Dukane AN400 User Manual

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Intelligent Assembly Solutions

The DPC 4 welding system offers several features that are intended to communicate with automation. These features
allow the automation to control and respond to events that occur during the welding process. This document will provide
guidelines that will help you interface automation to a DPC welding system per Dukane Corporation’s requirements.
Information within this document is intended to supplement the information in the DPC 4 manual (Dukane part # 403-557).

Automation Interface Requirements for J602 Basic I/O Interface

of a DPC 4 Welding System

Note: Early production models of the DPC IV welding system referred to J602 as the User I/O interface. The
functionality of the Basic I/O Interface and the User I/O Interface are identical. Only the name has changed.

Application Note Topics:

• The J602 Pin assignments

• The 200-1203 Basic Interface Cable

• Status Output Signal Descriptions

• Status Output Interface Examples

• System Input Signal Descriptions

• System Input Interface Examples

Basic I/O
Interface

AN400

© Dukane Corporation 2004. All rights reserved.

Dukane Corporation

2900 Dukane Drive Saint Charles, IL 60174 USA

Phone [phone] FAX [phone]

http://www.dukane.com/us

11101

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Intelligent Assembly Solutions

The J602 User Interface connector is the primary communications link between the DPC IV and user automation
equipment. This connector provides status signals that can be used to monitor DPC weld data analysis resu lts as well
as timing issues related to the processing of the weld sequence. It also provides the automation with dedicated
communication lines that allows the automation to control the beginning and the end of a welding sequence.

Pin Number DPC Signal Name DPC Signal Type

1 Power Suppl
2 Groun
3 Bad Part Output
4 Suspect Part (see note #2
5 Good Part Output
6 Ready (see note #1
7 Isolated Output Common Common Pin for Output Signals
8 Automation Input Input

9 Automation Stop N/C Input
10 Automation Stop N/O Input
11 Hand Probe Press Inhibit Input
12 Input Common Common Pin for Input Signals
13 Groun
14
15 Ground Detect Input

Note #1: This input can be reconfigured in the DPC IV menu choices to activate during

the following weld sequence event:

In Cycle
Sonics On
In Hold

Note #2: This input can be reconfigured in the DPC IV menu choices to activate during

the following weld sequence event:

Network Active
Sonics On

Note: Please refer to the Hardware Setup section of the DPC IV manual for details on

reconfiguring pin 4 or pin 6 to the required status output signal.

J602 User Interface Connector

+22 VDC (0.5 amp max)

Power Supply Return

Output

Output

Power Supply Return

AN400

© Dukane Corporation 2004. All rights reserved.

Dukane Corporation

2900 Dukane Drive Saint Charles, IL 60174 USA

Phone [phone] FAX [phone]

http://www.dukane.com/us

22102

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Intelligent Assembly Solutions

Status Output signals for the J602 Connector:

There are four status output signals available on the J602 connector. Each of these outputs are driven by a solid state
relay that creates a switch closure between the specified output pin and the Output Common pin. These pins can be
configured within the DPC software menus to provide a signal that accommodates the requirements of most automation
interface equipment. The available configurations for these output signals are:

Note: Please refer to the Hardware menu section of the DPC IV manual for further information on these features.

Active High Outputs – This setting will produce a closed switch condition between the spe cified outp ut pin and

the Output Common pin when the output signal is activated. (Factory default setting)

Active Low Outputs - This setting will produce an open switch condition between the specified output pin and

the Output Common pin when the output signal is activated.

Maintained Outputs - This setting will produce an output signal that is maintained from the completion of a

welding cycle until the beginning of the next welding cycle activation. (Factory default
setting)

Pulsed Outputs - This setting will produce an output signal that is pulsed a single time for 100 mS as the

end of the welding cycle.

Pin # Conductor Color

1 Red
2 Black
3 Blue / Black
4 Green / White
5 Blue / White
6 Red / Black
7 White / Black
8 White

9 Orange
10 Blue
11 Orange / Black
12 Red / White
13 Green Black
14 Black / White
15 Green

Part Number Length

200-1203 10 FT
200-1203-15 15 FT
200-1203-20 20 FT
200-1203-25 25 FT
200-1203-30 30 FT

AN400

© Dukane Corporation 2004. All rights reserved.

Dukane Corporation

2900 Dukane Drive Saint Charles, IL 60174 USA

Phone [phone] FAX [phone]

http://www.dukane.com/us

33103

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