Intelligent Assembly Solutions
Series
ULTRASONIC GENERATOR/POWER SUPPLY
ES
AUTOMATED HAND PROBE
PRESS
User's Manual
Dukane Part No. 403ꢀ–575ꢀ–00
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797–4900 • FAX (630) 797–4949
Dukane products are manufactured
in ISO registered facilities.
ISO 9001:2008
www.dukane.com/us
Download from Www.Somanuals.com. All Manuals Search And Download.
Revision History
Revision
Number
Revision
Summary
Date
- 00
Original release.
08/19/2011
Page iii
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page iv
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Contents
Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . 1
General User Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Press System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 2 - Health and Safety . . . . . . . . . . . . . . . . . . 5
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Lifting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 3 - Installation . . . . . . . . . . . . . . . . . . . . . . . 11
Before Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Placement in a Seismic Region . . . . . . . . . . . . . . . . . . . . . . . 16
Rear Panel Layout Overview . . . . . . . . . . . . . . . . . . . . . . . . . 18
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Connecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Recheck Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Connect AC Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Section 4 - Operation . . . . . . . . . . . . . . . . . . . . . . . . 39
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Start up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Stopping the Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
iQ Explorer Support Features . . . . . . . . . . . . . . . . . . . . . . . . . 42
Numeric Pad and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . 42
Help System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Quick Start - Servo Welder. . . . . . . . . . . . . . . . . . . . . . . . 44-55
Quick Start - Pneumatic Welder . . . . . . . . . . . . . . . . . . . . 56-69
Continued
Page
v
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Contents Continued
Section 5 - System Operational Testing. . . . . . . . . 71
Section 6 - Troubleshooting . . . . . . . . . . . . . . . . . . 79
Section 7 - Maintenance. . . . . . . . . . . . . . . . . . . . . . 93
Section 8 - Options. . . . . . . . . . . . . . . . . . . . . . . . . . 97
Section 9 - Contacting Dukane . . . . . . . . . . . . . . . 103
Section 10 - Specifications . . . . . . . . . . . . . . . . . . 107
Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Weights, Dimensions, Operating Environment. . . . . . . . . . . 112
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Interpreting the Model Number. . . . . . . . . . . . . . . . . . . . . . . 114
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . 115
Section 11 - Appendices . . . . . . . . . . . . . . . . . . . . 117
Appendix A - List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . 119
Appendix B - List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . 122
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Page vi
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 1 - Introduction
SECTION 1
Introduction
General User Information . . . . . . . . . . . . . . 3
Press System Overview . . . . . . . . . . . . . . . 4
Key Features . . . . . . . . . . . . . . . . . . . . 4
Page
1
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page
2
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 1 - Introduction
General User Information
Read This Manual First
Before operating your ultrasonic system, read this User’s
Manual to become familiar with the equipment. This will
ensure correct and safe operation. The manual is organized
to allow you to learn how to safely operate this equipment.
The examples given are chosen for their simplicity to il-
lustrate basic operation concepts.
This manual provides information to set up, operate, and
interface this generator/power supply as an integral part of
Dukane’s iQ Series ES press system.
NOTE
Note statements provide additional
information or highlight procedures.
Particular models are listed in Section 10 - Specifications
.
Notes, Cautions and Warnings
Throughout this manual we use NOTES to provide infor-
mation that is important for the successful application and
understanding of the product. A NOTE block is shown to
the right.
CAUTION
Caution statements
identify conditions or
practices that could result
in damage to the equipment or other
property.
In addition, we use special notices to make you aware
of safety considerations. These are the CAUTION and
WARNING blocks as shown here. They represent increas-
ing levels of important information. These statements help
you to identify and avoid hazards and recognize the conse-
quences. 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 a operator protection issue.
WARNING
Warning statements
point out conditions or
practices that could re-
sult in personal injury or
loss of life.
Drawings and Tables
The figures and tables are identified by the section num-
ber followed by a sequence number. The sequence num-
ber begins with one in each section. The figures and
tables are numbered separately. The figures use Arabic
sequence numbers (e.g. –1, –2, –3) while the tables use
roman sequence numerals (e.g. –I, –II, –III). As an ex-
ample, Figure 3–2 would be the second illustration in sec-
tion three while Table 3–II would be the second table in
section three.
Electrical
Condition
Operator
Protection
(hearing)
or Practice
Safety Issue
Page
3
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
•
Load Regulation provides constant ultrasound
amplitude automatically regardless of power draw.
The ultrasonic output amplitude level is held to
within ±1% to provide weld process consistency
and reduced weld cycle times.
Press System Overview
An iQ Series Ultrasonic Press System ES consists of
these components: the iQ generator, press (with thruster,
switches, controls, cables, transducer, booster, horn, and
fixture) and iQ Explorer software. The software allows
the operator to control the system either remotely or at the
press location.
•
High Line Voltage Power Supply means that
standard systems will operate worldwide at the lo-
cal high line voltage level, whether it is 200VAC
@60Hz in Japan, 240VAC @50Hz in Europe or
208VAC @60Hz in the United States. There are no
internal transformer taps to change for worldwide
operation.
The iQ Series ES generator has rugged internal ultrasonic
circuitry and ensures a continuous resonant frequency lock
at the start of each weld.
The generator’s compact size allows multiple units to be
placed into an industrial equipment cabinet. This genera-
tor will operate at the same international line voltage input
specifications as the other generators of this product fam-
ily (unless the 120V option is installed). It also includes an
RFI line filter that passes FCC and strict CE test specifica-
tions for global applications.
•
•
Low Line Voltage Power Supply - This optional
120V power supply is designed for North Ameri-
can applications.
Flow Through Cooling Tunnel with a matched
high–performance heatsink and thermostatically
controlled fan reduces thermal gradients and in-
creases component life.
Key Generator Features
•
Digital Control of all power supply functions, includ-
ing digital frequency synthesis, and parameters allows
for unique configurations and allows for future up-
grades.
•
•
AC Power Inrush protection reduces electri-
cal stress on the internal components by protect-
ing them from AC power startup transient current
surges.
•
Process Parameters such as frequency, amplitude
Multiple Electronic Overload protection circuits
prevent instantaneous component failure in the
event of extreme output overload conditions. The
overload power limit is based on the actual true RMS
power output level.
and power are all updated at a 0.5 ms rate.
•
Pulse Width Modulation incorporates patented
circuitry giving the power supply the ability to
efficiently change the output amplitude. This makes
it possible to start large horns with reduced power. It
also provides more power-efficient switch-mode gen-
erator operation and increased reliability.
•
Process Limits include: distance, time only, time
and energy, and peak power. These programmable
limits provide the means to adapt to a wide variety
of welding applications.
•
•
Linear Ramp Soft-Start circuitry allows the acoustic
stack to be brought to operating amplitude smoothly,
minimizing start-up surges and abnormal stress to the
stack and generator.
•
•
Rear Panel Expansion Slot is available to allow
for custom configurations for OEM and cost effec-
tive solutions.
Digi-Trac Tuning tracks the resonant frequency of
the acoustic stack (horn, booster, transducer) and ad-
justs the generator output frequency to match it. This
is done for every weld cycle and eliminates the need
to manually tune the generator.
RS232 Serial Configuration Port is used for field
software upgrades, troubleshooting and advanced
hardware setup with optional PC-based configura-
tor.
•
CE Certification means that the system meets the
required European standards to be sold and used in
Europe (high line voltage models only).
•
Line Voltage Regulation automatically maintains
constant amplitude regardless of line voltage devia-
tion. The available output power is maintained with
any voltage input within the specified range. This
provides consistent system performance regardless of
line voltage fluctuations. It also eliminates the need
for bulky, external constant–voltage transformers.
•
ISO 9001 Certification means that this system has
been manufactured to high quality standards and
assures you of manufacturing excellence.
Page
4
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 2 - Health and Safety
SECTION 2
Health and Safety
General Considerations . . . . . . . . . . . . . . . . 7
Plastics Health Notice . . . . . . . . . . . . . . . . . 8
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Domestic Power Grounding . . . . . . . . . . . . . . . . . . . . . . 9
International Power Grounding . . . . . . . . . . . . . . . . . . . . 9
Lifting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 10
Page
5
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page
6
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 2 - Health and Safety
General Considerations
Please observe these health and safety recommenda-
tions for safe, efficient, and injury-free operation of your
equipment.
NOTE
These recommendations apply to the
welding system. System in this manual
refers to a complete group of components
associated with the welding of parts, also
known as an ultrasonic assembly system.
A typical iQ Series System consists of
the iQ generator, a press with thruster,
switches, controls, cables, transducer,
booster, horn, and fixture, and iQ Explorer
software.
Proper Installation - Operate system components only
after they are properly installed.
No Unauthorized Modifications - Do not modify your
system in any way unless authorized to do so by Dukane
Corporation. Unauthorized modifications could cause
equipment damage and/or injury to the operator. In ad-
dition, unauthorized modifications will void equipment
warranty.
Keep the Cover On - Do not remove any equipment
cover unless directed to do so by Dukane Corporation. The
generator produces hazardous electrical voltages which
could cause injury.
WARNING
Never operate the genera-
tor with the cover off. This
Grounded Electrical Power - Operate this equipment
only with a grounded electrical connection.
is an unsafe practice and
may cause injury.
See Electrical Safety for grounding instructions, Page 9.
Comply with Regulations - You may be required to add
accessories to bring the system into compliance with
applicable regulations (OSHA in the USA) for machine
guarding and noise exposure.
Use Eye Protection - WearANSI approved safety impact
goggles.
Acoustic Stack Hazard - When an acoustic stack (trans-
ducer, booster, horn and tip) is energized by the ultrasound
signal, it presents a potential hazard. Stay clear of an
energized stack.
CAUTION
At some time you may be asked to
remove equipment covers by the
Dukane Service Dept. personnel.
Before doing so, disconnect the
unit electrically from the incoming line AC
power. If the unit is a press/thruster, lock the
Air Lockout Valve, located on the rear panel,
in its closed position.
System Abort Switch - Install a system abort switch at
each operator station when ultrasonic plastic assembly
equipment is used with automatic material handling equip-
ment in an automated system.
Foot Switch - Using a foot switch in place of the optical
touch finger switches (activation switches) violates OSHA
regulations.
Continued
Page
7
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
General Considerations
Continued from previous page
Pre-trigger SwitchAdjustment - The pre-trigger switch
option starts the horn vibrating before contacting the part
to be welded. To ensure safe operation, adjust the pre-
trigger so the ultrasound signal will not activate if the
horn is more than ¼ in (7 mm) from the part to be welded.
CAUTION
Parts being joined ultrasoni-
cally will at times vibrate at
audible frequencies. Wear ear
protectors to reduce annoying
or uncomfortable sounds. In
addition, ultrasound baffles, sound enclo-
sures, or materials that absorb sound may
be located to surround the system.
System Electrical Cabling - Electrical power must be
off when connecting or disconnecting electrical cables.
Do Not Wear Loose Clothing or Jewelry - They can
become caught in moving parts.
Stay Alert - Watch what you are doing at all times. Use
common sense. Do not operate the press when you are
tired or distracted from the job at hand.
Do not Operate the Equipment - Your judgement or
reflexes could be impaired while taking prescription medi-
cations. If so, do not operate the equipment. Be familiar
with warning labels and recommended activity restrictions
that accompany your prescription medications. If you have
any doubt, do not operate the equipment.
WARNING
Keep head, hands, limbs
and body at least six
inches (152 mm) away
from an operating press/
thruster. A vibrating, descending horn
can cause burns and/or crushing
injuries.
Plastics 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 OSHAregulations for a particular plastic prior
to processing with Dukane ultrasonic equipment.
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
removed from their receptacles.After the
cables have been securely connected
and the connections and cable routing
checked a final time, the power may be
restored.
Page
8
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 2 - Health and Safety
Electrical Safety
Domestic Power Grounding
For safety, the power cords used on this product have a
three-wire, grounding-type power cord. Figure 2-1 il-
lustrates the appropriate electrical outlet to use with the
power cord that is included with systems shipped to North
America.
CAUTION
If you have a two-prong elec-
trical receptacle, we strongly
recommend that you replace
it with a properly grounded
three-prong type. Have a
qualified electrician replace it following the
National Electric Code and any local codes
and ordinances that apply.
See Figures 2–1 and 2–2.
Approved 2 pole, 3 wire grounding
receptacle HUBBELL No. 5652 or equivalent
to NEMA 6–15R or 6–20R
CAUTION
Figure 2–1 Example of 220/240 Volt,
If there is any question about
the grounding of your recep-
tacle, have it checked by a
Grounded, 3-Prong Receptacle
International Power Grounding
qualified electrician. Do not
The power cable normally provided for international use is
compatible with the power outlet used in many Continen-
tal European countries (Refer to Figure 2–2.) However,
if your application requires another type of power cord,
check with your equipment supplier, and follow local reg-
ulations concerning proper wiring and grounding.
cut off the power cord ground-
ing prong, or alter the plug in any way.
If an extension cord is needed, use a
three-wire cord that is in good condi-
tion. The cord should have an adequate
power rating to do the job safely. It must
be plugged into a grounded receptacle.
Do not use a two-wire extension cord with
this product.
Grounding Contacts
100/120 Volt Systems (North America or
Japan)
Typical Outlet
The power cord (including strain relief) supplied
with the 100/120 AC systems is permanently
attached to the rear of the generator. Units with this
power cord are for use in North America or Japan.
Provided Cable
Figure 2–2 International 220/240V Grounding
Page
9
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Lifting the Equipment
High Profile
Low Profile
lb
kg
lb
kg
Generator
Only
25
11.3
20
9.1
Generator
+ Packing
Materials
CAUTION
30
13.6
25
11.3
Take care when lifting the
equipment. We recommend
using a mechanical lift device
to assist.
Table 2–I iQ Generator Weights
How to Lift Safely
•
Before lifting, take a moment to think about what
you’re about to do.
•
Examine the object for sharp corners, slippery spots
or other potential hazards. Know your limit and don’t
try to exceed it.
•
•
Ask for help if needed, or if possible, divide the load
to make it lighter.
Know where you are going to set the item down, and
make sure it and your path are free of obstructions.
Then follow these steps:
Step 1. Stand close to the load with your feet
spread apart about shoulder width, with
one foot slightly in front of the other for
balance.
Step 2. Squat down bending at the knees (not your
waist). Tuck your chin while keeping your
back as vertical as possible.
Step 3. Get a firm grasp of the object before be-
ginning the lift. Begin slowly lifting with
your LEGS by straightening them. Never
twist your body during this step.
Step 4. Once the lift is complete, keep the object
as close to the body as possible. As the
load’s center of gravity moves away from
the body, there is a dramatic increase in
stress to the lumbar region of the back.
Step 5. If you must turn while carrying the load,
turn using your feet-not your torso. To
place the object below the level of your
waist, follow the same procedures in re-
verse order. Remember, keep your back
as vertical as possible and bend at the
knees.
Page 10
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
SECTION 3
Installation
Before Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 13
When to Use Lockout/Tagout Devices. . . . . . . . . . . . . . . 13
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Placement in a Seismic Zone. . . . . . . . . . . . . . . . . . 16
Rear Panel Layout Overview . . . . . . . . . . . . . . . . . . 18
AC Power Inlet Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 19
System I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ultrasound Output Connector. . . . . . . . . . . . . . . . . . . . 27
Configuration Port Connector. . . . . . . . . . . . . . . . . . . . 27
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Connecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . 29
Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Recheck Connections . . . . . . . . . . . . . . . . . . . . . . . 37
Connect AC Power. . . . . . . . . . . . . . . . . . . . . . . . . . 37
Page 11
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 12
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Before Installation
As you plan for the installation of your generator,
please consider these important subjects as listed
below:
• When to use lockout / tagout devices
• Lifting the generator safely - See Section 2 -
Health and Safety, Page 10.
When to Use Lockout /
Tagout Devices
Figure 3-2 Bottom Lockout Device
In Closed Position, Locked
Figure 3-1 Lockout Device In Open Position, Unlocked
The typical kind of LOTO device for this generator
is a clam shell type device (with lockout capability).
The LOTO device is placed over the plug end of the
generator electrical cord. This effectively prevents
access to the energy isolation point. See the example
of one such device in the figure above.
WARNING
Electrical safety hazards
existinsidethegenerator
chassis. Before making
any internal adjustments
to the generator, apply a
lockout/tagout (LOTO)
device to the generator
chassis.
The figure to the right shows the lockout device in the
closed, locked position.
Continued
Page 13
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Lockout/Tagout
Continued from previous page
Procedure to use BEFORE making any internal
adjustments to the generator:
1. Push the generator's AC power switch/breaker
to the OFF position.
2. Unplug the generator's electrical cord from its
source.
3. Authorized personnel apply a lockout/
tagout (LOTO) device to the plug end of the
generator's electrical cord. Using a typical clam
shell type LOTO device:
1) Open the clam shell.
2) Place the electrical cord plug end inside the
shell.
3) Close the shell.
4) Secure the shell with its lock, and lock it.
4. Wait a minimum of five minutes for the
generator to discharge its electrical energy.
5. After taking these steps, make the necessary
adjustments to the generator.
Assuming the generator is being put back into
service. . .
Procedure to use AFTER making any internal
adjustments to the generator:
1. Authorized personnel remove the lockout/
tagout device from the plug end of the
generator's electrical cord. Using a typical clam
shell type LOTO device:
1) Unlock the protective shell.
2) Open the shell, exposing the electrical cord
end.
3) Remove the LOTO device, and set it aside.
2. Plug the generator's electrical cord into its AC
power source.
3. Push the generator's AC power switch/breaker
to the ON position.
Page 14
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Unpacking
Carefully open your shipping container, and make sure
it contains the items shown on the shipping documents.
Inspect all items, and report any damage immediately.
Placement
Generator placement and cable routing should permit
easy access and not interfere with normal system opera-
tion.
CAUTION
Allow 5 inches for air ventila-
tion at the cooling air inlet and
at the exhaust air outlet. The
fan draws in fresh air to cool
Allow at least 5 inches (13 cm) of space on both ends of
the generator chassis for air circulation. Allow space -
between 3-6 inches, [8-15 cm] - at the rear of the chassis
for cable clearance. (The amount of space depends on the
chassis type and what rear panel connections there are.)
the internal components, reduce thermal
gradients and increase component life.
See Section 10 - Specifications, for generator drawings.
17.16
[435.86]
3.45
[87.63]
3.81
[96.8]
Q
i
EXHAUST AIR
OUTLET
COOLING AIR
INLET
IN
[mm]
OPTIONAL
POWER BUTTON
Figure 3-3 Generator Front View (typical) Low Profile
Continued
Page 15
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Placement in a Seismic Region
Continued from previous page
If the iQ generator is to be used in an active seismic region,
secure the unit by rack-mounting it or by securing the unit
to a benchtop.
Rack-Mounting
Install the four brackets from Dukane's rack-mount kit to
the generator. See Table 3-I, and Figure 3-4 (showing a
low profile unit) below.
System Type
High Profile
Dukane Part Number
147-4721
147-4720
Mount the generator to a 19-inch equipment rack.
Low Profile
Table 3-I
Rack Mount Bracket Part Numbers
17.16
[435.9]
ALLOW 3" IN BACK FOR CABLES
11.37
[288.8]
12.99
[330.0]
12.57
[319.3]
ALLOW 5"
BOTH
ALLOW 5"
SIDES
FOR
COOLING
BOTH
SIDES
FOR
COOLING
0.12
[3.0]
0.81
[20.6]
18.76
[476.5]
18.16
[461.2]
3.25
0.25 X 0.50 SLOT
(2 PLCS)
[82.6]
3.44
3.82
[97.0]
[87.4]
OPTIONAL RACK
MOUNT BRACKETS
147-4720
IN
[mm]
Figure 3-4 Rack Mounting iQ Generator
Continued
Page 16
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Benchtop Mounting
Continued from previous page
If you choose to mount the generator on a benchtop follow
these instructions:
1) Install the four (4) optional hold down
brackets. See Figure 3-5 below.
2) Secure the slot side of each bracket to the
generator's sheet metal cover.
3) Secure the hole side of each bracket to the
bench itself.
18.84
[478.47]
18.04
[458.22]
0.280 HOLE
ALLOW 3" IN BACK FOR CABLING.
1.14
[29.0]
13.20
[335.28]
ALLOW 5" BOTH
SIDES
FOR COOLING.
10.00
[254.0]
12.54
[318.52]
ALLOW 5" BOTH
SIDES
FOR COOLING.
OPTIONAL HOLD DOWN BRACKETS
147-1398
17.16
[435.86]
5.19
[131.83]
5.50
[139.7]
1.40
[35.6]
IN
OPTIONAL HOLD
DOWN BRACKETS
[mm]
Figure 3-5 Securing iQ Generator to Benchtop
Page 17
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Rear Panel Layout Overview
This section provides an overview of the generator rear
panel layout, which includes panel areas dedicated to var-
ious standard system functions and options that are avail-
able. Figure 3-6 illustrates a typical panel layout.
B
K
D
-WARNING-
POWER LINE OUTLET
MUST BE GROUNDED.
DISCONNECT LINE POWER
BEFORE REMOVING COVER.
I
0
SYSTEM INPUTS
LINE VOLTAGE:
200-240 Vac
E
50/60Hz, 15A
J2
J9 ETHERNET
J10 RS-232
SYSTEM OUTPUTS
J3
DUKANE CORP
ULTRASOUND
J1
ST. CHARLES IL 60174
MADE IN U.S.A.
J6 BASE/ABORT
J5 THRUSTER
J11 ENCODER
CONFIGURATION
PE
A
U.S. PATENT 5,880,580
OTHER PATENTS PENDING
J4
F
H
G
C
Figure 3-6 Generator Rear Panel - Pneumatic Press/Thruster
Options Module Panel
AC Power Inlet Panel
H Communications board
A IEC Power Inlet Connector – Attaches to an IEC style
power cord.
Shown in the example above are these ports:
J9 - Ethernet, and
B Power Switch – Circuit Breaker – Used to switch
system power ON and OFF.
J10 - Serial RS232
C Chassis Grounding Stud – Chassis connection for a
protective earth ground.
K Press interface board.
Shown in the example above are these ports:
J6 - Base/Abort
The System I/O Panel
J5 - Thruster
D System Input Connector (J2) – Connections for sys-
tem control input signals.
J11 - Encoder
E System Output Connector (J3) – Connections for sys-
tem status output signals.
NOTE
F Ultrasound Output Connector (J1) – Coaxial high
The press interface board is avail-
able in several different configura-
tions. See Section 8, Options for
more information.
voltage connection to ultrasonic stack.
G Configuration Port Connector (J4) – Digital control
port to modify system parameters.
Page 18
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Chassis Grounding Stud
AC Power Inlet Panel
The chassis grounding stud is used to attach a protec-
tive earth ground to the generator. This will aid in the
suppression of electrical interference or radio frequency
interference (RFI) that is common in a industrial envi-
ronment. The chassis ground stud is C in Figure 3-7.
Proper system grounding is discussed on Page 9.
The standard AC power inlet panel is described in this sec-
tion.
IEC AC Power Inlet Connector
The IEC AC power inlet connector mounted on the system
AC power inlet panel requires a properly configured IEC
compliant power cord, which enables worldwide system
operation by simply changing the power cord.
Low profile systems are equipped with a 10 amp rated IEC
inlet connector. The high profile systems include a 16/20
amp rated IEC inlet connector. 120 VAC and 3600/4800W
systems include a non-detachable power cord.
I
LINE VOLTAGE:
200-240 Vac
50/60Hz, 10A
0
An appropriately rated power cord must be securely at-
tached to the welding system’s IEC inlet connector. If the
correct power cord configuration is not included with the
system for the local AC power outlet at your location, an
appropriate IEC power cord should be available from a
local electrical parts supplier. Note that the system under-
voltage lockout will inhibit system operation if a North
American power cord configured for 120V is connected to
the system. A minimum of 200V is required for the system
to operate.
PE
C
Figure 3-7 IEC AC Power Inlet Connector
System I/O Panel
The standard system I/O panel is described in this sec-
tion.
Power Switch/Circuit Breaker
System Inputs Connector
The power switch/circuit breaker has a rocker type actua-
tor switch that will activate or deactivate the AC power
to the system. The power ON position is marked with the
internationally recognized I symbol, the power OFF posi-
tion is marked with the 0 symbol. This power switch also
integrates an appropriately sized over-current protection
circuit breaker function in the generator.
The SYSTEM INPUTS connector mounted on the sys-
tem I/O panel includes connections for all of the basic
system control input signals, that will typically come
from an automated control system. The cable attached to
this connector includes all of the available system con-
trol signals, which will be controlled by an output card
or output port on the automation controller.
If an over-current condition trips the circuit breaker, it will
automatically switch to the OFF position. If the overload
current that caused the circuit breaker to trip is due to a
transient condition, the circuit breaker can be reset by
switching the actuator back to the ON position. If when
resetting the circuit breaker after it has tripped, it imme-
diately trips again, there is likely an internal system mal-
function, and the generator will require service.
The user can determine which signals to use for each
particular welding application, but there must be at least
one connection to this connector in order to activate the
ultrasound output.All of the input signals on this connec-
tor are electrically isolated (signals are NOT referenced
to chassis ground) and activated when a 24VDC voltage
source is connected to the signal input pin, referenced
to the isolated common pin. The electrically isolated in-
put signals can be driven from an automation controller
output that is either sinking (NPN) or sourcing (PNP),
depending upon how the isolated common connection
is terminated. All inputs sink or source 10mA of current
from a 24VDC power supply.
Do not repeatedly try to reset the circuit breaker. If it trips,
this will only cause more damage to the generator.
Continued
Page 19
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Continued from previous page
Note that a simple switch closure (relay contact) con-
nected to a control input can not activate the input with-
out adding an external power supply to power the input.
Adding jumper connections to pins available on the Sys-
tem Inputs connector, can configure switch closure inputs
to operate referenced to generator chassis ground (non-
isolated), without adding a separate power supply, if de-
sired.
Refer to Application Note AN507 (Automation Interface
Guidelines) at http://www.dukane.com/us/DL_ApplDa-
ta.asp for wiring diagrams of example applications.
System Inputs Connector Pinout
The SYSTEM INPUTS connector is a HD-15F (high
density D-subminiature 15 circuit female) connector.
Connector pin numbers for this connector are shown in
Figure 3-9. The male connector on the cable is a mirror
image of the panel-mounted connector and is shown in
Figure 3-10. Table 3-II lists the signal names and descrip-
tions, with more detailed descriptions that follow. The
wire color coding for the system input cable is listed in
Table 3-II, to assist with custom automation system wir-
ing and assembly.
Figure 3-8 System I/O Panel (standard panel shown)
NOTE
Refer to Section 8, Options for information
on optional features.
Page 20
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Pin
1
Signal Name
Cable Color Code
BLK
Signal Option Requirements
+22V
2
Power Ground
WHT
3
Remote Setup Selection Bit 0 Input
Remote Setup Selection Bit 1 Input
Remote Setup Selection Bit 2 Input
Remote Setup Selection Bit 3 Input
Remote Setup Selection Bit 4 Input
Ultrasound Activation/Cycle Start Input
Not Used
RED
4
GRN
5
ORN
6
BLU
7
WHT/BLK
RED/BLK
GRN/BLK
ORN/BLK
BLU/BLK
BLK/WHT
RED/WHT
GRN/WHT
BLU/WHT
8
9
Not Used
10
11
12
13
14
15
Front Panel Control Lock Input
Press Inhibit for Hand Probes
System Latch Reset Input
Isolated Common
Not Used
Hand Probe
Not Used
Automation Cycle Stop Input
Table 3-II Generator Input Signals (J2)
System Inputs Signal Descriptions
5
4
3
2
1
Pin 1 (+22V)
This pin can supply +22VDC at up to 250mA to power
the user’s automation controls.
10
6
Pin 2 (Power Gnd)
Pin 2 is the 22VDC return and is tied to the system chas-
sis ground.
15 14 13 12 11
Figure 3-9 HD-15F, Generator Input Connector
Pin 3 (Remote Setup Selection Bit 0 Input)
Pin 3 is the Remote Setup Selection Bit 0, which is the
least significant bit used to select different welding setups
with an automation control system.
1 2 3 4 5
6
10
Pin 4 (Remote Setup Selection Bit 1 Input)
11 12 13 14 15
Pin 4 is the Remote Setup Selection Bit 1, which is the
second least significant bit used to select different weld-
ing setups with an automation control system.
Figure 3-10 HD-15M, Generator Input Cable
Connector
Continued
Page 21
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Continued from previous page
.
Pin 12 (System Latch Reset Input)
Pin 5 (Remote Setup Selection Bit 2 Input)
Pin 12 is used to reset the Any Fault or System Overload
status outputs (See Status Output descriptions.). If a fault
occurs during a weld cycle, these outputs will normally
remain active until the next weld cycle is initiated.Activat-
ing this input will reset the status output faults and may
simplify automation programming.
Pin 5 is the Remote Setup Selection Bit 2, which is the
third least significant bit used to select different welding
setups with an automation control system.
Pin 6 (Remote Setup Selection Bit 3 Input)
Pin 6 is the Remote Setup Selection Bit 3, which is the
second most significant bit used to select different weld-
ing setups with an automation control system.
Pin 13 (Isolated Common)
Pin 7 (Remote Setup Selection Bit 4 Input)
Pin 13 is electrically isolated from chassis ground. Using
isolated sourcing (PNP) output drivers, this common line
would be connected to isolated ground potential. Using
isolated sinking (NPN) output drivers, this common line
would be connected to the isolated positive supply volt-
age output.
Pin 7 is the Remote Setup Selection Bit 4, which is the
most significant bit used to select different welding setups
with an automation control system.
Pin 8 (Ultrasound Activation/ Cycle Start
Input)
Pin 14 (Not Used)
Pin 14 is an open connection.
Pin 8 is used to activate the generator ultrasound output.
Activation of this control input will switch the ultrasound
output ON, and deactivating this signal will switch ultra-
sound OFF. This input signal will also function as a cycle
start input, where the ultrasound activation and timing
are completely under the control of the process control-
ler. Depending on the welding process controller setup,
this input signal could be activated momentarily to start
a welding cycle.
Pin 15 (Automation Cycle Stop Input)
Pin 15 is an input control signal that when enabled, can
be used by the automation control system as a redundant
signal to shut the ultrasound output off. This signal could
also be reconfigured through menu selections to function
as an automation end-of-weld control signal input.
Pin 9 (Not Used)
Pin 10 (Not Used)
Pin 11 (Press Inhibit for Hand Probes)
Pin 11 is used to disconnect power applied to a press or
thruster, if a hand probe is connected to the system input
connector, for safety considerations. The hand probe acti-
vation switch could unexpectedly start a welding cycle that
activates a press or thruster to the down position. The hand
probe cable connector is wired to apply chassis ground to
this pin, when it is attached to the system, which activates
a press inhibit relay that disconnects power from the pneu-
matic press valves. This pin must be left open whenever
a press control board is installed. Connecting this pin to
chassis ground will inhibit press operation.
Page 22
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Pin
1
Signal Name
Cable Color Code Signal Option Requirements
+22V
BLK
WHT
2
Spare Output
3
+22V Power Ground
RED
4
Programmable Status Output 1
Programmable Status Output 2
Ultrasound Active Status Output
Any Fault Status Output
GRN
5
ORN
6
BLU
7
WHT/BLK
RED/BLK
GRN/BLK
ORN/BLK
8
Press Trigger Status Output
System Overload Status Output
System Online Status Output
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Press Top of Stroke Status Output
Current Loop OK Status Output
Analog Monitor Signal Common
Not Used
BLU/BLK
BLK/WHT
Not Used
Not Used
RED/WHT
GRN/WHT
BLU/WHT
Power Signal Monitor Output
Amplitude Monitor Output
Amplitude/Power Regulation Status Output
MPC Ready Status Output
System Power OK Status Output
Bad Part Status Output
BLK/RED
WHT/RED
ORN/RED
BLU/RED
RED/GRN
Good Part Status Output
System Ready Status Output
Suspect Part Status Output
Isolated Common
ORN/GRN
BLK/WHT/RED
WHT/BLK/RED
RED/BLK/WHT
GRN/BLK/WHT
Not Used
Table 3-III System Output Connector Signals (J3)
13
11
9
7
5
3
1
System Outputs Connector
The SYSTEM OUTPUTS connector mounted on the gen-
erator I/O panel includes connections for all of the basic
system status and monitor output signals, which will typi-
cally connect to an automated control system. The cable
attached to this connector includes all of the available
system output signals, which will be read or monitored by
a digital input card or analog inputs on the user-supplied
automation controller.
25
23 21
19
17
15
Figure 3–11 DB-25F, Generator Output Connector (J3)
1
3
5
7
9
11
13
The user can determine which signals are appropriate for
each welding application.
The system monitor output signals are analog signals used
to monitor ultrasonic amplitude setting and ultrasonic output
power levels, referenced to the Monitor Common (Pin 13).
15
17
19
21
23
25
Figure 3–12 DB-25M, Generator Output Cable
Connector
Continued
Page 23
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Continued from previous page
This is at system chassis ground potential (non-isolated).
All of the digital output status signals on this connector,
are isolated (signals are not referenced to generator chassis
ground). When a status output signal is activated, it will
sink current (500mA Max. sourced by a 24VDC supply)
to isolated common. In automation terms, the outputs are
NPN (sinking) and would drive a PNP (sourcing) input
that is referenced to the Isolated Common pin.
System Outputs Signal
Descriptions
Pin 1 (+22V Power Supply)
This pin can supply +22VDC at up to 250mAto power
the user’s automation controls.
Pin 2 (Not Used)
Pin 2 is an open connection.
Pin 3 (+22V Power Ground)
Pin 3 is the 22VDC return and is tied to the system
chassis ground.
The digital status output signals can only sink current to
isolated common. They cannot be changed to a sourcing
(PNP) type output. If sourcing status outputs are required,
there is an optional isolated NPN to PNP conversion
module that is DIN rail mountable. The module converts
the standard isolated sinking (NPN) status output signals
to isolated sourcing (PNP) status output signals. Consult
your local sales representative for information about the
conversion module.
Pin 4 (Programmable Status Output 1)
Pin 4 is a digital active low status output that can be
reprogrammed and assigned to other system status sig-
nals (from the available selections) from the System
tab in iQ Explorer.
Pin 5 (Programmable Status Output 2)
Pin 5 is a digital active low status output that can
be reprogrammed and assigned to another system
status signal (from the available selections) from the
System tab in iQ Explorer.
System Outputs Connector Pinout
The SYSTEM OUTPUTS connector is a DB-25F (standard
D-subminiature 25 circuit female) connector. Connector
pin numbers for this connector are shown in Figure 3-11.
The male connector on the cable is a mirror image of the
panel mounted connector and is shown in Figure 3-12.
Table 3-III lists the signal names. Detailed descriptions
Pin 6 (Ultrasound Active Status Output)
Pin 6 is a digital active low status output that activates
when the system is delivering ultrasonic power to the
load attached to the ultrasound output connector. This
output will be an open circuit when the ultrasound
output is off.
are listed in System Outputs Signal Descriptions that fol-
low. To assist with custom automation system wiring and
assembly, the wire color coding for the system outputs
cable is listed in Table 3-III.
Pin 7 (Any Fault Status Output)
Pin 7 is a digital active low status output that activates
whenever any fault condition is detected that inhibits
ultrasound output and normal system operation. This
output will be an open circuit when no system fault
conditions are detected.
Generator faults that will activate theAny Fault output:
• Overload (Average, Peak, or Frequency)
• Overtemperature Fault
• System Power Fault
Pin 8 (Press Trigger Status Output)
Pin 8 is a digital active low status output that activates
when the specified trigger type has occurred. It will
remain active until the thruster head raises to the top
of the stroke. This output will be an open circuit when
a trigger condition hasn’t been detected.
Continued
Page 24
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Continued from previous page
Pin 9 (System Overload Status Output)
Pin 15 (Power Signal Monitor Output)
Pin 9 is a digital active low status output that activates
whenever any overload condition is tripped. Activation
of the overload status output signal could be caused by an
average overload, a positive peak overload or a negative
peak overload condition. After the overload status output
activates, it will remain active until the next ultrasound
activation cycle begins and this output will automatically
reset. This output will be an open circuit when no overload
conditions have been detected.
Pin 15 is an analog output signal used to monitor the power
output from the welding system. The scaling on this output
signal is as shown below:
15kHz, 20kHz, 30kHz and 40kHz systems
1 Watt = 0.001 VDC (1mV per Watt)
50kHz and higher systems
1 Watt = 0.010 VDC (10mV per Watt)
Examples:
Power Monitor Output = 525 Watts
50kHz system measures 0.525 VDC on
20kHz system measures 0.525 VDC on
Pin 10 (System On-Line Status Output)
Power Monitor Output = 52.5 Watts
Pin 10 is a digital active low status output that activates
when the system is in the ON LINE operating mode, which
enables the activation of the ultrasonic output. This output
will be an open circuit if the system is switched to the OFF
LINE operating mode, which will prevent the start of a
welding cycle or activation of the ultrasound output. Note
that an automation controlled process can not weld any
parts, if the system is, accidentally or otherwise, switched
to the OFF LINE operating mode.
Pin 16 (Amplitude Monitor Output)
Pin 16 is an analog output signal used to monitor the
system amplitude setting. The scaling on this output sig-
nal is 100% amplitude = 10.0 VDC, or 0.1 VDC per 1%
amplitude. This monitor signal output would typically
be used when a remote control option board is installed
in the system. The automation control system will adjust
the system’s amplitude setting remotely, using a 4-20mA
current loop attached to the input of the remote control
board. Using this monitor output, the control system can
verify that the amplitude is set to the expected programmed
amplitude level.
Pin 11 (Press Top of Stroke Status Output)
Pin 11 is a digital active low status output that activates
when the press/thruster head is in the top of stroke posi-
tion. This output will be an open circuit when the press/
thruster head is not at the top of stroke position.
Pin 12 (Not Used)
Pin 13 (Analog Monitor Signal Common)
Pin 13 is the signal common (ground) connection for all
of the analog monitor signals (on Pins 15 and 16). This
signal common pin is connected to system chassis ground
and is not isolated from the generator chassis. This is an
analog signal ground connection. Do not connect anything
to this ground connection, except the wiring to the inputs
of the analog instrumentation devices used to measure the
monitor output signals.
Pin 14 (Not Used)
Pin 14 is connected to the system chassis ground.
Continued
Page 25
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Continued from previous page
Pin 17 (Amplitude/Power Regulation Status
Output) (Contact your sales representative about
Power Regulation availability.)
Pin 21 (Good Part Status Output)
Pin 21 is a digital active low status output that activates,
either momentarily or until the start of the next welding
cycle, when the welding parameters recorded during the
previous welding cycle do not exceed the programmed
suspect or bad part limits. This output will be an open
circuit after a welding cycle when either a suspect or bad
part has been detected.
This status signal is most useful when the power regula-
tion mode is selected. This Out of Regulation status signal
would indicate that due to inadequate pressure against the
ultrasonic horn, the power regulation level setting can
not be achieved when the amplitude level is set to the
maximum level of 100%.
Pin 22 (System Ready Status Output)
In the amplitude regulation mode, this signal will be
activated at the end of the ramp-up time until the begin-
ning of the ramp-down time. This status signal will be
active for the time the ultrasound is at the programmed
amplitude setting.
This status output signal will activate only when the system
is ready to activate ultrasound or begin a weld cycle. Pin
22 is a digital active low status output that activates when
a weld processing cycle is completed and the welding
process control system is ready to start the next welding
cycle. This output will be an open circuit when the welding
process controller determines that the next welding cycle
cannot be started. This includes system faults or off line
active, but not a process fault like Overload.
Pin 17 is a digital active low status output that activates
when the system is regulating the amplitude or power
level correctly. This output becomes an open circuit when
the system falls out of regulation. When that happens, it
cannot adjust the system output to the output level that
was programmed as the regulation set point.
Pin 23 (Suspect Part Status Output)
Pin 23 is a digital active low status output that activates, ei-
ther momentarily or until the start of the next welding cycle,
when the welding parameters recorded during the previous
welding cycle are outside of the programmed suspect part
limits. This output will be an open circuit after a welding
cycle when a suspect part has not been detected.
Pin 18 (Not Used)
Pin 19 (System Power OK Status Output)
Pin 19 is a digital active low status output that activates
when no fault conditions are detected by any of the power
fault detection circuits included in the system. This output
will be an open circuit when any power related fault is
detected in the system.
Pin 24 (Isolated Common)
Pin 24 is electrically isolated from chassis ground. This
common line should be connected to negative output at a
user-provided isolated 24VDC power supply. The isolated
NPN status output signals can drive PNP inputs.
Pin 25 (Not Used)
Pin 20 (Bad Part Status Output)
Pin 20 is a digital active low status output that activates,
either momentarily or until the start of the next welding
cycle, when the welding parameters recorded during the
previous welding cycle are outside of the programmed
bad part limits. This output will be an open circuit when
a bad part has not been detected.
Pin 25 is an open connection.
Page 26
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Ultrasound Output Connector
The ultrasound output connector used with all standard
generators is a high voltage (5000V) coaxial style SHV-
BNC connector. This connector provides superior shielding
of electrical noise, compared to other types of connectors.
The ultrasound output connector mates with fully shielded
coaxial ultrasound cables that are secured with a simple and
reliable quarter-turn bayonet style attachment mechanism.
Figure 3-13 Ultrasound Output Connector
CAUTION
Configuration Port Connector
The ultrasonic output from
this connector (that drives
the attached ultrasonic load)
is a very high AC voltage
(1200VAC). At high power lev-
els this can exceed 2 amperes
The configuration port connector is a DB-9M (standard
D-subminiature 9 circuit male) typically used for RS-232
serial communications. This serial port (DTE) connects to a
serial port (DCE) on a computer via a standard 9 pin serial
cable. If the computer does not have a serial port, you may
use a USB-to-serial conversion cable.
of current and must be securely terminated
via the ultrasound cable for safe operation.
Use original equipment ultrasound cables
for safe and reliable system operation. Im-
properly assembled ultrasound cables can
result in high voltage arcing and will destroy
the ultrasound connectors.
This port is used for field updates to the generator firmware,
without removing the enclosure cover. This port can also be
used with a software application running on a Windows PC
to modify the factory default system settings and hardware
configurations. Contact your local sales representative for
software availability information and access to documenta-
tion that will allow you to make use of the configuration
port features.
Do not use your generator if there is any
evidence of arcing (black carbon deposits)
on either the ultrasound output connector
or the ultrasound cable connectors.
Figure 3-14 Configuration Port Connector
Page 27
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
RFI Grounding
CAUTION
The iQ Series generator provides the operating power
and power returns. Make sure the generator is grounded
properly.
To minimize electrical noise
and eliminate ground cur-
rents, ground the chassis
as shown. Use a STAR con-
figuration (illustrated below).
Do not DAISY CHAIN the
grounds.
In addition to the safety considerations, proper grounding
is essential for the effective suppression of RFI (Radio
Frequency Interference). Every generator contains a
RFI filter which blocks noise on the AC power line from
entering the generator control circuitry. This filter also
prevents ultrasonic RFI from being fed back into the AC
power line.
Chassis Grounding
Stud
Fixed Probe Mount
or 2nd Chassis
Grounding Stud
#14 Gauge
Stranded or
Solid Wire
Recommended protective
earth ground connection
wire color: green or green
with yellow stripe.
If you experience problems with RFI from the press, run
an additional grounding wire from the press base ground-
ing stud to the nearest grounded metal pipe or equivalent
earth ground by means of a ground clamp. Use at least 14
AWG wire for the connection to the press base.
3rd Chassis
Grounding
Stud
Earth
Ground
Page 28
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Connecting Cables
CAUTION
The power cord is equipped
with a three-prong, ground-
ed-type plug for your safety.
Whenever a two-slot recep-
tacle is encountered, we
Step 1. Ground the generator chassis with the supplied
14-Gauge wire, and attach it to the grounding stud.
See Figure 3-7.
Step 2. Ultrasound (J1) - This output connects the Ul-
trasound Output of the iQ Series generator to the
transducer, through a coaxial cable. The electrical
welding signal is transmitted through this cable.
strongly recommend that it is replaced
with a properly grounded three-lead
receptacle.
Step 3. Operational Control (J201) - This cable runs from
J201 on the thruster to the generator's Thruster
connector (J5). The generator provides controls
for triggering the weld, operating the thruster’s
pneumatic system, and providing 24 VDC oper-
ating voltage through this cable. The press driver
card in the generator also provides monitoring for
these functions.
Have a qualified electrician do the
replacement in accordance with the
National Electrical Code and local
codes and ordinances. DO NOT cut
off the power cord grounding prong or
alter the plug in any way.
Step 4. Encoder (J11) (Optional) - The purpose of the
encoder cable is to connect the distance encoder
option to the generator's Encoder Port (J11).
Step 5. Ethernet Cable (J9) - Connects to the PC, LAN
port.
Step 6. RS-232 Cable (J10) - Connects to the PC, RS-232
port.
Step 7. Base/Abort Cable (J6) - Connects to the press
base plate connector (J35) or an automation PLC.
Step 8. Connect the AC power cord to the IEC power
inlet connector on the ultrasonic generator, and
plug the other end into an approved AC outlet.
Power Cords
The AC line cords supplied with the standard generators
are matched to the ultrasonic output power rating and the
continent of specified use. See Table 3-IV.
Continent of Use
North America
Power Cord
Part Number
Power
200 - 1110
200 - 1541
200 - 1111
200 - 1542
240V, 15A
240V, 10A
240V, 16A
240 V, 10A
Continental Europe
Table 3-IV Power Cords
Page 29
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Three Configurations
The iQ generator, ES models are configured in three basic ways:
1) With a pneumatic press/thruster
2) With a remote controller and a servo press/thruster
3) With a servo press/thruster
Diagrams and tables that follow show these three configurations
and list the cables used respectively.
Page 30
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Connecting Cables
Pneumatic Press/Thruster
Figure 3-15 iQ Generator and Pneumatic Press/Thruster - Connections Diagram
Continued
Page 31
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Continued from previous page
Pneumatic Press/Thruster
Table 3-V iQ Generator and Pneumatic Press/Thruster Cables
Continued
Page 32
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Servo Press/Thruster (Version 1)
Figure 3-16 iQ Generator, Remote Controller, and Servo Press/Thruster - Connections Diagram
Continued
Page 33
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Servo Press/Thruster (Version 1)
Continued from previous page
Table 3-VI iQ Generator, Remote Controller, and Servo Press/Thruster Cables
Page 34
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Servo Press/Thruster (Version 2)
Figure 3-17
iQ Generator and Servo Press/Thruster - Connections Diagram
Continued
Page 35
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Servo Press/Thruster (Version 2)
Continued from previous page
Table 3-VII iQ Generator and Servo Press/Thruster Cables
Page 36
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 3 - Installation
Networking
Where several welders are connected, please refer to the iQ
Explorer User's Manual, 403-579-00, Section 5 - Multiple
Welder Connections.
After some introductory material, there is information
about:
• Simple Stand-alone Configuration
• Unique IP Address, and
• Connection to Local Area Network
Recheck Connections
Recheck all cabling connections for the:
• iQ ES Generator
• Remote Controller
• Press/Thruster
• Connections to Local Area Network
Connect AC Power
When all cabling connections have been made, and they
have been systematically rechecked, connectAC line power
to your system.
Page 37
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 38
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
SECTION 4
Operation
Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Stopping the Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
iQ Explorer Support Features. . . . . . . . . . . . . . . . . . . . . . . . . 42
Numeric Pad and Keypad. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Help System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Quick Start Servo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-55
Quick Start Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . .56-69
Page 39
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 40
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Overview
The iQ Series generator, model ES, is usually part of a
system.
Main components of the system are:
• iQ generator,
• iQ Explorer (software),
• iQ Explorer User Interface (HMI),
or computer (user supplied), and
• iQ Press System.
.
With this type of system, the user controls nearly all aspects
of the welding process with the iQ Explorer User Interface
(HMI) or a computer (user supplied), using iQ Explorer.
In addition the press, acoustic stack and any tooling are
adjusted as necessary.
For additional information about the other key Dukane
components of the system, see these User Manuals:
• iQ Explorer (Part No. 403-579-00), and
• iQ Press System ES (Part No. 403-569-00).
Start-up
The main power switch for the iQ Series generator is found
on the generator's rear panel. When that switch is in the ON
position, the front panel power button is RED (standby).
When the front panel power button is pressed, the button
color changes from RED to GREEN.
Q
i
OPTIONAL
POWER BUTTON
Figure 4–1 Front Panel with Power Button
Page 41
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Other Control
iQ Explorer Support
Functions
Features
Other control functions - such as monitoring the weld-
ing process and controlling the system are accomplished
using the iQ HMI or your computer and Dukane's iQ
Explorer software.
Two support features incorporated into your iQ Explorer
software are its virtual numeric pad/keyboard and its help
system.
Numeric Pad and Keyboard
Stopping the Weld
Cycle
NOTE
iQ Explorer provides a touch screen
numeric pad and a keyboard for easy
parameter entry.
Normal Conditions
The cycle stops when the programmed welding cycle ends
or when the rear panel's Cycle Stop input is activated.
A
Select c for the keyboard.
Emergency Conditions
1
Select c for the numeric pad.
If the generator's front panel power button is lighted, press
the button so that the light goes out.
Figure 4-2 shows the
numeric pad.
In addition, you may push the power switch on the
generator's rear panel to the OFF position.
Figure 4-2 iQ Explorer, Numeric Pad
Page 42
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Help System
The help system is a reference tool to assist in understand-
ing key terms of the ultrasonic welding process.
The iQ Explorer help function can be accessed using the top
menu bar, or by pressing the F1 key as explained below.
Top Menu Bar
Help is one of the top menu bar items as shown in Figure
4-3.
Figure 4-3 Help from Top Menu Bar
Clicking on Help and then clicking on iQ Explorer Help
will open the Help window.
A Contents tab and an Index tab are two entry points to
the help file information.
Using Contents in Help
Contents groups the help file information into these seven
categories:
1 - Hardware
2 - Process Control
3 - Process Limits
4 - Graph
5 - Utilities
6 - System
7 - Options
The Index is an alphabetical list of words and phrases.
Using the Index in Help
Figure 4-4 Contents and Index in Help
Figure 4-4 illustrates that the term, Trigger was found
through both Contents and the Index.
Using the F1 Key
The F1 key can be pressed to activate Help when:
1) the cursor is positioned in an item that can be edited, such
as a text box, drop down list, or check box and,
2) that item is linked to Help.
NOTE
If no keyboard is available - perhaps you
are using a touchscreen. Use the iQ HMI
Windows keyboard, or press Help in the
top menu bar, and navigate to the desired
topic.
Page 43
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Quick Start - Servo Welder
Servo Step 1 - Read Section 3,
Installation of the iQ Explorer User's Manual
403-579-00. Insure that proper connection of the iQ
Explorer software and the servo press are in place.
See Figure 4-5 below.
Pneumatic Welder
Quick Start
See Pages 56-69
It is important that you understand and familiarize your-
self with the operation and navigation of the iQ Explorer
user interface software. Be familiar with iQ Explorer
Name of the connected welder.
User's Manual - Section 4, Operation.
Icon indicates
connection has
been made.
Dukane iQ Explorer - [Welder 1]
Figure 4-5
iQ Explorer, Start-up
Servo Step 2 - Hardware Tab
After moving to the Hardware tab, click on the Setup
File Name box, and select an unused setup. This will
ensure that you do not overwrite a pre-existing setup.
See Figure 4-6 below.
Dukane iQ Explorer - [Welder 1- Setup 4]
Hardware Tab
Figure 4-6 iQ Explorer, Start-up, Hardware Tab
Page 44
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Servo Step 3 - Navigate to the Process Settings Tab
Process Settings Tab
See Figure 4-7.
]
Figure 4-7 iQ Explorer, Process Settings
Servo Step 4 - Process Settings > Initiate Mode > Manual
See Figure 4-8.
NOTE
This Initiate Mode selection as-
sumes there is a stand-alone,
benchtop system with manual acti-
vation switches.
]
Select Manual in
Initiate Mode.
Figure 4-8 iQ Explorer, Process Settings > Initiate Mode
Page 45
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Servo Step 5 - Process Settings > Trigger > Type
Select Force as the type of trigger.
NOTE
Then program the desired pounds of force.
The example shown in Figure 4-9
assumes trigger force for a part with
four linear inches of weld would need
between 32 - 42 lbs of trigger force
A 20 inch linear weld may require
between 52 - 70 lbs. of trigger force.
See Figure 4-10, Initial Trigger Force
Settings.
Next, program Max Trigger Time. This provides a mea-
sure of safety insuring the welder will fault if for some
reason the welder never achieves the programmed trigger
force. See Figure 4-9.
40
4
6.000
Figure 4-9
iQ Explorer, Process Settings > Trigger > Type > Force > Max Trigger Time
110
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
Linear Weld Joint (inches)
Figure 4-10
Suggested Initial Trigger Force Setting
Page 46
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Servo Step 6 - Program Sensing Speed
On the Process Settings tab, find Sensing Speed.
This is the speed (inches per second) at which actua-
tion will move during the approach just before reaching
trigger position. Speed range is from 0.001 to 1.00 in/s
(inches per second). (A typical base start speed is in the
range of 0.20 to 0.40 in/s.)
This feature is exclusive to the servo-controlled systems
and allows for precise, accurate trigger forces.
Servo Step 7 - Program Sensing Start Distance
See Figure 4-11. Sensing Start Distance is the actual
position in the machine travel where motion changes to
Sensing Start Distance
Sensing Speed
Sensing Speed. To program this distance, you must
know how far the horn travels to come in contact with
the top of the part to be welded. If you do not know this
position where this contact is made, select the Teach
button. See Figure 4-12 on the next page.
0.20
Figure 4-11
iQ Explorer, Process Settings > Sensing Speed
Page 47
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Servo Step 8 - Teach Start Sensing Distance
After pressing Teach, you will see a window similar to
the one shown in Figure 4-12.
Place an unwelded part into the fixture. Press both opti-
touch activation switches to jog the horn down to within
0.010 - 0.030 inches above the part. The stroke position
of the thruster will be shown in the Current Position
box. Once you are at the desired position, press Set to
program that distance. Select Exit, and follow instruc-
tions to Home the machine.
Figure 4-12 iQ Explorer, Teach Start Sensing Distance
Servo Step 9 - Select Trigger Method
Still on the Process Settings tab, select Normal as the trigger
method.
Select Trigger
Method,
Normal
Figure 4-13
iQ Explorer, Select Trigger Method
Page 48
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Servo Step 10 - Program Weld Characteristics
On the Process Settings tab, select Weld > Method,
Parameter, and Max Time.
NOTE
Collapse Distance - The distance the welder advances
Programming these weld parameters
is similar to programming the DPC
IV Plus or other pneumatic systems.
Weld methods are: Time, Collapse
Distance, Absolute Distance, Energy
and Peak Power.
once programmed trigger force is reached. Usually the dis-
tance is the height of the energy director, or shear joint of
the part being welded.
Max Time - A secondary weld characteristic offering a
measure of safety. If the programmed parameter is not
achieved (as in the example shown in Figure 4-14) within
10 seconds, the system will fault.
,
Figure 4-14
iQ Explorer, Weld > Method > Parameter > Max Time
Servo Step 11 - Program Start Motion After Force Decreases By:
Continuing with the Process Settings tab. . .
See Figure 4-15.
This patented feature is found only on Dukane's servo
press systems. If the feature is selected, the system will
stop motion once the desired Trigger Force is achieved.
The ultrasound will be initiated at this moment. Once
the programmed force drop is detected, the motion will
continue. This is the basis for Dukane's exclusive Melt-
Match™ technology.
Figure 4-15
iQ Explorer, Start Motion After Force Decreases By:
Benefits - Figure 4 -15 illustrates that motion of the
thruster will not continue unless the system detects that
the trigger force has decreased by 2 pounds. In theory,
this force drop will occur as the plastic starts to melt. The
benefit of this option is significantly less stress on the
parts and stronger weld bonds.
Page 49
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Servo Step 12 - Select Motion Control Mode > Speed > Constant
Continuing with the Process Settings tab. . . This is the
speed of the thruster during the weld cycle (after Trigger
Sensing Speed and Motion Force Decrease have oc-
curred). This motion feature is only available on servo-
press systems. The speed range is from 0.001 to 1.0 in/s.
Motion Control Mode - Select Speed.
Motion Type - Select Constant.
Speed - Program speed. A typical initial setting range for
a standard energy director might be 0.010 to 0.060 in/s.
Select Motion Type, Constant
Select Motion Control Mode, Speed
Program Desired Motion Speed
0
Figure 4-16
iQ Explorer, Motion Control Mode, Speed
Advanced Users - NOTE
Advanced users will optimize the Motion Speed
using Profile to produce superior weld strength
and excellent cosmetic appearance. See Figure
4-17 where Profile was selected as the Motion
Type.This feature allows creating a speed mo-
tion profile during the weld cycle. The speed
motion profile can be created to match the actual
melt collapse of the weld joint.
View Speed Profile
Selecting View Speed Profile brings
up a screen like one shown below.
Figure 4-17
iQ Explorer, Speed, Motion Type, Profile
Optimizing the Feature
The easiest way to make best use of this feature
is to optimize the power draw throughout the
weld cycle. This can be done by manipulating
the Speed Profile until the Power Graph shows a
smooth, constant result.
See Figure 4-18 at right for a view of a Speed
Profile.
Figure 4-18
iQ Explorer, View Speed Profile
Page 50
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Servo Step 13 - Set Amplitude
Continuing with the Process Settings tab. . . A typical
initial amplitude setting is 100%. The range for this fea-
ture is between 20% and 100%.
Typical amplitude setting is
100%.
Range is between 20% and
100%.
Figure 4-19
iQ Explorer, Amplitude Setting
Continue with Post Weld settings on the next page.
Page 51
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Servo Step 14 - Post Weld Settings
Continuing with the Process Settings tab. . .
The post weld phase of the process is often overlooked,
however it is important in achieving desired weld results.
The iQ Servo Welder has several exclusive post weld
control parameters that can improve weld bond strength
and process repeatability.
Hold
There are two types of hold - Dynamic Hold and Static
Hold. These types can be used together or separately.
Dynamic Hold Method
During Dynamic Hold, with Collapse Distance enabled,
the actuator will continue to travel the programmed col-
lapse Distance at the programmed speed with the ultra-
sound signal turned off.
This occurs immediately after the weld phase. This unique
feature provides the ability to collapse the molten plastic
after the ultrasonic signal is turned off, before material
solidification. This feature can be beneficial in producing
superior weld strength and appearance.
Figure 4-20
iQ Explorer, Process Settings> Post Weld > Dynamic Hold Method
Continued
Page 52
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Continued from previous page
Hold
Static Hold Method
If Time has been enabled in the Static Hold Method, the
actuator motion will stop at the end of the weld cycle for
the programmed interval (Hold Dwell Time). When the
interval is ended, the actuator motion changes so that it
goes upward and travels to the Home position.
This unique feature allows for superior consistency on
overall part height. This is unlike a pneumatic press that
continues to compress the part during the hold phase.
In addition, Static Hold can contribute to stronger weld
bonds. See Figure 4-21 below.
Figure 4-21
iQ Explorer, Process Settings> Post Weld > Static Hold Method
Servo Step 15 - Test the Acoustic Stack
Run a test of the acoustic stack.
Please go to Section 5 of this User's Manual, System Op-
erational Testing, where the system test procedures are
outlined.
Page 53
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Servo Step 16 - Navigate to the Process Limits Tab
See Figure 4-22. For each limit that is important to
your application, use the drop down menu, and select
Display.
Those limits will be displayed on the Cycle Data
screen, and this will be important for future diagnostics
of the welder setup.
Process Limits Tab
]
Figure 4-22 iQ Explorer, Process Limits Tab
Page 54
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Servo Step 17 - Cycle Data
After all the parameters have been programmed, initiate
the weld cycle. View the results at the Cycle Data tab to
insure all parameters have been achieved.
See the example shown below in Figure 4-23.
]
Figure 4-23
iQ Explorer, Cycle Data
Page 55
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Quick Start - Pneumatic Welder
Pneumatic Step 1 - Read Section 4
of the iQ Explorer User's Manual 403-579-00. It is im-
portant that you understand and familiarize yourself with
the operation and navigation of the iQ Explorer user
interface software.
Servo Welder Quick
Start
Insure that proper connection of the iQ Explorer soft-
ware with the pneumatic press is in place. See Figure
4-24 and Section 3 of the iQ Explorer User's Manual.
See Pages 44-55
Name of the connected welder.
Icon indicates
connection has
been made.
Dukane iQ Explorer - [Welder 1]
Figure 4-24
iQ Explorer, Start-up
Pneumatic Step 2 - Hardware Tab
After moving to the Hardware tab, click on the Setup
File Name box, and select an unused setup. This will
ensure that you do not overwrite a pre-existing setup.
See Figure 4-25 below.
Dukane iQ Explorer - [Welder 1 - Setup 4]
Figure 4-25
iQ Explorer Start-up, Hardware Tab
Page 56
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Pneumatic Step 3 - Process Settings
Navigate to the Process Settings tab. All welder setup
related control parameters are programmed on this tab.
The Process Settings page is organized into 8 boxes:
1 - Welder Type
2 - Initiate Mode
3 - Trigger
4 - Weld
5 - Post Weld
6 - Pressure
7 - Amplitude
8 - Secondary Control
These boxes organize the weld process into the events
that occur during the weld process.
Figure 4-26 shows the Welder Type selection.
LDaukane iQ Explorer - [Welder 1- Setup 4]
Select Press.
NOTE
This Initiate Mode selection as-
sumes there is a stand-alone,
benchtop system with manual acti-
vation switches.
Figure 4-26
iQ Explorer, Process Settings>Welder Type
Pneumatic Step 4 - Process Settings>Initiate Mode> Manual
Lab
Dukane iQ Explorer - [Welder 1- Setup 4]
Select Manual.
Figure 4-27
iQ Explorer, Process Settings>Initiate Mode> Manual
Page 57
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Pneumatic Step 5 - Process Settings>Trigger
Trigger Type - Select Force as the Trigger Type.
Program a force value.
For this example we used values typical for welding an
energy director part with approximately 10 inches of
linear weld joint. This type of weld may need about 50
pounds of trigger force.
See Figure 4-28.
110
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
Linear Weld Joint (inches)
Figure 4-28
Suggested Initial Trigger Force
Max Trigger Time - Program a Max Trigger Time
of 3 seconds. This is the allowable cycle time from weld
initiation until the welder develops the programmed
force. Max Trigger Time will time the cycle out should
the machine, for some reason, not reach its programmed
force value.
Compensation Point - For a basic setup this value
can be programmed at zero. Typically force values
above 10 pounds are programmed at zero.
See Figure 4-29 on the next page.
Continued
Page 58
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Continued from previous page
Pneumatic Step 6 - Process Settings>Trigger>Type
Figure 4-29 below shows Trigger Type and the other
example values discussed on the previous page.
Dukane iQ Explorer - [Welder 1- Setup 4]
Figure 4-29
iQ Explorer, Process Settings > Trigger >Type
Trigger, Method - In the programming example here,
we have chosen Normal.
Figure 4-30 below shows this selection.
Figure 4-30
iQ Explorer, Process Settings > Trigger > Method
Page 59
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Pneumatic Step 7 - Process Settings> Weld
Mode - Select Single Method.
Method 1 - Select Collapse Distance. This is the
distance the welder will advance once the programmed
trigger force is achieved. Usually the distance is the
height of the energy director, or shear joint of the part be-
ing welded.
NOTE
Max Time - Max Time is a secondary weld characteristic
offering a measure of safety. If the programmed parameter
is not achieved (as in the example shown in Figure 4-31)
within 2.000 seconds, the system will terminate the weld
process.
If the energy director or shear joint
collapse value can not be determined,
See Figure 4-32, and use Time as the
initial basic setup.
Figure 4-31
iQ Explorer, Process Settings > Weld
Suggested Initial Weld Time
1.4
1.3
1.2
1.1
.95
.90
.85
.80
.75
.70
.65
.60
.55
.50
.45
.40
.35
.30
.25
.20
.10
0
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
Linear Weld Joint (inches)
Figure 4-32
Suggested Initial Weld Time
Page 60
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Pneumatic Step 8 - Post Weld Settings
Process Settings > Post Weld > Hold Method
Select Time.
Program in a time of 0.500 seconds.
See Figure 4-33.
After the weld process (In this example setup, Collapse
Distance has a programmed value.), the welder will shut
off the ultrasound signal and continue to apply force for
the programmed time.
This phase is important to insure the molten plastic cre-
ated during the weld phase has a chance to solidify before
pressure is removed from the part.
Figure 4-33
iQ Explorer, Process Settings > Post Weld > Hold Method > Hold Time
Continued
Page 61
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Pneumatic Step 9 - Process Settings > Pressure
For systems equipped with the Electronic Pressure
Regulator option, weld pressure parameters need to be
programmed in this section of the Process Settings
NOTE
Downstroke pressure must be pro-
grammed so that enough force will be
available to achieve the programmed
Trigger Force. If there is not enough
downstroke pressure, it may cause the
system to fault at Max Trigger Time.
page. See Figure 4-34.
Downstroke - This is the approach pressure before
Trigger. For a basic setup, program a value here equal to
Pressure 1.
Weld Pressure 1 - Program a pressure value based
on the force requirement suggested in the Initial Weld
Force chart. See Table 4-I and Figure 4-35.
Figure 4-34
iQ Explorer > Process Settings > Post Weld > Pressure
500
150
400
360
340
320
300
280
260
240
220
200
180
160
140
120
100
80
60
40
20
0
34 36
0
2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
Linear Weld Joint (inches)
Suggested Initial Weld Force
Figure 4-35
Continued
Page 62
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Air Cylinder Size
Verify the size of your air cylinder diameter. Use Table 4-I
to determine actual force at a given pressure.
Pressure
(psi)
Cylinder Diameter (in)
1.5
0
2.0
0
2.5
0
3.0
0
0
5
9
16
25
35
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
105
110
18
39
49
71
27
47
74
106
141
177
212
247
283
318
354
389
424
460
495
530
566
601
636
672
707
742
778
35
63
98
44
79
123
147
172
196
221
246
270
295
319
344
368
393
417
442
466
491
516
540
53
94
62
110
126
141
157
173
188
204
220
236
251
267
283
298
314
330
345
71
80
89
97
106
115
124
133
142
150
159
168
177
186
195
Table 4-I Pounds of Force Comparison
between Dukane Air Cylinders
Page 63
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Pneumatic Step 10 - Process Settings > Pressure Continued from Page 62
Hold Pressure - This pressure determines the amount
of force applied during Hold.
Typical weld setups have Hold Pressure higher than
programmed Weld Pressure.
Increasing hold force (pressure) during Hold helps to
produce stronger weld bonds.
For a basic weld setup, program Hold Pressure at 10 psi
above Weld Pressure. See Figure 4-34.
Upstroke Pressure - This pressure is applied at the
end of the Hold time. This is the air pressure that drives
the air cylinder to move the system back to its home posi-
tion.
Upstroke pressure has little or no effect on weld results.
However, overall cycle time is affected by upstroke travel
time.
For a basic weld setup, program Upstroke Pressure at
80 psi. See Figure 4-34.
Page 64
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Pneumatic Step 11 - Process Settings >Amplitude
Amplitude - This refers to the peak-to-peak displacement
of the horn at its workface. Amplitude settings are given
as a percent of the horn's nominal amplitude in the range
of 20% to 100%.
Select Local.
Then, at Weld, select 100%.
For a basic setup, leave Ramp Up Time and Ramp Down
Time at 0.150 and 0.000 respectively (the default settings).
NOTE
Default settings for Ramp Up Time and
Ramp Down Time are dependent on the
frequency of the welding system.
See Figure 4-36 below.
Local
100
0.150
0.000
Figure 4-36 iQ Explorer, Process Settings > Amplitude
Page 65
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Pneumatic Step 12 - Process Settings >Secondary Control
Secondary controls provide additional ways to end the
weld portion of a cycle together with the primary control
method specified.
This means control of the weld process can be accom-
plished either by the primary control or by one or more
secondary controls.
Secondary control is not typically needed for basic setup.
See Figure 4-37 below.
Figure 4-37 iQ Explorer, Process Settings > Secondary Control
Pneumatic Step 13 - Test the Acoustic Stack
Run a test of the acoustic stack.
Please go to Section 5 of this User's Manual, System Op-
erational Testing, where the system test procedures are
outlined.
Page 66
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Pneumatic Step 14 - Process Limits Tab
Navigate to the Process Limits tab.
If this is the first time on this tab (for your selected
setup), the status for each parameter will be blank.
See Figure 4-38 below.
Dukane iQ Explorer - [Welder 1- Setup 4]
Figure 4-38
iQ Explorer, Process Limits Tab - I
Continued
Page 67
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Continued from previous page
Pneumatic Step 14 - Process Limits Tab
Using the drop down menu for each limit that is im-
portant to your application, select Display. That limit
will be displayed on the Cycle Data screen, and this
will be important for future diagnostics of the welder
setup.
Figure 4-39 shows a typical basic setup with several
parameters selected.
Dukane iQ Explorer - [Welder 1- Setup 4]
Figure 4-39
iQ Explorer, Process Limits Tab - II
Page 68
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 4 - Operation
Pneumatic Step 15 - Cycle Data
Navigate to the Cycle Data tab.
Begin a weld cycle using the cycle activation switches.
•
•
•
Inspect the weld results of your finished part on the
Cycle Data page.
Review weld data to insure the process was done as
programmed.
NOTE
Values for the completed cycle should be displayed
under each programmed parameter.
Use the scroll bar at the bottom of the
Cycle Data screen to display all of the
parameters.The bar moves the screen
image right and left because a typical
display will not show the entire set of
parameters at once.
Figure 4-40 below shows the top and bottom parts of the
Cycle Data page. Because all of the parameters will not
fit on one page, move the scroll bar (right and/or left) at
the bottom to view the entire set of weld parameters.
Parameters
Dukane iQ Explorer - [Welder 1- Setup 4]
Scroll Bar
Figure 4-40
iQ Explorer, Cycle Data Page
Page 69
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 70
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 5 - System Operational Testing
SECTION 5
System Operational Testing
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Operational Test of the Acoustic Stack . . . . . . . . . . . . . . . . 74
Procedure for Cycling the System . . . . . . . . . . . . . . . . . . . . 77
Page 71
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 72
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 5 - System Operational Testing
Overview
An iQ Series generator must be operating and connected
to the press/thruster in order to test the system.
For efficient operation of a Dukane ultrasonic assembly
system, the ultrasound signal from the generator must
match the frequency and phase angle (vibrational charac-
teristics) of the stack that is being driven. Each stack has
unique vibrational characteristics dependent on the combi-
nation of stack components. In addition, the characteristics
of a particular stack may vary slightly during operation
because of temperature and loading factors.
To match the generator output signal with the character-
istics of a particular stack, the generator output frequency
is adjusted by Dukane’s patented phase-locked-loop Digi-
Trac pulse-width modulation circuitry.
The Digi-Trac feature automatically adjusts the ultrasound
signal to match the vibrational characteristics of the stack
being driven. When the ultrasound turns on during each
operating sequence, the Digi-Trac circuit monitors the
motion of the stack on a frequency cycle-by-cycle basis
and adjusts the ultrasound signal for the optimum setting.
Because the Digi-Trac continuously monitors each operat-
ing sequence, it compensates for vibrational changes that
occur during repeated operations due to heating of the
stack components. It also compensates for changes that
occur over longer time periods due to aging of the piezo
electric crystals in the transducer, or possible wear of the
ultrasonic horn.
The Digi-Trac feature excels in environments hostile to
reliable operation, such as high duty cycles or high stress,
and continuous-duty applications. In such situations, the
Digi-Trac circuit compensates for the unique vibrational
characteristics of each stack due to differences caused by
aging, loading, temperature changes, and differences in
horn configurations.
Page 73
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Operational Test of
the Acoustic Stack
The following test procedure is suggested before starting
the generator, to verify that the vibrational characteristics
of the stack fall within the range of the Digi-Trac. All
Dukane stack components are manufactured to tolerance
specifications within this range. A non-Dukane horn,
an improperly assembled stack, or a stack component
that is worn or damaged, can result in vibrational char-
acteristics outside these specifications, and will require
some adjustment. This test reveals the existence of any
problems and directs you to corrective action.
1. Check the following:
a. Make sure that the correct booster and horn for
the application are installed in the thruster.
b. Check the iQ Series system components for
proper grounding.
c. Check the ultrasound cable connections on the
generator and thruster for proper seating and
security.
d. Verify that the horn is not under load (not in
contact with a fixture or part).
e. Verify that the REAR panel AC switch is ON.
The front panel AC button should be RED.
2. Push the generator front panel power button to ON.
The power button will start to flash RED on and
off for LESS THAN 20 seconds. It will then turn
GREEN. This indicates that the system is operating.
If the power button display stops flashing but re-
mains RED, do not go any further, there is a problem
with the input circuit.
3. Using iQ Explorer, go to the Utilities tab. Press the
TEST button. See Figure 5-1.
a. System Power Output:
•
If the power output display remains less
than 20% of the power supply's rated out-
put (See Table 10-III, Page 113.) and the
horn frequency (ie: 220 Press) is within
19,500 Hz and 20,500 Hz, the stack is
operational.
TEST Button
(340 Press) within: 29,500-30,500 Hz, &
39,500-40,500 Hz.
Figure 5-1 iQ Explorer Utilities TEST Button
•
If the power output exceeds the 20% indica-
tion, there may be a problem with the stack.
Continued
Page 74
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 5 - System Operational Testing
Figure 5-2 iQ Explorer TEST, Screen Display
Acoustic Stack Test Continued from previous page
b. If an overload fault is displayed, a mis-
match has occurred between the genera-
tor’s ultrasonic output signal and the stack.
NOTE
Note the Frequency and Power
values in the graph above.
Refer to the next section, Troubleshooting, and see
the Press Error Message tables.
You have the option of saving the
test data for future reference.
Also see Figure 5-3 that shows an example of an
error that caused cycling to stop.
4. While pressing the TEST button, lightly touch
the side of the horn to check for ultrasonic vi-
brations. If any vibrations are felt, the stack is
operational. If there is no vibration, there may
be a problem with the stack.
Monday, March 14, 2011 3:13:48 PM
Error detected:
If all the indicators pass their tests, the stack is within
the Digi-Trac range.
Overload peak overload fault!
The generator is operating at the optimum setting
for this stack when the Watts displayed on the graph
(after the test) is between 10 and 20 percent of the
power supply's available output. The vibration
amplitude of the horn and booster and the mass of
the horn determine the amount of energy needed to
vibrate the stack.
Figure 5-3 iQ Explorer Error Detected - Cycle Stop
•
If the system passes the tests of these four steps,
proceed to the section called Procedure for Cy-
cling the System, on the next page.
•
If one or more of these tests have failed, go to
the next step.
Continued
Page 75
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Acoustic Stack Test Continued from previous page
If any failure indications are present with the horn
removed, check the booster and the transducer for the
following
5. Turn the generator off. Check the stack for proper
assembly, damaged components, or dirty mating
surfaces. Recheck the ultrasound cable for proper
connections. Repeat Steps 1 through 4. If the test still
fails, go to the next step.
•
•
•
Any visible damage
Loose or cracked stud
Pitted or dirty mating surfaces
6. Turn the generator off, remove the stack from the
thruster, and remove the horn from the stack. Reinstall
the transducer-booster assembly in the thruster and
turn the generator on. Repeat Steps 2 through 4.
Make any necessary repairs or adjustments.
Go to Step 7.
7. Repeat Steps 1 through 6.
•
If the failure indications disappear, reassemble the
horn to the stack and repeat Steps 2 through 4.
If any failure indications are still present, do not
run this stack. Return the transducer and booster
to Dukane for analysis.
If the assembly passes with the horn removed, the horn
is outside the specifications required for operation with
the Digi-Trac preset range. Reassemble the horn to the
stack.
The System tab of iQ Explorer has a section for
Advanced Hardware. These features are designed for
unique horns and applications. See Figure 5-4.
•
NOTE
Consult Dukane Corporation before making adjustments
to these settings.
For more information about stacks, see this
article: www.dukane.com/us/SE_stackarticle.
Dukane iQ Explorer - [Welder 1]
Figure 5-4 iQ Explorer System Tab - Advanced Hardware
Page 76
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 5 - System Operational Testing
Procedure for Cycling
the System
1. Check that you have correctly performed the
following:
a. Installed the stack in the thruster and have closed
the stack access cover securely.
b. Secured the fixture in place.
c. Performed the Operational Test of the Acoustic
Stack as detailed on Page 74 of this section.
2. Verify that all controls on the Press/Thruster and the
generator are set as required for this operation.
3. Place a part in the fixture.
4. Cycle the system.
Activate both opti-touch switches at the same time
to start the system, and hold fingers in place until
the ultrasound starts. Releasing the fingers before
ultrasound starts will abort the cycle.
Page 77
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 78
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 6 - Troubleshooting
SECTION 6
Troubleshooting
Page 79
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 80
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 6 - Troubleshooting
Troubleshooting
Problem
Possible Solution
Unit power-up sequence stops, and front panel ON/OFF
button is flashing RED rapidly.
Operation of the front panel ON/OFF button at
power up:
• Steady Green - Generator is ready to cycle.
• Red - Generator is in standby mode.
• Slow Flashing Red - Generator is charging the internal
power supplies.
• Fast Flashing Red - AC line over/under voltage de-
tected or internal power supply failure. -
NOTE
See the error message Tables for Servo and Pneumatic
presses following this page.
NOTE
If troubleshooting does not provide satisfactory re-
sults, please contact Dukane Corporation (see Sec-
tion 9 - Contacting Dukane) for servicing. The iQ ES
generator and iQ Explorer are serviceable only by
Dukane personnel. Unauthorized attempts to service
either product will void any warranty.
Continued
Page 81
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Table 6 - I
Error Messages, Servo-related
Page 82
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 6 - Troubleshooting
Table 6 - I
Error Messages, Servo-related (continued)
Page 83
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Table 6 - II Error Messages, Pneumatic-related
Page 84
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 6 - Troubleshooting
Verifying Feature Operation
The iQ ES generator can be configured with several features that provide
interfaces from the control board to encoders and transducers outside the
system. These features include the following:
•
•
•
•
Distance Encoder
Power
EPR (electronic pressure regulator) with Pressure Transducer
Force Transducer (Load Cell)
Each of these features has a corresponding output on the iQ Explorer's
Cycle Data page. The Cycle Data page allows you to see the last cycle of
a control/monitor parameter. In order for values to appear in the computer
display, the system may have to be cycled or manipulated in some way.
Distance
To verify the distance feature, go to the Utilities page of iQ Explorer. Put
a check in the box (p) for Monitor Encoder Position in order to view the
encoder position.
To check encoder function, either remove air pressure from the press or
depress the Emergency Stop switch that is grouped with the activation
switches.
As the thruster head moves up or down, the displayed value changes. The
value should increase as the head travels down and decrease as the head
travels up. On power-up, the reference mark (distance value) internal to the
iQ generator is set between - 0.03 inches to - 0.10 inches.
This means that only after the head passes the reference mark, will the
distance data from the iQ generator be useful as it relates to the phases of
the weld cycle.
Page 85
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Power
To verify operation of this feature perform an acoustic stack test.
If no power is displayed, contact Dukane.
Electronic Pressure Regulator and the Pressure Transducer
The electronic pressure regulator and pressure transducer are components of
the same system. The electronic pressure regulator accepts commands from
the iQ generator and sets the air pressure to the desired user-selected value.
The pressure transducer senses the pressure and transmits it to the iQ genera-
tor via a 4-20mA current loop. To check the pressure components:
1) On the Process Settings page, verify that a Weld Pressure 1 setting
has been made.
2) Go to the Process Limits page, and make sure the parameter, Contact
Pressure has been set to be displayed
3) Cycle the machine. Then, go to the Cycle Data screen and see that the
pressure reading is shown for the cycle just completed.
Force Transducer (Load Cell)
The force transducer senses force exerted on the part and controls when the
ultrasound signal is applied. Check the force transducer by looking at the
FORCE measurement on the View Parameters menu. The measurement
should change when upward pressure is applied to the acoustic stack.
1) On the Process Settings page, select FORCE as the Trigger Type,
and make sure Trigger Method is Normal.
2) Enter a FORCE value, perhaps 10 lbs for purposes of this check.
3) Go to the GRAPH page. Select an axis, and define it as FORCE.
4) Go to the GRAPH DISPLAY page.
5) Cycle the machine, then look at the graph to verify that the FORCE
was at or near 10 lbs (the programmed FORCE setting).
CAUTION
Avoid injury when touching the acoustic
stack! Wear proper hand protection, and
grasp the acoustic stack in areas that are
smooth or dull. Then, carefully apply upward
pressure until a change in the Force mea-
surement is seen on the iQ Explorer display.
Page 86
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 6 - Troubleshooting
Effects of I/O and System Errors
on Process Flow
The welding cycle can be divided into a series of segments: Cycle Start,
Downstroke, Trigger, Weld Pressure 1, Weld Pressure 2, and Hold. In each
of these segments, operator action, rear panel inputs, and process limits can
affect the flow of the process. What follows are examples of how some events
can alter the flow of the welding process, and how they can be identified.
An Uninterrupted Cycle
Figure 6-1 shows the results of a weld process that was not interrupted by
any I/O signal or system error. The setup conditions for this process were
as follows:
•
•
•
Normal Trigger
Weld by Time for 50 ms.
Hold by Time for 1.0 sec.
PART
COUNT
DOWNSTROKE
TIME
DOWNSTROKE
DIST
WELD TIME
PRESSURE 1
WELD DIST
PRESSURE 1
WELD ENERGY
PRESSURE 1
HOLD
TIME
TOTAL
CYCLE TIME
TOTAL
STROKE
35
36
37
0.975
0.879
0.877
1.7921
1.7927
1.7928
0.050
0.050
0.050
0.0023
0.0020
0.0022
28.4
28.4
28.4
1.000
1.000
1.000
2.025
1.929
1.927
1.8090
1.8092
1.8092
Figure 6-1 Data from an Uninterrupted Cycle
Page 87
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
The Cycle Terminates During Downstroke
The system is in downstroke when the cycle has been successfully started and the
head travels towards the part. If the cycle is terminated during downstroke, all trig-
ger, weld, and hold characteristics are displayed as zeroes.
Figure 6-2 shows results of a cycle terminated during downstroke due to either
an end of weld/ground detect error or a condition where activation switches were
released before the trigger (there is no error code for this condition).
PART
COUNT
DOWNSTROKE
TIME
DOWNSTROKE
DIST
WELD TIME
PRESSURE 1
WELD DIST
PRESSURE 1
WELD ENERGY
PRESSURE 1
HOLD
TIME
TOTAL
CYCLE TIME
TOTAL
STROKE
39
40
41
0.655
0.748
0.819
1.1959
1.4229
1.7946
0
0
0
0
0
0
0
0
0
0
0
0
0.655
0.748
0.819
1.1959
1.4229
1.7946
Figure 6-2 Cycle Terminated by I/O During Downstroke
Process limits can be set for all process segments including downstroke.
Figure 6-3 shows the effect of a high bad part limit on Downstroke Time.
In this example, the Downstroke Time was limited to 0.500 second. When
the Downstroke Time reached 0.500 second, the cycle terminated and
marked the part as Bad.
PART
COUNT
DOWNSTROKE
TIME
DOWNSTROKE
DIST
WELD TIME
PRESSURE 1
WELD DIST
PRESSURE 1
WELD ENERGY
PRESSURE 1
HOLD
TIME
TOTAL
CYCLE TIME
TOTAL
STROKE
12
>>0.500
0.3462
0
0
0
0
0.500
0.3462
Figure 6-3 Cycle Terminated by High Bad Limit During Downstroke
When using pre-trigger, part contact must occur within 0.75 inch after the
application of ultrasound. If the weld is not complete or the trigger switch
does not close within 0.75 inch from the start of pre-trigger, the cycle is
aborted. Figure 6-4 shows cycles terminated for this reason. The pre-trigger
distance was set at 1.000 inch. Note that the Downstroke Distance is 1.7527
inch for part number 56. This is equal to the 1.000 inch pre-trigger distance
plus the 0.75 inch overtravel. The system can overshoot slightly due to
thruster momentum.
PART
COUNT
DOWNSTROKE
TIME
DOWNSTROKE
DIST
WELD TIME
PRESSURE 1
WELD DIST
PRESSURE 1
WELD ENERGY
PRESSURE 1
HOLD
TIME
TOTAL
CYCLE TIME
TOTAL
STROKE
56
57
58
0.887
0.831
0.827
1.7527
1.7522
1.7516
0
0
0
0
0
0
0
0
0
0
0
0
0.887
0.831
0.827
1.7527
1.7522
1.7516
Figure 6-4 Cycle Terminated Due to Pre-trigger Overtravel
Page 88
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 6 - Troubleshooting
Premature Weld Termination
Weld Termination Due to End of Weld/Ground Detect
An End-of-Weld signal from the thruster limit switches and a Ground Detect signal
to the J602 connector cause the Weld portion of the cycle to terminate. A character-
istic of this type of weld termination is Hold Time. If the Hold portion of the cycle is
executed, then the weld was terminated by an end of weld/ground detect error. Figure
6-5 illustrates this condition.
PART
COUNT
DOWNSTROKE
TIME
DOWNSTROKE
DIST
WELD TIME
PRESSURE 1
WELD DIST
PRESSURE 1
WELD ENERGY
PRESSURE 1
HOLD
TIME
TOTAL
CYCLE TIME
TOTAL
STROKE
55
0.882
1.7928
0.015
0.0006
6.5
1.000
1.897
1.8094
Figure 6-5 Weld Termination Due to End of Weld/Ground Detect
Weld Termination Due to Trigger Lost
If the trigger type is set to Maintained, loss of the trigger signal causes an
immediate termination of the cycle when the ultrasound is applied. This
results in a shortened weld and zeroes for both Hold Time and Hold Distance.
Figure 6-6 shows a cycle terminated by a lost trigger input.
PART
COUNT
DOWNSTROKE
TIME
DOWNSTROKE
DIST
WELD TIME
PRESSURE 1
WELD DIST
PRESSURE 1
WELD ENERGY
PRESSURE 1
HOLD
TIME
TOTAL
CYCLE TIME
TOTAL
STROKE
55
0.882
1.7928
0.015
0.0006
6.5
0
1.897
1.8094
Figure 6-6 Weld Termination Due to Trigger Lost
Page 89
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Weld Termination Due to Secondary Control
Secondary controls are additional controls that allow the weld to be con-
trolled by more than one process parameter. In this example, the weld por-
tion of the cycle ends when either the primary control parameter (in this
case, Weld by Time for 50 ms) or the secondary control parameter (Weld
Energy for 20.0 joules) is reached. In either case, the cycle proceeds to
the hold portion of the cycle provided that no process characteristics fall
outside of the bad limits. Figure 6-7 shows the results using Weld Energy
as a secondary control.
PART
COUNT
DOWNSTROKE
TIME
DOWNSTROKE
DIST
WELD TIME
PRESSURE 1
WELD DIST
PRESSURE 1
WELD ENERGY
PRESSURE 1
HOLD
TIME
TOTAL
CYCLE TIME
TOTAL
STROKE
3
4
5
0.999
0.944
0.906
1.7915
1.7919
1.7922
0.037
0.038
0.038
0.0024
0.0024
0.0021
20.3
20.9
20.9
1.000
1.000
1.000
2.036
1.982
1.944
1.8089
1.8089
1.8090
Figure 6-7 Weld Segment Terminated by a Secondary Control
Weld Termination Due to a Bad Limit
As with all bad part limits, falling outside of a limit results in an immediate
termination of the process. Figure 6-8 illustrates the results when a bad part
limit was exceeded for Weld Energy. The two “greater than” arrows (>>)
preceding the Weld Energy measurement indicates that a bad part upper
limit was exceeded. These arrows, known as limit indicators, are always
displayed in the Cycle Data.
PART
COUNT
DOWNSTROKE
TIME
DOWNSTROKE
DIST
WELD TIME
PRESSURE 1
WELD DIST
PRESSURE 1
WELD ENERGY
PRESSURE 1
HOLD
TIME
TOTAL
CYCLE TIME
TOTAL
STROKE
13
0.994
1.7916
0.038
0.0026
>>20.9
0
1.032
1.7942
Figure 6-8 Weld Segment Terminated by a Bad Part Limit
Page 90
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 6 - Troubleshooting
The iQ Generator Won’t
Cycle
Just before a weld cycle starts, the iQ generator waits for an initiating signal.
If an initiating signal is applied and the system does not begin to cycle,
check the following:
•
Make sure the iQ generator’s Initiate Mode in the Process Control
menu is set to the appropriate setting:
Manual if using activation switches; Auto if the system is configured
for use with an automated system.
NOTE
The Initiate Mode selection must be set for each setup
used. This is extremely important in the case of Sequenc-
ing and setup selection.
•
Remove all inhibiting inputs and check that no Cycle Start error mes-
sages are displayed.
•
Ensure that cabling is connected properly and that user interface cir-
cuitry is operating.
No Ultrasound
•
To verify that the generator is producing an ultrasonic signal, use the
acoustic stack test procedure described in Section 5, System Opera-
tional Testing.
•
•
Verify at the Utilities page, that the OFFLINE box is empty (not
checked.)
Verify pressure settings.
•
Review the program. There should be a Weld Time P1 (and Weld Time
P2 if dual pressure is used). Set the weld characteristic to Display in
the iQ Explorer's Process Limits tab.
•
Select Cycle Data, start the cycle, and view the reported Weld Time
shown on the display. This tells that the controller has directed the
generator to produce the ultrasonic signal for the programmed time.
•
•
Verify that a time for the weld cycle is displayed.
NOTE
Verify that a value shows in Weld Peak Power, Method 1.
If no value displays, there is a
problem. For help, go to Contact-
ing Dukane, Page 105.
Page 91
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 92
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 7 - Maintenance
SECTION 7
Maintenance
Page 93
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 94
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 7 - Maintenance
I/O Connector
Front and Rear Panels
The Input/Output connector has a pair of 4-40 threaded
jack screws to secure the connector. Make sure the screws
are snug, but do not overtighten them.
Cleaning
•
•
•
Do not use any solvents or abrasive cleaners to
clean any of the panels.
Do not spray or apply cleaner directly on the gen-
erator.
AC Power Cord
TheAC power cord should be kept in good condition and
free from any cuts. The AC plug should be straight with
no bent prongs.
Apply a small amount of cleaner on a soft, clean
cloth first. Then, clean the panel with the moistened
cloth.
Power Button
The button responds well to firm, gentle finger pressure.
Do not use sharply pointed tools or other objects that could
damage the button.
Chassis
Sheet Metal Cover
The cover is preformed to fit over the chassis and has pro-
tective grills over the cooling air vents. Keep the cover on
at all times because there are high voltages present which
could cause injury. The internal case also contains capaci-
tors which continue to hold a high electrical charge, even
after the power is shut off.
WARNING
Never operate the gen-
erator with the cover off.
This is an unsafe prac-
tice, and the high voltage
present may cause in-
jury.
Air Ventilation Slots
Keep the ventilation slots free from obstructions. If exces-
sive dust or dirt collects on the slots, wipe or vacuum them
clean. Do not use compressed air to clean them as this may
force the dirt inside the chassis.
Allow 5 inches (127 mm) of clearance outside each ventila-
tion slot.
The air intake is on the right, and the exhaust is on the left.
This is shown in Figure 3–3, Page 15.
Page 95
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 96
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 8 - Options
SECTION 8
Options
Power Inlet Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
120V Systems for North American and Japan . . . . . . . . . . . . . 99
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
120V Power Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
AC Power Inlet Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
AC Power Cord. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Power Switch/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Chassis Ground Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Press Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
P4 Dual Pressure Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
P5 Dual Pressure with Distance . . . . . . . . . . . . . . . . . . . . . . . . 101
P6 EPR/Load Cell with Distance. . . . . . . . . . . . . . . . . . . . . . . . 101
P7 Servo Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Page 97
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 98
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 8 - Options
This section of the User’s Manual provides a general
overview of some options/upgrades, all of which are
subject to availability, for the basic ultrasonic gen-
erator:
CAUTION
Power Inlet Options
If you have a two-prong elec-
trical receptacle, we strongly
recommend that you replace
it with a properly grounded
three-prong type. Have a
120V Systems for North America and
Japan
120V systems for North America and Japan have a fixed
(non-detachable) power cord.
qualified electrician replace it following the
National Electric Code and any local codes
and ordinances that apply.
This option is available on generators with power
ratings of 1200 watts or less and with operating fre-
quencies of 20kHz, 30kHz, or 40kHz.
Electrical Safety
120V Power Ground
CAUTION
If there is any question about
the grounding of your recep-
tacle, have it checked by a
For safety, the power cords used on all Dukane prod-
ucts have a three-prong, grounding-type plug.
qualified electrician. Do not
cut off the power cord ground-
ing prong, or alter the plug in any way. If
an extension cord is needed, use a three-
wire cord that is in good condition. The
cord should have an adequate power rat-
ing to do the job safely. It must be plugged
into a grounded receptacle. Do not use a
two-wire extension cord with this product.
Approved 2 pole, 3 wire grounding
receptacle HUBBELL No. 5262 or equivalent
to NEMA 5–15R or 5–20R
Figure 8-1 Example of 120 Volt,
Grounded, 3-Prong Receptacle
Page 99
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
AC Power Inlet Panel
The optional AC power inlet panel is described here.
AC Power Cord
The AC power cord (A in Figure 8-2) is appropriately
rated and permanently mounted to the power inlet panel.
Power Switch/Circuit Breaker
B
The power switch/circuit breaker (B in Figure 10-2) has
a rocker type actuator switch that will activate or deacti-
vate the AC power to the system. The power ON position
is marked with the internationally recognized I symbol,
the power OFF position is marked with the 0 symbol.
This power switch also integrates an appropriately sized
over-current protection circuit breaker function in the
generator.
LINE VOLTAGE:
100-120 Vac
50/60Hz, 10A
A
PE
If an over-current condition trips the circuit breaker, it
will automatically switch to the OFF position. If the over-
load current that caused the circuit breaker to trip is due
to a transient condition, the circuit breaker can be reset by
switching the actuator back to the ON position. If when
resetting the circuit breaker after it has tripped, it imme-
diately trips again, there is likely an internal system mal-
function, and the generator will require service.
C
120 Volt line cord
Figure 8-2 120VAC Power Inlet Panel
Do not repeatedly try to reset the circuit breaker. If it
trips, this will only cause more damage to the generator.
Chassis Ground Stud
The chassis ground stud is used to attach a protective
earth ground to the generator. This will aid in the sup-
pression of electrical interference or radio frequency in-
terference (RFI) that is common in an industrial environ-
ment. The chassis ground stud is C in Figure 8-2. Proper
system grounding is discussed on Page 9.
Page 100
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 8 - Options
P7 - Servo Board
P/N 110-4466
Press Interface Board
This board is also known as the Options Slot Board as
shown in Figure 10-4, Interpreting the Model Number.
Board location is shown in Figure 3-6.
This board allows the generator to communicate with the
iQ Servo press.
The Dukane iQ servo-driven welder is different from
pneumatic systems. Instead of using pressure from an air
cylinder, the servo welder uses an electrical servo actuator
in place of the pneumatic cylinder. Instead of controlling
the force, the servo system controls the speed of the horn
during the weld and hold phases. Typical process control
parameters are ultrasound amplitude, weld distance, weld
speed (constant or profile), hold distance, hold speed, and
static hold time.
Each option is described in general terms:
P4 - Dual Pressure Only
P/N 110-4426
Dual pressure is a feature that is exclusive to Dukane press
systems. It increases clamp force to improve the plastic
melt and flow during the weld portion of a cycle and as-
sures tight assembly during the hold portion by welding
parts at one pressure and holding them together at a second,
higher pressure. Dual pressure can also be used to begin
a weld at one pressure, finish the weld at a second, higher
pressure, then hold the assembly together at the second
pressure.
Servo systems have taken parts assembly to higher levels
of precision and repeatability.
P5 - Dual Pressure with Distance P/N 110-4427
Dual pressure is a feature that is exclusive to Dukane press
systems. See the P4 description above.
Weld by distance mode controls the melt collapse distance
to ensure that the same volume of material melts on each
part. The result: finished joint strength is consistent.
All distance parameters - downstroke, trigger delay, weld
hold, absolute weld, total weld, and total stroke distance -
are monitored to show upper and lower limits for bad and
suspect parts. This will verify part quality and uniformity.
Dukane's linear optical encoder has a one-micron resolu-
tion to insure exceptional precision and repeatability.
P6 - EPR/Load Cell with Distance P/N 110-4428
This option offers programmable pressure profiling and
force by interfacing with the EPR (electronic pressure
regulator), pressure transducer, and load cell. Increased
control, repeatability and consistency are benefits.
The electronic pressure regulator and pressure transducer
are components of the same system. The electronic pressure
regulator accepts commands from the generator and sets the
air pressure to the user-selected value. The pressure transducer
senses the pressure and transmits it to the generator via a 4-20
mA current loop.
The force transducer (load cell) senses force exerted on
the part and controls when the ultrasound signal is applied.
See P5 for more information on distance.
Page 101
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 102
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 9 - Contacting Dukane
SECTION 9
Contacting Dukane
Page 103
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 104
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 9 - Contacting Dukane
Contacting Dukane
Identify Equipment
When contacting Dukane about a service–related problem,
be prepared to give the following information:
• Model number, line voltage and serial number.
• Fault/error indicators from the iQ Explorer.
• Software version.
• Problem description and steps taken to resolve it.
Many problems can be solved over the telephone, so it is
best to call from a telephone located near the equipment.
Intelligent Assembly Solutions
Mailing Address: Dukane Ultrasonics
2900 Dukane Drive
St. Charles, IL 60174 US
Phone:
E-mail:
(630) 797–4900
Fax:
Main
(630) 797–4949
Service & Parts (630) 584–0796
Website
The website has information about our products, processes,
solutions, and technical data. Downloads are available for
many kinds of literature.
Here is the address for the main website:
www.dukane.com/us/
You can locate your local representative at:
www.dukane.com/us/sales/intsales.htm
Page 105
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 106
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 10 - Specifications
SECTION 10
Specifications
Generator Outline Drawings. . . . . . . . . . . . . . . . . . . 109
Weights, Dimensions, Operating Environment. . . . . 111
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . 113
Interpreting the Model Number. . . . . . . . . . . . . . . . . 114
Regulatory Agency Compliance . . . . . . . . . . . . . . . . 115
Page 107
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 108
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 10 - Specifications
Figure 10-1 Layout - Low Profile iQ Generator
Page 109
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Figure 10-2
Layout - High Profile iQ Generator
Page 110
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 10 - Specifications
Figure 10-3 Layout - High Power iQ Generator
Page 111
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Weights
High Profile
Low Profile
High Power
lb
kg
lb
kg
lb
kg
Generator
Only
25
11.3
20
9.1
34
15.4
Generator
+ Packing
Materials
30
13.6
25
11.3
39
17.7
Table 9–I iQ Generator Weights
Dimensions
Model
Dimensions - in (mm)
Height **
Width
Depth
Low Profile
3.45 (87.5)
5.19 (131.8)
5.19 (131.8)
17.16 (435.7)
12.55 (318.7)
12.55 (318.7)
14.51 (368.5)
High Profile
17.16 (435.7)
17.16 (435.7)
High Power
Table 10–II iQ Generator Dimensions
.
NOTE
**Add approximately 0.4" (10 mm) to height when the generator is equipped with factory installed
feet.
Add between 3" and 6" (76 - 152 mm) behind the generator and 5" (1270 mm) for air flow and
cable connections.
Operating Environment
Operate the equipment within these guidelines:
Temperature:
Air Particulates: Keep the equipment dry.
Minimize exposure to moisture, dust, dirt, smoke
40°F to 100°F (+5°C to +38°C)
and mold.
Humidity:
5% to 95% Non–condensing @ +5°C to +30°C
Nonoperating storage guidelines:
Temperature:
-4°F to 158°F (-20°C to +70°C)
Air Particulates: Keep the equipment dry.
Minimize exposure to moisture, dust, dirt, smoke
and mold.
Humidity:
5% to 95% Non–condensing @ 0°C to +30°C
Page 112
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 10 - Specifications
AC Power Requirements
Overload
Power
Ratings
Input AC Power Requirements
Nominal AC Volt
@ Maximum RMS Current
North America/
Japan
AC Outlet Rating
Operating
Frequency
Generator
Model Number
(Watts)
3600
4800
1200
1200
1800
2400
3600
4800
900
15kHz
15kHz
20kHz
20kHz
20kHz
20kHz
20kHz
20kHz
30kHz
30kHz
30kHz
30kHz
30kHz
40kHz
40kHz
40kHz
40kHz
40kHz
40kHz
15HS360-2A-XX-XX
15HS480-2A-XX-XX
20HS120-1A-XX-XX
20HS120-2A-XX-XX
20HS180-2A-XX-XX
20HS240-2A-XX-XX
20HS360-2A-XX-XX
20HS480-2A-XX-XX
30HS090-1A-XX-XX
30HS090-2A-XX-XX
30HS120-1A-XX-XX
30HS120-2A-XX-XX
30HS180-2A-XX-XX
40HS060-1A-XX-XX
40HS060-2A-XX-XX
40HS090-1A-XX-XX
40HS090-2A-XX-XX
40HS120-1A-XX-XX
40HS120-2A-XX-XX
200-240V 50/60 Hz @ 25 Amps
200-240V 50/60 Hz @ 30 Amps
100-120V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 8 Amps
200-240V 50/60 Hz @ 12 Amps
200-240V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 25 Amps
200-240V 50/60 Hz @ 30 Amps
100-120V 50/60 Hz @ 8 Amps
200-240V 50/60 Hz @ 8 Amps
100-120V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 8 Amps
200-240V 50/60 Hz @ 12 Amps
100-120V 50/60 Hz @ 8 Amps
200-240V 50/60 Hz @ 5 Amps
100-120V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 8 Amps
100-120V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 8 Amps
30 Amps
15 Amps
30 Amps
900
1200
1200
1800
600
15 Amps
600
900
900
1200
1200
Table 10-III
AC Power Requirements
NOTES:
An X used above in the Model Numbers is a “wildcard” character meaning any valid character code combination.
Maximum line current requirement is specified at the minimum nominal AC line voltage and the rated power level.
Page 113
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Interpreting the Model Number
Figure 10-4 Interpreting the Model Number
Page 114
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 10 - Specifications
Regulatory Agency Compliance
FCC
The generator complies with the following Federal Com-
munications Commission regulations.
•
The limits for FCC measurement procedure MP-5,
“Methods of Measurement of Radio Noise Emissions
from ISM Equipment”, pursuant to FCC Title 47 Part
18 for Ultrasonic Equipment.
CAUTION
DO NOT make any modi-
fications to the generator
or associated cables as
the changes may result
in violating one or more
regulations under which
CE Marking
This mark on your equipment certifies that it meets the
requirements of the EU (European Union) concerning
interference causing equipment regulations. CE stands
for Conformité Europeéne (European Conformity). The
equipment complies with the following CE requirements.
this equipment is manufactured.
•
T h e E M C D i r e c t i v e 2 0 0 4 / 1 0 8 / E C
for Heavy Industrial —
EN 61000-6-4: 2001
EN 55011: 2003
EN 61000-6-2: 2001
EN61000–4–2
EN61000–4–3
EN61000–4–4
EN61000–4–5
EN61000–4–6
EN61000–4–8
EN61000–4–11
•
The Low Voltage Directive 2006/95/EC.
•
The Machinery Directive 2006/42/EC.
EN 60204: 2006
Safety of Machinery - Electrical Equipment of
Machines Part 1: General Requirements.
IP (International Protection)
Rating
The iQ generator has an IP rating from the IEC
(International Electrotechnical Commission).
The rating is IP2X, in compliance with finger-safe
industry standards.
Page 115
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 116
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 11 - Appendices
SECTION 11
Appendices
Appendix A, List of Figures. . . . . . . . . . . . . . . . . . . . 119
Appendix B, List of Tables . . . . . . . . . . . . . . . . . . . . 122
Page 117
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 118
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 11 - Appendices
List of Figures
Appendix A
No.
Description
Page
2-1
2-2
Example of 220/240 Volt Grounded 3-Prong Receptacle................................................9
International 220/240 Volt Grounding .............................................................................9
3-1
Lockout Device in Open Position, Unlocked .................................................................13
Bottom Lockout Device in Closed Position, Locked......................................................13
Generator Front View (typical) Low Profile....................................................................15
Rack Mounting iQ Generator.........................................................................................16
Securing iQ Generator to Benchtop ..............................................................................17
Generator Rear Panel - Pneumatic Press/Thruster ......................................................18
IEC AC Power Inlet Connector......................................................................................19
System I/O Panel (standard panel shown)....................................................................20
HD-15F, Generator Input Connector .............................................................................21
HD-15M, Generator Input Cable Connector..................................................................21
DB-25F, Generator Output Connector (J3)....................................................................25
DB-25M, Generator Output Cable Connector ...............................................................25
Ultrasound Output Connector........................................................................................27
Configuration Port Connector........................................................................................27
iQ Generator and Pneumatic Press/Thruster-Connection Diagram..............................31
iQ Generator, Remote Controller, and Servo Press/Thruster (Version 1) Connect.......33
iQ Generator, and Servo Press/Thruster (Version 2) Connection Diagram...................35
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
4-1
Front Panel with Power Button......................................................................................41
iQ Explorer, Numeric Pad..............................................................................................42
Help from Top Menu bar................................................................................................43
Contents and Index in Help...........................................................................................43
iQ Explorer, Start-up......................................................................................................44
iQ Explorer, Start-up Hardware Tab...............................................................................44
iQ Explorer, Process Settings Tab.................................................................................45
iQ Explorer Process Settings Tab>Initiate Mode...........................................................45
iQ Explorer, Process Settings Tab>Trigger Type> Force>Max Trigger Time.................46
Suggested Initial Trigger Force Setting .........................................................................46
iQ Explorer, Process Settings Tab>Sensing Speed ......................................................47
iQ Explorer, Teach Start Sensing Distance....................................................................48
iQ Explorer, Select Trigger Method ...............................................................................48
iQ Explorer, Select Welder Method, Parameter, Max Time...........................................49
Continued
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
Page 119
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
List of Figures
Appendix A
Continued
No.
Description
Page
4-15
4-16
4-17
4-18
4-19
4-20
4-21
4-22
4-23
4-24
4-25
4-26
4-27
4-28
4-29
4-30
4-31
4-32
4-33
4-34
4-35
4-36
4-37
4-38
4-39
4-40
iQ Explorer, Start Motion After Force Decreases By .....................................................49
iQ Explorer, Motion Control Mode Speed......................................................................50
iQ Explorer, Speed, Motion Type, Profile.......................................................................50
iQ Explorer, View Speed Profile ....................................................................................50
iQ Explorer, Amplitude Setting.......................................................................................51
iQ Explorer, Process Settings>Post Weld>Dynamic Hold Method................................52
iQ Explorer, Process Settings>Post Weld>Static Hold Method.....................................53
iQ Explorer, Process Limits Tab.....................................................................................54
iQ Explorer, Cycle Data.................................................................................................55
iQ Explorer, Start-up......................................................................................................56
iQ Explorer, Start-up Hardware Tab...............................................................................56
iQ Explorer, Process Settings> Welder Type ................................................................57
iQ Explorer, Process Settings>Initiate Mode.................................................................57
Suggested Initial Trigger Force .....................................................................................58
iQ Explorer, Process Settings>Trigger Type..................................................................59
iQ Explorer, Process Settings>Trigger>Method ............................................................59
iQ Explorer, Process Settings>Weld .............................................................................60
Suggested Initial Weld Time..........................................................................................60
iQ Explorer, Process Settings>Post Weld>Hold Method>Hold Time ............................61
iQ Explorer, Process Settings>Post Weld>Pressure.....................................................62
Suggested Initial Weld Force.........................................................................................62
iQ Explorer, Process Settings>Amplitude......................................................................65
iQ Explorer, Process Settings>Secondary Control........................................................66
iQ Explorer, Process Limits Tab - I ................................................................................67
iQ Explorer, Process Limits Tab - II ...............................................................................68
iQ Explorer, Cycle Data.................................................................................................69
5-1
5-2
5-3
5-4
iQ Explorer, Utilities TEST Button..................................................................................74
iQ Explorer, TEST, Screen Display................................................................................75
iQ Explorer, Error Detected, Cycle Stop........................................................................75
iQ Explorer, System Tab, Advanced Hardware..............................................................76
6-1
6-2
6-3
Data from an Uninterrupted Cycle.................................................................................87
Cycle Terminated by I/O During Downstroke.................................................................88
Cycle Terminated by High Bad Limit Downstroke..........................................................88
Continued
Page 120
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Section 11 - Appendices
List of Figures
Appendix A
Continued
No.
Description
Page
6-4
6-5
6-6
6-7
6-8
Cycle Terminated Due to Pre-trigger Overtravel............................................................88
Weld Terminated Due to End of Weld/Ground Detect...................................................89
Weld Terminated Due to Trigger Lost............................................................................89
Weld Segment Terminated by a Secondary Control......................................................90
Weld Segment Terminated by a Bad Part Limit.............................................................90
8-1
8-2
Example of 120 Volt, Grounded, 3-Prong Receptacle...................................................99
120VAC Power Inlet Panel..........................................................................................100
10-1
10-2
10-3
10-4
Layout - Low Profile iQ Generator...............................................................................109
Layout - High Profile Generator...................................................................................110
Layout - High Power iQ Generator.............................................................................. 111
Interpreting the Model Number....................................................................................114
Page 121
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
Appendix B
List of Tables
No.
Description
Page
2-I
iQ Generator Weights .....................................................................................................10
Rack Mounted Bracket Part Numbers ............................................................................16
Generator Input Signals (J2)...........................................................................................21
System Output Communication Signals (J3) ..................................................................23
3-I
3-II
3-III
3-IV
3-V
Power Cords ...................................................................................................................29
iQ Generator to Pneumatic Press/Thruster Cables ........................................................32
Servo Press/Thruster, Version 1 Connections ................................................................34
3-VI
3-VII Servo Press/Thruster, Version 2 Connections ................................................................36
4-I
Pounds of Force Comparison Between Dukane Air Cylinders........................................63
Error Messages, Servo-related.......................................................................................82
Error Messages, Pneumatic-related ...............................................................................84
iQ Generator Weights ...................................................................................................112
iQ Generator Dimensions .............................................................................................112
AC Power Requirements ..............................................................................................113
6-I
6-II
9-I
9-II
9-III
Page 122
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Index
Index
Page 123
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 124
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Index
G
General User Information
Index
3
Drawings and Tables
3
Notes, Cautions and Warnings
3
Read is Manual First
3
A
Acoustic Stack 74
Generator Features
AC Power Inrush
CE Certification
Digi-Trac Tuning
4
4
AC Power Cord 95
AC Power Requirements 113
Agency Compliance 115
CE Marking 115
4
4
Flow rough Cooling Tunne
High Line Voltage Power Supply
4
4
FCC 115
ISO 9001 Certification
Linear Ramp Sof-Start
Line Voltage Regulation
4
IP (International Protection) Rating 115
Air Cylinder Size 63
Amplitude 65
Appendices 117
List of Figures 119
List of Tables 122
4
4
Load Regulation
4
Low Line Voltage Power Supply
Multiple Electronic Overload
4
4
Process Limits
4
Process Parameters
4
Pulse Width Modulation
Rear Panel Expansion Slot
4
C
4
Configuration Port Connector 27
Connecting Cables 29
Cycle Data 55, 69
RS232 Serial Configuration Port
Generator Outline Drawings 109 -111
4
H
Health and Safety 5- 10
How to Lif Safely 10
Plastics Health Notice
D
Digi-Trac 73
Drawings and Tables
Dukane 73
3
8
Recommendations
Help System 43
F1 Key 43
7
Address 105
Contacting 103
E-mail 105
Fax 105
I
Installation 11
Configurations 30
Pneumatic Press/ruster 31
Servo Press/ruster (Version 1) 33
Servo Press/ruster (Version 2) 35
Connect AC Power 37
Connecting Cables 29
Networking 37
Intelligent Assembly Solutions 105
Phone 105
Website 105
Dynamic Hold Method 52
E
Electrical Safety
9
100/120 Volt Systems
9
Domestic Power Grounding
9
Placement
Benchtop Mounting 17
Rear Panel 18
International Power Grounding
E-mail 105
9
AC Power Inlet Panel 19
Chassis Grounding Stud 19
IEC AC Power Inlet Connector 19
Power Switch/Circuit Breaker 19
System I/O Panel 19
F
FCC 115
System Inputs Connector 19
Recheck Connections 37
Unpacking 15
Continued
Page 125
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
P
Power Cords 29
Press System Overview
Process Flow 87
Effects of I/O and System Errors 87
An Uninterrupted Cycle 87
Cycle Terminates During Downstroke 88
Premature Weld Termination 89
Process Limits Tab 54, 67
I Continued - Installation
Placement 15
4
Placement in a Seismic Region 16
When to Use Lockout /
Tagout Devices 13
Interpreting the Model Number 114
IP (International Protection) Rating 115
iQ Explorer
Help System 43
Sofware connection 56
Support Features
Numeric Pad and Keyboard 42
System Tab 76
View Speed Profile 50
iQ Explorer User's Manual 403-579-00 44
iQ HMI 42
Q
Quick Start - Pneumatic Welder 56
Air Cylinder Size 63
Cycle Data 69
Hardware Tab 56
Initiate Mode 57
Post Weld Settings 61
Hold Method 61
Process Limits Tab 67
Process Settings 57, 60
Amplitude 65
Initial Weld Time 60
Pressure 62
Hold Pressure 64
Initial Weld Force 62
Upstroke pressure 64
Secondary Control 66
Test the Acoustic Stack 66
Trigger 58
L
Low Line Voltage Power Supply
4
M
Maintenance 93
AC Power Cord 95
Air Ventilation Slots 95
Cleaning 95
Cover 95
I/O Connector 95
Initial Trigger Force 58
Trigger, Method 59
Trigger Type 59
N
Notes, Cautions and Warnings
3
Quick Start - Servo Welder 44
Cycle Data 55
O
Operation 39
Overview 41
Start-up 41
Dynamic Hold Method 52
Hardware Tab 44
Initiate Mode 45
nitial Trigger Force Setting 46
Post Weld Settings 52
Process Limits Tab 54
Process Settings Tab 45
Program Sensing Speed 47
Program Sensing Start Distance 47
Program Start Motion Afer Force Decreases By 49
Program Weld Characteristics 49
Select Motion Control Mode 50
Select Trigger Method 48
Set Amplitude 51
Stopping the Weld Cycle 42
Options 97
AC Power Inlet Panel 100
Power Inlet Options 99
Press Interface Board 101
P4 - Dual Pressure Only 101
P5 - Dual Pressure with Distance 101
P6 - EPR/Load Cell with Distance 101
P7 - Servo Board 101
Static Hold Method 53
Teach Start Sensing Distance 48
Test the Acoustic Stack 53
Trigger 46
View Speed Profile 50
Page 126
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Index
R
Ramp Down Time 65
Ramp Up Time 65
RFI Grounding 28
S
Specifications 107
AC Power Requirements 113
Dimensions 112
Interpreting the Model Number 114
Operating Environment 112
Weights 112
Static Hold Method 53
Stopping the Weld Cycle 42
System 77
Cycling 77
System Inputs Connector 19
System Inputs Connector Pinout 20
System Inputs Signal Descriptions 21
System Operational Testing 71
System Outputs Connector 23
System Outputs Signal Descriptions 24
System Power Output 74
System Tab 76
T
TEST button 75
Testing
Acoustic Stack 74
System Power Output 74
TEST button 75
Verifying Feature Operation 85
Distance 85
Electronic Pressure Regulator and the Pressure Transducer 86
Force Transducer (Load Cell) 86
Power 86
Test the Acoustic Stack 53, 66
Troubleshooting 79
iQ Generator Won’t Cycle 91
iQ Pneumatic Press Error Messages 84
iQ Servo Press Error Messages 82
No Ultrasound 91
U
Ultrasound Output Connector 27
Utilities tab 74
Page 127
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
iQSeries Ultrasonic Generator/Power Supply ES User’s Manual
This page intentionally left blank
Page 128
Dukane Manual Part No. 403-575-00
Download from Www.Somanuals.com. All Manuals Search And Download.
Dukane ISO
ISO CERTIFICATION
Dukane chose to become ISO 9001:2008 certi-
fied in order to demonstrate to our customers
our continuing commitment to being a quality
vendor. By passing its audit, Dukane can assure
you that we have in place a well–defined and
systematic approach to quality design, manu-
facturing, delivery and service. This certificate
reinforces Dukane's status as a quality vendor
of technology and products.
The ISO 9001:2008 standard establishes a
minimum requirement for these requirements
and starts transitioning the company from a
traditional inspection–oriented quality system
to one based on partnership for continuous
improvement. This concept is key in that Du-
kane no longer focuses on inspection, but on
individual processes.
Dukane's quality management system is based
on the following three objectives:
1. Customer oriented quality. The aim is to
improve customer satisfaction.
2. Quality is determined by people. The aim
is to improve the internal organization and
cooperation between staff members.
3. Quality is a continuous improvement.
The aim is to continuously improve the
internal organization and the competitive
position.
To achieve ISO 9001:2008 certification, you
must prove to one of the quality system regis-
trar groups that you meet three requirements:
1. Leadership
2. Involvement
3. Quality in Line Organizations and Quality
System Infrastructure.
ISO 9001:2008
C E R T I F I E D
Dukane products are manufactured in ISO
registered facilities.
Download from Www.Somanuals.com. All Manuals Search And Download.
Please refer to our website at:
www.dukane.com/us/sales/intsales.htm
to locate your local representative.
Series Ultrasonic Generator/Power Supply ES User's Manual
www.dukane.com/us
Part No. 403ꢀ-575ꢀ-00
Printed in the United States of America
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-ꢀ4900 • FAX (630) 797-4949
Download from Www.Somanuals.com. All Manuals Search And Download.
|