Dukane 403-570-01 user manual Electrical Safety, Mechanical Safety, AC Power Receptacle

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Section 2 - Safety Considerations

Electrical Safety

AC Power Receptacle

The power cord used on the Dual Servo Spin Welder has a two–blade, grounding type plug designed for 240 VAC at 20 Amps. It is designed to be plugged into a 240 VAC, 20 Amp NEMA type 6–20R receptacle as shown in Figure 2–1. Do not alter the plug or receptacle in any way.

Grounding

It is important for operator safety that the receptacle grounding wire be installed properly and securely attached to an effectively grounded rod. The function of the ground wire is to keep the Dual Servo Spin Welder base and housing at earth potential. In the event of a short circuit from one of the AC lines to the case, the circuit breaker will open, protecting the equipment and operator. If there is any question about the grounding of your AC power, have it checked by a qualified electrician.

Grounding lugs are also provided, one on the back of the base (see Figure 2-2) and one on the back of the welder housing. You should connect a separate 14 AWG* ground wire between these lugs and an effectively grounded metal pipe. This will minimize any external electrical interference from leaking into the Dual Servo Spin Welder control circuitry. This will not compromise the safety of the power ground.

*14 AWG wire has a diameter of 1.63mm or 0.064”

Mechanical Safety

The Dual Servo Spin Welder is capable of developing substantial torque, force, and high rotational velocity. Keep your hands and body away from the tool head during operation. The spinning head is capable of inflicting serious injury. Never attempt to retrieve a part from a spinning tool head. Always wear a face shield when operating the spin welder. Be extremely careful not to let long sleeves, ties, necklaces or long hair become entangled in the welder during operation. Always turn machine power off when installing or removing tooling.

240V

GND

G

Figure 2–1240VAC–20A Receptacle Wiring

J35 – Base

Interface

Grounding

Lug

Figure 2–2Grounding Lug on Base of Dual Servo Spin Welder

IMPORTANT

Always turn off the AC power at the power switch before servicing or working on the welder.. Failure to turn off the AC power is an unsafe practice and can result in injury or death..

Dukane Manual Part No. 403-570-01

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Contents Dual Servo Spin Welder Dukane Manual Part No Summary Date Revision HistoryRevision This page intentionally left blank Dukane Dual Servo Spin Welder ContentsThis page intentionally left blank Introduction SectionDukane Manual Part No Drawings and Tables Important User InformationRead This Manual First SVT042VR Dual Servo Spin Welder OverviewKey Dual Servo Spin Welder Features This page intentionally left blank Safety Considerations This page intentionally left blank  Caution Health and Safety TipsPlastics Health Notice Run SwitchesGeneral Safety AC Power Receptacle Electrical SafetyMechanical Safety This page intentionally left blank Unpacking and Setup This page intentionally left blank Packing List Unpacking WelderWork Area Qty Part NumberBench Capacity Securing to Work BenchLeveling Mounting HolesTooling Hub & Fixture Dimensions are in Inches mm20-Amp 240V Figure AC PowerControl Connectors Head Height AdjustmentBase Interface Connector User I/O ConnectorThis page intentionally left blank Display and Controls This page intentionally left blank 1Dual Servo Spin Welder Touch Screen Panel Touch Screen DisplayEmergency Stop Switch Operational SwitchesBrigtly Lit Red LEDs Data I/O ConnectorOpti-Touch Run Switches This page intentionally left blank View Parts Touch Screen MenusThis page intentionally left blank Screen Layout RUN ModeView Parts Tool Setup Setup MenuPRE-WELD Setup Trigger Position TOP of Stroke PositionPre-Spin Orientation Option Part Pickup OptionTime Method Weld SetupWeld Method Selection Distance Method Rotation MethodOrientation Option Energy Method18Weld Torque Trigger Option Screen Torque Trigger OptionConstant Torque Option POST-WELD SetupHold Setup 22Hold Setup Screen for Distance Mode 25Process Limit Definitions Screen 1 Part Tests28RUN Screen with Part Test Failed Button Utilities Tab Select Setup TabTools Menu Third tab is labeled System Setup and is shown in Figure System Setup Tab34Vertical Lower Limit Setup Screen with Set Position Button 35Password-Protected Screens and Menus Setting Time and Date On Touch Screen Parameter Value Range Screen Parameter Name Min.Value Max.Value Resolution UnitsThis page intentionally left blank 55-56 Machine OperationThis page intentionally left blank AC Power Machine SetupAdjust Thruster Position on Column Base Interface CableTurn Power on Reset E-StopSet Tool Parameters Initialize Home WelderSet Weld Process Parameters Set Vertical Travel Lower Limit PositionStarting a Weld Cycle Stopping a Weld Cycle Setup SheetDual Servo Spin Welder Setup Sheet Optimizing Performance This page intentionally left blank Material Considerations Spin Welding ProcessSurface Speed Control ParametersSpeed Rev/minSpin Average Weld Diameter inchWeld Depth Press Axial SpeedWeld Diameter Machine Peak RPM Part SizeHold This page intentionally left blank Welder Data Export Software Installation, StartupThis page intentionally left blank Hardware Software Requirements Installation Startup, and Cable ConnectionsPart Data List Part DataFile Write Profile GraphsIncoming Data Plot DataSpin Torque Setpoint Servo and DebugWelding Process TroubleshootingThis page intentionally left blank Welding Process TroubleshootingMechanical WelderProblem Symptom Possible Cause Recommended Solution Faults Message Description Cause Possible Solution InstructionsMessage Description Cause Possible Solution Time or number of rotations Message Description Cause Possible Solution ErrorsMessage Description Cause Possible Solution This page intentionally left blank Maintenance This page intentionally left blank Maintenance AC Power CordThis page intentionally left blank Contacting Dukane This page intentionally left blank Identify Equipment Contacting DukaneUltrasonics Division WebsiteThis page intentionally left blank Specifications This page intentionally left blank Machine Weight Tooling SpecificationsPower Requirements Operating Environment2Dual Servo Spin Welder Dimensions Welder Model & Serial Number Identification NumbersThis page intentionally left blank Appendix a Connector PinoutsThis page intentionally left blank Figure A-1Base Interface Connector Base Interface ConnectorSignal Description Function User I/O ConnectorPin Signal Description Function Slide Kit ConnectorAutomation Wiring Data Port ConnectorFigure A-5Schematic of Operate and Abort This page intentionally left blank Tooling Appendix BThis page intentionally left blank Explanation of Inertia Moment of InertiaTool and Fixture Design Appendix C Optional FeaturesThis page intentionally left blank Figure C-1Upper Tool Vacuum System Upper Tool VacuumFigure C-2 Remote Touch Screen Components Remote Touch ScreenDukane ISO