Dukane P220 User manual

P220
ULTRASONIC
PNEUMATIC
PRESS SYSTEM
USER MANUAL
www.dukane.com [email protected]

Copyright © 2023
Dukane
2900 Dukane Drive
St. Charles, IL 60174 USA
Noce of Rights:
All rights reserved. No part of this manual including the interior design, cover design and icons may be


Noce of Liability:




described herein.



Dukane Part Number: 403-624-00
Dukane ultrasonic equipment is manufactured under one or more U.S. Patents.



SECTION 1 - Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introducon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 - Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
General Consideraons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Ultrasonic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Grounding for RFI Suppression. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 3 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Before Installaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AC Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Unpacking the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Placement on a Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Air Supply Connecons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Cable Connecons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
System Inputs/Outputs Signal Pinouts on the J5 Connector . . . . . . . . . . . . . . . . . . 18
System Inputs/Outputs Signal Descripons on the J5 Connector . . . . . . . . . . . . . . . 19
Contents

SECTION 4 - Tooling Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Aaching the Fixture on the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Installing the Ultrasonic Stack Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Adjusng the Thruster Posion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Aligning the Fixture. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SECTION 5 - Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Control and Indicators Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Press System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Press Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Pneumac Controls, Gauge, and Ultrasound Indicator . . . . . . . . . . . . . . . . . . . . . 31
Pneumac Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Posion Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Mechanical Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operang Safety Switch Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
E-Stop Switch Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Generator Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
SECTION 6 - Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Press Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Operang Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Model Outline Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
P220 System Number Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
P220 Generator Number Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
P220 Thruster Number Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
SECTION 7 - Alarm Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SECTION 8 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Six-Month Periodic Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Contacting Dukane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Dukane ISO Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Contents


403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
SECTION 1
Introducon

2

403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
Introduction
Press System Overview



General User Information


Figure 1-1 Typical Press System
FIXTURING
COLUMN
BASE
ULTRASONIC STACK
THRUSTER
GENERATOR


3
403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
Drawings and Tables


Notes, Cautions and Warnings


    

Condion
or Pracce
Electrical
Hazard
Hearing
Protecon
NOTE


CAUTION


result in damage to the equipment
or other property.
WARNING




4

403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
SECTION 2
Health and Safety


5
403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
Health and Safety
General Considerations
Safe Operation
Please observe these health and safety recommendaons

Proper Installaon
installed.
No Unauthorized Modicaons - Do not modify your system in any
         
   

Keep the Cover On - Do not remove any equipment covers unless directed


Grounded Electrical Power

See Electrical Safety
Comply with Regulaons


Use Eye Protecon
Acousc Stack Hazard 


System Abort Switch

handling equipment in an automated system.
Foot Switch

System Electrical Cabling

NOTE


guide refers to a complete group


ultrasonic assembly system.
WARNING



be guarded as necessary. Dukane
does not assume any responsibility

by the customer or any third party
manufacturer.
CAUTION

to remove equipment covers by

Group personnel. Before doing so,
disconnect the system electrically

including the generator and press.
WARNING




6

403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
Ultrasonic Pressure
CAUTION

    
    
annoying or uncomfortable sounds.
    
enclosures, or materials that absorb
sound may be located to surround
the system. Ultrasound pressure level

CAUTION

    
system equipment, make sure electrical

      
     
    


     
    
     
    
   
or materials that absorb sound may be
located to surround the system.
WARNING
Keep head, hands, limbs and body at
       
   




7
403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
Figure 2-2
Grounded, 3-Prong Receptacle
Electrical Safety
       

• P220 Generator
• 
        
grounding and RFI suppression grounding.
North American Power Grounding
         



International Power Grounding
       
        
        



CAUTION
              
      
Electric Code and any local codes and ordinances that apply.






Figure 2-1
Grounded, 3-Prong Receptacle
Grounding Contacts
Typical Outlet
Provided Cable
Figure 2-3
Grounded, 3-Prong Receptacle

8

403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
Grounding for RFI Suppression






Operate Switches


CAUTION



Earth
Ground
#14 Gauge
Stranded or
Solid Wire
Fixed Probe Mount
or 2nd Chassis
Grounding Stud
3rd Chassis
Grounding
Stud
Chassis Grounding
Stud
Recommended protective
earth ground connection
wire color: green or green
with yellow stripe.


9
403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
FCC
         

• 

CE Marking



• 

EN 55011
 
EN61000–4–2
EN61000–4–3
EN61000–4–4
EN61000–4–5
EN61000–4–6
EN61000–4–8
EN61000–4–11
• 
• 
• 

measurement, Control and Laboratory Use.
IP Rating
            


UL


UL 61010–1, IEC 61010-1
CAN/CSA

Regulatory Agency Compliance
CAUTION
Do NOT make any

the generator or
associated cables
as the changes may



equipment is
manufactured.

10
SECTION 3 | INSTALLATION
403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
SECTION 3
Installaon

SECTION 3 | INSTALLATION
11
403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
Before Installation
         
generator and press, please consider these important

• 
• 
• 
• Placement
When to Use Lockout / Tagout Devices



Figure 3-1
Figure 3-2
WARNING

generator, press, and remote controller units .


device to each component.

12
SECTION 3 | INSTALLATION
403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
AC Power Requirements

Generators
TABLE 3-1 NOTES:
1. 
2. 
3. 
Table 3-1
Operating
Frequency
Generator Model
Number
Overload
Power
Ratings
(Watts)
Input AC Power Requirements
Nominal AC Volt at Maximum
RMS Current
North America/
Japan AC Outlet
Rating
Output
Voltage
(Nominal)
Output
Current
(Max)
  1200  15A 1300 1.0
  1800  15A 1300 1.5
  2600  15A 1300 2.2
  3600  20A or 30A 1300 3.0
AC Power Cords
Detached Cords
                  

Aached Cords

cords
Connent of Use Power Cord
Part Number
Voltage / Current
North America 200-1109 
200-1110 
Europe 200-1111 
India 200-1612 
China 200-1876 
Table 3 - 2 S

SECTION 3 | INSTALLATION
13
403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
Unpacking the System
The system has been assembled and packaged at the factory for shipment. Depending on the system, components may be





1. 
2. Remove the packing material, and temporarily set aside any other system components, leaving the press on the pallet.
3. 
Placement on a Workbench




Model Description
Weight

lbs kg
P220TMED on 43P290  260 118
P220TMED 
 65 30
Table 3-3

14
SECTION 3 | INSTALLATION
403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL

  


Figure 3-3
Figure 3-4

SECTION 3 | INSTALLATION
15
403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
Air Supply Connecons
1. 

Figure 3-5
NOTE

Provide adequate cooling air for your


 

3
 

3

16
SECTION 3 | INSTALLATION
403-624-00 P220 Pneumatic Ultrasonic Press System USER MANUAL
CAUTION
           


DO NOT   
            
possible damage to the generator.
Cable Connecons

• Ultrasonic Generator
• Press

1. 
2. 
3. 
4. 