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Dual Servo Spin Welder User’s Manual

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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 Contents Dukane Dual Servo Spin WelderThis page intentionally left blank Section IntroductionDukane Manual Part No Drawings and Tables Important User InformationRead This Manual First Dual Servo Spin Welder Overview SVT042VRKey Dual Servo Spin Welder Features This page intentionally left blank Safety Considerations This page intentionally left blank Health and Safety Tips  CautionPlastics Health Notice Run SwitchesGeneral Safety AC Power Receptacle Electrical SafetyMechanical Safety This page intentionally left blank Unpacking and Setup This page intentionally left blank Unpacking Welder Packing ListWork Area Qty Part NumberSecuring to Work Bench Bench CapacityLeveling Mounting HolesDimensions are in Inches mm Tooling Hub & FixtureAC Power 20-Amp 240V FigureHead Height Adjustment Control ConnectorsBase Interface Connector User I/O ConnectorThis page intentionally left blank Display and Controls This page intentionally left blank Touch Screen Display 1Dual Servo Spin Welder Touch Screen PanelOperational Switches Emergency Stop SwitchBrigtly Lit Red LEDs Data I/O ConnectorOpti-Touch Run Switches This page intentionally left blank Touch Screen Menus View PartsThis page intentionally left blank RUN Mode Screen LayoutView Parts Tool Setup Setup MenuPRE-WELD Setup TOP of Stroke Position Trigger PositionPart Pickup Option Pre-Spin Orientation OptionTime Method Weld SetupWeld Method Selection Rotation Method Distance MethodEnergy Method Orientation OptionTorque Trigger Option 18Weld Torque Trigger Option ScreenConstant Torque Option POST-WELD SetupHold Setup 22Hold Setup Screen for Distance Mode Part Tests 25Process Limit Definitions Screen 128RUN Screen with Part Test Failed Button Utilities Tab Select Setup TabTools Menu System Setup Tab Third tab is labeled System Setup and is shown in Figure34Vertical Lower Limit Setup Screen with Set Position Button 35Password-Protected Screens and Menus Setting Time and Date On Touch Screen Screen Parameter Name Min.Value Max.Value Resolution Units Parameter Value RangeThis page intentionally left blank Machine Operation 55-56This page intentionally left blank Machine Setup AC PowerAdjust Thruster Position on Column Base Interface CableReset E-Stop Turn Power onSet Tool Parameters Initialize Home WelderSet Vertical Travel Lower Limit Position Set Weld Process ParametersStarting a Weld Cycle Setup Sheet Stopping a Weld CycleDual Servo Spin Welder Setup Sheet Optimizing Performance This page intentionally left blank Spin Welding Process Material ConsiderationsControl Parameters Surface SpeedRev/min SpeedSpin Average Weld Diameter inchPress Axial Speed Weld DepthWeld Diameter Machine Peak RPM Part SizeHold This page intentionally left blank Installation, Startup Welder Data Export SoftwareThis page intentionally left blank Installation Startup, and Cable Connections Hardware Software RequirementsPart Data Part Data ListProfile Graphs File WriteIncoming Data Plot DataServo and Debug Spin Torque SetpointTroubleshooting Welding ProcessThis page intentionally left blank Troubleshooting Welding ProcessWelder MechanicalProblem Symptom Possible Cause Recommended Solution Message Description Cause Possible Solution Instructions FaultsMessage Description Cause Possible Solution Message Description Cause Possible Solution Errors Time or number of rotationsMessage Description Cause Possible Solution This page intentionally left blank Maintenance This page intentionally left blank AC Power Cord MaintenanceThis page intentionally left blank Contacting Dukane This page intentionally left blank Contacting Dukane Identify EquipmentUltrasonics Division WebsiteThis page intentionally left blank Specifications This page intentionally left blank Tooling Specifications Machine WeightPower Requirements Operating Environment2Dual Servo Spin Welder Dimensions Identification Numbers Welder Model & Serial NumberThis page intentionally left blank Connector Pinouts Appendix aThis page intentionally left blank Base Interface Connector Figure A-1Base Interface ConnectorUser I/O Connector Signal Description FunctionSlide Kit Connector Pin Signal Description FunctionData Port Connector Automation WiringFigure A-5Schematic of Operate and Abort This page intentionally left blank Appendix B ToolingThis page intentionally left blank Moment of Inertia Explanation of InertiaTool and Fixture Design Optional Features Appendix CThis page intentionally left blank Upper Tool Vacuum Figure C-1Upper Tool Vacuum SystemRemote Touch Screen Figure C-2 Remote Touch Screen ComponentsDukane ISO