Dukane TH3 User manual

www.dukane.com
Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 - 4900
Dukane Part No. 403 - 597- 01
TH3 - Thermal Hybrid Welder
Hot Gas, Infrared, & Hot Plate Welding
Model: TH3-1212
TH3-1432
TH3-2040
TH3-2460
User's Manual
Dukane products are manufactured in ISO
registered facilities

Copyright © 2020 Dukane
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, mechanical, 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.
Printed in the United States of America.
Dukane Part Number: 403 - 597 - 01
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Revision History
Revision Revision
Number Summary Date
00 Initial Release September 30, 2019
01 Add models TH3-1212 and TH3-2460. May 11, 2021
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Contents
Section 1- Introduction 1
Section 2 - Health and Safety 7
Section 3 - Installation 15
Section 4 - Display and Controls 23
Section 5 - Normal Weld Cycle 29
Section 6 - Touch Screen 35
Section 7 - Tooling Installation 73
Section 8 - Machine Operation 83
Section 9 - Optimizing Performance 89
Section 10 - Troubleshooting 93
Section 11 - Maintenance 97
Section 12 - Contacting Dukane 103
Section 13 - Specications 107
Section 14 - Appendix 115
Index 121
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SECTION 1
Introduction
General User Information ......................3
Welder Overview .............................4
Key Features ................................5
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Read This Manual First
Before operating the Thermal Hybrid 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 user 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.
General User Information
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Section 1 - Introduction

Welder Overview
The Thermal Hybrid welder excels at joining parts made
from glass–filled and high performance plastics with
minimum of particulate.
The TH3-XXXX differences are in the size of tooling they
can accommodate. The tooling capacity for each model is:
TH3-1212 ...............12 in. wide by 12 in. deep
305 mm wide by 305 mm deep
TH3-1432 ...............32 in. wide by 14 in. deep
813 mm wide by 355 mm deep
TH3-2040 ...............40 in. wide by 20 in. deep
1016 mm wide by 508 mm deep
TH3-2460 ...............60 in. wide by 24 in. deep
1524 mm wide by 610 mm deep
A large, color operator interface contains Dukane’s eld–
tested and proven control software. Every subassembly
has been selected to provide the maximum reliability with
a long and economical service life.
The electrical architecture if this machine series allows
a number of heating methods. Traditional heater/
thermocouple platens are one option. Infrared bulb heating
can provide more efcient, focused heating; hot gas heating
is a third option.
These Thermal Hybrid welders feature three independent
Servo-controlled motions. Parts are held on upper and
lower, vertically moving axis. Between these vertical axis
there is a heating platen which moves horizontally. The
heating platen moves forward, between the upper and
lower part plates. Once the parts are heated, the heating
platen moves rearwards out of the way. Then the upper
and lower part platens close together, joining the plastic
parts. Having independent servo control on the part platens
permits a variety of part height geometries. Servo motion
on all three axis provides rapid, smooth motion and soft,
controlled stopping.
All Dukane welders are CE/CSA/UL certied and meet
applicable regulatory and safety standards.
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Key Features
• Color Touch Screen Display uses Color Active Matrix
Thin-Film Transistors (TFT) for high contrast and
wide viewing angle even under high ambient–lighting
conditions. The display provides for all monitoring and
programming of the weld cycle.
• Intuitive User Interface allows for quicker machine
setup and less down time.
• English, Spanish, German, Japanese, or Chinese
menus shorten training time, reduce operator errors
and broaden the usefulness of the machine. (Other
languages are available.)
• Built-In Diagnostics minimize down time. Custom
automation outputs are a standard feature.
• Tooling Automation Capability options include pick-
and-place systems, conveyor and part feed systems.
Control for automation can be added to the core
software.
• Commercial Subassemblies are used to ensure a longer
and more economical service life than units built with
proprietary components. These readily available items
also lessen the need for expensive eld service calls.
• Rigid Square Tube welded tube frame with dual,
vertical linear rails.
• Digital Encoders for all 3 travel axis provide positioning
within .0005" (.013mm).
• Servo Electric Lift/Clamp System is self–contained.
Uses standard off the shelf components for ease of
maintenance and repair.
• Standard Software supports up to eight part presence
sensor inputs, and controls up to twelve programmable
valves, and eight vacuum valves.
• Dedicated Sensor Input for each programmable valve
with the option to enable or bypass.
• Servo Upper and Lower Part System (Fast, Precise)
• Servo Heater Plate Move (Fast, Precise)
• Hotplate & IR & Hot Gas
• Split Front Door for tall opening, easy part loading
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Section 1 - Introduction

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SECTION 2
Health and Safety
General Considerations .............................. 9
Special Health Notice ............................... 11
Electrical Safety ................................... 11
Pneumatic Safety ................................. 12
Operational Safety ................................. 13
High Temperature Safety ............................ 14
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General Considerations
Continued
Please observe these health and safety recommendations for
safe, efcient, and injury-free operation of your welder. In
this manual, the term welder and/or machine both refer
to the
Thermal Hybrid welder.
Proper Installation - Only operate the welder after all
tooling is installed and pneumatic and electrical systems
are properly setup.
No Unauthorized Modifications - Do not modify
your welder in any way unless authorized to do so by
Dukane. Unauthorized modications may cause injury
to the operator and/or equipment damage. In addition,
unauthorized modifications will void the equipment
warranty.
Keep the Service Doors Closed - Do not bypass or remove
any interlocks. High electrical voltages and elevated
temperatures are present which could cause injury or death.
Grounded Electrical Power - Operate this equipment only
with a properly grounded electrical connection. Refer to
the NEMA L16–30 wiring diagram in Figure 2-1 on Page
11. If there is any question about the grounding of yourAC
power, have it checked by a qualied electrician.
Comply with Regulations - You may be required to add
accessories to bring the system into compliance with
applicable OSHA regulations for machine guarding and
noise exposure.
Operate Safely – Do not operate the welder if under the
inuence of alcohol or drugs. Read the warning labels on
prescriptions to determine if your judgement or reexes are
impaired while taking drugs. If there is any doubt, do not
operate the machine.
WARNING
Never operate the Thermal
Hybrid welder with any of
the service doors open.
This is an unsafe practice
and can result in injury or
death.
Any xture manufactured by
a third party must comply
with all OSHA and ANSI
requirements. All fixtures
must be guarded as necessary.
Dukane does not assume any
responsibility or liability for
fixtures manufactured by the
customer or any third party
manufacturer.
WARNING
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Section 2 - Health and Safety

System Electrical Cabling - Electrical power must be
off when connecting or disconnecting electrical cables.
Do Not Wear Loose Clothing or Jewelry - These or
similar items can become caught in moving parts.
Stay Alert - Watch what you are doing at all times. Use
common sense. Do not operate the equipment when you
are tired or distracted from the job at hand.
General Considerations
CAUTION
When making cable connec-
tions to system equipment or
disconnecting cables from
system equipment, make
sure electrical power to the system is
turned off, and AC power cords are re-
moved from their receptacles. After the
cables have been securely connected
and the connections and cable routing
checked a nal time, the power may be
restored.
Continued from Previous Page
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Special Health Notice
Certain plastic materials, when being processed, may
emit fumes and/or gases that may be hazardous to the
operator’s health. Proper ventilation of the work station
should be provided where such materials are processed.
Inquiries should be made to the U.S. Department of Labor
concerning OSHA regulations for a particular plastic prior
to processing with Dukane welding equipment.
Electrical Safety
AC Power Cord
The customer must provide a suitable power entry code
rated for a minimum of 240VAC, 80 amps.
Do not use an extension cord. If there is any question
about the grounding or phasing of your AC power, have
it checked by a qualied electrician.
AC Power Disconnect
Always turn off the AC power at the disconnect switch
before opening any of the service doors or attempting
any maintenance on the welder. The recommended
practice is to also tag and lock out the disconnect switch.
The CE-compliant AC disconnect is standard. Turn
the switch to the off position as shown, then pull the
center horizontal bar out to insert a lockout as shown
in Figure 2-2.
Electrical Cabinet Door
The electrical cabinet service door is mechanically
interlocked to the CE-compliant AC power disconnect.
The cabinet door cannot be opened without rst turning
off the AC power.
Figure 2-1 240VAC 3-Phase,80A Disconnect Wiring
Figure 2-2 CE–Compliant AC Power Disconnect
with Lockout and Tag
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Section 2 - Health and Safety

Figure 2-3 Exterior Pneumatic Lockout Device with
Lockout and Tag
WARNING
Never operate the Ther-
mal Hybrid welder with
the electrical service door
open. This is an unsafe
practice and can result in
injury or death.
Pneumatic Safety
Always isolate and lock out the compressed air before
performing any maintenance on the Thermal Hybrid
welder. The isolation and lockout device is shown in Figure
2-3. The safety isolation device is installed externally, and
is in series with the internal compressed air lter. When
activated, this device will isolate the compressed air supply
from the air lter and pneumatic actuators in the welder.
This device complies with OSHA regulations.
Compressed air can develop a considerable amount of
force. The force is large enough to inict serious injury. The
Thermal Hybrid welder uses two air cylinders which convert
the air pressure to mechanical movement for opening and
closing the front access door.
With the right service doors open, you can see the
compressed air lter and pressure regulator. This is shown
in Figure 2-4. The ltered air is fed to the air distribution
manifold and pneumatic valves.
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Figure 2-5 Light Curtains
Operational Safety
The service doors are interlocked to prevent access while
the welder is energized. If either of the doors are opened,
the Thermal Hybrid welder will shut down. The electrical
cabinet is shown in Figure 3.1. It cannot be opened
without rst turning off the CE-compliant AC disconnect.
The front loading area is protected by a sliding access
door. This door is operated by two air cylinders which
are driven by compressed air. The door closes at the start
of a welding cycle to prevent access to the tooling and
platens. Sensors on the access door will stop the welder
if the compressed air fails and allows the door to open
partially during a weld cycle.
The safety light curtains prevent any access to the loading
area once the machine cycle has started and before the
access door is fully closed. Breaking the light beam while
the door is in transition will cause the machine to halt
operation. The light curtains are identied in Figure 2-5.
WARNING
Never attempt to remove
the lter housing while the
compressed air is on. Turn
off the compressed air us-
ing the pneumatic lockout
device, and make sure the
pressure gauge reads zero.
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Section 2 - Health and Safety
Light CurtainsLight Curtains
Air Distribution
Manifold
Main Pressure
Regulator
Adjustment
Main Pressure
Regulator
Gauge
Air In from
Lockout Device
Air Filter
Figure 2- 4 Internal Air Filter and Main Air Regulator

High Temperature
Safety
As the name implies, "Thermal" welding involves
considerable heat. Temperatures can be up to 750°F
(400°C). These high temperatures will burn even af-
ter power is removed from the machine. Extreme cau-
tion must be used whenever operating and servicing
equipment. Use a pyrometer to test the temperature of
components. Heavy, insulated gloves may be worn to
protect hands and ngers. Remember that hot metal
looks identical to cold metal. Pay careful attention to all
surfaces near the heater platen and heater platen drive
mechanism. Do not touch Infrared bulbs! They may be
hot, and are easily damaged by contact with the natu-
rally occuring oils on hands and ngers. Always wear
gloves when handling bulbs. Be careful of broken glass.
Bulbs are fragile and unbending!
It is unsafe to attempt to bypass the interlocks and op-
erate the welder with the side service doors open. The
interlocks are located at the top if the service doors.
Fig 2-6 shows a door interlock device and the mating
receptacle in the cabinet.
Figure 2-6 Side Service Door Interlocks
WARNING
Never operate the Ther-
mal Hybrid welder with
any of the service doors
open. This is an unsafe
practice and can result
in injury or death.
The rear service doors also
serve as acoustic shields.
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