Dukane Part No. 403–566-01
User’s Manual
Dukane Corporation • Ultrasonics Division • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL +1–630–797–4900 • FAX +1–630–797–4949
Dukane products are manufactured
in ISO registered facilities
www.dukcorp.com/us
ISO 9001:2000
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DPC II Plus & EZ Welder Manual Revision History
Revision
Number
Revision
History
Date
–00
Add information for EZ–Series Generator to DPC II Plus Manual.
Added EZ Welder™ Key Features to Section 1.
2003–Sept–25
Table 3—1 references new DPC II Plus/EZ Welder manual.
Figure 4–1B shows EZ Generator w/o Hot Key for P2.
Figure 4–8B added to show current software revision for
EZ Generator. Figure 4–8A shows DPC II Plus version.
Figure 5–1 notes Multi–Probe modules are for DPC II Plus only.
Added note that photo on page 49 does not apply to EZ system.
Added note to Figure 7–30 that P2 branch is for DPC II Plus
systems only. EZ Series are single pressure.
Updated Dukane’s telephone numbers on pages 143–144.
Added Table 15—II for EZ Generator Part Number.
–01
Modify Table 5—V on page 48 (Pin 9 is +22V DC)
Clarify AFTERBURST option bypass on page 73 and 80.
2004–Dec–07
Emergency Stop Switch Interface Diagram on page 25
New consolidated warranty.
Dukane Corporation •
• Ultrasonics Division
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Table of Contents
TABLE OF CONTENTS
Section 1 – Introduction........................................................... 1
Before Operating ................................................................................... 3
Read The Manual First...................................................................................3
Caution and Warnings...................................................................................3
Drawings Labels ............................................................................................. 3
Manual Organization............................................................................. 4
DPC–II Plus Overview.............................................................................. 6
EZ Welder Overview............................................................................... 6
Key DPC–II Plus Features ........................................................................ 7
Key EZ Welder Features ......................................................................... 8
Section 2 – Safety Tips.............................................................. 9
Health & Safety Tips............................................................................. 11
Plastics Health Notice ..................................................................................12
Electrical Grounding Safety ........................................................................12
RFI Considerations................................................................................ 13
Section 3 – Unpacking & Installation .................................... 15
Shipping Carton Contents ................................................................... 17
DPC Placement ..................................................................................... 17
Benchtop ......................................................................................................17
Rack Mounting.............................................................................................18
Rear Panel Overview ............................................................................ 19
Ground the System............................................................................... 19
Connect the Cables .............................................................................. 20
Hand Probe System......................................................................................20
Automated Probe System ...........................................................................20
Multiple Probe System ................................................................................22
Automated Thruster System .......................................................................23
Dukane Press System ...................................................................................24
Emergency Stop Switch Interface ...............................................................25
Rear Electrical Power Switch .......................................................................25
Section 4 – Controls & Displays.............................................. 27
Front Panel Layout ............................................................................... 29
AC Power .............................................................................................. 30
Generator Status Section ..................................................................... 30
Generator Control Keys...............................................................................30
System Status Display ..................................................................................31
System Power Output Display.....................................................................32
Process Control ..................................................................................... 33
Process Control Keys ....................................................................................33
Menu Display ...............................................................................................35
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DPC II Plus and EZ Welder System – User’s Manual
Section 5 – Rear Connectors .................................................. 37
Rear Panel Layout ................................................................................ 39
System Input Connector....................................................................... 40
System Output Connector ................................................................... 42
Remote Amplitude Control ................................................................. 46
Power Output Module Option ............................................................ 47
Press Control Module Option .............................................................. 48
Multi–Probe Module Options.............................................................. 50
Jumper Block Options .......................................................................... 51
Card Slot and Jumper Block Locations ....................................................... 52
Jumper Block Details ...................................................................................53
Section 6 – Menu Structure ................................................... 55
Process Setup ........................................................................................ 57
Process Control ..................................................................................... 58
Process Limits........................................................................................ 60
Utilities.................................................................................................. 61
Section 7 – Process Setup Menu ............................................ 63
Hand Probe........................................................................................... 65
Untimed Hand Probe...................................................................................66
Timed Hand Probe .......................................................................................66
Timed Hand Probe – Energy........................................................................67
MPC Probe ............................................................................................ 68
Auto Stop Option ........................................................................................68
Untimed MPC Probe – Probe Delay ............................................................68
Weld Method – Time ...................................................................................69
Weld Method – Energy................................................................................70
Weld Method – Ground Detect .................................................................. 70
Auto Probe ........................................................................................... 71
Auto Stop Option ........................................................................................72
Untimed Auto Probe – Delay ...................................................................... 73
Timed Auto Probe – Weld Method.............................................................73
HoldTime ......................................................................................................73
Afterburst .....................................................................................................73
Press Mode ........................................................................................... 75
Initiate Mode ...............................................................................................76
Auto Stop .....................................................................................................76
Head Up On Auto Stop ...............................................................................76
Trigger Type..................................................................................................76
Single/Dual Pressure Mode .........................................................................76
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Table of Contents
Press Mode Example ............................................................................ 77
Hot Keys................................................................................................ 81
Process Control Recap .......................................................................... 82
Section 8– Process Limits Menu ............................................. 87
Process Limits Menu ............................................................................. 89
Limit Definition .................................................................................... 90
Suspect and Bad Limits ........................................................................ 90
Process Limits........................................................................................ 90
Single Pressure Mode .................................................................................. 91
Dual Pressure Mode..................................................................................... 92
Section 9 – Utilities Menu ...................................................... 95
Setup Utilities ....................................................................................... 97
Select Setup ..................................................................................................98
Copy A Setup................................................................................................99
Erase Setups ................................................................................................. 99
Part Count........................................................................................... 100
Reset Part Count ........................................................................................100
Count Suspect/Bad Parts............................................................................100
Preset Part Count .......................................................................................101
Status Outputs.................................................................................... 101
Cycle Press Off Line ............................................................................ 101
Section 11 – Probes/Probe Stacks ........................................ 103
The Ultrasonic Probe.......................................................................... 105
Theory of Operation..................................................................................105
Probe Configuration..................................................................................105
Ultrasonic Horn ..........................................................................................106
Booster .......................................................................................................106
Stack Assembly ................................................................................... 107
Installing Replaceable Tips ........................................................................107
Mounting Stud to Horn/Booster ...............................................................108
Horn to Booster .........................................................................................109
Booster to Probe ........................................................................................109
Horn to Probe ............................................................................................109
Torque Unit Conversion Chart........................................................... 110
Stack Disassembly............................................................................... 111
Booster Notes ..................................................................................... 114
Stack Mounting .................................................................................. 115
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DPC II Plus and EZ Welder System – User’s Manual
Section 11 – DPC Checkout .................................................. 117
Startup and Self–Test ......................................................................... 119
System Test ......................................................................................... 120
Probe Operation................................................................................. 121
Stopping the Weld Cycle ................................................................... 121
Manual Systems .........................................................................................121
Automated System ....................................................................................121
End of Day..................................................................................................121
Section 12 – Troubleshooting .............................................. 123
No Ultrasonic Output......................................................................... 125
Probe ..........................................................................................................125
Cable ...........................................................................................................125
Generator ...................................................................................................126
Operate Input ............................................................................................126
Generator Faults................................................................................. 127
OVERLOAD Indicator .................................................................................127
OVERTEMP Indicator .................................................................................127
FAULT Indicator..........................................................................................127
Generator Errors................................................................................. 128
INPUT TEST Indicator .................................................................................128
TEST Control Key........................................................................................128
Troubleshooting Flowchart ............................................................... 129
Error Messages ................................................................................... 131
Section 13 – Care & Maintenance ....................................... 133
Front Panel ......................................................................................... 135
Rear Panel........................................................................................... 135
Chasis .................................................................................................. 135
Stack Surfaces ..................................................................................... 136
Stack Maintenance ....................................................................................136
Stack Inspection .........................................................................................136
Even Contact ..............................................................................................136
Uneven Contact .........................................................................................136
Crowning ....................................................................................................137
Center Depression......................................................................................137
Corrosion ....................................................................................................137
Probe Reconditioning ........................................................................ 138
Overview ....................................................................................................138
Machining the Mating Surfaces................................................................138
Manual Resurfacing...................................................................................138
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Table of Contents
Section 14 – Contacting Dukane ......................................... 141
Ultrasonics Division Main Office ....................................................... 143
Email Addresses.................................................................................. 144
Telephone Extensions ........................................................................ 144
Section 15 – Specifications................................................... 145
Regulatory Compliance...................................................................... 147
Federal Communications Commission......................................................147
CE Marking (Conformité Europeéne)....................................................... 147
Dimensions ......................................................................................... 148
Operating Enviornment..................................................................... 148
Power Requirements.......................................................................... 149
Interpreting The DPC Model Number............................................... 150
Section 16 – Warranty.......................................................... 151
Domestic warranty ............................................................................. 153
International Warranty...................................................................... 154
Appendix A - List of Figures ................................................ 155
Appendix B - List of Tables .................................................. 159
Appendix C - User Supplied Circuitry .................................. 161
Manual Switch Circuit ........................................................................ 163
Automation Switch Circuits ............................................................... 164
Isolated Automation Controls ........................................................... 165
Current Sink ...............................................................................................166
Current Source ...........................................................................................167
Index ..................................................................................... 169
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SECTION 1
Introduction
• General Information
• Manual Organization
• DPC–II Plus Overview
• Key DPC–II Plus Features
• Key EZ Welder Features
Before Operating ............................................ 3
Read The Manual First............................................3
Caution and Warnings ...........................................3
Drawings Labels .....................................................3
Manual Organization ...................................... 4
DPC–II Plus Overview ...................................... 6
EZ Welder™ Overview .................................... 6
Key DPC–II Plus Features ................................. 7
Key EZ Welder™ Features ............................... 8
Dukane Corporation •
• Ultrasonics Division
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™
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Section 1 – Introduction
Important User Information
Read This Manual First
Before operating the DPC™ II Plus, read this
User’s Manual to become familiar with the sys-
tem. This will ensure correct and safe operation.
The manual is organized to allow you to learn how
to safely operate an ultrasonic system. The ex-
amples given are chosen for their simplicity to il-
lustrate basic setup procedures.
Notes and Tips
Throughout this manual we use NOTES to provide
information that is important for the successful ap-
NOTE
NOTE statements provide additional informa-
tion or highlight procedures.
plication and understanding of the product. A
NOTE block is shown to the right.
Cautions and Warnings
In addition, we use special notices to make you
aware of safety considerations.These are the CAU-
TION and WARNING blocks as shown here. They
represent increasing levels of important informa-
tion. These statements help you to identify and
avoid hazards and recognize the consequences. One
of three different symbols also accompany the
CAUTION and WARNING blocks to indicate whether
the notice pertains to a condition or practice, an
electrical safety issue or a hand protection issue.
CAUTION
CAUTION statements
identify conditions or
practices that could result
in damage to the equip-
ment or other property.
WARNING
WARNING statements
point out conditions or
practices that could re-
sult in personal injury or
loss of life.
Drawings and Tables
The figures and tables are identified by the sec-
tion number followed by a sequence number. The
sequence number begins with one in each sec-
tion. The figures and tables are numbered sepa-
rately. The figures use arabic sequence numbers
(e.g. –1, –2, –3) while the tables use roman se-
quence numerals (e.g. –I, –II, –III). As an ex-
ample, Figure 3–2 would be the second illustra-
tion in section three while Table 3—II would be
the second table in section three.
ƽ Ꮨ
Condition
or Practice
Hand
Hazard
Electrical
Hazard
3
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DPC II Plus and EZ Welder System – User’s Manual
Manual Organization
Section 1 – Introduction describes the manual organization
and the key features of the Dukane DPCTM (Dy-
namic Process Controller) II Plus Generator.
Section 2 – Safety discusses OSHA regulations and safety
considerations.
Section 3 – Unpacking and Installation explains the DPC II
Plus placement and setup. It also shows the cable
connections for quick–start operation.
Section 4 – Controls describes the function of the front
panel controls, menu keys and status display.
Section 5 – Connectors gives the function, pinout and sig-
nal description of the rear panel connectors
on the DPC II Plus. Operation of the optional
modules is described in detail. The internal
jumper blocks to control process automation
are also identified.
Section 6 – Process Setup describes the overall menu or-
ganization of the DPC–II Plus, the setup and
operate modes and gives a brief summary of the
three main menus.
Section 7 – Process Control Menu describes the Hand
Probe, Timed Auto, MPC and Press mode
menus and the Weld Methods. It also covers
the user interface configuration and param-
eter values.
Section 8 – Limit Definition Menu describes the Suspect
Limit and Bad Limit menus in detail.
Section 9 – Utilities Menu describes the Setup File Utilities,
Part Count and Status Output menus in detail.
Section 10 –Hand Probe and StackAssembly describes the
assembly and mounting of both hand probes and
probe stack assemblies.
Section 11 –System Checkout describes basic system
tests to ensure that the DPC II Plus is func-
tioning properly.
4
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Section 1 – Introduction
Section 12 –Troubleshooting provides helpful tips on solv-
ing the most common problems.
Section 13 –Maintenance lists a schedule of suggested pre-
ventive maintenance items.
Section 14 –Contacting Dukane provides information on
contacting or obtaining support from your Du-
kane Ultrasonics team.
Section 15 –Specifications lists the DPC–II Plus dimen-
sions, power and space requirements. It also
interprets the model number coding.
Section 16 –Warranty contains a copy of our equipment
warranty and tooling warranty.
Appendices
A
B
C
– List of Figures.
– List of Tables.
– Sample Circuitry for user supplied automation.
Index
5
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DPC II Plus and EZ Welder System – User’s Manual
DPC II Plus Overview
The DPC™ II Plus is the newest model in Dukane’s Dy-
namic Process Controller product family.This system will
accept a wide variety of optional modules and is designed
for use with ultrasonic presses or applications that re-
quire the use of hand probes or thruster systems.
The DPC II Plus provides basic system control inputs
and system monitor and status outputs. This makes the
DPC II Plus ideal for automated control systems. Signal
conditioning and electrical isolation are also provided.
Like other DPC models, the II Plus includes the same
internal ultrasonic generator circuitry and features. Op-
tional modules are available to enhance the DPC’s abil-
ity to meet a wide variety of process requirements. The
most common combination includes the Timer board
and a Press control board. Other options include an
Remote Amplitude control, a Power Signal module for
Weld–by–Energy requirements and up to two Multi–
Probe controller modules (DPC II Plus only) for driv-
ing multiple probe systems. In most cases, DPC II Plus
systems in the field can be upgraded on-site if they al-
ready have the standard Timer board.
All DPC II Plus generators (except the highest power
models) and the EZ/EZ–X Model 1000 feature a univer-
sal power supply with dual line–voltage1 input. In addi-
tion, the equipment is designed and tested to comply with
FCC and CE regulations that apply to this product.
1
See Tables 15—I and 15—II
EZ Welder™ Overview
™
The EZ Welder system combines the best features of
the DPC II Plus ultrasonic generator with a quality press
in a matched, low–cost welding system. The generator
and press are sold as a package and are not upgradable or
interchangeable with other Dukane generators.
The EZ and EZX Welders are both single–pressure sys-
tems. The EZX model adds an energy mode and fea-
tures additional limit switches for pretrigger and end–
of–weld indication. The EZ Welder press has a
maximumstroke of 5–inches.
6
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Section 1 – Introduction
DPC II Plus™ Key Features
•
•
•
Timer Board option provides weld and hold
time control and stores up to eight setup files.
Press Board option provides control for a
Dukane ultrasonic press and thruster.
Multi–Point Control Module option permits
one DPC to handle up to eight probes in an
automation environment (DPC II Plus or DPC II).
•
•
Plug andWeld system recognizes when modules
are added or removed from the system
Process Control Menu automatically
reconfigures the user interface to conform to the
modules or hand probes currently installed.
•
•
4–Line LCD Display gives the complete
parameter setting to speedup the setup process.
System Connections are provided for
automation equipment to monitor and control
the ultrasonic welding process.
•
•
Modular Design simplifies upgrades and
increases flexibility as your application
requirements change.
Flow Through Cooling Tunnel is
thermostatically controlled to reduce thermal
gradients and increase component life. Fan runs
only when required to minimize dust buildup.
•
•
•
Pulse Width Modulation is Dukane’s patented
circuitry that allows the DPC power supply to
efficiently control the voltage sent to the
transducer in the acoustic stack.
Linear Ramp Softstart circuitry is provided
allowing the acoustic stack to be brought to
operating amplitude smoothly, minimizing the
startup shock stress.
Auto-Trac Tuning automatically tracks the
resonant frequency of the acoustic stack (horn,
booster, transducer), and adjusts the generator
output frequency to match it. 2
2
Within specified ranges
(continued on next page)
7
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DPC II Plus and EZ Welder System – User’s Manual
1
1
•
•
Dual Line–Voltage Universal Power Supply
means that the DPC will operate worldwide.
Auto-Ranging means that adjustments by the
operator related to power input are unnecessary.
See Tables 15—I and 15—II
Line Voltage Regulation automatically
maintains a constant output regardless of line
2
2
Within specified ranges
voltage deviation.
•
•
•
Load Regulation provides constant amplitude
automatically up to the rated overload power level.
Electronic Overload protection prevent
component failure.
CE Certification means that the DPC II Plus and
DPC EZ meets the required European standards
to be sold and used in Europe.
•
ISO 9001 Certification means that the DPC II
Plus and EZ are manufactured to very high quality
standards and assures you of Dukane’s
commitment to being a quality vendor and its goal
of continuous improvement.
EZ Welder™ Key Features
•
DPC Based generator means a rugged, quality
system for reliable operation.
•
Narrow–Profile Press (4.5 inches) for close
spacing in multihead and automation
installations.
•
•
Top–of–Stroke limit switch output for
automation applications.
Chrome plated press column and aluminum
alloy–booster are standard.
•
•
Cast Aluminum heavy–duty base for stability.
Calibrated dynamic trigger system with LED
indicator initiates the weld cycle at user
selectable force.
•
•
Pneumatic stroke speed adjustment on press
controls horn travel velocity to workpiece.
Hinged press transducer door for quick
tooling changeover.
8
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SECTION 2
Safety Tips
• Health & Safety
• RFI Considerations
Health & Safety Tips...................................... 11
Plastics Health Notice ...........................................12
Electrical Grounding Safety ..................................12
RFI Considerations ........................................ 13
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• Ultrasonics Division
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Section 2 – Safety Tips
Health and Safety Tips
Please observe these health and safety recommen-
dations for safe, efficient, and injury-free opera-
tion of your equipment. In this manual, the term
system refers to a complete group of components
associated with the welding of plastic or metal
parts, also known as an ultrasonic assembly sys-
tem. A typical system consists of a generator and/
or ultrasonic process controller, start and stop
switches, power controls, connecting cables, and
the probe assembly which includes the transducer,
booster, horn and replaceable horn tip.
Proper Installation – Operate system components
only after they are properly installed and checked.
IMPORTANT
Never operate the DPC II
Plus with the cover off.
This is an unsafe practice
and may cause injury.
No Unauthorized Modifications – Do not modify
your system in any way unless authorized to do so
by Dukane Corporation. Unauthorized modifica-
tions may cause injury to the operator and/or equip-
ment damage. In addition, unauthorized modifi-
cations will void the equipment warranty.
Ꮨ
CAUTION
Parts being joined ultra-
Keep the Cover On – Do not remove the equip-
ment cover unless specifically directed to do so by
Dukane Corporation. The generator produces haz-
ardous electrical voltages which could cause in-
jury.
sonically
vibrate at audible fre-
quencies. Wear ear
sometimes
protection to reduce an-
noying or uncomfortable
sounds. In addition,
sound absorbing materi-
als, enclosures or sound
deflectors may be in-
stalled to reduce the
noise level.
Grounded Electrical Power – Operate this equip-
ment only with a properly grounded electrical con-
nection. (See Electrical Safety Grounding Instruc-
tions on the next page.)
Comply with Regulations –You may be required
to add accessories to bring the system into com-
pliance with applicable OSHA regulations.
11
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DPC II Plus and EZ Welder System – User’s Manual
Plastics Health Notice
Before using any Dukane ultrasonic welding sys-
tem, be sure you are familiar with OSHA regula-
tions from the U.S. Department of Labor about the
particular type of plastic(s) you are using.
CAUTION
When plastic materials are being processed, they
may emit fumes and/or gases that could be haz-
ardous.
If you must have a two-
prong electrical recep-
tacle, we strongly
recommend that you re-
place it with a properly
grounded three-prong
type. Have a qualified
electrician replace it fol-
lowing the National Elec-
tric Code and any local
codes and ordinances
that apply.
Make sure there is proper ventilation whenever
these plastics are processed.
Ꮨ
Ꮨ
Electrical Safety Grounding
Instructions
For safety, the power cords used on all Dukane
products have a three-prong, grounding-type plug.
See Figures 2-1 and 2-2.
CAUTION
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 al-
ter the plug in any way.
If an extension cord is
needed, use a three-
wire cord that is in good
condition. The cord
should have an ad-
equate power rating to
do the job safely. It 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. 5621 or
equivalent to NEMA 5–15R or 5–20R
Figure 2-1
Example of 120 Volt, Grounded,
3-Prong Receptacle
Approved 2 pole, 3 wire grounding
receptacle HUBBELL No. 5652 or
equivalent to NEMA 6–15R or 6–20R
Figure 2-2
Example of 220 Volt, Grounded,
3-Prong Receptacle
12
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Section 2 – Safety Tips
The power cable normally provided for interna-
tional use is compatible with many power outlets
(refer to Figure 2-3.) However, if your applica-
tion requires another type of cable, check with
the local Dukane products representative, and fol-
low local regulations concerning proper wiring
and grounding.
Grounding Contacts
Typical Outlet
AC Power Cable (Provided)
Figure 2-3
International 220/240V Grounding
RFI Considerations
In addition to the safety considerations, proper
grounding at the generator power cord is essen-
tial for the effective suppression of RFI (Radio
Frequency Interference). Every DPC contains a
RFI filter which blocks noise on the AC power
line from entering the DPC control circuitry.This
filter also prevents ultrasonic RFI from being fed
back into the AC power line. In order for the RFI
filter to operate properly, it is necessary to ad-
equately ground the DPC. Run an additional
grounding wire from the rear grounding connec-
tion (see Figure 2-4) to the nearest grounded metal
pipe or equivalent earth ground by means of a
ground clamp. Use at least an 14 AWG** wire
for the connection to the DPC chassis. Stranded
is more flexible and easier to work with than solid
wire. However if you use stranded wire, crimp
spade lugs on the end to ensure a good connection.
If you have a color choice, green is the commonly
accepted color for an electrical ground connection.
10 – 24 x 1/2" threaded stud
I
O
14 AWG to Earth Ground
Figure 2-4
DPCGrounding Arrangement
If you have connected the DPC to a Press and/or
†
Thruster, use a star connection from the earth
ground to the DPC and Press as illustrated in
Figure 2–5.
** 14AWG wire has a diameter of 1.63mm or 0.064"
To
Ground
†
Run seperate ground wires from each piece of
equipment to the earth ground. See the appropri-
ate schematic diagram in Figures 3–4 thru 3–8.
Figure 2-5
Press Grounding Arrangement
13
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DPC II Plus and EZ Welder System – User’s Manual
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SECTION 3
Unpacking & Installation
• Unpacking the DPC
• Placement of the DPC
• Rear Panel Overview
• Grounding the System
• Connecting the Cables
Shipping Carton Contents ............................ 17
DPC Placement ............................................. 17
Benchtop .............................................................17
Rack Mounting ....................................................18
Rear Panel Overview ..................................... 19
Ground the System ....................................... 19
Connect the Cables ...................................... 20
Hand Probe System ..............................................20
Automated Probe System .....................................20
Multiple Probe System..........................................22
Automated Thruster System .................................23
Dukane Press System............................................24
Rear Electrical Power Switch.................................25
Dukane Corporation •
• Ultrasonics Division
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™
DPC II Plus and EZ Welder System – User’s Manual
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16
Dukane Manual Part No. 403–566–01
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Section 3 – Unpacking and Installation
Shipping Contents
Quantity
Item
Part Number
1
1
DPC II Plus or EZ Generator
**
DPC II Plus/EZ User's Manual 403–566–00
** DPC Part Number depends upon Frequency and Power Rating
AC power cord and cables as specified. See your Packing List.
Compare with Table 3—II on page 21.
Table 3—I
Contents of DPC II Plus Shipping Container
Carefully open the shipping container, and make
sure it contains the items shown in Table 3–I. In-
spect the DPC for damage. Report any damage
immediately to Dukane Ultrasonics Support/Ser-
vice.
CAUTION
Allow space for air venti-
lation around the DPC II
Plus chassis, the air intake
and exhaust. The fan draws
in fresh air to cool the in-
ternal components, reduce
thermal gradients and
increase component life.
When viewed from the
front, the fresh air intake is
on the right and the hot air
exhaust is on the left side.
If excessive dust accumulates
in the slots, wipe or vacuum
them clean. Do not use com-
pressed air as this may force
the dust inside the chassis.
ƽ
DPC Placement
Placement of the DPC depends on whether it is a
benchtop or rack-mounted configuration
Benchtop
Place the DPC on a flat surface with its front panel
easily accessible. Make certain the placement and
cabling do not interfere with the assembly opera-
tion.
Allow 5 inches (13 cm) at the rear of the DPC for
cable clearance. Allow 2 inches (5 cm) of space
on either side of the DPC for air circulation. Re-
fer to the illustration in Figure 3-1.
Allow 5 inches (13 cm) space for cables behind the DPC
Intake Vent for Thermostatically Controlled Fan
PUT
M
POW
ER OUT
SYSTE
WELD
P1
6
0
80
100
OWER
ILABLE POWER
GEN
INFO.
20
4
0
+
ENTE
R
0
GE OF AVAILABLE
A
A
PERCENT
ERCENTAGE OF
LOAD
LINE
ESTOVER
INPUT
T
WELD
P2
FAULT
ON LINE
MODE
EMP OFF
OVERT
S
STATU
AMP.
ADJUST
CANCEL
–
ENTER
0
OFF
LINE
ON
LINE
TEST
0
PLU
LUS
DPC II
PC II
2
ller
ntro
Controller
C
s
ces
Pro
a
mic Process
Dynam
2 2 0 0
Exhaust Air from
Flow–Thru Cooling Tunnel
ilation,
e for vent
5 cm) on
Allow spac
2 inches (
.
each side
Figure 3-1
Installing a Benchtop DPC
17
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DPC II Plus and EZ Welder System – User’s Manual
Rack Mounting
Figure 3-2 shows the use of a bracket kit in
mounting a DPC to a 19-inch equipment rack.
(Contact Ultrasonic Sales at Dukane, and request
Part Number US-1155.) The DPC illustrated
has the standard, angled front panel of impact-
resistant ABS plastic.
Allow 5 inches (13 cm) of space behind the DPC for cables
SYST
GEN.
OINFO.
EM
P
OWE
WELD
P1
R
OU
TPUT
+
WELD
P1
0
20
PERCENT
40 60
80 100
POWER
AGE OF AV
VAILABLE
WELD
P1
MODE
FAULT
INPUT
TEST
OVERL
OFF LI
OAD
ON LIN
E
OVE
RTEMP
NE
AMP.
ADJUST
0
–
ENTER
CANCEL
STATUS
0
2
ON
Dynamic Process Controller
nam
LINE
TEST
OFF
2200
ic Pro
LINE
ces
s C
ont
rol
ler
DPC II Plus
C I
I P
lus
ximate
Appro
Appro
ximate
17.35 inches
22.25 in
(44 cm)
(57 cm)
19 inch
es (48 cm)
Figure 3-2 Rack-mounted DPC Using Bracket Kit
CAUTION
Allow space for air venti-
lation around the DPC II
Plus chassis, air intake and
exhaust. The fan draws in
fresh air to cool the inter-
nal components, reduce
thermal gradients and
increase component life.
When viewed from the
front, the fresh air intake is
on the right and the hot air
exhaust is on the left side.
ƽ
If excessive dust accumulates
in the slots, wipe or vacuum
them clean. Do not use com-
pressed air as this may force
the dust inside the chassis.
18
Dukane Manual Part No. 403–566–01
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Section 3 – Unpacking and Installation
Rear Panel Overview
NOTE
Not all of the modules illustrated below can be
installed simultaneously. They are shown to rep-
resent the various configurations that can be
assembled to meet specific requirements.
Familiarize yourself with the connection points for
power, ground, ultrasound output, system I/O and
the optional modules on the rear of the DPC II
Plus shown below in Figure 3–3. The standard
modules and connectors are labeled with the black
boxes. The optional modules are labeled with ital-
ics. The EEPROM Serial Programming Port is
used to upgrade the DPC™ firmware.The ground-
ing lugs, serial number tags, etc. are located in the
same position on all DPC II, EZ Welder, DPC II
Plus, DPC III and DPC IV generators.
Slave Multi–Probe
EEPROM Serial
(DPC II Plus only)
Controller Module
Programming Port
Master Multi–Probe
Controller Module
(DPC II Plus only)
Power Signal
Output Module
Grounding
Lug
Rear AC
Power Switch
Press Control
Module
Remote Amplitude
Control Module
System
IEC
AC Power
Input
Model No. Tag
Output
System
Input
Connector
Serial
No.
Tag
Connector
J1 Ultrasound
Output (BNC)
Figure 3-3 DPC II Plus and EZ Welder Rear Panel and Optional Modules
Ground the System
The DPC II Plus includes an internal RFI filter.
The standard building AC ground connection is
normally not sufficient to completely suppress
the RFI. Attach a ground cable from the DPC
grounding lug (located next to the rear AC power
CAUTION
Before attaching the
cables, make sure the
DPC II Plus is properly
grounded. Refer to Figure
2–5 and the appropriate
diagram (Figures 3–4 thru
3–8) for the correct
grounding connections.
Ꮨ
switch) to an earth ground. If you are using a
press or automated probe system, each piece of
equipment must also be solidly grounded. Refer
to Figure 2–5 and Figures 3–4 through 3–8 for
the proper grounding arrangement.
19
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DPC II Plus and EZ Welder System – User’s Manual
Connect the Cables
CAUTION
The instructions here and the diagrams in Figures
3–4 through 3–7 are meant to serve as a quick–
start guide. The connectors and their pinouts are
discussed in greater detail in Section 5.
Make sure electrical power
is OFF before connecting/
disconnecting cables or in-
stalling/removing modules
from the DPC II Plus. Make
Ꮨ
sure BOTH the front and rear panel AC
power breaker switches are in the OFF
position.
Failure to turn off the power may re-
sult in damage to the DPC and/or the
modules.
Manual Probe System
Step 1.
Step 2.
Ground the DPC II Plus chassis.
Attach the System In adapter cable (see
Figure 3–4) to the 14-pin AMP
connector at the end of the probe cable.
Step 3.
Step 4.
Step 5.
Connect the other end of the adapter
to the System In HD-15 connector on
the rear of the DPC II Plus.
Attach the high voltage ultrasound
coaxial cable to the rear-panel J1
connector.
Optional – If your system has a Press
Control Module, you will also need a
jumper block (Part No. 200-1293) to
replace the normally closed contact
from the Emergency Stop safety switch.
Step 6.
Attach the power cord to the DPC II
Plus and plug the other end into an
approved AC outlet.
CAUTION
The power cord is
equipped with a three-
prong, grounded-type
Ꮨ
plug for your safety.
Automated Probe System
Whenever a two-slot re-
ceptacle is encountered, we strongly
recommend that it be replaced with
a properly grounded three-lead re-
ceptacle. Have a qualified electrician
perform the installation in accor-
dance with the National Electrical
Code and local codes and ordinances.
DO NOT cut off the AC power cord
grounding prong or alter the plug in
any way.
Step 1.
Ground the DPC II Plus chassis and
the probe support.
Step 2.
Attach the high voltage coax cable
from the probe mount to the rear-panel
DPC connector J1 (see Figure 3–5).
Step 3.
Connect the automation control cable
from the user–supplied automation
equipment to the System Input rear
panel HD-15 connector (Figure 3–5).
20
Dukane Manual Part No. 403–566–01
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Section 3 – Unpacking and Installation
Jumper Block
Part No. 200–1293
Pins 3 & 9
Connected
1
3
5
U.S.PATENT 4,277,710
SERIAL NUMBER
US 10000
Grounding Lug
6
9
Power Signal
Output Module
DUKANE CORP
ST. CHARLES, IL 60174
MADE IN USA
Power
Signal
Output
Ẅ
Ẉ
Zero
Adjust
–
WARNING!
–
– WARNING–
Power Monitor
Jacks
POWER LINE MUST BE
GROUNDED AT OUTLET
POWERLINE MUST BE GROUNDED
AT OUTLET
+
REMOVE ALL POWER BEFORE
REMOVING COVER OR CONNECTING
OR DISCONNECTING CABLES.
LINEVOLTAGE
200–240Vac 50/60Hz
15A
–
J1
ƽ
Ꮨ
SYSTEM OUT
SYSTEM IN
ẇ
Ꮨ
ULTRASOUND
OUTPUT
MODEL NUMBER
200-240 VAC, 50-60Hz, 15A
ẉ
Ẇ
#14 Gauge
Wire
14–Pin AMP to
HD–15 Adapter
Part No. 200–1248
ẅ
Flexible + Coaxial Cable
20kHz Part No. 200–624
40kHz Part No. 200–759
(Included with probe)
110 VAC or
220 VAC
Earth Ground
Figure 3-4 DPC II Plus and EZ Welder Hand Probe Cable Connections
Step 4.
Optional – Attach the status output
cable from the user–supplied
automation equipment to the System
Output DB-25 connector. Not all
automation systems will have this cable.
The 3–prong AC Line cords supplied are
matched to the DPC II Plus power rating and
the continent of specified use.
The part numbers are —
200–1109 North America 110V
200–1110 North America 220V
200–1111 Continental Europe
Step 5.
Attach the power cord to the DPC II
Plus and plug the other end into an
approved AC outlet.
Table 3—II DPC II Plus AC Power Cord Part Numbers
U.S.PATENT 4,277,710
SERIAL NUMBER
US 10000
Grounding Lug
Power Signal
Output Module
DUKANE CORP
Power
Signal
Output
P/N 200–479
ST. CHARLES, IL 60174
MADE IN USA
Zero
Adjust
Ẅ
–
WARNING!
–
– WARNING–
Power Monitor
Jacks
POWER LINE MUST BE
GROUNDED AT OUTLET
POWERLINE MUST BE GROUNDED
AT OUTLET
Ultrasound
Input
+
REMOVE ALL POWER BEFORE
REMOVING COVER OR CONNECTING
OR DISCONNECTING CABLES.
LINEVOLTAGE
200–240Vac 50/60Hz
15A
–
J1
ƽ
Ꮨ
SYSTEM OUT
SYSTEM IN
ẅ
ẅ
Ꮨ
ULTRASOUND
OUTPUT
MODEL NUMBER
200-240 VAC, 50-60Hz, 15A
Grounding Lug
Ẉ
ẇ
Ẇ
Ẅ
#14 Gauge
Wire
Coaxial Cable
RG62B/U
Automation
Control
P/N 200–1203
Automation
Equipment
Status
Output
P/N 200–1302
110 VAC or
220 VAC
#14 Gauge Wire
Earth Ground
Figure 3-5 DPC II Plus and EZ Welder Automated Probe Cable Connections
Dukane Manual Part No. 403–566–01
21
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DPC II Plus and EZ Welder System – User’s Manual
Multiple Probe System
CAUTION
Step 1.
Ground the DPC II Plus chassis and
the probe support.
To ensure safe and trouble–
free operation, ground the
DPC chassis and probe
mount as shown in Figures
3–4 to 3–7.
Use a STAR configuration
(illustrated below). Do not
DAISY CHAIN the grounds.
Step 2.
First attach a short coaxial cable from
the rear-panel DPC generator U/S
output J1 (see Figure 3–6) to the MPC
U/S input.
Ꮨ
Step 3.
Step 4.
Attach another high voltage coax cable
from the rear MPC channel 1 probe
output to the first probe. Attach a
separate cable from each output
channel to each probe.
DPC Chassis
Grounding
Lug
Thruster or
Probe Mount
Grounding Lug
#14 Gauge
Stranded or
Solid Wire
Connect the automation control cable
from the user–supplied automation
equipment to the System Input rear
panel HD-15 connector.
#14 Gauge
Stranded or
Solid Wire
Earth
Ground
Step 5.
Step 6.
Attach the status output cable from the
user–supplied automation equipment to
the System Output DB-25 connector.
NOTE
The automated system cabling schematics in Fig-
ures 3–5, 3–6 and 3–7 are intended to represent
connections for a typical automation system. Your
system cabling may vary slightly from the diagrams.
Attach the power cord to the DPC II
Plus and plug the other end into an
approved AC outlet.
P/N 200–479
U.S.PATENT 4,277,710
SERIAL NUMBER
Grounding Lug
US 10000
Power Signal
Remote Ampltd
Control Mod.
Output Module
Ultrasound
Input(s)
DUKANE CORP
ST. CHARLES, IL 60174
MADE IN USA
Power
Signal
Output
Current Loop
Status
5
6
7
8
1
2
3
4
Zero
Adjust
Ẅ
Ẇ
–
WARNING!
–
– WARNING–
Power Monitor
Jacks
POWER LINE MUST BE
GROUNDED AT OUTLET
POWERLINE MUST BE GROUNDED
AT OUTLET
POS
NEG
SHLD
+
REMOVE ALL POWER BEFORE
REMOVING COVER OR CONNECTING
OR DISCONNECTING CABLES.
Ẇ
Ẇ
LINEVOLTAGE
200–240Vac 50/60Hz
15A
–
J1
Ẅ
ƽ
Ꮨ
SYSTEM OUT
SYSTEM IN
ẅ
Ꮨ
ULTRASOUND
OUTPUT
ẅ
MODEL NUMBER
200-240 VAC, 50-60Hz, 15A
Grounding
Lug
Multi–Probe
Master Module
Ultrasonic Input
RG62B/U Coax
Ẅ
ẉ
Ẉ
ẇ
#14 Gauge
Wire
Coaxial Cable(s)
RG62B/U
Automation
Control
P/N 200–1203
Automation
Equipment
Status Output
P/N 200–1302
110 VAC or
220 VAC
#14 Gauge Wire
Earth Ground
Figure 3-6 DPC II Plus Multiple Probe Conntroller Cable Connections
22
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Section 3 – Unpacking and Installation
Automated Thruster System
Step 1.
Ground the DPC II Plus and the
connector (J902) on the Press Control
Module. If the automation system does
not have a connection to J902, you may
need a jumper block (Part No. 200-1293)
to replace the normally closed contact
from the press base Emergency Stop
safety switch.
Thruster as shown in Figure 3–7.
Step 2.
Attach the high voltage RG62B/U coax
cable from the rear-panel DPC II Plus
connector J1 to the ultrasound input J1
on the thruster (see Figure 3–7).
Step 3.
Connect theAutomation Control cable
from the user–supplied automation
equipment to the System Input rear
panel HD-15 connector.
Step 6.
Step 7.
Connect the Operational Control cable
from the user–supplied automation
equipment to the 36–contact Thruster
control connector (J901) on the Press
Control Module.
Step 4.
Step 5.
Attach the Status Output cable from the
user–supplied automation equipment to
the Status Output DB-25 connector.
Attach the power cord to the DPC II
Plus and plug the other end into an
approved AC outlet.
Connect the Press Base Input cable
from J35 on the Press Base to the DB-9
80–100 psi
Air Supply
P/N 438–528
J901 Operational Control
Top–Of–Stroke
(Optional)
Part No. 200–1104
Ultrasound ẅ
ẉ
Input J1
J40
U.S.PATENT 4,277,710
SERIAL NUMBER
US 10000
Grounding Lug
Power Signal
Remote Ampltd
Control Mod.
Output Module
J3
DUKANE CORP
ST. CHARLES, IL 60174
MADE IN USA
Power
Signal
Output
Current Loop
Status
Zero
Adjust
Ẅ
–
WARNING!
–
– WARNING–
Power Monitor
Jacks
POWER LINE MUST BE
GROUNDED AT OUTLET
POWERLINE MUST BE GROUNDED
AT OUTLET
POS
+
NEG
SHLD
REMOVE ALL POWER BEFORE
REMOVING COVER OR CONNECTING
OR DISCONNECTING CABLES.
Grounding Lug
LINEVOLTAGE
200–240Vac 50/60Hz
15A
–
J1
ƽ
Ꮨ
Ẅ
SYSTEM OUT
SYSTEM IN
Ꮨ
ULTRASOUND
OUTPUT
MODEL NUMBER
200-240 VAC, 50-60Hz, 15A
Ẋ
Ẉ
ẇ
Ẇ
ẅ
#14 Gauge
Wire
Coaxial Cable
RG62B/U
Automation
Control
Cable
P/N 200–1203
Status
Output
Cable
Automation
Equipment
P/N 200–1302
Base Cable
Part No. 200–1124
— or —
110 VAC or
220 VAC
Jumper Block
Part No. 200–1293
1
6
3
5
Pins 3 & 9
Connected
to J902
9
#14 Gauge Wire
Earth Ground
Figure 3-7 DPC II Plus Automated Thruster Cable Connections
Dukane Manual Part No. 403–566–01
23
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™
DPC II Plus and EZ Welder System – User’s Manual
Dukane Press System
CAUTION
Step 1.
Ground the DPC II Plus, the Thruster
Use the STAR configuration
illustrated below and in
Figure 3–8 to ground the
DPC chassis, base and
thruster. Do not DAISY
CHAIN the grounds.
and the Base as shown in Figure 3–8.
Step 2.
Attach the high voltage coax cable
from the press J1 connector to the DPC
Ultrasound Out connector (J1).
Ꮨ
Step 3.
Step 4.
Step 5.
Connect the Press Base Input cable
from J35 on the Press Base to the DB-
9 connector (J902) on the Press
Control Module.
DPC Chassis
Grounding
Lug
Thruster
Grounding
Lug
#14 Gauge
Stranded or
Solid Wire
Connect the Operational Control cable
from J3 at the top of the press to the
36–contactThruster control connector
(J901) on the Press Control Module.
#14 Gauge
Stranded or
Solid Wire
Base/Fixture
Grounding
Lug
Attach the power cord to the DPC II
Plus and plug the other end into an
approved AC outlet.
Earth
Ground
80–100 psi
Air Supply
Ultrasound Input
ẅ
J1
J40
ẇ
J3
Grounding
Lug
Ẅ
U.S.PATENT 4,277,710
SERIAL NUMBER
US 10000
Power Signal
Remote Ampltd
Control Mod.
Output Module
DUKANE CORP
ST. CHARLES, IL 60174
MADE IN USA
Power
Signal
Output
Current Loop
Status
Zero
Adjust
Ẅ
–
WARNING!
–
– WARNING–
Power Monitor
Jacks
POWER LINE MUST BE
GROUNDED AT OUTLET
POWERLINE MUST BE GROUNDED
AT OUTLET
POS
+
NEG
SHLD
REMOVE ALL POWER BEFORE
REMOVING COVER OR CONNECTING
OR DISCONNECTING CABLES.
LINEVOLTAGE
200–240Vac 50/60Hz
15A
–
J1
ƽ
Ꮨ
SYSTEM OUT
SYSTEM IN
Ꮨ
ULTRASOUND
OUTPUT
MODEL NUMBER
200-240 VAC, 50-60Hz, 15A
Ẉ
ẇ
Ẇ
ẅ
#14 Gauge
Wire
J901 to
Thruster
Coaxial Cable
J902 to
Base/Abort
RG62B/U
Operational Control
Part No. 200–1104
#14 Gauge Wire
110 VAC or
220 VAC
8–conductor cable
Part No. 200–1124
Ẇ
J35
#14 Gauge Wire
Grounding Lug Ẅ
Earth Ground
Figure 3-8 DPC II Plus and EZ Welder Press Cable Connections
24
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Section 3 – Unpacking and Installation
on a common welding process. Multiple DPCs re-
quire individual contacts for each unit.
Emergency Stop Switch
Figure 3–9 is a simplified example that demon-
strates the basic requirements to interface with the
DPC II Plus on J902. This is excerpted from Ap-
plication Note AN201 available on our website.
Note that the emergency stop inputs cannot just
be tied together from multiple DPCs when used
Check with your local safety compliance office
before altering the factory connections. The user
is responsible for complying with all requirements
of the safety regulatory agencies governing the
geographic location where the Dukane equipment
will be operated.
Emergency
Stop Switch
DPC II or
DPC II Plus
+22V DC
Emergency
Stop Features
3
To Dukane
Pneumatic
Press
E–Stop Switch
9
7
4
+24V DC
Cable No.
200–1124
J902
E–Stop Sense
Figure 3-9 J902 Emergency Stop Interface Example
Electrical Power Switch
Grounding
Lug
Rear AC
Breaker/Power
Switch
The rear panel AC breaker switch (Figure 3–10)
is wired in series with the front panel breaker
switch (shown in Figure 4-2). When the rear
breaker switch is off, it isolates theAC power feed
in the chassis for safety considerations. Both the
front panel and rear panel switches must be on to
supply AC power to the DPC generator.
IEC
AC Power
Input
Figure 3-10 Rear Panel AC Breaker Switch
25
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DPC II Plus and EZ Welder System – User’s Manual
This page intentionally left blank
26
Dukane Manual Part No. 403–566–01
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SECTION 4
Controls & Displays
• Front Panel Layout
• AC Power
• Generator Status Panel
• Menu Function Keys
• Control Menu Display
Front Panel Layout ........................................ 29
AC Power ..................................................... 30
Generator Status Panel ................................. 30
Generator Control Keys........................................30
System Status Display...........................................31
System Power Output Display...............................32
Process Control Panel.................................... 33
Menu Function Keys.............................................33
Control Menu Display ..........................................35
Dukane Corporation •
• Ultrasonics Division
Download from Www.Somanuals.com. All Manuals Search And Download.
™
DPC II Plus and EZ Welder System – User’s Manual
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28
Dukane Manual Part No. 403–566–01
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Section 4 – Controls & Displays
Front Panel Layout
This section describes the DPC II Plus and DPC EZ front
panel controls, status, power output and menu displays.
The DPC front panel is laid out in three sections as
illustrated below in Figure 4-1A (DPC II Plus) and
Figure 4–1B (DPC EZ). The three sections are:
1. AC Power switch and indicator Ạ
2. Generator Status Panel which contains
• Three Generator Control keys ạ
• System Status display Ả
• System Power Output display ả
3. Process Control Panel which contains
• Menu Function keys Ấ
• LCD menu display ấ
ả
Ả
ạ
WELD
P1
GEN.
INFO
DPC II Plus v1.50
PRESS ENERGY
MORE INFO:
www.dukcorp.com/us/
HOLD
ấ
FAULT INPUT TEST
ON LINE OVERTEMP
OVERLOAD
OFF LINE
WELD
P2
MODE
Ạ
Ấ
AMP.
ADJUST
ENTER
CANCEL
Figure 4–1A DPC II Plus Front Panel Layout
ả
WELD
P1
GEN.
INFO
EZ Series v1.50
PRESS SYSTEM
MORE INFO:
www.dukcorp.com/us/
HOLD
ấ
FAULT INPUT TEST
OVERLOAD
OFF LINE
MODE
Ạ
Ả ON LINE
OVERTEMP
Ấ
AMP.
ADJUST
ENTER
CANCEL
ạ
Figure 4–1B DPC EZ Front Panel Layout
Dukane Manual Part No. 403–566–01
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DPC II Plus and EZ Welder System – User’s Manual
1. AC Power Section
Green
The front-panel AC power section has a switch and
power indicator that is shown in Figure 4-2.
Power
Indicator
ON/OFF
The AC power switch connects AC
power to the generator. This breaker
switch is wired in series with the rear
panel power switch (Figure 3–9). It also
serves as a circuit breaker that provides
overload protection for the DPC. Both
switches must be turned on to supply
AC power to the generator.
Green LED The green indicator above the switch
lights when the DC bus is up, after the
AC power has been switched on. At
this point the generator is capable of
producing an ultrasonic output signal.
Front
AC Power
Switch
Figure 4–2 Front Panel AC Power Section
2. Generator Status Panel
The Generator Status Panel is subdivided into three
sections which provide control and status displays.
1. Generator Control Keys
2. System Status Display
3. System Power Output Display
Generator Control Keys
The Generator Control Key section consists of three
keys as shown in Figure 4-3.
ON LINE
This places the generator in an opera-
tional state. It can produce an ultra-
sonic output signal when triggered.
ON LINE
Key
TEST
Key
OFF LINE
Key
TEST
The TEST key momentary activates the
generator to provide ultrasound out-
put for test or setup purposes. TEST
will only work in the ON LINE state.
Figure 4–3 Generator Control Keys
NOTE
If a Press module is installed, these keys are
only active if the Emergency Stop is not
engaged. If the Emergency Stop switch is
depressed, the System Status Display will
not be lit and the Control Keys inactive.
OFF LINE
This key places the generator in a
standby mode. This prevents the gen-
erator from producing an ultrasonic
output signal.
30
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Section 4 – Controls & Displays
System Status Display
The System Status Display indicates one of the six
system states. If that state is active, the correspond-
ing label is lit in the display. Figure 4-4 shows the
System Status Display with the ON LINE state acti-
vated. The six status conditions are described here.
FAULT
INPUT TEST
OVERLOAD
FAULT
This indicator lights when out-of-toler-
ance voltage fluctuations occur that are
related to one of the following condi-
tions.
1. AC Line Voltage
2. Internal DC Power Supply (+5VDC,
+12 VDC, -12V DC or +24V DC.)
INPUT TEST This indicator normally flashes red dur-
ing a power-up test. If there is a prob-
lem, a steady red light appears. This
means that either the inputAC line volt-
age is out of tolerance, or an internal
fault has occurred in the generator.
ON LINE
OVERTEMP
OFF LINE
Figure 4–4 System Status Display
OVERLOAD This red indicator lights when either of
the following conditions occur.
1. An instantaneous overload caused
by a mismatch between the ultrasonic
signal and the resonant characteristics
of the acoustic stack (transducer,
booster and horn.)
2. Excessive power beyond the
generator’s rated output is being drawn.
ON LINE The generator is capable of operation.
OVERTEMP One of the power modules has over-
heated and the generator has shut down.
This may be caused by excessive dust
in the cooling channel or a cooling fan
failure.The generator will automatically
reset when the module temperature
drops below the trip point which is 75°C
(167°F).
OFF LINE The generator is in a standby mode. The
ultrasound output cannot be activated.
31
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DPC II Plus and EZ Welder System – User’s Manual
System Power Output Display
The tricolor System Power Output Display indi-
cates the percentage of ultrasonic power being
drawn by the load.
GREEN
Green
Eight green vertical bars indicating
10% to 80% power output are dis-
played during normal operation. Fig-
ure 4-5 shows the display indicating
80% output power.
Figure 4–5 Normal Operation
Yellow
Red
Two yellow bars for 90% and 100%
power output warn that the genera-
tor is operating near its maximum
rated output.
RED
YELLOW
The last red bar indicates that the
generator is in an overload condition
delivering more than its rated out-
put power. Figure 4-6 shows the red
overload and two yellow warning in-
dicators. The red warning indicator
lights up just prior to an overload
condition. The ultrasonic signal is
shut down when an overload condi-
tion occurs.
Figure 4–6 Warning Indicators
NOTE
The available output power is directly propor-
tional to the Amplitude setting.
Example: A 2200 Watt rated DPC set to 80%
Amplitude will overload at 1760 Watts.
x
(2200W 0.80 = 1760 Watts)
32
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Section 4 – Controls & Displays
3. Process Control Panel
Menu Function Keys
The menu keys are shown in Figure 4–7. Their
function is described going across each row start-
ing at the upper left.
Mode
Increment
Hold
Weld
General
Information
Pressure 1
Pressing the GEN. INFO key displays
Weld
Pressure 2
(DPC II Plus only)
Left
Arrow
the DPC model, the firmware version
and the installed modules. A readout
for a DPC II Plus equipped with both
a Press Control module and a Power
Signal Output Module is shown in
Figure 4–8A. The DPC EZ Series is
shown in Figure 4–8B. Press CAN-
CEL to return to the previous menu.
GEN.
INFO
GEN.
INFO
WELD
HOLD
P1
+
WELD
P2
MODE
AMP.
ENTER
CANCEL
–
ADJUST
The up arrow key increments the data
value each time it is pushed. Hold-
ing the key in continuously incre-
ments the value.This key is also used
to move the cursor up one line on a
menu selection screen
Amplitude
Adjust
Cancel
Right
Arrow
Decrement
Enter
Figure 4–7 Menu Keys
Pressing the HOLD key immediately
brings you to the Hold Time data
entry menu. You can quickly check
and/or change the setting using the
four arrow keys. Pressing ENTER
completes the process and returns
you to your last menu screen.
HOLD
DPC II Plus v1.50
PRESS + ENERGY
MORE INFO:
www.dukcorp.com/us/
Pressing the WELD P1 key displays
the parameter(s) for the first pressure
setting. The value(s) can be quickly
checked and/or altered without go-
ing back through the menu sequence.
Pressing ENTER completes the pro-
cess and returns you to your last
menu screen.
Figure 4–8A DPC II Plus GEN INFO Display
WELD
P1
EZ Series v1.50
PRESS SYSTEM
MORE INFO:
www.dukcorp.com/us/
Pressing the left arrow key selects
the next digit to the left of a param-
eter setting. The key is used when
entering values and moves the flash-
ing bar under the selected digit. The
selection wraps around to the right
digit after the left most digit posi-
tion is reached.
Figure 4–8B DPC EZ GEN INFO Display
NOTE
For three of the ‘hot’ keys (HOLD, WELD P1,
and WELD P2), data can only be entered or
modified after the programming setup is
completed.
33
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DPC II Plus and EZ Welder System – User’s Manual
Pressing the MODE key toggles be-
tween the Weld mode (displays val-
ues for last weld cycle) and the Setup
mode (displays main Process Setup
menu).
MODE
Pressing the right arrow key selects
the next digit to the right of a pa-
rameter setting. The key is used
when entering values and moves the
flashing bar under the selected digit.
The selection wraps around to the
left digit after the right most digit
position is reached.
Pressing the WELD P2 (DPC II plus
only) key displays the parameter(s)
for the second pressure setting only
if a dual pressure mode has been
previously selected. The value(s)
can be quickly checked and/or al-
tered without going back through
the menu sequence. Pressing EN-
TER completes the process and re-
turns you to your last menu screen.
WELD
P2
TIP
For any of the four ‘hot’ keys (HOLD, WELD P1,
WELD P2 or AMP. ADJUST), pressing the
CANCEL key instead of ENTER returns you to
the last menu screen without altering the value.
Pressing this key displays the current
ultrasound amplitude setting. This
can be adjusted from 40% to 100%
using the up and down arrow keys
marked + and - respectively. Press
ENTER to confirm the value.
AMP.
ADJUST
NOTE
Reducing the amplitude with the AMP. ADJUST
key reduces the maximum power available. If
the amplitude is reduced to 40% (the lowest
setting), the maximum available power will be
limited to 40% of the rated output power.
The down arrow key decrements the
data value each time it is pushed.
Holding the key in continuously dec-
rements the value. This key is also
used to move the cursor down one
line on a menu selection screen
Pressing the ENTER key com-
pletes the menu operation and dis-
plays the next decision or naviga-
tion menu.
ENTER
Pressing the CANCEL key discards
any values you may have changed
and returns you to the previous de-
cision or navigation menu.
CANCEL
34
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Section 4 – Controls & Displays
Data Entry Menu
Process Control Menu Display
The menu display is a backlit 4–line LCD with 20
characters per line. The top line of the display con-
tains the menu title (with a few exceptions).
The data entry screens have the parameter name
on the first line and the parameter value on the
third line. Use the left and right triangle keys to
select the digit and the Increment (+) and Decre-
ment (–) keys to change the value. Press the EN-
TER key to accept the value. A typical data entry
screen is shown in Figure 4–11.
Selection Menus
The selection menus have a triangular cursor at
the far right of the display. These menus may also
be thought of as a decision menu. Move the cursor
to the menu choice and press the ENTER key to
select your choice. Pressing the CANCEL key re-
turns to the previous selection menu. A typical se-
lection menu is shown in Figure 4–9.
WELD TIME
0.750 SEC
PROCESS CONTROL
WELD MODE
HOLD TIME
Figure 4–11 Typical Data Entry Screen
AFTERBURST
Figure 4–9 Typical Selection menu
Confirmation Menus
A confirmation menu requests a Yes or No entry
to continue the process. Select YES from the menu
and press the ENTER key to proceed.A typical con-
formation menu is shown in Figure 4–10.
RESET PART COUNT
NO
YES
Figure 4–10 Typical Confirmation Screen
35
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DPC II Plus and EZ Welder System – User’s Manual
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36
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SECTION 5
Rear Connectors
• Rear Panel Layout
• System Input
• System Output
• Optional Modules
• Internal Jumper Blocks
Rear Panel Layout ......................................... 39
System Input Connector ............................... 40
System Output Connector ............................ 42
Remote Amplitude Control ........................... 46
Power Output Module Option....................... 47
Press Control Module Option ........................ 48
Multi–Probe Module Options ........................ 50
Jumper Block Options ................................... 51
Status Driver Normal Selection State.....................51
Status Driver Selection..........................................51
Automation Cycle Stop or End Of Weld ...............51
Switch Debounce Filter Time Delay.......................51
Timer Board Enable/Bypass...................................51
System Control Inputs ..........................................52
Card Slot and Jumper Block Locations ..................52
Dukane Corporation •
• Ultrasonics Division
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DPC II Plus and EZ Welder System – User’s Manual
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38
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Section 5 – Rear Connectors
Rear Panel Layout
All of the connectors contained on the DPC II
Plus and the optional modules are shown below
in Figure 5–1. No generator will have all the mod-
ules shown. Specifically the Multi–Probe Control-
ler and the Press Control Modules are mutually
exclusive. The modules are shown here to indi-
cate their installed locations and connector types.
EEPROM Serial
Multi–Probe
Multi–Probe
Master U/S
Outputs
Programming Port
Slave U/S
Outputs
Power Signal
Output Monitor
(DPC II Plus only)
(DPC II Plus only)
Grounding
Lug
Press Base
Abort
Remote Amplitude
Control
Rear AC
Power Switch
Multi–Probe
System
Input
IEC
AC Power
Input
Master U/S
Input
Thruster
Operational
Control
(DPC II Plus only)
System
Output
Ultrasound
Output
Figure 5–1 DPC II Plus and EZ Welder Rear Panel Connectors
39
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DPC II Plus and EZ Welder System – User’s Manual
System Input Connector
CAUTION
The System Input is a HD-15 (high-density, 15
contact) female connector. Pin assignments are
shown in Figure 5–2. Table 5—I below lists the
pinout and signal name for the System Input con-
nector.A complete description of the input signals
and their function is given on the next page. Users
of custom automation will also find a list of wire
color codes for the Dukane 200–1203 I/O cable
assembly in Table 5—III. This cable is used to
connect the DPC to custom automation equipment
to control the welding process.
The System Input port
uses the same type of
connector as a standard
computer video monitor
port, but it is electrically
very different. DO NOT
Ꮨ
connect any video monitor devices
to this connector. Doing so may re-
sult in damage to both the video
device and the DPC.
5 4 3 2 1
1 2 3 4 5
6
10
6
10
15 14 13 12 11
11 12 13 14 15
Figure 5–2 HD-15F System Input Connector
Figure 5–3 Cable end of SYSTEM IN connector.
P
in
S
ignal Name
Signal Description
NOTE
1
+22VDC
Gnd
Current limited to 250 mA maximum
22VDC Return (DPC Chassis Ground)
Isolated Operate Input
The connector pinout in Figure 5–2 is
the female DPC panel connector. The
male cable end is a mirror image and is
shown in Figure 5–3.
2
3
4
Iso Oper In
Iso Common
Isolated Input Common (if jumper is
selected – Figure 5–9/SH707)
5
6
7
Iso Press Cntrl
Not Used
Gnd
Isolated Press Control
Spare Input Pin
22VDC Return (DPC Chassis Ground)
Switch Closure Operate Input
Pin Pin Pin Timer
MPC Probe
14 13 12 Setup File Selected
8
9
Sw Oper Input
Iso Auto Stop
0 0
0 0
0 1
0 1
1 0
1 0
1 1
1 1
0
1
0
1
0
1
0
1
File 1
File 2
File 3
File 4
File 5
File 6
File 7
File 8
Probe 1
Probe 2
Probe 3
Probe 4
Probe 5
Probe 6
Probe 7
Probe 8
Isolated Automation Stop Input —OR—
Isolated Automation End–Of–Weld
(set by jumper SH704 see Figure 5–12)
10 Not Used
11 HPPI
Reserved for Future Use
Hand Probe Press Inhibit
12 Setup I.D. Bit 0 Remote Setup Selection Bit #0 (LSB)
13 Setup I.D. Bit 1 Remote Setup Selection Bit #1
14 Setup I.D. Bit 2 Remote Setup Selection Bit #2 (MSB)
Note: 1 = Pin Grounded (to DPC chassis)
0 = Pin Open (no connection)
15 F P Lock
Front Panel Control Lock
Table 5—I System Input Connector Signals
Table 5—II Remote Setup File Selection
40
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Section 5 – Rear Connectors
Pin Color
Signal Desc
Note
Input Signal Description
Red used by Belden
may appear brown
1
2
Red
+22V
Pin 1 (+22V)
Also connected to
connector metal shell
This pin can supply +22VDC at up to 250mA to
power the user's automation controls.
Black
Gnd
3
4
5
Blue/Blk
Iso Oper In
Pin 2 (Gnd)
Pin 2 and 7 are the 22VDC and Operate returns
and are tied to the chassis ground.
Green/Wht Iso Common
Blue/Wht
Red/Blk
Iso Auto Cntrl
Reserved
Red used by Belden
may appear brown
6
Pin 3 (Isolated Operate In)
7
8
9
White/Blk Gnd
This pin is used to initiate the operate sequence.
The factory default setting is a non-isolated sink
requiring a dry contact closure to ground (pins 2
or 7). This input can be changed to a source or
fully isolated input by jumper block SH707. See
Figures 5–11, 5–12 and Appendix C.
White
Sw Oper Input
Orange
Iso Auto Stop
Reserved
10 Blue
Hand Probe
Press Inhibit
Black may be faint –
Don't confuse with 9
11 Orange/Blk
Remote Setup
Selection (LSB) may appear brown
Red used by Belden
12 Red/Wht
13 Green/Blk
Pin 4 (Isolated Common)
Remote Setup
Selection
This pin is used as the isolated return common if
jumper block SH707 is configured as a fully iso-
lated input (position JU726). See Figures 5–11,
5–12 and Figure C-5.
Remote Setup
Selection (MSB)
14 Black/Wht
15 Green
F P Lock
Table 5—III System Input Cable Color Code (P/N 200–1203)
Pin 5 (Isolated Press Control)
This input can be changed to a source or fully iso-
lated input by jumper block SH707. See Figures
5–11, 5–12 and Appendix C.
This input is designed to be used in conjunction
with the optional Press Control Board. The signal
is used to activate the thruster up and down. The
factory default setting is a non-isolated sink re-
quiring a dry contact closure to ground (pins 2 or
7). This input can be changed to a source or fully
isolated input by jumper block SH707. See Fig-
ures 5–11, 5–12 and Appendix C.
Pin 10 (Not Used)
Isolated input reserved for future use.
Pin 11 (Hand Probe Press Inhibit)
The adapter cable (P/N 200–1203) has pin 11
grounded to indicate a hand probe is connected.
Pins 12, 13, 14 (Remote Setup)
Pin 6 (Not Used)
These pins are used to select one of eight setup
files. When using the multi–probe controller mod-
ule (MPC), these bits also select which probe is
activated. A dry contact closure between pins 12,
13 or 14 and ground (pins 2 or 7) will activate one
of the setup files. The pin combinations to select
setup files 1 through 8 are given in Table 5—II.
Note that file 1 is the default selection.
Isolated input reserved for future use.
Pin 7 (Gnd)
Pin 2 and 7 are the 22VDC and Operate returns
and are tied to the chassis ground.
Pin 8 (Operate)
A dry contact closure (no voltage) between pin 8
and ground (pins 2 or 7) will initiate the operate
sequence and is functionally the same as pin 3.
Pin 15 (F P Lock)
Pin 9 (Isolated Auto Stop)
A dry contact closure between pin 15 and ground
(pins 2 or 7) will lock out the front panel TEST
key and prevent it from being activated. This also
prevents any programming changes.
This signal stops the operation sequence. The fac-
tory default setting is a non-isolated sink requir-
ing a dry contact closure to ground (pins 2 or 7).
41
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DPC II Plus and EZ Welder System – User’s Manual
System Output Connector
The System Output panel connector is a DB-
25 Female type. Pin numbers are shown in Fig-
ure 5–4 and pin assignments are given in Table
5—IV. Dukane cable assembly P/N 200–1302
is used to connect the DPC to custom automa-
tion equipment to monitor the welding process.
A complete description of the signals and their
function is given on the following pages.
13 12 11 10 9
8
7
6
5
4
3
2
1
25 24 23 22 21 20 19 18 17 16 15 14
Figure 5–4 DB-25 System Output Connector
Pin Signal Name
Signal Description
CAUTION
1
2
3
4
5
6
7
8
9
+22VDC
Gnd
Current limited to 250 mA maximum
22VDC Return
(DPC Chassis Ground)
Gnd
Status Driver Output Ground (DPC Chassis Ground)
Ꮨ
Stat Drv
Not Used
U/S Active
Sys Fault
O T Fault
O L Fault
Status Driver Output
(1 amp maximum)
The System Output
port uses the same
type of connecor as
a standard RS-232,
DB-25 serial inter-
face, but it is
electrically very dif-
ferent. DO NOT
connect any RS-232
devices to this con-
nector. Doing so may
result in damage to
both the serial de-
vice and to the DPC
internal circuitry.
Spare Output Pin
Ultrasound Status Output
System Fault Output
Overtemperature Fault Output
Overload Fault Output
On Line Status Output
Status Outputs Ground
(Active Low)
(Active Low)
(Active Low)
(Active Low)
(Active Low)
10 On Line
11 Gnd
(DPC Chassis Ground)
1
12 Loop Fault
13 Gnd
4–20 mA Current Loop Fault Output
(Active Low)
Monitor Outputs Ground
Frequency Monitor Output
Amplitude Monitor Output
Power Signal Monitor Output
(DPC Chassis Ground)
(31Vrms maximum)
(10.0V = 100%)
14 Freq Out
15 Amp Out
16 Pwr Sig
2
(1mV = 1 watt)
3
17 Pwr Reg Stat Power Regulation Status Output
(Active Low)
4
18 MPC Ready Multi–Probe Controller Ready
(Active Low)
19 Iso Pwr Fail Isolated Power Fail Signal
(Active Low)
5
20 Iso BSP
21 Iso GP
22 Iso RDY
23 Iso ID
Isolated Bad/Suspect Part Output
(Active Low)
(Active Low)
(Active Low)
(Active Low)
(Isolated Gnd)
5
Isolated Good Part Output
Isolated Ready Signal
Isolated In–Dwell Signal
Isolated Outputs Common
Spare Output Pin
24 Iso Com
25 Not Used
Table 5—IV System Output Connector Signals
42
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Section 5 – Rear Connectors
Output Signal Description
Pin 1 (+22V)
This pin can supply +22VDC to supply power for
user automation controls. It is limited to 250mA.
Pin 2 (Gnd)
Pin 2 is the 22VDC and Status Out return. It is tied
to the chassis ground.
Pin 3 (Gnd)
Pin 3 is the 22VDC and Status Out return. It is tied
to the chassis ground.
Pin 4 (Status Driver)
An active low output on pin 4 indicates the condition
set on Jumper Block SH702 has occurred (see Fig-
ures 4-7 and 4-8).The factory default is OVERLOAD.
Pin 5 (Not Used)
Pin 5 is reserved for future use.
Pin 6 (U/S Active)
An active low output on pin 6 indicates the ultra-
sound is being delivered to the probe.
Pin 7 (System Fault)
An active low output on pin 7 indicates the generator
has detected an out of tolerance voltage fluctuation.
The front panel status display will indicate FAULT.
Pin 8 (OVERTEMP)
An active low output on pin 8 indicates that one of
the power modules in the generator has overheated
and automatically shut down. The front panel status
display will indicate OVERTEMP.
Pin 9 (OVERLOAD)
NOTE
An active low output on pin 9 indicates that exces-
sive power beyond the generators rated output is be-
ing drawn. The ultrasonic signal is shut down when
an overload condition is detected. The front panel
status display will indicate OVERLOAD. The over-
load signal resets when the operate input deactivates
or the TEST switch is released.
Active Low outputs are open collector
Darlington transistors that sink current to
ground (either chassis ground or isolated com-
mon @20mA maximum).
Custom automation users must supply their own
pullups. See Appendix C for sample circuits.
43
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Pin 10 (ON LINE)
An active low output on pin 10 indicates the gen-
erator is on line and is capable of being triggered
externally. The front panel status display will indi-
cate ON LINE.
Pin 11 (Gnd)
Pin 11 is the 22VDC and Status Out return. It is tied
to the chassis ground.
Pin 12 (Current Loop Fault)1
An active low output on pin 12 indicates the 4–20mA
current loop output has a fault. This output is only
available when a Remote Amplitude Control mod-
ule is installed.
Pin 13 (Monitor Gnd)
Pin 13 provides a return path to the chassis ground
for the monitor outputs on pins 14, 15 and 16.
Pin 14 (Freq Out)
The signal on pin 14 is the actual output frequency.
It is a sine wave with an amplitude of 31Vrms maxi-
mum.
Pin 15 (Amp Out)
The signal on pin 15 is proportional to the output
signal amplitude. The scale is 10.0V = 100%. This
allows automation equipment to monitor the DPC
amplitude setting.
Pin 16 (Pwr Sig)2
This output is only available when the optional Power
Signal Output module (part 438-826 ) is installed.
The signal on pin 16 is proportional to the true RMS
ultrasonic output power being drawn from the DPC.
The scale is 1mV = 1Watt on the 20kHz, 30kHz and
40kHz models. The maximum full scale output is
4.095V (4,095 Watts). On the 50kHz and 70kHz
models, the scale factor is 10mV = 1 Watt with a
maximum scaled output of 409.5 Watts.
Pin 17 (Pwr Reg Status)3
This option is not currently available.
44
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Section 5 – Rear Connectors
Pin 24 (Iso Common)5
Pin 18 (MPC Ready)4
Pin 24 provides the return path for the isolated out-
put signals on pins 19, 20, 21, 22 and 23.
An active low output on pin 18 indicates the MPC
module (Multi–Probe Controller) is ready and will
accept probe selection changes on the Remote Setup
inputs.
Pin 25 (Not Used)
Pin 25 is reserved for future use.
Pin 19 (Iso Power Fail)
An active low output indicates thatAC power is within
operating range. This output will turn off (high im-
pedance state which no longer sinks current), if the
AC power fails or is switched off.
Pin 20 (Iso Bad/Suspect Part)5
An active low output that indicates the weld cycle is
outside the boundary limits set in the Bad Limits
menu. This signal activates when the ultrasonic out-
put is terminated at the end of the weld. The de-
fault setting is maintained which means the signal
remains active until the beginning of the next cycle.
If the Utilities menu option is set to momentary,
the signal is pulsed for 100 msec.
Pin 21 (Iso Good Part)5
An active low output that indicates the weld cycle
did not cross the boundary limits set in the Suspect or
Bad Limits menu. This signal activates when the ul-
trasonic output is terminated at the end of the weld.
The default setting is maintained which means the
signal remains active until the beginning of the next
cycle. If the Utilities menu option is set to momen-
tary, the signal is pulsed for 100 msec.
Pin 22 (Iso Ready)
FOOTNOTES
An active low output that occurs at the end of all
portions of the weld cycle. The signal remains ac-
tive until the beginning of the next cycle.
1
2
3
4
5
Requires a Remote Amplitude Control module.
Requires a Power Signal Output module.
Not presently available.
Pin 23 (Iso In–Dwell)
Requires a Multi–Probe Controller module.
Requires the standard DPC II Plus timer feature.
This output is active low while the ultrasonic output
signal has been turned off during the HOLD time of
the weld cycle.
45
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DPC II Plus and EZ Welder System – User’s Manual
100%
80%
60%
Remote Amplitude Control
Module
Part No. 438–799
This optional module enables remote control of
output amplitude of the DPC II Plus. The control
interface is a 4–20mA current loop. The current
loop connector and fault indicator are shown in
Figure 5–5. The output can be adjusted from 36%
to 100%. The scale factor is ∆16mA = ∆64%
which is ∆1mA = ∆4%. The graph of output as a
function of loop current is shown in Figure 5–6.
The input compliance is 10 volts minimum.
)
Out% = (20% + 4 ILoop
%
e.g. Determine %Output delivered
for an 8mA Loop Current
x
20 + 4 8 = 52%
Out% – 20
ILoop
=
mA
4
e.g. Determine ILoop needed
for a 75% Output
75 – 20
= 13.75mA
4
40%
36%
JU2
Output
Enabled
Current
Loop
20%
Fault
Region
Failure to provide between 4mA and 20mA of loop
current is detected as a fault and will not produce
any output. The current loop fault indicator is a bi–
color LED. It is green when the current is between 4
and 20mA and red when the current is below this
value.The module contains an internal jumper block
(SH1) to select the current loop fault option. The
default setting (jumper JU1) disables ultrasonic
output if a loop fault occurs The setting can be
reversed with JU2 to enable the minimum level output
(36%) if a loop fault occurs. This is used primarily
for system testing when a current loop is unavailable.
Output
Disabled
JU1
0%
4mA
0mA
5mA
10mA
15mA
20mA
Figure 5–6 Current Loop Transfer Function Graph
NOTE
The equations for Out% and I
for normal operating conditions —
36% < Out% < 100% and
are only valid
Loop
4mA < I
< 20mA
Loop
Remote Amplitude
Control Module
P/N 438–799
Current Loop
Fault Indicator
NOTE
If you have a Re-
mote Amplitude
Control module in-
stalled, its setting
will override any
front panel setting.
The front panel
menu will accept
the value, but the
output amplitude
will be determined
by the 4–20mA
loop current.
Current Loop
Connector
Figure 5–5 Remote Amplitude Control Module
46
Dukane Manual Part No. 403–566–01
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