Dukane 5000 Series User manual

www.dukane.com/us
Dukane IAS, LLC • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 - 4900 • FAX (630) 797 - 4949
Dukane Part No. 403 - 589- 01
Linear Vibration Welder
5000 Series
Model VW - 5300 / 5500 / 5700 / 5900 / 5960
Model VW - 5700 / 5900 / 5960 - LPT
User's Manual
ISO 9001:2000
Dukane products are manufactured
in ISO registered facilities

Printed in the United States of America.
Dukane Part Number: 403 - 589 - 01
Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents:
(* = Inactive)
3,772,538 3,780,926 3,825,481 3,832,019 4,131,505 4,208,001 4,277,710
5,798,599 5,880,580 6,984,921 7,225,965 7,475,801 7,819,158 8,052,816
8,245,748 8,720,516 8,721,817 9,144,937
Copyright © 2016 Dukane Intelligent Assembly Solutions
2900 Dukane Drive
St. Charles, IL 60174 USA
Notice of Rights:
All rights reserved. No part of this manual including the interior design, cover design and icons
may be reproduced, transmitted or utilized in any form or by any means, electronic, mechani-
cal, photocopying, recording, or by any information storage and retrieval system, without written
permission from Dukane.
Notice of Liability:
The information contained in this manual is distributed on an “as is” basis, without warranty.
While every precaution has been taken in the preparation of this manual, Dukane shall not have
any liability to any person or entity with respect to any liability, loss, or damage caused or alleged
to be caused directly or indirectly by the instructions contained in this manual, or by the hardware
products described herein.
Specications are subject to change without notice.
This user’s manual documents product features, hardware, and controls software available
at the time this user's manual was published.
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Linear Vibration Welder 5000 Series User’s Manual
Dukane Manual Part No. 403-589-01

Revision History
Revision Revision
Number Summary Date
- 00 Initial Release 3/9/2017
- 01 Updated parts list, LPT model info, 8/9/2017
CSA details added
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Contents
Section 1- Introduction 1
Section 2 - Health and Safety 7
Section 3 - Installation 15
Section 4 - Display and Controls 25
Section 5 - Normal Weld Cycle 33
Section 6 - Touch Screen 39
Section 7 - Tooling Installation 101
Section 8 - Machine Operation 117
Section 9 - Optimizing Performance 123
Section 10 - Troubleshooting 129
Section 11 - Maintenance 139
Section 12 - Contacting Dukane 145
Section 13 - Specications 149
Section 14 - Appendices 163
Index 175
Linear Vibration Welder
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Linear Vibration Welder 5000 Series User’s Manual
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SECTION 1
Introduction
General User Information ......................3
Welder Overview .............................4
Key Features ................................5
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Linear Vibration Welder 5000 Series User’s Manual
Dukane Manual Part No. 403-589-01

Read This Manual First
Before operating the linear vibration welder, read this
User’s Manual to become familiar with the equipment.
This will ensure correct and safe operation. The manual
is organized to allow a uers to learn how to safely operate
this equipment. The examples given are chosen for their
simplicity to illustrate basic operation concepts.
Notes, Cautions and Warnings
Throughout this manual we use NOTES to provide
information that is important for the successful application
and understanding of the product. A NOTE block is shown
to the right.
In addition, we use special notices to make you aware
of safety considerations. These are the CAUTION
and WARNING blocks as shown to the right. They
represent increasing levels of important information.
These statements help 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 an operator protection
issue.
CAUTION
Caution statements
identify conditions or
practices that could result
in damage to the equipment or other
property.
WARNING
Warning statements
point out conditions or
practices that could re-
sult in personal injury or
loss of life.
NOTE
Note statements provide important
information or highlight procedures.
Drawings and Tables
The gures and tables are identied by the section number
followed by a sequence number. The sequence number
begins with one in each section. The gures and tables
are numbered separately. The gures use Arabic sequence
numbers (e.g. –1, –2, –3) while the tables use Roman
sequence numerals (e.g. –I, –II, –III).As an example, Figure
3–2 would be the second illustration in Section Three while
Table 3–II would be the second table in Section Three.
Condition
Or Practice
Electrical
Hazard
Operator
Protection
(Hearing)


General User Information
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Dukane Manual Part No. 403-589-01
Section 1 - Introduction

Welder Overview
The linear vibration welder excels at joining large
assemblies and parts made from glass–lled and high
performance plastics.
The VW5X00 (Vibration Welder 5300/5500/5700/5900)
family is Dukane’s fourth generation linear vibration
welder. These systems all share the same basic
mechanical components. Software and controls are
signicantly improved in this fourth generation.
The VW5X00 differences are in the size of tooling they
can accommodate. The tooling capacity for each model is:
VW5300 .................24 in. wide by 18 in. deep
610 mm wide by 457 mm deep
VW5500 .................38 in. wide by 18 in. deep
965 mm wide by 457 mm deep
VW5700 and VW5700LPT
52 in. wide by 24 in. deep
1,321 mm wide by 610 mm deep
VW5900 and VW5900LPT
72 in. wide by 24 in. deep
1,828 mm wide by 610 mm deep
VW5960 and VW5960LPT
62 in. wide by 24 in. deep
1,575 mm wide by 610 mm deep
Most VW5X00 models have the same vertical clearance
of 26 inches (660 mm) between the lift table and upper
springs, and have a 20-inch (508 mm) stroke. The
VW5960 and VW 5960LPT has 43 inches between the lift
table and the upper tool mounting plate. These machines
have 29 inches (736mm) of stroke.
Unlike competing machines, the upper vibration spring
is not held in place by a swing frame. It incorporates
a frameless design which has less vibrating mass to
accommodate heavier tooling and provide additional
tooling clearance.
The hydraulic system uses a commercial, readily
available, self–contained system. This allows customers
to do some of their own parts replacement, and it
minimizes costly eld service calls.
The new and larger color operator interface is also a
commercial unit containing Dukane’s eld–tested and
proven control software and interface. Every subassembly
has been selected to provide the maximum reliability with
a long and economical service life. The electrical cabinet
has been redesigned to increase reliability, minimize
electrical noise and meet the applicable CE regulations.
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Linear Vibration Welder 5000 Series User’s Manual
Dukane Manual Part No. 403-589-01