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Duro Dyne Mach I User manual

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- 1 -
OWNER’S
MANUAL
AUTOMATIC BULK
FEED PINSPOTTER
MACH II
MACH I / MACH II
MACH I / MACH II
MACHINERY
DIVISION
Owner’s Manual for
Mach I:
SN# 40112 to 40384
Mach II:
SN# 41044 to 41167
Approx:
March ‘05 to June ‘09
- 2 -
INTRODUCTION
Duro Dyne is proud to introduce the next generation bulk feed con-
cept of our popular FG-1 pinspotter. The Mach I and Mach II Pinspot-
ters were designed utilizing the best of current technologies to
provide greater power and reliability for insulation fastening.
Trouble free service was the foundation on which the original FG-1 was
built, with proven solid state components located for easy access.
The Mach I and Mach II series continue this concept and bring it
to a new level of reliability, serviceability and efficiency.
This Guide is designed to help you set up and operate your Mach I
or Mach II at peak performance for years to come.
IMPORTANT
Always follow manufacturer’s recommendations for proper safety
and handling procedures for all materials used in conjunction with
this machine as outlined in Manufacturer’s Safety Data Sheet
(MSDS) for each product.
LIMITED WARRANTY
Duro Dyne Machinery is manufactured by skilled mechanics, utilizing
the latest production techniques. Each unit has been rigorously
tested prior to packaging and shipment in order to ensure trouble-
free operation.
Your Duro Dyne machine has a two year warranty against defects
in material. Any component found to be defective will be repaired or
replaced (at the manufacturer’s discretion) at no cost if the faulty
component is returned freight prepaid to the nearest Duro Dyne
Service Department.
The warranty does not apply to expendable parts or repairs or service
due to improper maintenance or operation procedures.
Duro Dyne products have been engineered to maximize operator safety.
Unauthorized modification of this product will void the warranty.
All warranty claims must be accompanied by a serial number, date
of purchase and the name and address of the distributor it was
purchased from.
TABLE OF CONTENTS
Installation Instructions 10
Introduction 2
Maintenance 14
Operation 10
Parts List 23
Parts Locator 3-9
Servicing 15
Troubleshooting 16-22
Warranty 2
Wiring Diagrams 12-13
- 3 -
17340 Vibrator Bowl
17368 2 inch Vibrator Bowl
17341 Vibrator Coil
44004 Vibrator Line Cord
17079 Vibrator Foot
17338 Vibrator Base Plate
17257 Vibrator Support Casting
44045
Weld Cable Guard
17317 Feed Speed Control
44014 Feed Solenoid
17364 Feed Cylinder
17269 Feed Cylinder Bracket
17351 Pusher and Pawl
17266 Feed Channel
17348 Feed Channel Plate
44013 Feed Channel Spacer
17339 Vibrator Base
44001 Vibrator Sensor Cord
44002 Vibrator Sensor
44003 Vibrator Sensor Bracket
44008 Upper Feed Track
44016 Power Bar
44056
Upper Dwell Cylinder Bracket
17359 Bracket Insulator
44009 Upper Track Side Rails
44011 Lower Track Side Rails
44010 Lower Feed Track Casting
44017 Weld Cable
17394 Short Shaft Extension
17203 Fiber Insulator
17190 Replacement Plates
17192 Lower Weld Tip
17189 Replacement Plates
17191 Upper Weld Tip
17352 Upper Tip Retainer
17376 Lower Mandrel
PARTS LOCATION
DWELL & FEED ASSEMBLY
17133
- 4 -
44043 Dwell Cover
44044 Feed Cover
17377 Air Regulator
17372 Footswitch
44023 Control Module
44046 Component Module
44035 MACH I Power Pack
44036 MACH II Power Pack
44037 Power Pack Cover
PARTS LOCATION
FRAME ASSEMBLY
- 5 -
44041 Line Cord
44042 Line Cord Strain Relief
(Not Shown)
44040 Mach II Weld Transformer
44019 Weld Cable Camlock
17327 Footswitch Receptacle
PARTS LOCATION
44036 MACH II POWER PACK
- 6 -
PARTS LOCATION
44035 MACH I POWER PACK
17209 Line Cord
17210 Strain Relief
44038 Mach I Right Transformer
44039 Mach I Left Transformer
17327 Footswitch Receptacle
- 7 -
PARTS LOCATION
CONTROL CONSOLE
44026 Weld Poteniometer
39110 Pin Feed Switch
44025 LCD Display
44024 Main On/Off Switch
44023 Control Module
44029 Relay Selector Switch
44030 Troubleshooting Display Board
44008 Upper Feed Track
44031 Vibrator Potentiometer
44027 Knob
44032 Vibrator Lamp
44033 Vibrator Power Switch
44034 Weld Lamp
44010 Lower Feed Track Casting
44018 Weld Cable Retainer Block
17333 Vibrator Speed Control
Located Inside Control Module
17256 Vibrator Socket
44006 Vibrator Socket Guard
44007 Vibrator Circuit Breaker
44027 Knob
- 8 -
44008 Upper Feed Track Casting
44021 Head Mounting Plate
17359 Bracket Insulator
17363 Dwell Reed Switch
17231 Dwell Cylinder
44015 Dwell Solenoid
44057 Bracket Insulator
17237 Lower Dwell
Cylinder Bracket
17325 Pressure Switch
39353 Anti Friction Strip
44010 Lower Feed Track Casting
44056 Upper Dwell
Cylinder Bracket
17363 First Pulse Reed Switch
(not shown)
44020 Head Terminal Strip
17356 Adjustable Muffler
17363 Feed Reed Switch
PARTS LOCATION
HEAD & FEED ASSEMBLY
- 9 -
17319 Dwell Extend Timer
17222 Terminal Strip-
Low Voltage
17323 Short Cycle Relay
17302 Weld Timer
44090 Vibrator Control Relay Board
44051 Relay Board
17323 First Pulse Relay
17222 Terminal Strip-
Low Voltage
44091 24V Multi-Tap Transformer
44052 12 Volt DC Power Supply
44048 Terminal Strip-
High Voltage
44047 Power Contactor
39306 Incoming Voltage Selector Switch
44053 Weld Relay
17318 Feed Timer
44054 Heat Sink
44091 24V Multi-Tap Transformer
PARTS LOCATION
COMPONENT MODULE
- 10 -
OPERATION
Mach I and Mach II INITIAL ADJUSTMENTS
1) Turn the power switch to “ON”.
2) Turn the vibrator switch to “ON”.
3) Add the weld pins to the hopper (vibrator bowl).
4) Adjust the vibrator speed so that the weld pins climb the spiral track inside the vibrator bowl without
vibrating off.
5) When the weld pins fill the track up to the proximity track sensor, the vibrator automatically shuts off.
6) Flip the head test switch to either the “WELD #1” or “WELD #2” position.
NOTE: Your Mach I and Mach II Pinspotter has two redundant weld circuits. In the event that the solid state
relay controlling the weld fails you may simply flip the switch to the other circuit and continue production.
A replacement Weld Relay should then be ordered through your local Duro Dyne wholesaler.
INSTALLATION INSTRUCTIONS
1a) For the Mach I -
Connect the power pack to a source of 208-230 V 30 Amp. power. The power supply line to the power
pack pigtail should be #8 (or heavier) wire to minimize voltage losses. The black and white wires are the
power, the green is ground.
1b) For the Mach II -
Connect the power pack to a source of 208-230 V 100 Amp. power. This service should be connected
to a 60 amp disconnect box fitted with 60 amp slow blow fuses. The power supply line to the power pack
pigtail should be #6 (or heavier) wire to minimize voltage losses. The black and white wires are the power,
the green is ground.
2) Attach the foot switch to the foot switch socket on the rear of the power pack.
3) Connect the air line to the regulator. Adjust the regulator pressure to 80-85 PSI.
4) Plug the vibrator power plug into the socket on the rear of the control panel.
TECHNICAL SPECIFICATIONS
Mach II
AIR REQUIREMENTS:
Input pressure 80 PSI.
ELECTRICAL:
Input voltage: 208-230 V 60 HZ
single phase. 100 amp service
Fuse for 60 amps. using slow blow fuses
TECHNICAL SPECIFICATIONS
Mach I
AIR REQUIREMENTS:
Input pressure 80 PSI.
ELECTRICAL:
Input voltage: 208-230 V 60 HZ
single phase.
Fuse for 30 amps. using slow blow fuses