parallel port, you must enable the PAR port in the monitor setup menu. The monitors are con-figured to use the serial printer port. Remember, that serial printers are supported and parallel printers may work if they support the print-er codes listed on Page C–V of the DPC III User’s Manual. However, Du-kane does not guarantee that all parallel printers which support listed printer codes will work. To use the parallel port, it must be enabled using the procedure outlined at left. It has been found that it is best to reset the terminal before changing the output port.


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Verifying Module OperationDependingontheconfigurationof yoursystem,theDPCcontainsseveral modules that provide interfaces from the DPC main digital board to encoders and transducers outside the system. These mod-ulesincludethefollowing:• Distance Module

• Energy/PowerModule

• Pressure Transducer

• Force Transducer (Load Cell)Eachof thesemoduleshasacorresponding“view”optionintheDPCmenustructure.Theviewoptionallowsyoutoseethecurrentvalue of a control/monitor parameter to determine if the module is operating correctly.

Distance ModuleToviewthecurrentencoderposition,selecttheENCODERPOSITION menu item from the ENCODERUTILITIESsection of the Utilities Page. Viewthepositionontherightof theFrontPaneldisplayorontheStatus Line of the Advanced Programmer. As the thruster head movesupordown,thedisplayedvaluechanges.Thevalueshouldincreaseastheheadtravelsdownanddecreaseastheheadtravelsup.Uponpower-up,thedistancevalueinternaltotheDPCissetto-2.4inches. This guarantees that the DPC does not “see” a useful number until the reference mark on the distance encoder is crossed.

To check all encoder functions, either remove air pressure from the pressordepresstheEmergencyStopswitchthatisgroupedwiththeactivationswitches.Afterthepressheadisinthedownposition,switchoff powertotheDPC.SwitchthepowertotheDPConagain,andfromtheUtilitiesPage menu, select ENCODERPOSITION.The positionshould get increasingly negative until the reference mark is crossed at the top of the stroke. When the reference mark is crossed, the encoder value goes to zero and then becomes negative as the head continues up.(The reference mark is enabled upon start-up.)


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Energy ModuleCheck the POWERitem under POWERUTILITIES on the Utilities Page. This willshowthecurrentpowerbeingappliedtothetransducer.Thismea-surement can be seen on the right side of the Front Panel display, or on the Status Line of the Advanced Programmer. To test the energy module, press the TEST key on the generator status panel. (See Page 28.)

In the TESTposition, the generator applies ultrasound to the transducer. Thedisplayedpowerlevelshouldincreasetotheidlepowerof thegenera-tor/stack combination. When the TESTswitchisreleased,theultrasoundsignalstops.Thepowerlevelshoulddroptozero. If thesystemwillberun after testing the energy module, press theONLINE key. ON�

LINE

TEST


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Checking the Operation of InputsInputs can be tested by activating an input and observing the Operate Pagedisplay.Theprocedurefortestingtheinputsdependsonwheth-er the input is a control signal or a remote setup input. To see example circuitsandelectricalspecificationsfortheDPCIIIinputs,refertoAppendix A-I/O.

Control InputsForthepurposesof thisdiscussion,controlinputsare:• Auto-In,

• Cycle Stop,

•TriggerSwitch,

• End of Weld/Ground Detect,

•ActivationSwitches1and2,and

• Abort.

Each of these inputs is capable of producing an Input Active at Cycle Start error. The error mechanism can be exploited to determine if an input is being recognized by the system. A procedure for each inputisoutlinedbelowwiththeappropriatecautions.

Auto-InForcinganAuto-InsignaltotheDPCwilltestforAuto-In.Topre-ventthesystemfromgoingintocycle,applythesignalwiththeFrontPanelkeyswitchintheSETUPposition.Then,turnthekeyswitchtothe OPERATEposition. After three seconds, the error message E06:AUTOACTIVEATCYCLESTART should be displayed.

NOTE

This error message appears only if the Initiate Mode menu selection is set to AUTO.


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Cycle StopTheCycleStopinputcanbetestedbyactivatingtheinputandwait-ingatleastthreeseconds.If theinputisworkingproperly,theerrormessage E09:CYCLESTOPATCYCLESTART should appear.

Trigger SwitchTotesttheTriggerswitchinput,placetheFrontPanelkeyswitchinthe OPERATEposition,andturntheTriggerswitchdialonthethrusterclockwiseuntilthetriggerLEDlightsonthefrontpanelof thepress.Within three seconds, the error message, E08:TRIGGERATCYCLESTART should appear.

End of Weld/Ground DetectThese inputs share the same internal circuitry. The source of the End ofWeldsignalistheEndofWeldlimitswitchlocatedinthepresshead.TheswitchisconnectedtotheDPCthroughtheJ901Opera-tional Control-to-Thruster cable. The Ground Detect input enters the DPC through the J801 Auxiliary connector. Ground Detect is generallyusedtoendtheweldincuttingapplications.TotesttheEndof Weldinput,raisetheEndof WeldlimitswitchonthepressuntilitisatthesameheightastheStrokePositionflag.TurntheFrontPanelkeyswitchtotheOPERATEpositionandwaitatleastthreeseconds.The error message, E07:EOWATCYCLESTARTshould appear. To test theGroundDetectinput,activateitwiththekeyswitchintheOPER-ATEposition,andwaitfortheerrormessage.

Activation Switches - SS1 and SS2With Initiate Mode set to MANUAL,andtheFrontPanelkeyswitchin the OPERATEposition,presseitherof theactivationswitchesforat least three seconds. Errors E04 or E05:SSxACTIVEATCYCLESTART should appear.


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Theweldingcyclecanbedividedintoaseriesof segments:CycleStart,Downstroke,Trigger,WeldPressure1,WeldPressure2,andHold. In each of these segments, operator action, rear panel inputs, andprocesslimitscanaffecttheflowof theprocess.Whatfollowsareexamplesof howsomeeventscanaltertheflowof theweldingprocess,andhowthoseeventscanbeidentifiedbylookingattheprocess part data and at the DPC Front Panel and at the Advanced Programmer displays.

An Uninterrupted CycleFigure13-12showstheresultsof aweldprocessthatwasnotinter-rupted by any I/O signal or system error. The setup conditions for thisprocesswereasfollows:• Normal Trigger

• Weld by Time for 50 milliseconds

• Hold by Time for 1.0 second

PART DOWNSTROKE DOWNSTROKE WELD TIME WELD DIST WELD ENERGy HOLD TOTAL TOTALCOUNT TIME DIST PRESSURE 1 PRESSURE 1 PRESSURE 1 TIME CyCLE TIME STROKE

35 0.975 1.7921 0.050 0.0023 28.4 1.000 2.025 1.8090

36 0.879 1.7927 0.050 0.0020 28.4 1.000 1.929 1.8092

37 0.877 1.7928 0.050 0.0022 28.4 1.000 1.927 1.8092

Figure13-12 Data from an Uninterrupted Cycle

Effects of I/O and System Errors on Process Flow


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The Cycle Terminates During DownstrokeThesystemisinDownstrokewhenthecyclehasbeensuccessfullystartedandtheheadtravelstowardsthepart.If thecycleistermi-natedduringDownstroke,alltrigger,weld,andholdcharacteristicsare displayed as zeroes.Figure13-13showsresultsof acycleterminatedduringDownstrokedue to either an End of Weld/Ground Detect error or an Activation SwitchesReleasedBeforeTriggererror.


39 0.655 1.1959 0 0 0 0 0.655 1.1959

40 0.748 1.4229 0 0 0 0 0.748 1.4229

41 0.819 1.7946 0 0 0 0 0.819 1.7946

Figure13-13 Cycle Terminated by I/O During Downstroke

ProcesslimitscanbesetforallprocesssegmentsincludingDownstroke.Figure13-14showstheeffectof ahighlimitonDownstrokeTime.Inthisexample,theDownstrokeTimewaslimitedto0.500seconds.WhentheDownstrokeTimereached0.500seconds,thecycletermi-nated and marked the part as Bad.


12 >>0.500 0.3462 0 0 0 0 0.500 0.3462

Figure13-14 Cycle Terminated by High Bad Limit During Downstroke

Whenusingpre-trigger,partcontactmustoccurwithin0.75inchaftertheapplicationof ultrasound.If theweldisnotcompleteorthetriggerswitchdoesnotclosewithin0.75inchfromthestartof pre-trigger, the cycle is aborted. Figure13-15showscyclesterminatedforthisreason.Thepre-triggerdistancewassetat1.000inch.NotethattheDownstrokeDistanceis1.7527inchforpartnumber56.Thisisequaltothe1.000inchpre-triggerdistanceplusthe0.75inchover-travel. The system can overshoot slightly due to thruster momentum.

Figure13-15 Cycle Terminated Due to Pre-trigger Overtravel


56 0.887 1.7527 0 0 0 0 0.887 1.7527

57 0.831 1.7522 0 0 0 0 0.831 1.7522

58 0.827 1.7516 0 0 0 0 0.827 1.7516


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Premature Weld TerminationWeld Termination Due to End of Weld/Ground DetectAnEnd-of-WeldsignalfromthethrusterlimitswitchesandaGround Detect signal from the J801 auxiliary connector cause the weldportionof thecycletoterminate.Acharacteristicof thistypeof weldterminationisHoldTime.If theHoldportionof thecycleisexecuted,thentheweldwasterminatedbyanEnd-of-Weld/GroundDetect error. Figure13-16 illustrates this condition.


55 0.882 1.7928 0.015 0.0006 6.5 1.000 1.897 1.8094

Figure13-16 Weld Termination Due to End of Weld/Ground Detect

Weld Termination Due to Trigger LostIf the trigger type is set to Maintained, loss of the trigger signal causes animmediateterminationof thecyclewhentheultrasoundisapplied.ThisresultsinashortenedweldandzeroesforbothHoldTimeandHold Distance. Figure13-17showsacycleterminatedbyalosttriggerinput.

Figure13-17 Weld Termination Due to Trigger Lost


55 0.882 1.7928 0.015 0.0006 6.5 0 1.897 1.8094


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13 0.994 1.7916 0.038 0.0026 >>20.9 0 1.032 1.7942

Figure13-19 Weld Segment Terminated by a Bad Part Limit

Weld Termination Due to Secondary ControlSecondarycontrolsareadditionalcontrolsthatallowtheweldtobecontrolled by more than one process parameter. In this example, theWeldportionof thecycleendswheneithertheprimarycontrolparameter (in this case, Weld by Time for 50ms) or the secondary control parameter (Weld Energy) is reached. In either case, the cycle proceeds to the Hold portion of the cycle provided that no process characteristics fall outside of the Bad limits. Figure13-18showstheresults using Weld Energy as a secondary control.


3 0.999 1.7915 0.037 0.0024 20.3 1.000 2.036 1.8089

4 0.944 1.7919 0.038 0.0024 20.9 1.000 1.982 1.8089

5 0.906 1.7922 0.038 0.0021 20.9 1.000 1.944 1.8090

Figure13-18Weld Segment Terminated by a Secondary Control

Weld Termination Due to a Bad LimitAswithallBadlimits,fallingoutsideof alimitresultsinanimme-diate termination of the process. Figure13-19illustrates the results whenaBadpartlimitwasexceededforWeldEnergy.Thetwo“greaterthan”arrows(>>)precedingtheWeldEnergymeasurementindicatesthatabadpartupperlimitwasexceeded.Thesearrows,knownaslimit indicators,arealwaysdisplayedonboththeFrontPaneland Advanced Programmer displays

NOTEFor the limit indicators to be printed by the output device, they must be enabled in the Configure Serial Port menu item


��

MiscellaneousThe DPC Won’t CycleJustbeforeaweldcyclestarts,theDPCwaitsforaninitiatingsignal.If an initiating signal is applied and the system does not begin to cycle,checkthefollowing:

• Make sure the DPC’s Initiate Mode in the Process Control menu issettotheappropriatesetting:

MANUALif usingactivationswitches;AUTO if the system is con-figuredforusewithanautomatedsystem.

NOTE

The Initiate Mode selection must be set for eachsetup used. This is extremely important in the case of Sequenc-ing and setup selection.

• Remove all inhibiting inputs and check that no Cycle Start er-ror messages are displayed (Errors 04 - 09).

• Ensure that cabling is connected properly and that user inter-face circuitry is operating.

• MakesuretheFrontPanelkeyswitchisintheOPERATEposition. TheDPCwillnotcyclewhenthekeyswitchisintheSETUPposi-tion.


��

No Ultrasound• Push TEST on the generator status panel to verify that the

generator is producing an ultrasonic signal.

• Next, push ONLINE on the generator status panel. This

transfers generator regulation to the controller.

• Reviewtheprogram.ThereshouldbeaWeldTimeP1(andWeldTime P2 if dual presssure is used). Set the characteristic to “Dis-play”. (See Section 7 - Setup Mode, Process Limits Page.)

In the OPERATEmode:FrontPanel-Pressleftorrightarrowkeysto check for the Weld Time process characteristic. Advanced Programmer-ViewtheOperatePagedisplayforWeldTime.

Startthecycle,andviewthereportedWeldTimeshownonthedisplay(s). This tells that the controller has directed the generator to produce the ultrasonic signal for the programmed time.

• PowercanbecheckedinasimilarmannerwhileintheOPERATEmode:

When POWERcan be seen on the Front Panel display or on the Advanced Progammer Operate Page display, start a cycle, and recordthePowerreadingfromthedisplay.Thisreadingtellsthatthe ultrasonic signal has been produced by the generator.

• Look over the process setup carefully to make certain there are noconflicts.

• Youmaywanttoremoveallprocesscharacteristicwindows,andsimply set all to “display”. This can be done to make it easier to determinethesourceof aproblem.Windowscanthenberesetafterthesourceof theconflicthasbeenidentified.

ON�LINE

TEST


��


SECTION 14

Dukane Corporation Contacts and Warranty• This section gives Dukane Corporation contact andwarrantyinformation.

Dukane Corporation



Section 14 Dukane Corporation Contacts and Warranty

��

Contacting DukaneIdentify EquipmentWhen contacting Dukane about a service–related prob-lem, be prepared to give the following information:

• Model number, line voltage and serial number

• Fault/error indicators from the display

• Firmware version

• 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 equip-ment.

Intelligent Assembly SolutionsMailing Address: Dukane Ultrasonics 2900 Dukane Drive St. Charles, IL 60174 USA

Phone: (630) 797–4900

E-Mail: [email protected]

Fax: Main (630) 797–4949 Service & Parts (630) 584–0796

Website

The website has information about our products, pro-cesses, solutions, and technical data. Downloads are available for many kinds of literature. This is our main web address:

www.dukane.com/us/

You can locate your local representative at:

www.dukane.com/us/sales/intsales.htm


��


Section 14 Dukane Corporation Contacts and Warranty

��

Subject to the terms, limitations and exclusions set forth below, Dukane Corporation IAS Division (Dukane) warrants to the original Purchaser, 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.

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. Equipment 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 & Living (T&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 af-filiates, 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 limited warranty may apply to certain components of the equipment, and/or for certain types of applica-tions of the equipment, including those noted below.

❑ 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.❑ This warranty does not cover failures of equipment and components attributable to improper cooling or overheating of the trans-

ducer.❑ 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, description, 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.

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.

Hot Plate Welder 24 months none

Laser Welder For all laser sources, Original equipment All internal laser optics and external beam delivery manufacturer (OEM) warranty is applicable. optics are warranted for only 30 days.

Spin Welder 24 months none

Thermal Press 24 months none

Ultrasonic Welder 36 months See WARRANTY EXCLUSIONS OR EXCEPTIONS below.

Vibration Welder 24 months none

All Production 12 months, one-time replacement. (6-month, none Tooling one-time replacement for carbide tipped horns)

Prototype Tooling • 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 • All other prototype tooling is warranted as of Dukane.

described in each specific proposal.

DUKANE CORPORATION NORTH AMERICAN WARRANTY POLICY


��0

Subject to the terms, limitations and exclusions set forth below, Dukane Corporation IAS Division (Dukane) warrants to the original Purchaser, 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.

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. Equipment 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 & Living (T&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 extent 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.

❑ 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.❑ 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, lubri-

cants, 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, description, 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.

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.

Hot Plate Welder 12 months none

Laser Welder For all laser sources, Original equipment All internal laser optics and external beam delivery manufacturer (OEM) warranty is applicable. optics are warranted for only 30 days.

Spin Welder 12 months none

Thermal Press 12 months none

Ultrasonic Welder 12 months See WARRANTY EXCLUSIONS OR EXCEPTIONS below.

Vibration Welder 12 months none

All Production 12 months, one-time replacement. (6-month, none Tooling one-time replacement for carbide tipped horns)

Prototype Tooling • 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 • All other prototype tooling is warranted as of Dukane.

described in each specific proposal.

DUKANE CORPORATION INTERNATIONAL WARRANTY POLICY

SECTION 15

Appendices• Appendix A - Input/Output Interface Board

• Appendix B - Connector Pinout Descriptions

• Appendix C - External Serial Device Support

• Appendix D - Reference Guide to DPC III Menu Structure

Dukane Corporation



Appendix A The Input/Output Board

A-I

TableA-1 Signals: J�0�

Appendix AThe Input/Output Board

OverviewThisAppendixdealswiththeDPCIIIInput/OutputBoard, P/N 110-3812. It includes I/O signal descriptions,andwiringdiagramsthatillustrateexamplecircuits.Refertothismaterialwhenmakingconnections to external equipment such as automated systems, programmable logic controllers (PLCs) and other control circuitry.

Red

Color Isolated? Can beIsolated?Pin Signal Name Signal DescriptionInput/

Output

Blk

Blu/Blk

Red/Blk

Wht/Blk

Wht

Orn

Grn

Blu

Orn/Blk

Grn/Blk

Grn/Wht

Red/Wht

Blk/Wht

Blu/Wht

No No

No No

No No

No No

No Yes

No Yes

No Yes

No Yes

YesYes

YesYes

No Yes

No Yes

No Yes

No Yes

No Yes

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

Power

Gnd

Output

Output

Output

Output

Output

Input

Input

Input

Input

Input

Input

Input

Input

Internal DC Power Supply

Internal Ground Ground

Activate to start cycle

Solid state relay output, 100 mA max.




Normally open dry contact to ground




Normally open; connect to ground toterminate weld portion of cycle.

Input common if inputs are set up asisolated; otherwise not used. **

Output common if outputs are set up asisolated; otherwise not used. **

Ground Detect Input

Bad Part

Suspect Part

Good Part

Ready

Cycle Stop

Hand Probe Inhibit

Not Used

Not Used

Not Used

Output Common

Input Common

Automation Input

Internal +22 Volt Power SupplyMaximum 0.25 AmpsCan power external relay

** The signal is active only when a jumper is used on the I/O board to fully isolate the circuit.

For outputs, SH801 is in the fully isolated state when the jumper is in the JU803 posi-tion.


A-II

J801 Signals

J801-1 User +22 VDC SupplyThisisa+22VDC.25Acurrentlimitedsupply.

J801-2 Ground

J801-3 Bad Part Output:Theoutputisactivatedwhentheprogrammedprocesslimit(UPPERLIMIT)iseitherequaltoorgreater than the value entered in the Bad Part Limit section of the Process Limits menu. The output is alsoactivatedwhentheprogrammedprocesslimit(LOWERLIMIT)islessthanthevalueentered.

Factory Setting:Theoutputisconfiguredtosinkcurrenttochassisgroundwhenactivated.

Optional Settings:Thesystemcanbereconfiguredfor:CurrentSourcingorforFullyIsolatedOutputsby changing a jumper (SH801) on the 110-3812 I/O PCB.

NOTE

Refer to Figure A-1, Page A-VIII, for the jumper options on Current Sourcing and on Fully Isolated Output.

J801-4 Suspect Part Output:Theoutputisactivatedwhentheprogrammedprocesslimit(UPPERLIMIT)iseitherequaltoorgreater than the value entered in the Suspect Part Limit section of the Process Limits menu. The output isalsoactivatedwhentheprogrammedprocesslimit(LOWERLIMIT) is less than the value entered.

Factory Setting:Theoutputisconfiguredatthefactorytosinkcurrenttochassisgroundwhenacti-vated.

User Settings:TheusercanreconfigurethesystemforCurrentSourcingorforFullyIsolatedOutputsby changing a jumper (SH801) on the 110-3812 I/O PCB.


A-III

J801 Signals, continued

NOTE


J801-5 Good Part Output:Outputisactivatedwhennoupperorlowerlimitsareexceeded.ThisoutputcanberedefinedundertheI/Osectionof theCommunicationsPage.ThefourpossibledefinitionsareGoodPart,InDwell,In Cycle, and Sonics On.

Factory Setting:Outputisconfiguredtosinkcurrenttochassisground.


J801-6 Ready Output:Outputisactivatedwhenthesystemisreadytostartanewcycle.ThisoutputcanberedefinedundertheI/Osectionof theCommunicationsPage.ThefourpossibledefinitionsareReady,GoodPart,InCycle, and Sonics On.

Factory Setting:Outputisconfiguredtosinkcurrenttochassisground.

User Setting:TheusercanreconfigurethesystemforCurrentSourcingorforFullyIsolatedOutputsby changing a jumper (SH801) on the 110-3812 I/O PCB.

Do not use Ready output as the Top-of-Stroke NOTE


A-IV

J801-7 Isolated Output Common:IsolatedOutputCommonisnormallyopenunlessthesystemisreconfiguredbytheuserforFullyIsolated Outputs.

Factory Setting:Outputsareconfiguredtosinkcurrenttochassisground.


J801-8 Automation Input:Thisinputisusedinautomatedsystemstostartanewcycle.A50millisecondorlongeractivationpulseonthispinwillstartanewcycleandactivatetheactuator.Properguardingmustbeprovidedtopreventaccesstotheactuatorwhenthesystemisactivated.Thisinput is enabled under the Initiate menu in the Process Control portion of the setup menus. To enable this input, select AUTO under the Initiate menu.

Factory Setting:Inputisconfiguredatthefactorytosinktochassisground.

User Settings:TheusercanreconfigurethesystemforCurrentSourcingorforFullyIsolatedInputsby changing a jumper (SH802) on the 110-3812 I/O PCB.

NOTE




A-V

J801-10 Cycle Stop:Whenincycle,theCycleStopinputcausesanimmediateterminationof theweldcycle,andtheheadretractsunderpower.NoweldcharacteristicsarereportedtotheAdvancedProgrammerortheoutputdevice.If CycleStopissetwhenthesystemisnotincycle,allpartstatusoutputs(Bad,Suspect,andGood), are reset.

Factory Setting:Inputisconfiguredtosinktochassisground.

User Settings:TheusercanreconfigurethesystemforCurrentSourcingorforFullyIsolatedInputbychanging a jumper (SH802) on the 110-3812 I/O PCB.


J801-11 Hand Probe Inhibit:WhenusingahandprobeinJ801thissignalwillremovepowerfromthepressheadif itisconnectedatthe same time as a hand probe.

J801-12 Isolated Input Common:IsolatedInputCommonisnormallyopenunlessthesystemisreconfiguredbytheuserforFullyIso-lated Inputs.

Factory Setting:Inputsareconfiguredatthefactorytosinktochassisground.

User Settings:TheusercanreconfigurethesystemforCurrentSourcingorforFullyIsolatedinputsbychanging a jumper (SH802) on the 110-3812 I/O PCB.

NOTE


J801-15 Ground Detect Input:To activate this input, momentarily connect it to ground. When activated, the signal terminates the Weld portionof thecycle.Itisgenerallyusedtodetectwhenthehorncontactsanelectricallyisolatedanvil(fixture).Thegrounddetectinputisconnectedtotheelectricallyisolatedanvil.Whenthehorn,whichisalwaysatgroundpotential,contactstheanvil,thegrounddetectinputisactivated.


A-VI

J801 �Connector

SH 801 OUTPUTS

JU801 JU802

JU803

JU804

JU806

JU805

SINK

SOURCE �� ISO.

SINK

Abort Only �Connector

SH 802 INPUTS

SOURCE �� ISO.

JumperFactorySetting

System I/O (110-3812) Jumper Block SettingsSystem Control InputsSH802

*JU804–SinkstoDPCground (Drycontactbetweeninput&ground)JU805–SourcetoDPCground (Drycontactbetweeninput&+22VDC)JU806 – Isolated from DPC ground (Input common can be either sinking or sourcingwith+24VDCmaximum.)

System Status OutputsSH801

* JU801 – Sinks DPC to ground (Open collector output to ground )JU802–SourcetoDPCground (Opencollectoroutputto+22VDC)JU803 – Isolated from DPC ground (Output common can be either sinking or sourcingwith+24VDC100Maperoutput.)* Jumper factory setting

SINK=SinktoChassisGround

SOURCE=CurrentSourcing

ISO.=FullyIsolatedInputorOutput

FigureA-1 I/O Jumper Block Location


A-VII

Status SignalsReadyTheReadysignalindicatesthesystemisreadytostartanewcyclewhenitisactive. The Ready signal is on J801-6.

NOTE

The Ready signal is not the same as Top-of-Stroke. See Page 58, Figure 6-5.

Home PositionTheactuatorhasahomeortop-of-strokeswitchtoindicatetheactuatorisintheupposition.Thisindi-cateswhenitissafetoindexotherelementsof anautomatedsystem.

Other Control SignalsGround DetectGroundDetectinputonJ801-15,whenactivated,terminatestheweldportionof thecycle.Generallyitisusedtodetectwhenthehorncontactsanelectricallyisolatedanvil.GroundDetectInputisconnectedtotheelectricallyisolatedanvil.Whenthehorn,whichisalwaysatgroundpotential,contactstheanvil,thegrounddetectinputisactivated.Theweldportionof thecycleisthenterminated.Thesystemwillnotstartanewcycleuntilthegrounddetectinputisdeactivated.

Alarm SignalsTherearethreealarmsignalsavailable:GoodPart,SuspectPart,andBadPart.

ThesesignalsareatJ801-5,J801-4,andJ801-3respectively.ThesuspectpartalarmisassociatedwiththesuspectpartslimitsintheProcessLimitsmenus.Thebadpartalarmisassociatedwiththebadpartslimits in the Process Limits menus. The good part signal indicates neither suspect nor bad part limits wereexceeded.

NOTEWith the DPC buzzer set to ON, audible tones can be heard when suspect or bad parts are detected. There will not be any audible tone to signal good parts.


A-VIII

Customer PLC+24VDCPLCOutput

Device DPCInputDevice

DPC

PLCOutput

OutputCommon

DPCInput

J801 2 8,9,10,13,14

200-1203Cable

+24

Customer 24V

Relay

FigureA-3 DPC III Input Configuration 2

snoitpircseDniP108J

niP noitpircseD

2 dnuorG

8 t upnInoitamotuA

9 0tiBetomeR

01 potSelcyC

31 1tiBetomeR

41 2tiBetomeR


Customer PLC

DryContactPLCOutput

DeviceDPCInput

Device

DPC

PLCOutput

OutputCommon DPC

Input

J801 2 8,9,10,13,14

200-1203Cable

snoitpircseDniP108J

niP noitpircseD

2 dnuorG

8 t upnInoitamotuA

9 0tiBetomeR

01 potSelcyC

31 1tiBetomeR

41 2tiBetomeR

NOTE

This connection is made with the DPC III I/O board’s factory setting: SH802 jumper installed on JU804.


A-IX

Customer PLC+24VDCPLCOutput

Device DPCInputDevice

DPC

PLCOutput

OutputCommon

DPCInput

J801 2 8,9,10,13,14

200-1203Cable

+24

Customer 24V

Relay


snoitpircseDniP108J

niP noitpircseD

2 dnuorG

8 t upnInoitamotuA

9 0tiBetomeR

01 potSelcyC

31 1tiBetomeR

41 2tiBetomeR


Customer PLC

DryContactPLCOutput

DeviceDPCInput

Device

DPC

PLCOutput

OutputCommon DPC

Input

J801 2 8,9,10,13,14

200-1203Cable

snoitpircseDniP108J

niP noitpircseD

2 dnuorG

8 t upnInoitamotuA

9 0tiBetomeR

01 potSelcyC

31 1tiBetomeR

41 2tiBetomeR

NOTE

This connection is made with the DPC III I/O board’s factory setting: SH802 jumper installed on JU804.


A-X

FigureA-5 DPC III Output Configuration 2

Customer PLC

DPCOutputDevice

DPC

PLCInput

InputCommon

DPCOutput

J801 7 3,4,5,6

+24V

Customer Power Supply

PLCInputDevice

200-1203Cable

+24VDC,100mAMAX.

J801 Pin Descriptions

Pin Description

3

4

5

6

7

Bad Part

SuspectPart

Good Part

Ready

Output Common

NOTE

This connection is made with an optional DPC III I/O board setting: SH801 jumper installed on JU803.

Customer PLC

PLCInputDevice

DPCOutputDevice

DPC

PLCInput

InputCommon

DPCOutput

J801 7 3,4,5,6

200-1203Cable

OutputCommon

+24VDC,100mAMAX.



Pin Description

3

4

5

6

7

Bad Part

SuspectPart

Good Part

Ready

Output Common


A-XI


Customer PLC

DPCOutputDevice

DPC

PLCInput

InputCommon

DPCOutput

J801 7 3,4,5,6

+24V

Customer Power Supply

PLCInputDevice

200-1203Cable

+24VDC,100mAMAX.


Pin Description

3

4

5

6

7

Bad Part

SuspectPart

Good Part

Ready

Output Common

NOTE

This connection is made with an optional DPC III I/O board setting: SH801 jumper installed on JU803.

Customer PLC

PLCInputDevice

DPCOutputDevice

DPC

PLCInput

InputCommon

DPCOutput

J801 7 3,4,5,6

200-1203Cable

OutputCommon

+24VDC,100mAMAX.



Pin Description

3

4

5

6

7

Bad Part

SuspectPart

Good Part

Ready

Output Common


A-XII


Customer PLC

DPCOutputDevice

DPC

PLCInput

InputCommon

DPCOutput

J801 7 3,4,5,6

+22V

PLCInputDevice

200-1203Cable

1 2

OutputCommon

JU802


Pin Description

1

2

3

4

5

6

7

Internal DC Power Ground

Internal Ground

Bad Part

SuspectPart

Good Part

Ready

Output Common


A-XIII

Customer EmergencyStop Switch

NormallyClosed

DPCInputDevice

DPC

J802Auto Stop

3 9

200-1124 Cable

NormallyOpen

7 4

PowertoDPCThruster

+22V

FigureA-7 DPC III Input for Emergency Stop

NOTEUse Automation Stop only for automated systems. The J902 connector is used for stand alone welding systems.

J802 Auto StopPin Descriptions

Pin Description

9

3

4

7

Hardware AbortPower Out

Hardware AbortPower In

Software Abort

Internal Ground


A-XIV

Thruster PLCInput

Device

Customer PLC

NOTE: This output device Figure indicates the switch position when the thruster isat the top-of-stroke position. The connector on the thruster is labeled "J40" or "TOP-OF-STROKE SWITCH".The customer can choose either set of pins in the connector:Use Pins 1 and 2 for a normally closed switch; Use Pins 3 and 4 for a normally open switch.

J40

3

4

1

2

Top-of-StrokeOutputDevice

InputCommon

PLCInput

+24VDCMaximum

Do not apply AC voltage.

CAUTION:

438-528Cable

FigureA-8 PLC Input for Thruster Top-of-Stroke Switch

Appendix B Connector Pinout Descriptions

B-I

The tables in this Appendix give descriptions of the pins for DPC connectors J901 (Thruster Cable), and J902 (Press Base Cable).

NOTICE All unlisted pins are unused and should remain unconnected from all external equipment.

Connector Pinout Descriptions

J901 Thruster Cable Connections

Continued

Appendix B


B-II

TableB-2 J�0� Press Base Cable Connections

DPC Connector Pinout Descriptions, continued

NOTICE All unlisted pins are unused and should remain unconnected from all external equip-

J902 Press Base Cable Connections

Pin No. Input/Output Function Signal Types

1 Input Activation Switch 1 Normally open dry contact closure to ground

2 Input Activation Switch 2 Normally open dry contact closure to ground

3 Input Hardware Abort Power In Normally closed emergency switch contact

4 Input Software Abort Normally open dry contact closure to ground

5 Ground Internal Ground Internal Ground

7 Ground Internal Ground Internal Ground

8 Input Automation Input Normally open dry contact closure to ground

9 Ground Hardware Abort Power Out Normally closed emergency switch contact

NOTEThe DPC–2 uses pins 5, 6 & 7 for Ground The DPC–3 uses pins 5 & 7 for Ground The DPC–4 uses pins 6 & 7 for Ground

To keep any custom automation circuits compatible with all DPC models, only use pin 7 for a ground connection.

Appendix C External Serial Device Support

C-I

OverviewTheDPChasarearpanelserialport( J3)tousewithdatacollectorsandcomputersoftwaresuchas

statistical process control (SPC) and data analysis programs. This port matches RS-232 mechanical and

electricalspecifications.

ThisAppendixhasinformationabout:

•SignalDefinitions •CommunicationEquipmentTypes

• Printer Support • Output Formats

Signal DefinitionsTheserialinterfaceusesa5-pinconnection.Numbersforeachof thefivesignals(pins)refertotheDPCrearpanelserialconnectorandarestatedas“J3.x”wherexisthepinnumber.Thefivesignalsarelistedbelow.

NOTICE

Serial cables generally use 24 AWG (American Wire Gauge) wire and should be shielded for best results.

J3.7 – Signal GroundSignalGroundprovidesacommonreferenceforallof thesignalsexchangedbetweentheDPCandtheexternal serial device.

J3.2 – Receive (RXD)Serial data is received by the DPC from the Receive (RXD) line. This signal is generated by the Transmit (TXD) line of a connected serial device.

J3.3 – Transmit (TXD)The DPC sends out information on the Transmit (TXD) line to other serial devices. This line connects to the Receive input of the connected serial device.

Appendix CExternal Serial Device Support

Continued


C-II

DCE and DTE refer to Data Communication Equipment and Data Terminal Equipment, respectively.

Data Communication EquipmentTheDPC’sserialportisdefinedasaDCE.SeeTableC-1forDCEdevicesignalsandpinnumbers:

Data Terminal EquipmentOtherdevices,suchastheAdvancedProgrammerandprinters,aredefinedasDTEs.SeeTableC-1 for DTE device signals and pin numbers.

TableC-1 DCE/DTE Signals with Pin Numbers

J3.4 – Clear to Send (CTS)TheCleartoSendsignalisrequiredonlywhentheDPCisusingRTS/CTSprotocol.Thislineinformsthe DPC that the connected device has information to transmit (to the DPC). The DPC sets the Re-questtoSend(RTS)lineinresponsetotheCTSlinewhenitisreadytoacceptinformationfromtheconnected device. If the DPC cannot receive information, the RTS line is reset. CTS input is connected to the RTS output of the connected device.

J3.5 – Request to Send (RTS)AswithCleartoSend,RequesttoSend(RTS)isonlyrequiredwhenusingtheRTS/CTSprotocol.TheDPCsetstheRTSlinewhenitisreadytosendinformationtoanotherserialdevice.TheCTSlineischecked to see if the connected device can receive information. RTS output is connected to the CTS input of the connected device.

Communication Equipment Types

EquipmentType

SignalwithPinNumber

Receive Transmit CleartoSend

RequesttoSend Ground

DCE 2 3 4 5 7

DTE 3 2 5 4 7

Signal Definitions, continued


C-III

FigureC-1DCE to DTE Serial Connections

DCE DTE23457

23

54

7

Rxd

CtsTxd

RtsGnd

Txd

Rts

Gnd

Rxd

Cts

When a DCE is connected to a DTE by a straight-through cable (i.e., Pin 2 to Pin 2, Pin 3 to Pin 3, etc.), communicationcantakeplace.Inotherwords,aReceivelinemustbeconnectedtoaTransmitlineanda Clear to Send line must be connected to a Request to Send line.

If thetwoconnecteddevicesarebothDCEsorDTEs,nocommunicationcanoccurbecauseReceiveisconnected to Receive, Transmit is connected to Transmit, etc.

FigureC-1showscorrectconnectionsbetweenDCEandDTEdevices.


C-IV

Printer SupportSerial vs. ParallelAprintermusthaveaserialinterfacetoconnectwiththeDPCIII.Todeterminewhetheryourprinter’sinterface is serial or parallel, consult the printer’s user manual or compare the printer’s interface connec-tor to FigureC-2.

FigureC-2showsthedifferencebetweenserialandparallelconnectors.If yourprinterhastheparallelinterfaceconnector,aserialinterfacecardwithaserialinterfaceconnectorcanbepurchasedfromtheprinter manufacturer or from a local computer supply store. As an alternative to a serial interface card, a parallel-to-serial converter may be used.

Determining Printer Software CompatibilityPrintersusecontrolcharactersandescapesequencestocontrolthewaytheoutputisprinted.Thesecontrolcodesvaryfrommanufacturertomanufacturerandoftenvarywithinamanufacturer’sproductline.TheDPCsupportscommonprintertypes(andthegenericASCII)toensurecompatibilitywithmost printers currently on the market. Your printer can probably emulate or imitate, one of the printers listed in the Serial Port Output Device menu. Consult your printer’s user manual to determine the avail-ableemulationmodes.If yourprintermanualisnotclearonwhichprinteremulationsaresupported,compare the printer codes listed in TableC-2 to the codes listed in the Command Reference section of your printer manual to determine compatibility.

FigureC-2 Parallel and Serial Interface Connectors

A:CentronicsParallelConnector B:DB-25SerialConnector

Should you have questions about printer compatibility, please refer to the printer manufacturer. When this manual was printed, these were the contacts for IBM and Epson respectively:

IBMPCHelpCenter:1-800-772-2227(USAonly)IBMwebsite: http://www.ibm.comEpsonwebsite:http://www.epson.com

NOTE

Dukane recommends these Epson printers for use with the DPC:LQ570+ (8.5” x 11”) and LQ2080 (11” x 17”)


C-V

EpsonFX-85 IBMProPrinterXL IBMProPrinterX24 OkiData182/183

Pica 12HESCP 12H 12H 1EHElite 12HESCM ESC!1H 12HESC: 1CHCompressedPica ESCP0FH ESC!4H 12H0FH 1DHCompressedElite ESCM0FH ESC!5H ESC:0FH N/ABlockGraphics ESCt1 N/A N/A ESC!31HReset 18H 18H 18H 18HLineSpacing ESC33Hn ESC33Hn ESC33Hn ESC%39HGraphics ESCKnn ESCKnn ESCKnn 03HExitGraphics N/A N/A N/A 03H02H

TableC-2 Printer Control Codes

Output FormatsPrinter Output FormatWhen part record information is sent to a printer, each characteristic is embedded into a 12-character fieldanddelimitedbyspaces.Thelocationof thecharacteristicisdeterminedbythenumberof charac-tersallowedforthecharacteristic’sdatatype(e.g.,time,distance,power,etc.).

Threespacesarereservedatthebeginningof eachfieldtoserveasplaceholdersforthelimitindicators(e.g.,<<,>>)andanegativesign.Eachlineisprecededbyprintercontrolcodestosetthepitchof thetype.An80-columnprinterisassumed.Eachlineof outputisfollowedbyacarriagereturn(<CR>)andanoptionallinefeed(<LF>).Thenumberof charactersprintedisequalto12timesthenumberof fields(characteristicsplusthepartcount).TableC-3belowshowswhichcharacterpitchisusedperlinelength. Refer to this table to determine your printer control codes as they relate to the printer pitch type.

PrinterPitch CharactersPrintedPerLine Pica 1–80 Elite 81–96 CompressedPica 97–138 CompressedElite 139–160

TableC-3 Printer Pitch per Characters Printed


C-VI

ASCII Output FormatThe ASCII output format is essentially the same as the printer output format. The only difference is thatwiththeASCIIformatnocontrolcodesorescapesequencesaretransmitted.Thisallowstheinputof dataintoprogramsordevicesthatwouldnotunderstandtheprinter-specificcontrolcodes.Exam-plesof thistypeof deviceare:• Unsupported printers• Communicationsprograms(CrossTalk,QModem,etc.)• PLCswithserialportsAswiththeprinteroutputformat,eachcharacteristicisembeddedina12-characterfieldanddelimitedbyspaces.Thelocationof thecharacteristicisdeterminedbythenumberof charactersallowedforthecharacteristic’sdatatype.Threespacesarereservedatthebeginningof eachfieldtoserveasplacehold-ersforthelimitindicators(e.g.,<<,>>)andanegativesign.Eachlineisprecededbyprintercontrolcodestosetthepitchof thetype.Eachlineof outputisfollowedbyacarriagereturn(<CR>)andanoptionallinefeed(<LF>).FigureC-3showsanexampleof theoutputformatforeachdatatype.

FigureC-3 ASCII Output Format

0

00 1 1.

00 1.

CR LF

93

74 1

0 0

001 .2

1 1. 2

Part Count = 417

Downstroke Time = 0.101sec.

Weld Distance = 0.0100in.

Weld Energy = 210.0j.

Weld Peak Power = 392w.

Total Cycle Time = .211sec.

Carriage Return and optional Linefeed

2


C-VII

1-2-3 FormatThe1-2-3formatisacommadelimitedformatthatallowsforcollectingthepartdataintoacomputerfileandthenimportingthatfileintoacompatiblespreadsheetprogram,suchasLotus1-2-3orMi-crosoft Excel, for analysis or the creation of presentation quality graphics. Each characteristic is right justifiedinan11-characterfieldfollowedbyacarriagereturn(<CR>)andanoptionallinefeed(<LF>).FigureC-4showsanexampleof theoutputformat.

FigureC-4 1-2-3 Output Format

4

00 1 1.

00 1.

CR LF

93

71

0 0

001 .2

0 1 1. 2

Part Count = 417







2

,

,

,

,

,

,


C-VIII

CSV or LKI Format (Also known as LKS for Lyle-Kearsly Systems) LKI(alsoknownasLKSfor Lyle-Kearsly Systems) is a CSV (Comma Separated Value) format used by somestatisticalprocesscontrol(SPC)programs.Withthisformat,eachcharacteristicvalueisoutputwithanadditionaltagvalue.Thetagvalueisatwo-digitnumberuniquetothecharacteristic.Thisallowsaprogramtoidentifyeachindividualcharacteristicandstoreitinanappropriatefileregardlessoftheorderinwhichthecharacteristicisreceived.Eachlineofoutputisfollowedbyacarriagereturn(<CR>)andanoptionallinefeed(<LF>).FigureC-5showsanexampleof thisoutputformatandTableC-4 provides the tag description for each tag value.

FigureC-5 CSV Output Format

74 1

Part Count = 417

,0 0 0 0

00 1 1.

00 1.

CR LF

93

0 0

001 .2

0 1 1. 2

Downstroke Time = 0.101 second

Weld Distance = 0.0100 inch

Weld Energy = 210.0 joules

Weld Peak Power = 392 watt

Total Cycle T ime = 0.211 second


2

,

,

,

,

,0

0

0

0 0

0

0

0 0 2

0

1 0

1

9

1

0 0 2 5

Tag Tag NumberDescription Decimal HexPart Count 0 00HLine Pressure 1 01HDownstrokeTime 2 02HDownstrokeDistance 3 03HContact Pressure 4 04HTrigger Delay Time 5 05HTrigger Delay Distance 6 06HReserved 7 07HWeld Time Pressure 1 8 08HWeld Distance Pressure 1 9 09HWeld Energy Pressure 1 10 0AHPeakPowerPressure1 11 0BHReserved 12 0CHWeld Time Pressure 2 13 0DHWeld Distance Pressure 2 14 0EHWeld Energy Pressure 2 15 0FHPeakPowerPressure2 16 10HReserved 17 11HAbsolute Weld Distance 18 12HTotal Weld Time 19 13HTotal Weld Distance 20 14HTotal Weld Energy 21 15HHold Time 22 16HHoldDistance 23 17HReserved 24 18HTotal Cycle Time 25 19HTotal Stroke 26 1AHTimeStampReal-TimeClock 27 1BH

TableC–4 CSV/LKI Tag Description and Tag


C-IX

Zontec FormatTheZontecformatisdesignedforusewiththeZontecSPCTimesaverAdvancedprogramandcon-formstotheZontecASCII2DeviceInterfaceSpecification.AsdataisreceivedbytheZontecpro-gram,itisroutedtocharacteristicfilesbasedonachannelnumber.Thechannelnumberisafour-char-acter number that contains the tag value of the characteristic. The channel number and the characteris-ticvaluefieldareseparatedbyacomma.Thecharacteristicvalueisembeddedinaneight-characterfieldandisterminatedbyacarriagereturn(<CR>)andalinefeed(<LF>).FigureC-6showsanexampleof this output format.

FigureC-6 Zontec Output Format

Part Count = 417






00 1 1.

00 1.

93

74 1

0 0

001 .2

0 1 1. 2

2

,

,

,

,

,

,

0 0 0 0

0

0

0

0 0

0

0

0 0 2

0

1 0

1

9

1

0 0 2 5

CR LF

CR LF

CR LF

CR LF

CR LF

CR LF


C-X

DataMyte FormatSomemodelsof theDataMytedatacollectorsdonotacceptcharacteristicswithoutdecimalpoints.WheninDataMytemode,theDPCaddsadecimalpointtothepowermeasurementsandsuppressesthecompressionof a“0.000”parametertoasinglezero(0).Allcharacteristicsareright-justifiedinatwelve-characterfield.

Computerized Data CollectionWith the serial interface, it is very easy to collect data from the DPC to a computer. Any one of the commerciallyavailablecommunicationssoftwarepackagescanbeused.

Cheap and Dirty Data CollectionIn addition to commercial packages, a BASIC language program can be cobbled together to accept DPCIIIoutputthatcanbeinsertedinacomputerfile.ThefollowingprogramswerecreatedusingtheQuickBasiclanguage.Linenumbershavebeenusedforcompatibilitywithearlierversionsof BASIC.The programs shown below and on the next page are provided as examples only and are not supported by Dukane.

Data Collection to a FileThis program accepts DPC III data from COM port 1 of an IBM compatable PC and places it into a diskfilecalledDUKANE.Tostoptheprogram,presstheF1functionkey.

10OPEN“COM1:9600,N,8,1,DS”FORINPUTAS#1

20OPEN“DUKANE”FORAPPENDAS#2

30 ON COM(1) GOSUB 90

40 COM(1) ON

50 ON KEY(1) GOSUB 120

60 KEY(1) ON

70GOTO120

90LINEINPUT#1,C$

100PRINT#2,C$

110RETURN70

120CLOSE#2

130CLOSE#1

140 KEY(1) OFF

150 COM(1) OFF

160 END


C-XI

Data Collection to a File with Output to the PC ScreenThis version adds line 105 to output the data to the PC Screen.




40 COM(1) ON


60 KEY(1) ON

70GOTO120

90LINEINPUT#1,C$

100PRINT#2,C$

105PRINTC$

110RETURN70

Data Collection to a File, the PC Screen, and the PrinterInthisexampleline108hasbeenaddedtooutputthedatatoLPT1:parallelprinterportofthePC.




40 COM(1) ON


60 KEY(1) ON

70GOTO120

90LINEINPUT#1,C$

100PRINT#2,C$

105PRINTC$

108LPRINT;C$

110RETURN70

120CLOSE#2

130CLOSE#1

140 KEY(1) OFF

150 COM(1) OFF

160 END

120CLOSE#2

130CLOSE#1

140 KEY(1) OFF

150 COM(1) OFF

160 END


C-XII

This page intentionally left blank.

2200

STATUS

FAULT

ON LINE

INPUT TEST

OVERTEMP

OVERLOAD

OFF LINE

ONLINE TEST OFF

LINE


SYSTEM POWER OUTPUT


OPERATECANCEL

SETUP

ENTER

S01 PROCESS CONTROL

DPC™ III

Ultrasonics

DPC III User's Manual Appendix D

Reference Guide to Menu Structure

Dynamic Process Controller DPC™ III

DPC III PROCESS CONTROL PAGE

InitateMode

Scrub

Manual

Auto

Maintained

Momentary





Disabled


TriggerMethod

Probe Delay

Normal Trigger

Probe Mode



DelayTrigger til Auto In

Pre-trigger by Dist

WeldMethod

Enter Time (sec)





Enter Time (sec)





Enter Time (sec)






Pressure 1

Pressure 2

Time

Peak Power

Abs Distance

Distance

Energy

Time

Peak Power

Abs Distance

Distance P1

Energy

Time

Peak Power

Abs Distance

Distance P2

Energy

Dual Pressure

Single Pressure

Continuous

AfterburstDisabled

Enabled

HoldMethod



SecondaryControls

S01 - PROCESS CONTROL

Trigger

Pre-trigger

Enable Hold

Disable Hold



Off

OnSelect Secondary Control

Enter Secondary Control Parameter

Start Weld At

Weld Distance P1Peak Power P1Weld Distance P2Peak Power P2Absolute DistanceTotal Weld TimeTotal Weld DistanceTotal Weld EnergyTotal Cycle TimeTotal Stroke

DPC III PROCESS LIMITS PAGE

S01 - PROCESS LIMITS

Bad Limits

Downstroke Time

Disabled

Window

Display

Downstroke Distance

Disabled

Window

Display

Trigger Delay Time Disabled

Window

Display

Disabled

Window

Display

Weld Time P1

Low Bad Limit

High Bad Limit Enter Max Time (sec)

Enter Min Time (sec)

Disabled

Window

Display

Weld Distance P1

Weld Energy P1 Enter Max Energy (joules)

Enter Min Energy (joules)

Enter Max Distance (in)

Enter Min Distance (in)

Enter Max Power (watts)

Enter Min Power (watts)

Absolute Distance Enter Max Distance (in)


Enter Max Time (sec)Enter Min Time (sec)



Total Cycle Time

Total Stroke

Enter Max Time (sec)




Trigger Delay Dist

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Weld Peak Power P1

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Total Weld Energy

Hold by Distance

Hold by Time

Total Weld Time

Total Weld Distance

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display


Enter Max Energy (joules)

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display





SuspectLimits Low Suspect Limit

High Suspect Limit Disabled Enabled

NOTESuspect Limits process characteristic selections are the same as those for Bad Limits.

NOTEIf the weld method is Dual Pressure, limits for Weld Time P2, Weld Distance P2,Weld Energy P2, and Weld Peak Power P2will be added.

Page1of6 Page2of6

DPC III PROCESS CONTROL PAGE

InitateMode

Scrub

Manual

Auto

Maintained

Momentary





Disabled


TriggerMethod

Probe Delay

Normal Trigger

Probe Mode



DelayTrigger til Auto In

Pre-trigger by Dist

WeldMethod

Enter Time (sec)





Enter Time (sec)





Enter Time (sec)






Pressure 1

Pressure 2

Time

Peak Power

Abs Distance

Distance

Energy

Time

Peak Power

Abs Distance

Distance P1

Energy

Time

Peak Power

Abs Distance

Distance P2

Energy

Dual Pressure

Single Pressure

Continuous

AfterburstDisabled

Enabled

HoldMethod



SecondaryControls

S01 - PROCESS CONTROL

Trigger

Pre-trigger

Enable Hold

Disable Hold



Off

OnSelect Secondary Control

Enter Secondary Control Parameter

Start Weld At

Weld Distance P1Peak Power P1Weld Distance P2Peak Power P2Absolute DistanceTotal Weld TimeTotal Weld DistanceTotal Weld EnergyTotal Cycle TimeTotal Stroke

DPC III PROCESS LIMITS PAGE

S01 - PROCESS LIMITS

Bad Limits

Downstroke Time

Disabled

Window

Display

Downstroke Distance

Disabled

Window

Display

Trigger Delay Time Disabled

Window

Display

Disabled

Window

Display

Weld Time P1

Low Bad Limit

High Bad Limit Enter Max Time (sec)


Disabled

Window

Display

Weld Distance P1

Weld Energy P1 Enter Max Energy (joules)




Enter Max Power (watts)

Enter Min Power (watts)

Absolute Distance Enter Max Distance (in)


Enter Max Time (sec)Enter Min Time (sec)



Total Cycle Time

Total Stroke





Trigger Delay Dist

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Weld Peak Power P1

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Total Weld Energy

Hold by Distance

Hold by Time

Total Weld Time

Total Weld Distance

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display


Enter Max Energy (joules)

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display

Low Bad Limit

High Bad Limit

Disabled

Window

Display





SuspectLimits Low Suspect Limit

High Suspect Limit Disabled Enabled

NOTESuspect Limits process characteristic selections are the same as those for Bad Limits.

NOTEIf the weld method is Dual Pressure, limits for Weld Time P2, Weld Distance P2,Weld Energy P2, and Weld Peak Power P2will be added.

Page1of6 Page2of6

DPC III COMMUNICATIONS PAGE

PartSampling

Up Valve on Abort

Sample Size

User I/O

Outputs

AdvancedProgrammer

S01 - COMMUNICATIONS

Start At

Stop At

Left Axis

Right Axis

Time Scale

Power Scale

Distance Scale

Exclude

Store

Lot Size

ConfigureSerial Port

Time Tag

LF After CR

Limit Indicators

Baud Rate

Protocol

Output Device

Output Mode

Epson FX-85IBM PRO XLASCII1-2-3Tagged CSVZontecDataMyte

AllNone

GoodBadSuspect

Sample

Bad and SuspectGood and BadGood and Suspect

960019200

24004800

XON/XOFFRTS/CTS

YesNo

DisabledEnabled

DisabledEnabled

End of Weld

Status Outputs

Define J801-6 As

Define J801-5 As

Buzzer Status

Active HiActive Lo

OffOnDisabled Enabled

MaintainedPulsed Good Part

In DwellIn CycleSonics On

ReadyGood PartIn Cycle

Sonics OnOffOn

StatusEnabledDisabled

Baud Rate9600

19200

24004800

Enter Lot Size

Enter Sample Size

NoneBadSuspect

Bad and Suspect


Sonics On

Graphing

PowerDistance

Weld

Cycle Start

End of WeldEnd of Hold

Trigger

Auto Range0.25 - 32 sec Select Time (8 Choices)

Auto Range250 - 3000 W Select Power (5 Choices)

Auto Range0.1in/.25mm - 7 in/175mm Select Distance (8 Choices)

PowerDistance

SetupUtilities

UserParameters

PowerUtilities

Copy This Setup From OK ?No

Yes

OK ?No

Yes

OK ?No

YesText

Erase Current Setup

Erase All Setups

Reset/PresetPart

Count

S01 - UTILITIES

Hex

Time andDate

Utilities

Encoder Utilities

Job I.D.

Horn

Booster

Fixture

Pressure 1

Pressure 2

Trigger Force

Power Average

Power

Enter Job Number

Enter Horn Type ( )

Enter Booster Type ( )

Enter Fixture Type ( )

Enter Pressure 1

Enter Pressure 2

Enter Trigger Force

1. Eight2. Four3. Two4. Disabled

Current Power

Enter Date

Enter Preset Part Count No. ( )

Enter Time

1. MM-DD-YY2. DD-MM-YY3. YY-MM-DD

1. English2. Metric

Displays Real Time Encoder Position

Reset Part Count

Preset Part Count

Encoder Units

Encoder Position

Print Setup

Set Date

Set Time

Check Date

Check Time

Date Format

Select a Setup No. ( )

Select a Setup No. (1-8)Select New Setup

Copy a Setup

Erase Setups

DPC III UTILITIES PAGEPage3of6 Page4of6

DPC III COMMUNICATIONS PAGE

PartSampling

Up Valve on Abort

Sample Size

User I/O

Outputs

AdvancedProgrammer

S01 - COMMUNICATIONS

Start At

Stop At

Left Axis

Right Axis

Time Scale

Power Scale

Distance Scale

Exclude

Store

Lot Size

ConfigureSerial Port

Time Tag

LF After CR

Limit Indicators

Baud Rate

Protocol

Output Device

Output Mode

Epson FX-85IBM PRO XLASCII1-2-3Tagged CSVZontecDataMyte

AllNone

GoodBadSuspect

Sample

Bad and SuspectGood and BadGood and Suspect

960019200

24004800

XON/XOFFRTS/CTS

YesNo

DisabledEnabled

DisabledEnabled

End of Weld

Status Outputs

Define J801-6 As

Define J801-5 As

Buzzer Status

Active HiActive Lo

OffOnDisabled Enabled

MaintainedPulsed Good Part

In DwellIn CycleSonics On


Sonics OnOffOn

StatusEnabledDisabled

Baud Rate9600

19200

24004800

Enter Lot Size

Enter Sample Size

NoneBadSuspect

Bad and Suspect


Sonics On

Graphing

PowerDistance

Weld

Cycle Start

End of WeldEnd of Hold

Trigger

Auto Range0.25 - 32 sec Select Time (8 Choices)

Auto Range250 - 3000 W Select Power (5 Choices)

Auto Range0.1in/.25mm - 7 in/175mm Select Distance (8 Choices)

PowerDistance

SetupUtilities

UserParameters

PowerUtilities

Copy This Setup From OK ?No

Yes

OK ?No

Yes

OK ?No

YesText

Erase Current Setup

Erase All Setups

Reset/PresetPart

Count

S01 - UTILITIES

Hex

Time andDate

Utilities

Encoder Utilities

Job I.D.

Horn

Booster

Fixture

Pressure 1

Pressure 2

Trigger Force

Power Average

Power

Enter Job Number

Enter Horn Type ( )

Enter Booster Type ( )

Enter Fixture Type ( )

Enter Pressure 1

Enter Pressure 2

Enter Trigger Force

1. Eight2. Four3. Two4. Disabled

Current Power

Enter Date

Enter Preset Part Count No. ( )

Enter Time

1. MM-DD-YY2. DD-MM-YY3. YY-MM-DD

1. English2. Metric

Displays Real Time Encoder Position

Reset Part Count

Preset Part Count

Encoder Units

Encoder Position

Print Setup

Set Date

Set Time

Check Date

Check Time

Date Format

Select a Setup No. ( )

Select a Setup No. (1-8)Select New Setup

Copy a Setup

Erase Setups

DPC III UTILITIES PAGEPage3of6 Page4of6

DPC III SEQUENCING PAGE

S01 - SEQUENCING Sequencing

SequenceDefinition

Disabled

Bad

Cycle

Sequence

Segment Length

Reset Sequence

Define Part As

Preset Segment

Preset Cycles

Enter Segment Length (0–8)

Enter Preset Segment (0–8)

Enter Number of Cycles (0 –255)

Suspect

Abort

Select Segment Enter Number of Cycles (0 –255)Select Setup

Disabled

Enabled

Page5of6

DPC III OPERATE PAGE

001 - PART COUNT 0 Function

Keys

Print Consecutive

Memory

PrintSample

Memory

PrintHeaders

DisplayConsecutive

Memory

DisplaySample

Memory

PrintGraph

ResetSequence

Keys F01 - F09

Key Defined

Key Undefined

Parts to Download Enter Number of Parts to Print


Parts to Display Enter Number of Parts to Display


No

Yes

Text

Raw Data

NOTEIn OPERATE mode, front panel display on start-up shows parameters. Use left and right arrow keys to display them.

Perform Function

Page6of6

DPC III SEQUENCING PAGE

S01 - SEQUENCING Sequencing

SequenceDefinition

Disabled

Bad

Cycle

Sequence

Segment Length

Reset Sequence

Define Part As

Preset Segment

Preset Cycles

Enter Segment Length (0–8)

Enter Preset Segment (0–8)

Enter Number of Cycles (0 –255)

Suspect

Abort

Select Segment Enter Number of Cycles (0 –255)Select Setup

Disabled

Enabled

Page5of6

DPC III OPERATE PAGE

001 - PART COUNT 0 Function

Keys

Print Consecutive

Memory

PrintSample

Memory

PrintHeaders

DisplayConsecutive

Memory

DisplaySample

Memory

PrintGraph

ResetSequence

Keys F01 - F09

Key Defined

Key Undefined





No

Yes

Text

Raw Data

NOTEIn OPERATE mode, front panel display on start-up shows parameters. Use left and right arrow keys to display them.

Perform Function

Page6of6


INDEX

Dukane Corporation



Index

ACPower,30NominalInput,129

AdvancedProgrammer,17–18,141–145BaudRate,93ChoosingPrinterPort,19,143Keyboard,31-34,142FunctionKey,32PrinterConnections,18,144PrintingtheScreen,145Resetting,141-143SpecialPurposeKeys,33Status,93

Afterburst,67

AmplitudeControl,21

ASCII,84

Axis,leftandright,97

BBadLimits,75

BaudRate,85

Booster,108

BuzzerStatus,92

CCableConnections,16-18,144

CommunicationsPage,81-98ConfigureSerialPort,82UserI/O,88-92AdvancedProgrammer,93PartSampling,94-96Graphing,97-98

ConnectorPinoutDescriptions,AppendixB

ControlParameters,63Time,63Distance,63AbsoluteDistance,64Energy,64PeakPower,64MaximumWeldTime,64

Controls,21-34

CopyaSetup,101

CSVFormat,C–VIII

DataMyte,84

DefineJ801-5As,90

DefineJ801-6As,91

Dimensions,128

DisplaysProcessControlPage,51ProcessLimitsPage,70CommunicationsPage,81UtilitiesPage,99SequencingPage,111OperatePage,119

DistanceEncoderUtilities,106

DPCWon’tCycle,154

DukaneCorporationPhone,Fax,E-Mail,157

A

D


EnablingProcessLimits,79

EndofWeld/GroundDetect,89

EntryFields,41-42

Environment,131

EraseSetups,101

ErrorMessages,135-139

Exclude,96

Fixture,108

FrontPanel,21-30Care,131Keypad,22-26Keyswitch,27

FunctionKeysProgramming,32Sequencing,117

GeneratorModels,129

GeneratorStatusPanel,28

GoodPart,90

Graphing,97

Grounding,7-9

HandProbe,19

HealthandSafety,6Plastics,7

HoldMethod,66

Horn,108

I/OInterfaceBoard,AppendixA

InCycle,91

InDwell,90

InitiateMode,52Manual,52Auto,53

Inputs,CheckingOperation,148-149 Installation,11-20

LFAfterCR,87

LimitIndicators,87

LotSize,94

F

G

H

I

L

E

Index

MemoryConsecutive,94Sample,94

MenuItem,40

MenuOrientation,39-48

MenuStructure,AppendixF

Menu,40

ModelNumber,130

ModuleOperation,Verifying,146-147

NavigatingInSetupMode,43-47InOperateMode,48

NewSetup,Select,100

NoUltrasound,155

1-2-3,84

OperateFunctionsFunctionKeys,122PrintPartMemory,122PrintHeaders,122DisplayPartMemory,123PrintGraph,123ResetSequence,125

OperateModeNavigatingin,48OperatePage,119-125

OperatePagewithFrontPanel,120withAdvancedProgrammer,121

OperatingEnvironment,129

OutputDevice,83

OutputMode,85

Outputs,88

Page,40

PartMemory,Display,123

PartSampling,94

PlacementBenchtop,11Rack-mount,12

PowerAverage,110

PowerConnection,20

PowerSupplyElectricalSourceRequirements,129

PowerUtilities,110 PresetCycles,115

PresetPartCount,107

PresetSegment,115

Pressure1and2,108

PrintSetup,Hex,104

M

N

O

P


PrintSetup,Text,102

PrinterCompatibility,C-IV

PrinterCableConnectiononAdvProgrammer,17-18,143

PrinterPortSelectiononAdvProgrammer,143-145

ProbeCabling,19

ProcessCharacteristics,71-74

ProcessControlPage,50-68InitiateMode,52TriggerMethod,54-60WeldMethod,61-64Scrub,65HoldMethod,66Afterburst,67SecondaryControls,68

ProcessFlow,EffectsofI/OSystemErrors,152-155

ProcessLimitsPage,69-80BadLimits,75-77SuspectLimits,77-78EnablingProcessLimits,79SecondaryControl,80

Protocol,86

Ready,91

RearPanel,13-14

RegulatoryAgencyCompliance,127

ReplaceableParts,132

ResetPartCount,107

RFIFilter,9

RTS/CTS,86

SampleSize,95

Scales,selecting,98

Scrub,65

SecondaryControl,80

SecondaryControls,68

Sequence,Whatisit?,112

SequencingPage,111-117

Sequencing,114-116

SerialDeviceSupport,AppendixC

SetupMode,49-118BlockingAccessto,34Navigatingin,43-47

ShortingBlock-HandProbe,19

SonicsOn,91

Specifications,127-130

StartAt,97

Start-up,35-38WithoutAdvancedProgrammer,35WithAdvancedProgrammer,36

S

R

Index

StatusLine,52,134

StatusOutputs,90

StopAt,97StoppingtheWeldCycle,38

Store,96

SuspectLimits,77

SystemPowerOutput,30

SystemStatus,29

TaggedCSV,84

TestingRemoteSetupSelectionInputs,151

TimeandDateUtilities,105

TimeTag,88

TriggerForce,109

TriggerMethod,54Normal,56DelaybyTime,56DelaybyDistance,57DelaytillAuto-In,57Pre-triggerbyDistance,59Probe,60

TriggerType,54Maintained,54Momentary,55

Troubleshooting,133

UserI/O,88

UserParameters,107-109

UtilitiesPage,99-110SetupUtilities,100TimeandDateUtilities,105EncoderUtilities,106Reset/PresetpartCount,107UserParameters,107PowerUtilities,110

WarningMessages,140

Warranties,159-160

WeldMethod,61-62

Xon/Xoff,86

Zontec,84

T

U

X

W

Z



Dukane ISOISO CERTIFICATIONDukane chose to become ISO 9001:2000 certi-fied 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, manu-facturing, delivery and service. This certificate reinforces Dukane's status as a quality vendor of technology and products.

To achieve ISO 9001:2000 certification, you must prove to one of the quality system regis-trar groups that you meet three requirements:1. Leadership2. Involvement3. Quality in Line Organizations and Quality

System Infrastructure.

The ISO 9001:2000 standard establishes a minimum requirement for these requirements and starts transitioning the company from a traditional inspection–oriented quality system to one based on partnership for continuous improvement. This concept is key in that Du-kane 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.

Dukane products are manufactured in ISO registered facilities

ISO 9001:2000C E R T I F I E D

Part No. 403-541-03

DukaneIntelligentAssemblySolutions•2900DukaneDriveSt.•Charles,Illinois60174USA•TEL(630)797-4900•FAX(630)797–4949

DPC III, User's Manual

PrintedintheUnitedStatesofAmerica

www.dukane.com/us

Please refer to our website at:

www.dukane.com/us/sales/intsales.htm

to locate your local representative.

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