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LS User`s Manual

1. 8 2 2 International 220 240V Grounding L 8 3 1 Lockout Device in Open Position Unlocked 13 3 2 Bottom Lockout Device in Closed Position Locked 13 3 3 Generator Front View low profile 15 3 4 Rack Mounting cana DO O A d 16 3 5 Securing iQ Generator to Benchtop aanak belt ese RAR pue Ub UR KU DA Ra EE 17 3 6 Generator Rear View low profile Re Re RE KA He Gee Re kk AR EE seed 20 4 1 Generator Rear Panel 23 4 2 IEG AC Power Inlet ConrieCtOF maana a ANAK la ea Gor on 24 4 3 CNN eli Ree 25 4 4 HD 15F for Generator Input Connechor emm 26 4 5 HD 15M for Generator Input Cable Connechor Y 26 4 6 DB 25F for Generator Output Connector s s ee s s s ee A eee ee ee ee ee ee 30 4 7 DB 25M for Generator Output Cable Connector 30 4 8 Ultrasound Output emere nennen 32 4 9 COMMU RIOT For o 33 5 1 Front Panel Monitoring Detail E 37 5 2 Front Panel Control Detail Hem mer 38 5 3 LCD Display at Start up Diwa ABA ate AN GR aav x RR a a nahua 40 5 4 LCD Display at Start up 2 teet ANA RED RR a eg 40
2. meme 82 10 12 Remote Amplitude Control Module 82 10 13 Amplitude Control Menu Deia 83 10 14 Automation Thruster Control Module 84 10 15 DB 9 Connector with Pin Locations JD aenean OR RR Aa ako pm imb Roten Ee De 84 10 16 HD 26 Connector with Pin Locations J5 issie esse cemere enn annuus 84 10 17 NPN to PNP Conversion n nsn 86 10 18 PNP to NPN Conversion mm memes 87 10 19 5V to 24V PNP Conversion eee 88 10 20 PROFIBUS Communications Module 90 CAN e En E e EG 91 11 1 Low Profile Chassis Dawid se ROSE EE ERK 95 11 2 Biighi rona Chassis DWING u u u OE EES eae dtu AGAD ANA a Ee 96 11 3 High Power 3600W Chassis Drawing Re a AE RENE GO ga GER ENE see he 97 11 4 High Power 4800W Chassis Drawing daaa aaa aaa a 98 11 5 Interpreting the Model Number al D A na mund 101 List of Tables No Description Page 2 1 iQ Generator Weights AA 9 3 1 Rack Mount Bracket Part Numbers nere 16 3 Standard IEC AC Power Cord Part Numbers esses 19 4 System Input Connector Signals J2 AAA AAA da maala abaka 26 4 II System Output Connector Signals J3 AAA 31 5 Default Frequency Dependent Settings cesses 42 5 II Default Frequency Independen
3. 37 System Power Output Level Bar Graph 37 System Operating Mode 37 4 line LCD Display E DE DERE RED RES 6 37 COD rol Keys AG PEN 38 NFO EE 38 ON OFF LINE EE EE 38 Er ea dk ood R AA done o Rad x EE bdo asl 39 Ane AL 0000000000 39 ENTER sie soas Sade skeie de RR Sad RES KANA r 39 ses EA EE 0 E s s si 39 Start up Sequence 40 Stopping the Weld Cycle 41 System Parameter Settings Overview 42 Default System Parameter Settings 42 Dukane Manual Part No 403 574 01 Page 35 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 36 Dukane Manual Part No 403 574 01 Front Panel Overview This section provides an overview of the front panel s two main functions monitoring with the system displays and controlling the system with the user navigation control keys eys System Power Output Level Bar Graph SYSTEM POWER OUTPUT LEVEL oven 20 40 60 80 100 mm SYSTEM OPERATING MODE emm ON LINE POWER TEST 1 PART COUNT WELD TIME POWER ENERGY Figure 5 1 Front Panel Monitoring Detail System Displays System Power Output Level Bar Graph A bar graph displays the percentage of ultrasonic power being drawn by the load The display use
4. o o J2 0 BUS ERROR J16 o o o o o J3 TATE c PROFIBUS 2 ME o o o lo Fi 10 20 PROFIB icati Modul igure 10 OFIBUS Communications Module PROFIBUS Module Page 90 Dukane Manual Part No 403 574 01 iQLinQ u Ethernet IP Module Part Number 110 4644 The EtherNet IP option module allows the iQ generator to connect to an EtherNet IP network The option module is an external DIN rail mounted device that acts as a bridge between the automation network and an iQ generator s RS 232 port See Figure 10 21 below Control Parameters available via EtherNet IP 1 Set weld method to Time Energy or Peak Power Set associated value in seconds joules or watts 2 Set Amplitude Ramp Up Time and Ramp Down Time Enable and set Trigger by Power parameters Enable and set Hold time Enable and set Afterburst delay and duration Oyo des Do Enable checking for Suspect Parts Set maximum and minimum values for Time Power and or Energy 7 Enable checking for Bad Parts Set maximum and minimum values for Time Power and or Energy 8 Configure advanced hardware settings including Phase Free Run Frequency Frequency Lock and Hold and Frequency limits Front View EtherNet IP oo Connect to EtherNet IP Network Connect to iQ Generator s J4 Port BN iQLinQ 17 45 Figure 10 21 EtherNet IP1 Module Dukane Manual Part No 403 574 01
5. 111 Dukane Manual Part No 403 574 01 Section 1 Introduction Introduction General User Information 3 Read the Manual First 3 Notes Cautions and VVarnings 3 Drawings and Tables 5 xui Dux Ek rtr m sd a E eve dik 3 Generator OvervieW 4 Key Generator Features 4 Dukane Manual Part No 403 574 01 Page 1 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 2 Dukane Manual Part No 403 574 01 General User Information Read the Manual First Before operating your ultrasonic generator 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 generator The examples given are chosen for their simplicity to illustrate basic operation concepts Notes Cautions and Warnings Throughout this manual we use NOTES to provide in formation that is important for the successful applica tion and understanding of the product A NOTE block is shown to the right In addition we use special notices to make you aware of safety considerations These are the CAUTION and WARNING blocks as shown here They have important information that if ignored could have increasingly se vere outcomes These stat
6. Dukane Manual Part No 403 574 01 EISE Abiauz Ya iepuooss 42510 LEM xyeed iepuooes palgesig Sua MID PISM MO PIS Kiepuooag Kiepuooasg nus 10 1402 pn lduly s uoneung 1sinqi v 9UIlL pleM XelN L L PI M XEN JaMOd ABsauz Dia weed PIIM J MOd KBjeu3 q pie yead Aq pleM 01400 pnulduly eu ejeg aqold Kejag SU pam au Aq pleM nu l jon uo apngjdwy s SU ploH p lqeuz p lqesiq KEE TOYINOD TOYINOO pajgewogny 3anindwv LSYNEYALIVY TOM NO 0 OH TOYLNOO Q T3M IN31SAS O NOILVWOLNV SAILITILA A8 1OH1NOO p lle sul spseog SU 5300 3gosd aaivWoinv uondo oN 0055007 eqoJd pa gwojny GL Jo g abed snu l BJeu3 pue eu dfildS SS4204d Page 120 PROCESS SETUP Time and Energy Menus Appendices Page 9 of 15 Ha nd Probe NOTE Trigger by Power is not supported in Hand Probe mode PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES HAND PROBE WELD CONTROL BY iQ SYSTEM AMPLITUDE WELD CONTROL CONTROL HAND PROBE SWITCH See by Timo Weld by Peak See Amplitude Weld by Time Power Weld by Energy Amplitude Control Control Menu Menu Weld Energy 1 Weld Time Weld Peak Power Max Weld Time Weld Time Page 121 Dukane Manual Part No
7. 6096 4096 factor is a 4 amplitude change for each mA change A 36 graph of amplitude output as a function of loop current Is shown in Figure 10 11 The current loop compliance d m T voltage is 6 volts minimum ALO Failure to provide at least 4mA of loop current is sensed as a fault and will produce minimum amplitude output 096 st 5mA 10mA 15mA 20mA The current loop fault indicator is a bi color LED It is green when the current is between 4 and 20mA and red when the current is below 2MA Figure 10 11 Current Loop Transfer Function Graph Future Availability Current Loop Fault In the future Remote Power Regulation Control will Ifa current loop source is not available an external 24VDC become available This option module will be able to power supply can be connected to the POS and NEG remotely control the power regulation setpoint using new terminals of J7 See Figure 10 12 A 422VDC supply is user selection menu choices made from the front panel also available on System Output Pins 1 and 3 Current Loop Fault Indicator Green Red LED Current Loop Connector 7 o o SYSTEM INPUTS o o o J2 SYSTEM OUTPUTS Iesst J3 ol 37 CONFIGURATION Us ENT LOOP J1 NPUT o o J4 POS NEG o o o SHIELD e e E STOP Co STATUS CURI sD Figu
8. HAMOd OV SOU WALSAS 3 aNnosvarin SNI1OOO Mos 3QIS MOTIV 8 41e LSZ 9NI1002 HOH 30IS uova S MOT V 0 08 oe L Figure 11 3 High Power 3600W Chassis Drawing Page 97 Dukane Manual Part No 403 574 01 iQ Series Ultrasonic Generator Power Supply LS User s Manual ONIT8 VO YOS MOVE NI MOTIV uni 8 Lell 615 1 6611 09 s 1 YIMOd OV e sev SV 11 SO NILSAS 8 ONNOSVAHLIN HO4 3019 S MOTIV c e9 LG 71 ONNOOS uod 3aIS S MOTIV 0 08 ee El Dukane Manual Part No 403 574 01 Figure 11 4 High Power 4800W Chassis Drawing Page 98 Section 11 Specifications High Profile Low Profile High Power 3600W High Power 4800 W Generator 11 3 9 1 32 14 5 Only Generator Packing 30 13 6 25 11 3 n 16 7 39 17 7 Materials Table 11 1 iQ Generator Weights Operating Environment Operate the generator within these guidelines Temperature 40 F to 100 F 4 C to 38 C Air Particulates Keep the equipment dry Minimize exposure to moisture dust dirt smoke and mold Humidity 5 to 95 Non condensing 5 C to 30 C Storage guidelines generator is not operating 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 D
9. Enable Maximum Weld Time ENERGY LIMIT Minimum Weld Time PEAK POWER LIMIT Maximum Energy Minimum Minimum Weld Time PEAK POWER LIMIT Minimum Peak Power Energy Maximum Peak Power Maximum Energy Minimum Energy Maximum Peak Power Minimum Peak Power Page 123 Dukane Manual Part No 403 574 01 iQ Series Ultrasonic Generator Power Supply LS User s Manual SIA paidog dm s sdm s iiv Bursei3 Ado OL MO OL AdO2 pesei43 dm s INOH4 Ad00 sdm s IV dm s 1 selz asesz Sans IsvdI SdNLAs 35 dNLAS V AdOO dNLIS 1 SINVN SAILNILA dNLIS qa1O313S dNLaS XX dNLIS 1031as NOILYWOLNY WALSAS Ol NOILO313S 4 135 9311111 41135 IOH LNOO dfi13S SAILITLLA SIILITILA SILINIT 55832044 OHINOO SS390Hd d 113S SS3008d Son GL JO ZL eBeg snue N A uo eut pue AB1eu3 pue au dNLas SS320Yd Dukane Manual Part No 403 574 01 Page 124 Appendices PROCESS SETUP Time and Energy and Time Only Menus Page 13 of 15 Amplitude Control AMPLITUDE CONTROL AMPLITUDE SETTING RAMP UP DOWN TIME AMPLITUDE SETTING 90 Yo SELECT DIGIT gt CHANGE VALUE WARNING MODIFIED SETTINGS MAY EFFECT OPERATION OF UNIT Amplitude Ramp Time Ramp Up Time Time Page 125 Dukane Manual Part No 403 574 01 f XXXXX MXXXX 4 Mod eed
10. Setting Description Setting Ranges for All Frequencies User Adjustment Limit Minimum Maximum Amplitude Setting 10096 Free Run Frequency Default Free Run Default Free Run Frequency minus 500 Hz Frequency plus 500 Hz Ramp up Time 0 010 second 1 250 second Phase Delay Default Phase Delay Default Phase Delay plus minus 20 20 Table 5 III System Parameter Adjustment Limits NOTE Free Run Frequency for 15kHz generators Minimum Default Free Run Frequency minus 600 Hz Maximum Default Free Run Frequency plus 600 Hz Dukane Manual Part No 403 574 01 Page 43 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 44 Dukane Manual Part No 403 574 01 Section 6 Process Control Settings Process Control Settings User Provided Process Control Overview 47 Manual Welding 47 Automated Welding 47 Automated Process Control Input Signals 47 Status Output Signals 47 Screen Navigation Basics 48 Programming the Generator Some Examples 49 Dukane Manual Part No 403 574 01 Page 45 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 46 Dukane Manual Part No 403 574 01 User Provided Process Control Overview The generator includes
11. gt Status LEDs Section 10 Options Parameters that can be obtained via Ethernet IP 1 All parameters that are configured via EtherNet IP 2 Realtimedata which includes welder state ultrasound active or not frequency power and amplitude 3 Weld cycle data from previous weld which in cludes Cycle Count Good Bad and Suspect Part information Process Limit setting exceeded or not reached if Bad or Suspect Part checking is enabled Weld Time Weld Energy Peak Power For information on how to control and or monitor specific parameters iQ Generator EtherNet IP Communication and Control documentation is available Signing a non disclosure agreement is required to obtain this documentation Top View L Ie 24V 5 41 137 5 Q CONFIG Page 91 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 92 Dukane Manual Part No 403 574 01 Section 11 Specifications Specifications BEE EE 00000 95 Low Profile Chassis aga a OR ER RR RR EE ad 95 High Profile Chassis excede o a PAKANA DAANG Se 4345858845 96 High Power 3600W en EE 97 High Power 4800W Chassis 98 fi O 99 Operating Environment 99 AC Povver Requirements 100 Interpreting the Mode
12. For this test the generator must be ONLINE If the OFFLINE LED is showing yellow in Fig ure 7 3 press the ON OFFLINE key The ONLINE LED Q in Figure 7 5 should turn green Connect a probe to the generator ultrasonic out put Place the probe so that the tip of the horn is not in contact with anything If you are using a hand probe you may feel a slight vibration or sensation in your hand This is normal There should not be any loud or unusual noise Momentarily press the TEST control key O in Figure 7 5 The first segment LED of the SYSTEM POWER OUTPUT LEVEL bar graph in Figure 7 5 turns green The probe will operate as long as the TEST key is pressed When the TEST key is released the SYSTEM POWER OUTPUT LEVEL bar graph turns off gray This test cannot be performed with the generator OFFLINE Page 58 80 100 SYSTEM OPERATING MODE ON Figure 7 5 System Test Dukane Manual Part No 403 574 01 Probe Operation 1 Ifthe generator is not online press the ON OFFLINE mode key labeled in Figure 7 6 The System Op erating Mode ONLINE indicator in Figure 7 5 will be green 2 Hand Probe Apply the probe tip to the components to be ultrasonically joined and press the hand probe s activation switch Automation System Activate the automation system program to trigger the generator This will move the probe tip in contact with the components t
13. PEAK AT X XXX SECONDS CHECK STACK OR COUPLING TO PART END OF WELD SIGNAL DETECTED END OF CYCLE SIGNAL DETECTED SYSTEM OVER TEMP DETECTED OVERLOAD FREQUENCY AT X XXX SECONDS CHECK STACK AND CABLE amp RAMP UP TIME OVERLOAD FREQUENCY AT X XXX SECONDS CHECK FOR COUPLING BETWEEN STACK AND PART CURRENT LOOP FAULT DETECTED SYSTEM POWER FAULT DETECTED FRONT PANEL LOCKED KEYPAD ENTRY NOT ALLOWED CURRENT SETUP HAS NOT BEEN PROGRAMMED WELD CYCLE STOPPED Pop Up Status Screens An Average Overload fault tripped Output power exceeded rated wattage Lower the welding pressure or amplitude Fault will reset when next weld cycle starts A Peak Overload fault tripped Peak IGBT transistor current exceeded Caused by a severe frequency mis match Fault will reset when next weld cycle starts Automation activated End of Weld input This ends the weld then hold time begins Status message is displayed a few seconds Automation activated the End of Cycle input This terminates the remaining weld cycle Status message is displayed a few seconds System Over Temperature fault detected Check that cooling fan is operational Check for dust build up in cooling channel Generator operation can continue after the system cools down Resonant frequency was not found Check for a defective stack component or for improper stack assembly Check for a defective stack cable Fault will reset when next we
14. Page 63 iQ Series Ultrasonic Generator Power Supply LS User s Manual System Power Output Level Red Red Fault Condition When the SYSTEM POWER OUTPUT LEVEL turns red arrow on the right end of the bar graph there is an overload condition that disables generator operation See in Figure 8 2 below Overload When an overload occurs it will automatically reset when the next ultrasound activation signal begins If the condition persists Place the generator OFFLINE and 1 Check the system including cables the acoustic stack mounted probe and or hand probe Replace existing components with ones you know are reli able 2 Place the generator ONLINE and see if the fault condition has been corrected Over Temperature When the system overheats there is an over temperature condition that will cause the fault SYSTEM OVERTEMP DETECTED Fault status is indicated on the LCD screen See Table 8 I When the system cools the system automatically resets SYSTEM POWER OUTPUT LEVEL 0 20 40 60 80 100 a SYSTEM OPERATING MODE ON LINE Figure 8 2 Overload Indication NOTE The LCD screen displays a variety of pop up status changes as they oc cur Check Table 8 1 Pop up Status Screens Page 58 Page 64 Generator Fault Does Not Reset When the system does not automatically reset the generator needs servicing System Power Diagnostic Procedure
15. tion is marked with the O symbol This power switch also integrates an appropriately sized over current protection circuit breaker function in the generator 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 Do not repeatedly try to reset the circuit breaker If it trips this will only cause more damage to the generator Page 24 Chassis Grounding Stud 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 an industrial envi ronment The chassis ground stud is 9 in Figure 4 2 Proper system grounding is discussed in Section 3 0 LINE VOLTAGE 200 240 Ve 50 60Hz 10A D 1 O e Cf Figure 4 2 IEC AC Power Inlet Connector System VO Panel The standard system I O panel is described in this sec tion System Inputs Connector The SYSTEM INPUTS connector mounted on the sys tem I O panel includes connections for all of the basic system co
16. I IN 3 5V OFF I N 3 COM OUT 3 LOAD I I l O INA OUT 4 10 IN Qv On hy IN 4 5V OFF I a N 4 COM OUT 4 LOAD I I GND 110 4397 S Gawa Gi 65 SPECIFICATIONS INPUTS MINIMUM VOLTAGE 5 0 Vdc MAXIMUM VOLTAGE 30 0 Vdc CURRENT 1 5mA 5 0 Vdc 9 5mA Q 24 0 Vdc OUTPUTS 7 SHOULD NOT BE CONFIGURED TO SINK A TTL LOAD TO MAXIMUM VOLTAGE 30 0 Vdc MAXIMUM CURRENT 50mA GROUND A RELAY CONNECTION SHOULD BE USED INSTEAD VOLTAGE DROP TO 1 0 Vdc MAX Figure 10 19 5V to 24V PNP Conversion Page 88 Dukane Manual Part No 403 574 01 IQ LinQ iQLinQ communication options allow automated systems to monitor and change settings in iQ generators These options provide machine builders the ability to integrate the generator into an electrical cabinet and to use the machine s HMI to program or monitor weld settings All Dukane iQ LS generators include the RS 232 Interface option which can be used to set amplitude and monitor power Using this option avoids adding expensive analog cards into PLC racks iQLinQ also provides a cost effective solution for adding the Weld by Energy feature that is only available in the more advanced iQ generators In addition to RS 232 iQLinQ is also available for PROFIBUS and Ethernet IPrw iQLinQ solutions are available to provide complete ladder logic and HMI screens that can be dropped into Allen Bradley RSLogi
17. Page 48 Dukane Manual Part No 403 574 01 Section 6 Process Control Settings Programming the Generator Some Examples On the following pages these programming examples cover how to e Have a PLC Control the Ultrasound Activation e Weld by Time e Weld by Energy e Adjust Amplitude e Adjust Ramp Up Time Soft Start e Adjust Ramp Down Time Soft Stop NOTE Once a primary weld method has been selected Time Energy Peak Power pressing the INFO key takes you to a Hot Key screen There you can quickly move to the weld method s frequently used programming areas HOW TO Have a PLC Control the Ultrasound Activation 1 Press CANCEL until you see the Main Menu screen as it is shown here E NE MODE Move the selection indicator to PROCESS SETUP 2 Press ENTER and you will see the screen as shown PROCESS SETUP 4PROCESS CONTROL here EE PROCESS LIMITS UTILITIES 3 Select PROCESS CONTROL and press ENTER With no option boards installed in the generator you will get a WELD BY choice of iQ SYSTEM or AUTOMATION AUTOMATED PROBE WELD CONTROL BY 4 Select AUTOMATION SS Dukane Manual Part No 403 574 01 Page 49 iQ Series Ultrasonic Generator Power Supply LS User s Manual HOW TO Weld by Time 1 Press CANCEL until you see the Main Menu screen as it is shown here Move the selection indicator to PROCESS SETUP 2 Press ENTER and you will see the sc
18. nental 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 Grounding Contacts Typical Outlet Provided Cable Figure 2 2 International 220 240V Grounding Page 8 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 CAUTION If there is any question about the grounding of your recep tacle have it checked by a 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 ad equate power rating to do the job safely It must be plugged into a grounded receptacle Do not use a two wire exten sion cord with this product NOTE See Section 10 Options if your sys tem has a non detachable power cord for 120VAC operation Dukane Manual Part No 403 574 01 Section 2 Health amp Safety Lifting the Equipment Pa Pete K Generator 11 3 91 22 14 5 34 15 4 Only 25 Generator Packing 13 6 Materials Table 2 1 iQ Generator Weights How to Lift S
19. 15 14 13 12 11 Figure 10 3 HD15F for System Inputs Outputs Connector ES Signal Name Signal Description 6 Overload Faut Status OveroadFautOuput Lom Isolated Operate Input Common 7 amp 8 JU726 8 Operate Input SwClosureOperate nut 288 JU724 725 9 Over Temperature Faut Over Temperature Fault Output Low Amplitude Setting Monitor 10 0V 10096 Power Signal Monitor Output 1mV 1 Watt Table 10 1 HD15F Example of Customized System Inputs Outputs Connector Signals Dukane Manual Part No 403 574 01 Page 75 iQ Series Ultrasonic Generator Power Supply LS User s Manual Option Panel Modules A single optional module can be installed in the iQ gener ator s Option Module Panel See in Figure 10 4 where the option panel is set up for a Remote Control Module Multi Probe Control MPC Interface Option Part Number 110 4251 The iQ generator can be configured with an optional MPC Interface circuit board that powers and controls an external MPC multi probe control module This external module that can be ordered with a minimum of two probe controls up to a maximum of 16 probe controls must be purchased Optional MPC Interface Connections Complete Steps 1 4 of the basic connections as de scribed on Pages 19 20 These involve Grounding optional Ultrasound Output System Control Inputs Status Outputs and AC Line Input AC Breaker Switch In addition
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21. 574 01 Section 6 Process Control Settings HOW TO Adjust Ramp Up Down Times The Ramp Up feature also called soft start applies amplitude at the beginning of the weld cycle to start the stack assembly transducer booster horn inearly rather than in two instantaneous surges The stack is brought up to operating amplitude smoothly without shock stress Although the Ramp Up time is factory set it is variable and can be adjusted to account for starting character istics of a particular horn The Ramp Up setting depends on the generator load at the start of a cycle Ramp Down or soft stop decreases amplitude as the weld cycle comes to an end The stack is brought down from its maximum operating amplitude smoothly reducing shock stress 1 Asin the previous HOW TO example navigate to the AMPLITUDE CONTROL screen 2 Select RAMP UP DOWN TIME and then press a ESE SAN ENTER j mweuPbowvTME P 3 AWARNING will appear as shown to the right Call Dukane Service with any questions about mak WARNING MODIFIED SETTINGS ing this adjustment oOo iim MAY EFFECT OPERATION OF UNIT 4 Select the feature Ramp Up Time or Ramp Down RAMP UP DOWN TIME Time you want to adjust E Adjust ramp up down times See the table below RAVRIDOWNTIME Select the digits with the RIGHT and LEFT arrows Use the UP and DOWN arrows to sele
22. AC Power Inlet Panel System UO Panel Section 5 Standard System Status and Controls 35 Front Panel Overview System Displays Control Keys Start up Sequence Stopping the Weld Cycle System Parameter Settings Overview Continued on next page Dukane Manual Part No 403 574 01 Page v Page vi Contents Continued Section 6 Process Control Settings 45 User Provided Process Control Overview Manual Welding Automated Welding Automated Process Control Input Signals Status Output Signals Screen Navigation Basics Programming the Generator Some Examples Section 7 System Operational Testing 55 Section 8 Troubleshooting 61 No Ultrasonic Output System Power Output Level Red System Power Diagnostics Procedures Welding Problems Pop up Status Screens Section 9 Maintenance 67 Section 10 Options 71 Power Inlet Options Electrical Safety AC Power Inlet Panel VO Panel Options Multi Probe Control MPC Interface Module Remote Amplitude Control Module Automation Thruster Control Module Isolated I O Conversion Module IQ LinQ Section 11 Specifications 93 Section 12 Contacting Dukane 103 Appendi CeS Ee RE EE ENEE ax 107 List of Figures bon or eee ab ad RI 109 List of Tables cee eee 110 Guide to Generator Menu Structure
23. MM PROBE1 PROBE2 Figure 10 9 MPC Interface Status LEDs Dukane Manual Part No 403 574 01 Section 10 Options MPC Cycle Illustration The flow chart below illustrates a typical welding cycle when the MPC feature is used Confirm probes 7 a ms 7 PLC monitors all are retracted 7 nary co T other generator status from weld aS VEE IE EEN output features position by generator Load part to be PLC activates welded generator s automation start input Have all probes processed a weld Move part to the welding position Generator s MPC Ready Status Output deactivates Move probes to the welding position Move probes to part loading position Generator processes the weld according to its hardware and software settings MPC Ready Status Output active No Remove welded part Generator Ready Status Output PLC activates active generator s binary code inputs to select Yes active probe Figure 10 10 MPC Cycle Flow Chart Dukane Manual Part No 403 574 01 Page 81 iQ Series Ultrasonic Generator Power Supply LS User s Manual Remote Amplitude Control ER Module Part Number 110 4183 80 This optional module enables remote control of output amplitude of the IQ system The control interface is a 4 20mA current loop The current loop connector and fault indicator are shown below in Figure 10 12 The output can be adjusted from 36 to 10096 The scale
24. SJojeuJBJeg Wa sAs S XXX X BWIL PIM SONSNEIS sseooJg sseooJd AAILOV 171435 vidas snjejs 5 O ul snle S ploH snjejs duieueAQ smeis dojs 3 G3AYOLSAY SONILLIS Srinvdaa LINVAAG 3HOLS3MH eui 91042 JO pug PI9M 40 puda eounoqeq UAMS G Uld Ef euyeq y Uld f eugeq dogs ony suyag asind SW 001 paulejule 1 3dAL 39IAdG INANI SLNdLNO 3NI43a NOLLWYN SALLOV INANI LAVLS OLNV p lqesiq 1NdNI 4015 OLNV 911 9 4 MBMOd AG 399141 81141 34 914 SG MUD TANANG XR 3HOLS3H WILSAS SLNANI 34 214 ANL3S 1404 ON 2 3YYMOYYVH apon Jo 3002 JeuJeyx3 2187510 dfiL4S dnl3S SS400Md 4 1 39 1YOd O I j dNLIS LYOd 1 AGOW 41V4440 d z 5p 3IANN dNL3S 18 abed jxeu uo panuiuo2 xxx GL JO yl iQ Series Ultrasonic Generator Power Supply LS User s Manual snue N Bi ug pue eui JH VMQSHVH Dukane Manual Part No 403 574 01 Page 126 Appendices Time and Energy Menus ADVANCED HARDWARE 05 1 SETUP NAME e OPERATE MODE VO PORT SETUP WARNING ADVANCED HARDWARE PROCESS SETUP ADVANCED HARDWARE MODIFYING HARDWARE SETTINGS HARDWARE SETUP SYSTEM RESTORE SETTINGS MAY AFFECT RESTORE DEFAULTS TRIGGER BY POWER OPERATION OF UNIT FREE RUN FREQUENCY SYSTEM FRE
25. Switch Circuit Breaker 74 Chassis Ground Stud 74 VO Panel OptionSs 75 Single Connector System VO Panel T Option Panel Modules 76 Multi Probe Control MPC Interface Option 76 Remote Amplitude Control Module 82 Automation Thruster Control Module 84 Isolated I O Conversion Module 85 AE NR OT ER 89 iQLinQ RS 232 Interface Option 22222222222 89 iQLinQ PROFIBUS Communications Module 90 iQLinQ EtherNet IP Module 91 Dukane Manual Part No 403 574 01 Page 71 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 72 Dukane Manual Part No 403 574 01 Section 10 Options This section of the User s Manual provides a general overview of some options upgrades all of which are sub ject to availability for the basic ultrasonic generator Power Inlet Options 120V Systems for North America and Japan 120V systems for North America and Japan have a fixed non detachable power cord This option is available on generators with power ratings of 1200 watts or less and with operating frequencies of 20kHz 30kHz or 40kHz See Table 11 II in Section 11 Specifications Electrical Safety 120V Power Groun
26. Ultrasonic Generator Power Supply LS User s Manual System Parameter Settings Overview This section provides the default system settings programmed at the factory Some of these system parameter settings are dependent on the nominal system operating frequency while other parameters are independent of the frequency The default settings should work with over 90 of the ultrasonic loads and welding applications that might be encountered In some cases adjusting the system setup parameters might enable the NOTE system to drive difficult or unusual loads which would An ultrasonic stack will not operate if the not be possible with the standard system settings mechanical resonance is outside of the frequency limits In addition to the default system parameter settings a list of user adjustable settings 1s included Default System Parameter Settings Default Frequency Dependent Settings 15000 19900 30000 40000 15 000 19 900 30 000 40 000 Phase Delay Seting degrees v o L v o Table 5 1 Default Frequency Dependent Settings Default Frequency Independent Settings Setting Description Default Setting for All Frequencies Amplitude Setting for Weld and Test Percent 10096 maximum user adjustment limit Table 5 II Default Frequency Independent Settings Continued Page 42 Dukane Manual Part No 403 574 01 Section 6 Process Control Settings System Parameter Adjustment Limits Continued from previous page
27. Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 6 Dukane Manual Part No 403 574 01 Section 2 Health amp Safety General Considerations Please observe these health and safety recommendations for safe efficient and injury free operation of your equip k um um EE ME EE EE EE ME EE EE EE EE EE UO EN ment In this manual the term system refers to a complete WARNING 7 of 7 vvith EE welding of d Never operate the gen ic or metal parts also known as an ultrasonic assembly 2557000 system A typical system consists of a generator and or ul I I off This is an unsafe trasonic process controller start and stop switches power controls connecting cables and the probe assembly which practice LU aae ELE includes the transducer booster horn and replaceable horn injury tip 421 EN EZ EH EH EH EA EH EH OI am SJ EN EN EA Proper Installation Operate system components only after they are properly installed and checked No Unauthorized Modifications Do not modify your system in any way unless authorized to do so by the manufacturer Unauthorized modifications may cause injury to the operator and or equipment damage In ad dition unauthorized modifications will void the equip ment warranty Keep the Cover On Do not remove any equipment cover unless specifically directed to do so by the manu facturer The generator produces hazardous electrical voltages which could cau
28. and 6 below Step 4 The POWER TEST indicator QO in the Sys tem Operating Mode display should flash red for several seconds and then will go out Step 5 Mode Key Tests a Set mode key to OFFLINE The System Operating Mode OFFLINE indicator O will be yellow b Press the TEST key U S INPUT The ultrasound should not activate and the SYS TEM POWER OUTPUT LEVEL bar graph will stay OFF Gray c Set the MODE key to ONLINE The System Operating Mode ONLINE indicator will be green d Press the TEST key Ultrasound should activate and the first segment of the SYSTEM POWER OUTPUT LEVEL bar graph turns green Release theTEST switch Ultrasound should deactivate and the SYSTEM POWER OUTPUT LEVEL bar graph should be OFF gray Step 6 Optionally system status outputs can be moni tored during this test The ultrasound status output activates only when ultrasound is active Dukane Manual Part No 403 574 01 Section 7 System Operational Testing 4 LINE VOLTAGE 200 240 Vac 50 60Hz 10A e c Figure 7 1 Rear Panel AC Breaker Switch Figure 7 4 Front Panel ONLINE LED Page 57 iQ Series Ultrasonic Generator Power Supply LS User s Manual System Test To test the system s ultrasound operation perform the following steps Step 1 Step 2 Step 3 Step 4 Step 5 Step 6
29. e UM IOnUO pjam Abiaua pue euin Jo paubisap oul OVA Ovz 00Z e uo Bunejedo sisseuo le GC uoueq jejuozuou MOOZ L Jo ZHYOZ V SUBAW SIU 1 9 32 0208 042 S l q UMOUS Jequinu apow ejduuexe au p109 1e od pexij wojeq pue M00ZL SISSEYD lle GC G JO AOZL 00L L NO 9Q pue MOO SISSEYO WEI GC 40 00 AOQE pue M008L SISSEYD Ile GC GO AOT C 00 Z y ndul ur1 OV SISSEUD uoueg IEIUOZUOH SH a Ajs sissey9 p1eog seH lul DAN LIN pJ amp og JONUOD LS SHEM 009 090 ba paeog 3015 suondo S 0J3UO SS920Jg WajsAs SHEM 002 021 ZH 0S 0S SHEM 0081 08L 2 Or SHEM 0077 OVE ZHYO 06 SHEM 009 09 ZHOc 0c pue awn 19 0 U09 p AA padukapy V SREM 009v O87 2 49 GL ER 1 MOd d 021 Jequunw I DOIN ou K u nb lg SIN yeuruoN Figure 11 5 Interpreting the Model Number Page 101 Dukane Manual Part No 403 574 01 iQ Series Ultrasonic Generator Power Supply LS User s Manual Regulatory Agency Compliance FCC The generator complies with the following Federal Com munications Commission regulations e 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 CE Marking This mark on your equipment c
30. user supplied 14 Gauge wire Input Cable Attach the automation control cable from the user supplied automation equip ment to the system input HD 15 connector J2 on the I O panel in Figure 3 6 Output Cable Attach an output cable DB25 type from J3 to your equipment to monitor sys tem status Attach the high voltage coaxial cable from the probe to the ultrasound output connector J1 Q in Figure 3 6 Connect the AC power cord to the generator IEC power inlet connector and plug the other end into an approved AC outlet in Figure 3 6 Page 20 NOTE Refer to Section 10 Options for information about other features Section 4 Standard Connections Standard Comnections Rear Panel Layout Overview 23 AC Power Inlet Panel 24 IEC AC Power Inlet Connector 24 Power Switch Circuit Breaker 24 Chassis Grounding Stud dab gos 24 System VO Panel 24 System Inputs Connector 24 System Inputs Connector Pinout 25 System Inputs Signal Descriptions 26 System Outputs Connector 28 System Outputs Connector Pinout 28 System Outputs Signal 22 22 2 28 Ultrasound Output
31. voltage arc ing and will destroy the ultrasound connectors Page 77 iQ Series Ultrasonic Generator Power Supply LS User s Manual MPC Interface Installation Guide Cut Outs The MPC interface is designed for assembly systems For panel mounted modules where one ultrasonic generator is sequenced to as many as 16 ultrasonic probes Use Figure 10 6 below to determine the size of the The MPC interface is typically supplied as a stand alone Cutout needed for your equipment panel bench top unit or as a component that can be mountedin Maketheappropriate cut and install the MPC interface a through panel configuration securing the mounting flange to the equipment panel before continuing with the cable connections No special installation is needed for a stand alone MPC interface that can be put on a bench top or a shelf Use the following installation recommendations for a panel mounted MPC interface 0 25 6 35 6 PLCS PANEL CUTOUT A D e MODEL A C D MPC0402 7 12 6 75 2 25 MPC0404 181 mm 171 5 mm 57 2 mm MPC0806 10 88 10 50 2 25 MPC0808 277 mm 266 7 mm 57 2 mm MPC1610 MPC1612 18 00 MPC1614 457 2 mm MPC1616 Figure 10 6 MPC Module Cutout Guide Page 78 Dukane Manual Part No 403 574 01 Connecting Cables For stand alone interfaces and securely installed panel mounted interfaces Rear Connections Refer to Figure 10 7
32. 1 83 139 59 IN Ki VA 400 2254 OPTIONAL HOLD mm DOWN BRACKETS Figure 3 5 Securing iQ Generator to Benchtop Dukane Manual Part No 403 574 01 Page 17 iQ Series Ultrasonic Generator Power Supply LS User s Manual RFI Grounding In addition to the safety considerations previously men tioned proper grounding at the generator power cord is essential for the effective suppression of electrical noise or RFI Radio Frequency Interference Every ultrason ic generator contains a RFI filter which blocks noise on the AC power line from entering the system control cir cuitry This filter also prevents ultrasonic frequency noise from being fed back into the AC power line In order for the RFI filter to operate properly it is necessary to cor rectly ground the system Run a grounding wire from the grounding stud connection to the nearest grounded met al pipe or equivalent earth ground and secure it with a ground clamp See Figure 3 6 on Page 20 Page 18 Dukane Manual Part No 403 574 01 Section 3 Installation Connecting Cables Quick Start Guide Details about the various system connectors and their pin assignments are covered in Section 4 Manually Operated Probe System Hand Probe Step 1 Ground the generator chassis using the supplied 14 Gauge wire and attach it to the grounding stud O in Figure 3 6 Step 2 Attach the hand probe s HD 15 system input con nector to J2 on the VO panel Q in F
33. 5 5 Ee at Star EE 40 5 6 Main TER EE ET EE a E 40 7 1 Rear Panel AC Breaker Switch ee ee ee ee ee ee ee ee ee ee ee ee 57 7 2 Front Panel POWER TEST LED 57 7 3 FrontiPanel OFFLINE EED u u uuu u uuu nda lo ceca e DAR Aaaa ER NG 57 7 4 FrontPanel ONLINE LED sam AG ARNAN ANG 57 7 5 System 5506600000 58 7 6 Stop Ultrasound Output GITGITAN AREE AE YA 59 8 1 Cable End or System VO Coreen ses edes tetas 63 8 2 Overload Wu e te E 64 8 3 Fower Status nie e Te 64 10 1 Example of 120 Volt Grounded 3 Prong Receptacle 73 10 2 120VAC Power Inlet Panel 74 10 3 HD15F for System Inputs Outputs Connechor mem 75 10 4 Option Panel and VO Panel exa unde See iet redu NI o se ext ea o Ud led 75 10 5 Generator Rear View Optional MPC Model 76 10 6 MPG Module Cutout Guide aa aaa al a m DR BALAY ka 78 10 7 MPC Module Rear Connectors ll manna ee ee KANG GANGBANG AKNG ARAR RAYA YARA YAYA nennen nnne 79 Dukane Manual Part No 403 574 01 Page 109 iQ Series Ultrasonic Generator Power Supply LS User s Manual List of Figures continued No Description Page 10 8 MPC Module Front Connectors 79 10 9 MPC Module Status E EDS eter ee a AKA haa ie 80 10 10 MPG Cycle er E 81 10 11 Current Loop Transfer Function Graph
34. 574 01 Page 51 iQ Series Ultrasonic Generator Power Supply LS User s Manual HOW TO Adjust Amplitude 1 Press CANCEL until you see the Main Menu screen as it is shown here Move the selection indicator to PROCESS SETUP Press ENTER and you will see the screen as shown here Select PROCESS CONTROL and press ENTER With no option boards installed in the generator you will get a WELD BY choice of iQ SYSTEM or AUTOMATION Select iQ SYSTEM and press ENTER Select AMPLITUDE CONTROL Select AMPLITUDE SETTING Adjust the amplitude This is a value with a minimum of 2096 and a maximum of 10096 Selectthe digits with the RIGHT and LEFT arrows Use the UP and DOWN arrows to select the value When done with the amplitude entry press ENTER and an ENTRY ACCEPTED message will appear Page 52 1 OPERATE MODE PROCESS SETUP HARDWARE SETUP PROCESS SETUP 4PROCESS CONTROL PROCESS LIMITS UTILITIES AUTOMATED PROBE WELD CONTROL BY 4iQ SYSTEM AUTOMATION WELD CONTROL HOLD CONTROL AFTERBURST CONTROL 4 AMPLITUDE CONTROL AMPLITUDE CONTROL 4 AMPLITUDE SETTING gt RAMP UP DOWN TIME AMPLITUDE SETTING 0 Yo 4 SELECT DIGIT gt a CHANGE VALUE NA NOTE Once the amplitude is set and the entry is accepted the program takes you back to the AMPLITUDE CONTROL screen From there you may adjust the RAMP UP DOWN times or go to some other part of the menu Dukane Manual Part No 403
35. ANCEL until you see the Main Menu screen as it is shown here Selection indicator is on OPERATE MODE OPERATE MODE 4PROCESS DATA PROCESS STATISTICS SYSTEM PARAMETERS 2 Press ENTER to view OPERATE MODE selections Selection indicator is on PROCESS DATA 3 Press ENTER The screen you see is the one that ap 1 PART COUNT pears just after the generator is first switched ON Boner ENERGY 4 After viewing this screen press CANCEL once to return to the OPERATE MODE menu 5 Press the down arrow key and select OPERATE MODE PROCESS STATISTICS Benocsss STATISTICS SYSTEM PARAMETERS 6 Press ENTER PART COUNT GOOD BAD The next screen shovvs part statistics SUSPECT 7 Press CANCEL to return to OPERATE MODE selections OPERATE MODE 8 Using the up and down arrow keys select SYSTEM AR PARAMETERS SYSTEM PARAMETERS FREE RUN FRQ 20000 Hz fammee 50 9 Press ENTER and view the parameters OPERATE MODE 10 Press CANCEL to return to OPERATE MODE 4PROCESS DATA selections EE EE EE PROCESS STATISTICS SYSTEM PARAMETERS Selection Indicator NOTE POWER is added to the parame ters display on E model genera tors as shown in the screen illus tration below AMPLITUDE 50 FREE RUN FRQ 20000 Hz POWER 60 W
36. Connector 32 Configuration Port Connector 33 Dukane Manual Part No 403 574 01 Page 21 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 22 Dukane Manual Part No 403 574 01 Section 4 Standard Connections 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 4 1 illustrates the panel layout Figure 4 1 Generator Rear Panel AC Power Inlet Panel Options Module Panel IEC Power Inlet Connector Attaches to an IEC style A blank panel is installed on standard systems power cord An option module can be installed here Power Switch Circuit Breaker Used to switch system power ON and OFF 9 Chassis Grounding Stud Chassis connection for a NOTE protective earth ground See Section 10 Options for more information The System UO Panel 9 System Input Connector Connections for system control input signals Q System Output Connector Connections for system status output signals Ultrasound Output Connector Coaxial high voltage connection to ultrasonic stack Configuration Port Connector Digital control port
37. EN SE HARDWARE SETUP it 1s shown here Move the selection indicator to PROCESS SETUP 2 Press ENTER and you will see the screen as shown PROCESS SETUP 4PROCESS CONTROL here 1 PROCESS LIMITS UTILITIES 3 Select PROCESS CONTROL and press ENTER With no option boards installed in the generator you will get a WELD BY choice of iQ SYSTEM or 40 SYSTEM WELD CONTROL AUTOMATION 4 Select iQ SYSTEM and press ENTER 5 Select WELD CONTROL wep CONTROL HOLD CONTROL AFTERBURST CONTROL AMPLITUDE CONTROL WELD BY TIME WELD BY PEAK POWER 6 Select WELD BY ENERGY 4 WELD BY ENERGY 7 Selectthe digits with the RIGHT and LEFT arrows Use q EE the UP and DOWN arrows to select the value energy 2 de in Joules EA SELECT VALUE 8 VVhen done vvith the energy entry press ENTER and an ENTRY ACCEPTED message will appear NOTE In the above example Energy was the primary method of weld control Next the energy of the weld was set in Joules The program then asks the operator to choose and set a MAX WELD TIME a secondary characteristic that also controls the weld Select a time between 0 and 30 seconds The time forces the weld portion of the cycle to stop even if the energy parameter is not met Press ENTER An ENTRY ACCEPTED message will appear Dukane Manual Part No 403
38. Hz 40XX090 2X XX 900 200 240V 50 60 Hz Q 8 Amps 40kHz 40XX120 1X XX 1200 100 120V 50 60 Hz 15 Amps 40kHz 40XX120 2X XX 1200 200 240V 50 60 Hz Q 8 Amps Table 11 II AC Povver Requirements NOTES An X used above in the Model Numbers is a vvildcard 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 Models rated for 200 240V nominal AC line voltage include an IEC power inlet to attach an international IEC type power cord The 3600VV and 4800VV models include a 30A fixed power cord A power cord with a domestic three wire grounding plug is included with each standard system NEMA 6 15P Models rated for 200 240V nominal AC line are fully CE compliant for use in Europe or any other country in the world Models rated for 200 240V nominal AC line require a 16 Amp or 30 Amp grounded AC outlet rating outside of North America Japan Models rated for 100 120V nominal AC line are for use in North America or Japan and include a 15 A fixed power cord The fixed power cord includes a three wire grounding plug NEMA 5 15P configuration These models are fully FCC compliant but are not usable in European countries and therefore are not CE certified Page 100 Dukane Manual Part No 403 574 01 Section 11 Specifications p1eog onuoo Jejsnuu uonewo ny Od ojs suondo ay ui pieod 0 1400
39. Intelligent Assembly Solutions IQ Series ULTRASONIC GENERATOR POWER SUPPLY LS AUTOMATED HAND PROBE PRESS User s Manual Dukane Part No 403 574 01 Dukane Intelligent Assembly Solutions 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949 150 9001 2008 tnn 4 www dukane com us Copyright 2010 Notice of Rights All rights reserved No part of this manual including the interior design cover design and icons may be reproduced transmitted or utilized in any form or by any means electronic mechanical photocopying recording or by any information storage and retrieval system without written permission from the manufacturer Notice of Liability The information contained is this manual is distributed on an As is basis with out warranty While every precaution has been taken in the preparation of this manual the manufacturer shall not have any liability to any person or entity with respect to any liability loss or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual or by the hardware products described herein Specifications are subject to change without notice This user s manual documents product features hardware and controls software available at the time this user s manual was published Printed in the United States of America Part Number 403 574 01 This ultrasonic equipment is
40. LO3NAs dni3as XX it dNLIS 10313S paido9 dnjes NOLLYWOLNY WALSAS O NOILO3 13S dALAS peser3 sdnieg IV S3A Buiseig Ad09 ol YO OLAdO2 INOH3 AdOO dnjas jualing Sdni3s dS Vua sdm s Iv a ias ANAHHNS 3INVN 540135 3SVH3 dN13S V AdO2 dNLIS 1 SalLrTun dnas 9311 dNLIS TOYLNOO d 113S SAILITILA SLINIT SS300d4d SS3J0Yd dNLas 953204 s n nn SI Jo 9 eDeg snu yy luoO w L 41139 SS45204d Dukane Manual Part No 403 574 01 Page 118 OPERATE Appendices OPERATE MODE PROCESS DATA PROCESS STATISTICS SYSTEM PARAMETERS Rxx Remote Setup Number and xx Local Setup Number RR 14 PART COUNT XXXXX WELD TIME 0 000 S PEAK POWER ow ENERGY 0J PART COUNT XXXXX GOOD XXXXX XXX BAD XXXXX XXX Yo SUSPECT XXXXX XXX AMPLITUDE XXX Yo POWER XXXX W FREE RUN FRQ XXXXX Hz AMPLITUDE POWER OPERATE FRQ Time and Energy Menus Page 7 of 15 SYSTEM PARAMETERS screen changes to this screen if TEST button is pressed Page 119 Dukane Manual Part No 403 574 01 iQ Series Ultrasonic Generator Power Supply LS User s Manual nueui dnjes aJempJeH ay Ul pejqeue SI Ja mod Aq 196611 ueuM aldelleAe K uo aie snu w 141 Saul ILON 1noawWliL399nml SLIVM 3399IH L 3aniridiv 3399 gi KBieu3 FLSE Kiepuodag yel Aiepuooes MID PI8M Kiepuooasg
41. N SHOULD BE USED INSTEAD Figure 10 17 NPN to PNP Conversion Page 86 Dukane Manual Part No 403 574 01 Section 10 Options CC am PNP TO NPN CONVERSION LOAD LOAD LOAD LOAD 110 4397 Coat Gm Ge Co SPECIFICATIONS INPUTS MINIMUM VOLTAGE 5 0 Vdc MAXIMUM VOLTAGE 30 0 Vdc CURRENT 1 5mA 5 0 Vdc 9 5mA 24 0 Vdc OUTPUTS MINIMUM VOLTAGE 5 0 Vdc MAXIMUM VOLTAGE 30 0 Vdc NOTES MAXIMUM CURRENT 50mA 1 OUTPUTS SHOULD NOT BE CONFIGURED TO SINKA TTL LOAD TO VOLTAGE DROP TO 1 0 Vdc MAX GROUND A RELAY CONNECTION SHOULD BE USED INSTEAD Figure 10 18 PNP to NPN Conversion Dukane Manual Part No 403 574 01 Page 87 iQ Series Ultrasonic Generator Power Supply LS User s Manual 5 4 5V TO 124V PNP CONVERSION sv I A 5V I OPEN COLLECTOR gt WITH PULL UP I RESISTOR l N1 OUT 1 i amp IN 1 0V ON l SY IN 1 5V OFF I IN 1COM OUT 1 LOAD I I 7757 mi KE I Ha N2 OUT 2 2 I IN 2 0V OFF IN 2 5V ON N 2 COM OUT2 C LOAD SS N3 OUT 3 I IN 3 Q 0V ON
42. No 403 574 01 Page 114 Appendices PROCESS SETUP PROCESS S PROCESS CONTROL PROCESS LIMITS UTILITIES Hand Probe ETUP 1 HAND PROBE WELD CONTROL BY iQ SYSTEM HAND PROBE SWITCH HAND PROBE Weld Control Amplitude Control See Amplitude Control Menu Weld Time See Amplitude Control Menu Time Only Menus Page 3 of 15 Page 115 Dukane Manual Part No 403 574 01 iQ Series Ultrasonic Generator Power Supply LS User s Manual nualN jon u09 epnyjduy s SU Aejaq aaoid Kejag eqoJd Ionuoo apnjjduy nuay 101 u09 pny dwy aag Bawi pI A 1 3001174 1 Q 13M eqoJd Odin 38Otd OdW NOILVWOLNVY IN31SAS Ol q si enr SALLITILA Ad TIOH LNOO ISA 912919 SLIWIT ss300y4d 38oxd oan lt p o9 9q JOMINOO SS300Md 3I29 U JdIN dni3s SS300Md 9qoJd OdIN GL Jo y bed snue A AUG ul l dfiL3S SS4204d Dukane Manual Part No 403 574 01 Page 116 Appendices PROCESS SETUP PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Process Limits PROCESS LIMITS SUSPECT PART BAD PART WELD TIME WELD TIME LIMIT LIMIT Maximum Weld Time Enable Maximum Weld Time Minimum Weld Time Minimum Weld Time Time Only Menus Page 5 of 15 Page 117 Dukane Manual Part No 403 574 01 iQ Series Ultrasonic Generator Power Supply LS User s Manual Q3a
43. ON AMPLITUDE SETTING 90 Yo CHANGE VALUE e Dukane Manual Part No 403 574 01 Page 111 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 112 Dukane Manual Part No 403 574 01 OPERATE Time Only Menus Appendices Page 113 Page 1 of 15 Rxx Remote Setup Number and xx Local Setup Number D 1PART COUNT XXXXX OPERATE MODE PROCESS DATA WELD TIME 0 0000 S PROCESS STATISTICS SYSTEM PARAMETERS PART COUNT XXXXX GOOD XXXXX XXX BAD XXXXX XXX SUSPECT XXXXX XXX AMPLITUDE 10076 POVVER ow FREE RUN FRQ 19 899 Hz AMPLITUDE 100 POWER 60 W OPERATE FRQ 20 020 Hz SYSTEM PARAMETERS screen changes to this screen if TEST button is pressed Dukane Manual Part No 403 574 01 iQ Series Ultrasonic Generator Power Supply LS User s Manual uoneung jsunqueyv Kejag ysunqeyy 0318 nus jon uo09 pmuldury s 03187510 eur Kejag eqoud Ionuoo apnydwy Kejag eqoJd nus jo qu09 apnyjduy ees SLL pleM eui P OH aqold JOMINOO pejeuiojny a4an r d v TOYULNOD 1SYNGYILIV IOH LNOO QOH TOYINOO q 44 IN31SAS Ol NOILVWOLNV S3lLIT LO Ad 1041NO Q13M Payjeysul spseog SLINIT SS300Md 390d aaivWoinv uondo ON ge dud eqoJd pa gwojny G Jo z abe 30 g bed dfildS SS45204d snu lN AI UO SWI Dukane Manual Part
44. P AA EEE EES sas 64 Over Temperature 64 Generator Fault Does Not Reset 64 System Power Diagnostic Procedures 64 AC Line Fault EE EE RE OE EE 64 DG Bus Fault seie von AGA Ee GWA nA chee AE SN ER EE ER Sas 64 Control Power Supply Fault 64 Welding Problems 65 Weak WeldS EES EL SERE REG EE AA AA 65 Excess Fl sh AE EE 00 65 Inconsistent Welds cs s ES EE ROER dabo BEDRAE SERE SEE ORE deus 65 Pop up Status Screens 66 Dukane Manual Part No 403 574 01 Page 61 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 62 Dukane Manual Part No 403 574 01 No Ultrasonic Output Probe Make sure that the probe coaxial cable is connected to the generator ultrasonic output connector J1 Basic generator models have the BNC connector on the rear panel Also make sure the probe stack was properly assembled Cables Make sure that both the U S coaxial and system O cables are securely connected You must activate the ultrasound activation input to Pin 8 on the system input HD 15 connector either by the hand probe s control cable or with a custom automation input signal Refer to Table 4 I Generator Input Signals for details Place the generator OFFLINE and 1 Check the coaxial cable for any signs of d
45. Parts Set maximum and minimum values for Time Power and or Energy 8 Configure advanced hardware settings including Phase Free Run Frequency Frequency Lock and Hold and Frequency Limits Parameters that can be Obtained via RS 232 Time and Energy option 1 All control parameters that are configured via RS 232 2 Real time data that includes welder state ultrasound active or not frequency power and amplitude 3 Weld cycle data from previous weld that includes Cycle Count Good Bad and Suspect Part information Process Limit setting exceeded or not reached if Bad or Suspect Part checking is enabled Weld Time Weld Energy Peak Power For information on how to control and or monitor specific pa rameters iQ Generator RS 232 Communication and Control documentation is available Signing a non disclosure agreement is required to obtain this documentation Page 89 iQ Series Ultrasonic Generator Power Supply LS User s Manual iQLinQu PROFIBUS Communications Module Part Number 110 4554 The PROFIBUS option module allows the iQ generator to connect to a PROFIBUS network Since PROFIBUS is multipoint instead of point to point more than one generator can be connected to a single bus cable The PROFIBUS module offers access to generator parameter settings and status information listed below In addition if desired all I O wiring can be replaced with a single PROFIBUS cable Control Parameters a
46. Q LIMITS PHASE SHIFT FREQ LOCK HOLD Page 127 Phase Shift Free Run Frequency X Deg XXXXX Hz Wide Normal 21000 19000 20500 19500 Narrow Manual 20200 19800 Entry Entry Accepted LOCK AND HOLD MODE IS ENABLED DO NOT TRIGGER UNDER PRESSURE Default Settings Restored WARNING ALL SETUPS RESTORE SYSTEM TO WILL BE ERASED AND FACTORY DEFAULTS FACTORY DEFAULTS NO WILL BE RESTORED YES RESTORE SYSTEM TO FACTORY DEFAULTS PLEASE WAIT Disable NOTE TRIGGER BY POWER menus shown with Automated Probe Page 8 of 15 and with MPC Probe Page 10 of 15 Dukane Manual Part No 403 574 01 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 128 Dukane Manual Part No 403 574 01 Dukane 50 0 0 IS0 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 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 Organ
47. Think of it as a back key Selection is not stored in memory Dukane Manual Part No 403 574 01 Section 5 Standard System Status and Controls NOTE To activate the TEST mode the system must be ONLINE AMPLITUDE 85 POWER 40 W OPERATE FRQ 19990Hz SYSTEM POWER OUTPUT LEVEL OVER 20 40 60 80 100 iem SYSTEM OPERATING MODE ex In this illustration one LED segment is shown as lit after TEST was pushed Left Right Down Navigation Keys 4 Page 39 iQ Series Ultrasonic Generator Power Supply LS User s Manual Start up Sequence After all connections have been completed 1 Push the rear panel AC breaker switch to ON The generator begins its self diagnostics sequence 2 POWER TEST flashes RED for several seconds 3 First the entire System Power Output Level bargraph lights up momentarily verifying that all bar graph LED segments are functional Next two short beeps are sounded as the OVERLOAD LED flashes 4 TheSystem Operating Mode shifts to either ONLINE or OFFLINE depending on what was previously selected See System Operating Mode on Page 31 5 The LCD display identifies the Dukane iQ Series type first Then another screen provides system detail See the Start up 1 and 2 Figures 5 3 and 5 4 to the right 6 When the diagnostics sequence is finished the next screen to appear will look like Figure 5 5 This is the Process Data screen and that is l
48. a process control system to control welding process The basic B models can be programmed to weld by time E model generators can weld by time and energy See Figure 11 5 for model number information Manual Welding Generally a trained operator will start the welding process using a hand probe with an activation switch that starts the welding controller that controls the duration of the ultrasonic power applied to the parts being welded The operator applies an appropriate amount of pressure to the parts to be ultrasonically joined Then the operator activates the welding cycle and the process controller begins the ultrasound output for a time or energy period that will reliably weld the final assembly The quality of the finished product is particularly dependent on the skill of the hand probe operator Automated Welding This automated welding control approach is custom designed by the user and can be very simple or quite sophisticated depending upon the user s requirements In most cases a Programmable Logic Control PLC system will be used to initiate the welding process Then the front panel process controller controls the welding process Output signals from the PLC system will determine when the ultrasound or weld cycle starts Control signals for a Multiple Probe Control MPC system can also be easily added if needed A variety of ultrasonic welding status output signals are available to the automation system wh
49. afely 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 Step3 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 Ifyou 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 Dukane Manual Part No 403 574 01 Page 9 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentio
50. am 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 Plug the generator s electrical cord into its AC power source Push the generator s AC power switch breaker to the ON position Page 14 Dukane Manual Part No 403 574 01 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 Allow at least 5 inches 13 cm of space on both ends of the generator chassis for air circulation Allow a 3 inch space 8 cm at the rear of the chassis for cable clear ance See Specifications Section 11 for detailed generator drawings 3 45 87 53 EXHAUST AIR OUTLET IN mm OPERATOR OPERATOR CONTROLS DISPLAY Figure 3 3 Generator Front View low profile model Dukane Manual Part No 403 574 01 Section 3 Installation 17 16 435 86 COOLING AIR INLET Page 15 iQ Series Ultrasonic Generator Power Supply LS User s Manual Placing the Generator when Used in an Active Seismic Region 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
51. amage which may result in an open circuit preventing the cable from transmitting the signal from the generator to the probe 2 Ifyou have a mounted probe replace the coaxial cable with a known good cable 3 If you are using a hand probe try a different known good probe to determine if the problem is related to the generator or the external cables and probe Generator The generator will not produce an output signal when triggered if it is offline If the generator is OFFLINE the system mode indicator shows OFFLINE in yellow To change the system to ONLINE press the ON OFFLINE mode key When ONLINE the system mode indicator shows ONLINE in green Verify that at least one segment on the LED bar graph lights when the ultrasonic activation input signal starts a welding cycle Operate Input If you are using a hand probe make sure the control cable and adapter cable are securely connected to the system I O connector The trigger switch on the hand probe activates the ultrasonic output through the control cable Dukane Manual Part No 403 574 01 Section 8 Troubleshooting NOTE The cable end of the system I O con nector is a mirror image of the panel connector Figure 8 1 below shows the cable pinout Make sure you have correctly wired the connector if you are using custom automation signals Also refer to Table 4 I for the cable color pin assignment 11 12 13 14 15 Figure 8 1 Cable End of System I O Connector
52. at Step 1 for each of the remaining probes in sequence 2 3 4 etc in your system PROBE SELECTION STATUS uu MODEL MPC0404 PROBE 4 Figure 10 8 MPC Interface Front Connectors System Probe P N Cable PIN Frequency MPC to Probe 41C25 20kHz 41C27 200 479 XX 30kHz 41A60R 129 200 615 XX 40kHz 41A40 Table 10 IV Probe Cables Page 79 iQ Series Ultrasonic Generator Power Supply LS User s Manual MPC Interface Status LEDs System Status When the system is powered and ready the front panel SYSTEM STATUS LED lights up and becomes GREEN in Figure 10 9 If this LED is lit with a YELLOW ORANGE color a recoverable fault condition has tripped This indicates that the system is operational but a fault condition has occurred preventing normal operation Examples of this type of fault would be a generator overload that will automatically reset when the next weld cycle begins or the automation control system is selecting a channel that doesn t exist for instance trying to select channel 10 for an 8 channel system If this LED lights up RED a hardware fault has been sensed and the unit should be returned to Dukane for servicing Probe Selection Status The PROBE SELECTION STATUS LED in Figure 10 9 lights up GREEN indicating it is the selected probe A probe s LED turns to RED from GREEN when ultrasonic power is activated Page 80 PROBE SELECTION STATU SYSTEM sms
53. atus 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 Activating this input will reset the status output faults and may simplify automation programming Pin 13 Isolated Common 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 voltage output Pin 14 Not Used Pin 14 is an open connection 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 Page 27 iQ Series Ultrasonic Generator Power Supply LS User s Manual System Outputs Connector The SYSTEM OUTPUTS connector mounted on the generator I O panel includes connections for all of the basic system status and monitor output signals which will typically 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 contr
54. below and complete these connections l Earth ground Connect one end of a user supplied 14 Gauge ground wire to the ground connection at the rear ofthe MPC Oin Figure 10 7 Connect the other end of the wire to an earth ground potential at the electrical box that supplies power to the equipment or to the equipment enclosure into which your system is installed U S ultrasonic cable Dukane P N 200 479 XX Order the correct cable length for your installation Connect one end of the cable to the left rear U S con nector of the MPC interface O in Figure 10 7 The other end of the cable connects to J1 of the ultrasonic generator MPC Interface cable Dukane P N 200 1408 XX Order the correct cable length for your installation Connect one end of the cable to the right rear MPC Interface connector Q in Figure 10 7 The other end of the cable connects to the MPC INTERFACE connector on the ultrasonic generator DUKANE MPC PATENT SOVAYSLNI Odi PENDING Figure 10 7 MPC Interface Rear Connectors Dukane Manual Part No 403 574 01 Section 10 Options Front Connections Refer to Figure 10 8 below Complete these connections l Probe Cable s Beginning with PROBE 1 con nect one end of the cable See Table 10 IV below to the U S connector on the MPC s front panel O in Figure 10 7 Connect the other end of the cable to the corresponding probe for your specific welding application Repe
55. chines The generator design accepts several control input signals and provides system status output signals This product has rugged internal ultrasonic generator cir cuitry and ensures a continuous resonant frequency lock at the start of each weld Users may program the generator setup parameters to meet a wide variety of ultrasonic processing requirements 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 Key Generator Features Program the Generator with up to 16 setups Process Parameters such as frequency amplitude and power are all updated at a 5 ms rate e 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 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 Automatic Tuning tracks the resonant frequenc
56. ct the value Table 6 1 Ramp Up Down Times When done with the entry press ENTER and the ENTRY ACCEPTED message will appear The program will take you back to the AMPLITUDE CONTROL screen Dukane Manual Part No 403 574 01 Page 53 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 54 Dukane Manual Part No 403 574 01 Section 7 System Operational Testing System Operational Testing System Verification T S S 57 Preliminary Setup 57 Testing the Generator 57 System NOSE s uaa skua ER XA da ERES OE REI 58 Probe Operation 59 Stopping the Ultrasound Output 59 System with a User supplied Emergency Stop Switch 59 Dukane Manual Part No 403 574 01 Page 55 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 56 Dukane Manual Part No 403 574 01 System Verification Tests Preliminary Setup Step 1 Plug in the AC line cord to the correct AC power outlet See Table 11 II for the model power requirements Step 2 Attach a compatible ultrasonic probe to the ultrasound output connector J1 Step 3 Activate the AC Breaker Switch to the ON position Testing the Generator Complete steps 1 3 above and then continue with steps 4 5
57. ctivated at the end of the ramp up time until the beginning of the ramp down time This status signal will be active for the time the ultrasound is at the programmed amplitude setting 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 18 MPC Ready Status Output This status output signal will activate only when an MPC interface board is installed in the generator Pin 18 is a digital active low status output that activates when the MPC controller is ready to accept changes on the probe selection control bits and ready to start the next MPC welding cycle This output will be an open circuit when the MPC system is not ready to accept changes to control input signals Any changes will be ignored until this status output signal activates to the ready state This status output signal will also be open MPC NOT READY if a fault condition is detected inside the MPC system If this status output will not activate check for a red fault status indication the SYSTEM STATUS LED on the front of the MPC module 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 fa
58. d For safety the power cords used on all Dukane products have a three prong grounding type plug Approved 2 pole 3 wire grounding receptacle HUBBELL No 5262 or equivalent to NEMA 5 15R or 5 20R Figure 10 1 Example of 120 Volt Grounded 3 Prong Receptacle Dukane Manual Part No 403 574 01 Page 73 iQ Series Ultrasonic Generator Power Supply LS User s Manual AC Power Inlet Panel The optional AC power inlet panel is described here AC Power Cord The AC power cord in Figure 10 2 is appropriately rated and permanently mounted to the power inlet panel Power Switch Circuit Breaker The power switch circuit breaker 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 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 1s likely an internal system mal function and the gen
59. e active but not a process fault like Overload Dukane Manual Part No 403 574 01 Section 4 Standard Connections Pin 23 Suspect Part Status Output Pin 23 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 suspect part limits This output will be an open circuit after a welding cycle when a suspect part has not been detected 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 25 is an open connection Pin Signal Name Cable Color Code Signal Option Requirements 22 BLK EE WHT ORN 7 o E 14 18 16 7 E NPC Option Board 19 20 2 22 23 24 25 Nouse S ow 4 Table 4 II System Output Connector Signals J3 Dukane Manual Part No 403 574 01 Page 31 iQ Series Ultrasonic Generator Power Supply LS User s Manual 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 fu
60. ements help you to identify and avoid hazards and recognize the consequences One of three different symbols also accompany the CAU TION and WARNING blocks to indicate whether the notice pertains to a condition or practice an electrical safety issue or an operator protection issue 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 ro man sequence numerals e g I II IIT As an example Figure 3 2 would be the second illustration in Section 3 while Table 3 II would be the second table in Section 3 Dukane Manual Part No 403 574 01 Section 1 Introduction NOTE Note statements provide additional information or highlight procedures WARNING SC Warning statements point out conditions or 5 practices that could re ka sult in personal injury or loss of life Condition Electrical Hearing or Practice Hazard Protection Page 3 iQ Series Ultrasonic Generator Power Supply LS User s Manual Generator Overview This generator is designed for basic ultrasonic applications that use either manually operated hand probes or ultrasonic probes controlled by automation systems Using the avail able system control inputs and output status signals it can easily be controlled by automated ma
61. erator will require service 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 suppression of electrical interference or radio frequency interference RFI that is common in an industrial environment The chassis ground stud is in Figure 10 2 Proper system grounding is discussed in Section 3 Page 74 o o o I O seyon KRACK ES gu CE o 120 volt line cord Figure 10 2 120VAC Power Inlet Panel Dukane Manual Part No 403 574 01 Section 10 Options VO Panel Options Single Connector System UO Panel o See in Figure 10 4 where the I O panel is set up for the single I O connector a HD15F type The generator label for this connector is SYSTEM INPUTS OUTPUTS Another label identifies the connector as J12 The I O panel can be customized with multiple types of connectors such as the single HDISF terminal blocks etc Contact your local sales representative for more details Table 10 I shows an example of a customized option Option Panel I O Panel Pins Signals duplicate a Dukane DPC I generator Figure 10 4 Option Panel and UO Panel NOTE Shovvn are the Option panel vvith Remote Control Module and the I O panel with single VO connector APEC
62. ertifies that it meets the requirements of the EU European Union concerning interference causing equipment regulations CE stands for Conformit Europe ne European Conformity The equipment complies with the following CE requirements The EMC Directive 2004 108 EC 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 1s IP2X in compliance with finger safe industry standards Page 102 Dukane Manual Part No 403 574 01 Section 12 Contacting Dukane Contacting Dukane Dukane Manual Part No 403 574 01 Page 103 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 104 Dukane Manual Part No 403 574 01 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 LCD display Software version Press INFO With selection indica tors at System Inf
63. he up position This option is typically used for a continuous welding process when the user wants to retract the ultrasonic stack away from the process or material when the ultrasound is off or some changes in the process are being made Dukane Manual Part No 403 574 01 Section 4 Standard Connections Pin 10 Front Panel Control Lock Input Pin 10 is used to lock the front panel user interface so an operator cannot change any welding setups or configuration parameters that are stored in memory The user can use the interface controls to view welding information but no setup changes are allowed Deactivation of this signal allows normal operation without any lockout restrictions Pin11 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 activation 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 pneumatic 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 Pin 12 System Latch Reset Input Pin 12 is used to reset the Any Fault or System Overload st
64. ich are useful in monitoring the welding process Dukane Manual Part No 403 574 01 Section 6 Process Control Settings Automated Process Control Input Signals Refer to Section 4 for the available input control signals on the system input connector The ultrasound cycle start activation input will always be used with the other available control input signals optional depending upon the user s processing requirements The Front Panel Control Lock input and the System Latch Reset input are used with the front panel controller The Auto Stop input provides an added means to shut off the ultrasound output and the Remote Setup Bit inputs allows the automation system to switch the system setups remotely Status Output Signals Refer to Section 4 for the available status output signals that are on the system output connector Note that some of the listed status output signals are not functional if the system is not equipped with certain optional features Using the available status output signals the automation system can easily monitor when the ultrasound output is activated and other fault status signals to assist in controlling the automated welding process Page 47 iQ Series Ultrasonic Generator Power Supply LS User s Manual Screen Navigation Basics This section gives you a step by step guide to navigating through some of the basic menu structure 1 OPERATE MODE gt PROCESS SETUP HARDWARE SETUP 1 Press C
65. igure 3 6 Step 3 Attach high voltage coaxial cable to J1 the ultra sound output connector 9 in Figure 3 6 Step 4 Connect the AC power cord to the IEC power inlet connector on the ultrasonic generator in Fig ure 3 6 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 II NOTE Continent of Use ERE il Refer to Section 10 Options for informa Part Number tion about optional features 200 1110 240V 15A 200 1541 240V 10A 200 1111 240V 16A Continental Europe 200 1542 240V 10A Table 3 II Standard IEC AC Power Cord Part Numbers Dukane Manual Part No 403 574 01 Page 19 iQ Series Ultrasonic Generator Power Supply LS User s Manual J7 is optional INPUTS O N o o o X A C A 0 s is OUTPUTS Fai A ABE o An Y r CE o x o AC POVVER m O INLET STUD ULTRASOUND OUTPUT Figure 3 6 Generator Rear View low profile model Automation Controlled Probe System Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Ground the generator chassis using the supplied 14 Gauge wire and attach it to the grounding stud in Figure 3 6 Optional Ground the probe support This is a
66. inked to the OPERATE MODE menu This screen is updated after each weld cycle 7 Press CANCEL twice and you will be at the Main Menu as shown at right Page 40 SYSTEM POWER OUTPUT LEVEL 20 40 60 80 a SYSTEM OPERATING MODE emm NOTE A welding cycle cannot be started when the mode is OFFLINE because this blocks the ultrasound activation signal input DUKANE iQ LS SERIES o Figure 5 3 LCD Display at Start up 1 AUTOMATED PROBE TIME ENERGY 20kHz 2400W SYSTEM Figure 5 4 LCD Display at Start up 2 WELD TIME PEAK POWER 1 PART COUNT ENERGY Figure 5 5 LCD Display at Start up 3 1 OPERATE MODE PROCESS SETUP HARDWARE SETUP Figure 5 6 Main Menu Dukane Manual Part No 403 574 01 Stopping the Weld Cycle Normal Conditions The cycle stops when the programmed welding cycle ends Emergency Conditions Manual System Press OFFLINE to stop the ultrasound signal This may be done under any condition Automated System Customer supplied external controls provide the means to stop the cycle for an automated system An auxiliary cable connects these external controls to the iQ generator at connector J2 Control input labeled Automation Cycle Stop Input Pin 15 when activated will stop the weld cycle if configured as End of Weld Dukane Manual Part No 403 574 01 Section 5 Standard System Status and Controls Page 41 iQ Series
67. is the second most significant bit used to select different weld ing setups with an automation control system This input is also used to select different channels when a Multiple Probe Controller MPC Interface option board is in stalled Pin 7 Remote Setup Selection Bit 4 Input Not used on the basic model generator Pin 7 is the Remote Setup Selection Bit 4 which is the most significant bit used to select different welding setups and can only be used with an advanced control system This bit will not be used when a Multiple Probe Controller MPC Interface option board is installed Pin 8 Ultrasound Activation Cycle Start Input 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 ultrasound 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 controller Depending on the welding process controller setup this input signal could be activated momentarily to start a welding cycle See Section 6 for more information Pin 9 Automation Thruster Control Input Pin 9 is used only when an optional automation thruster control board is installed See Page 76 Activation of this input would cause the thruster attached to the option board to go to the down position When this signal deactivates the thruster will move to t
68. izations and Quality System Infrastructure 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 ISO 9001 2008 Dukane products are manufactured in ISO registered facilities Please refer to our website at www dukane com us sales intsales htm to locate your local representative ZEB jQ Series LS Generators User s Manual www dukane com us Part No 403 574 01 mu 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
69. l Number 101 Regulatory Agency Compliance 102 EE re EE EE E 102 CE Marking ee re a ANAL APA w uw wa 102 lui curo cT 102 Dukane Manual Part No 403 574 01 Page 93 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 94 Dukane Manual Part No 403 574 01 Section 11 Specifications SO W31SAS 8 GANNOSVYLIN TANVd SNOILdO AYLNA HAMOd OV S IOHLNOO HO1VHAdO AV1dSIa HOLVHAdO HOLIMS H3MOd INO TVNOLLdO ww NI e928 98 Sey 91 ONITOOO Mod ONIT000 dais HOv3 X04 S MOTIV 3016 HOV3 13 MOTIV zz oec 066 ev esc 866 ONITEVS HO4 MOVE NI MOTIV Figure 11 1 Low Profile Chassis Drawing Page 95 Dukane Manual Part No 403 574 01 iQ Series Ultrasonic Generator Power Supply LS User s Manual IaNVd SNOLLdO S O l WALSAS aNnosvarin HOLIMS HAMOd ANOHA TYNOLLdO 04 6ET ce er 05 5 615 og sev 9121 DNTIOOD S3QIS HLOg S MOTIV NT 18V2 30d MOVE NI E MOTIV 51041 02 HOLVAAdO AV IdSIG M Olydado NI NT1002 04 SaqIS H 1O8 S MOTIV 16 72521 S6 6 ww Figure 11 2 High Profile Chassis Drawing Dukane Manual Part No 403 574 01 Page 96 Section 11 Specifications HAMOd OV HO4 MOVE NI E MOTIV eet 61 s uu NI 6eilos c CD E 22 7 Z serl9r it
70. l Part No 403 574 01 Section 9 Maintenance Air Ventilation Slots Keep the ventilation slots free from obstructions If excessive 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 ventilation slot The air intake is on the right and the exhaust is on the left This is shown in Figure 3 3 Page 15 O Connector 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 AC Power Cord The AC power cord should be kept in good condition and free from any cuts The AC plug should be straight with no bent prongs WARNING 1 Never operate the gen erator with the cover off This is an unsafe practice and the high voltage present may E cause injury g amp EZ ESI EZ 22 22 EI 22 EI EIL EI E EI E3 ES Page 69 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 70 Dukane Manual Part No 403 574 01 Section 10 Options Options Power Inlet Options RE mne RE E ee d e 73 120V Systems for North American and Japan 73 Electrical Safety 73 120V Power Ground sesse RES di ED ENE RE SE t DR or 73 AC Power Inlet Panel iis tekse SEE NE RR 74 AC Power G0 d EEN 74 Power
71. ld cycle starts Resonant frequency was lost during the cycle Check for a defective stack component or for improper stack assembly Check for stack coupling to the fixture Fault will reset when next weld cycle starts Remote control current loop fault detected Current loop current is less than 2mA Check current loop wiring and loop source This fault will set minimum amplitude level System AC line or power supply fault detected Check that AC line voltage level is normal Likely there will be no power for the front panel display Service may be required if this fault is displayed Front panel lockout input is activated Front panel changes are not allowed Warning pops up if user attempts changes Status message is displayed a few seconds Warning text pops up if a setup is empty User must program a valid welding setup Dukane Manual Part No 403 574 01 Section 9 Maintenance Maintenance Front and Rear Panels 69 El CA PAPA IE 69 Display AAP N N OE 0 0 69 Control Keys Buttons iss a aad asa bU EE Bad y ya B s 69 e TE RE OR OE EO EEE i E 69 Sheet Metal Cover cet pba GR ARA KLEE ALE MPD EK OE Ge BR RR Rd 69 Air Ventilation Slots AA PAPA ox eux 0000 a 69 I O Connector OE ER ET EEN EE 1 69 AC PONSI RD 1 bos EDE DER ER a rir en 69 Dukane Manual Part No 403 574 01 Page 67 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentional
72. le for J5 is Part No 200 1413 XX The accessory cable for J6 is Part No 200 1546 XX where XX is a length designation Isolated UO Conversion Module Part Number 110 4397 The Isolated I O Conversion Module is a solid state DIN rail mounted module that can be used to convert an iQ s NPN sinking outputs to PNP sourcing outputs This module should be used in place of relays if the mechanical life of relays in the automated machine is a concern Each of the four channels are completely isolated from each other and can also be used to convert PNP signals to NPN or to convert 5V TTL signals to 24V levels Examples Three examples of conversion possibilities are shown on the pages that follow NPN to PNP Figure 10 17 PNP to NPN Figure 10 18 and 45V to 24 V PNP Figure 10 19 Dukane Manual Part No 403 574 01 Section 10 Options Page 85 iQ Series Ultrasonic Generator Power Supply LS User s Manual 7755 5 NPN TO PNP CONVERSION 110 4397 EE gt SPECIFICATIONS INPUTS MINIMUM VOLTAGE 5 0 Vdc MAXIMUM VOLTAGE 30 0 Vdc CURRENT 1 5mA 5 0 Vdc 9 5mA 24 0 Vdc OUTPUTS MINIMUM VOLTAGE 5 0 Vdc NOTES 17 7 77 1 OUTPUTS SHOULD NOT BE CONFIGURED TO SINK A TTL LOAD TO GROUND A RELAY CONNECTIO
73. lly shielded coaxial ultrasound cables that are secured with a simple and reliable quarter turn bayonet style Figure 4 8 Ultrasound Output Connector attachment mechanism Page 32 Dukane Manual Part No 403 574 01 Configuration Port Connector The configuration port connector is a DB 9M standard D subminiature nine 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 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 documentation that will allow you to make use of the configuration port features Dukane Manual Part No 403 574 01 Section 4 Standard Connections Figure 4 9 Configuration Port Connector Page 33 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 34 Dukane Manual Part No 403 574 01 Section 5 Standard System Status and Controls Standard System Status and Controls Front Panel OvervieW 37 System Displays
74. lt 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 Any Fault output remains active until cleared by the System Latch Reset input or by the start of the next weld cycle Generator faults that will activate the Any Fault output Overload Average Peak Frequency Over Temperature Fault System Power Fault Current Loop Fault Pin 8 Press Trigger Status Output NOT AVAILABLE Pin 9 System Overload Status 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 Peak or Frequency 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 10 System On Line Status Output Pin 10 is a digital active low status output that activates when the system is in the ONLINE operating mode which enables the activation ofthe ultrasonic output This output will be an open circuit if the system is switched to the OFFLINE operating mode or if an externally connected E Stop has been activated and the open circuit prevents the start of a welding cycle or activation of the ultrasound output Note tha
75. ly left blank Page 68 Dukane Manual Part No 403 574 01 Front and Rear Panels Cleaning Do notuse any solvents or abrasive cleaners on the any of the panels including the LCD display Do not spray any cleaning product directly on the pan els To remove dust first try gently dusting with a microfi ber cleaning cloth If further cleaning is needed apply a small amount of screen cleaner to a soft microfiber cloth Then clean the panels LCD display with the moistened cloth Screen Cleaning Solutions Make your own Mix distilled water and white vinegar in 1 to 1 proportions Pour this mixture into a spray bottle from which it can be used or Buy a cleaning solution There are several on the market suitable for cleaning LCD screens Do not spray or apply cleaner directly on the genera tor Do not allow any liquid to collect around the AC power switch Display Do not apply any pressure to the display Control Keys Buttons Control keys buttons will respond to firm gentle finger pressure Please do not use sharp objects on the keys buttons Chassis Sheet Metal Cover The cover is preformed to fit over the chassis and has protective 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 capacitors which continue to hold a high electrical charge even after the power is shut off Dukane Manua
76. manufactured under one or more of the following U S Patents 3 780 926 3 825 481 4 131 505 4 277 710 5 798 599 5 880 580 6 984 921 7 225 965 7 475 801 and 7 819 158 B2 Page ii Dukane Manual Part No 403 574 01 Revision History Revision Revision Number Summary Date 00 Original release 01 25 2008 01 Add High Power models 09 21 2010 Update system I O pin descriptions Add Trigger by Power Add iQ LinQw Web address revised Revise Regulatory Agency Compliance statement Health and Safety Add safe lifting practices Installation Add lockout tagout information and seismic zone information Page 25 Edited to clarify need for external power supply 11 24 2010 Dukane Manual Part No 403 574 01 Page iii This page intentionally left blank Page iv Dukane Manual Part No 403 574 01 Contents Section 1 Introduction 1 General User Information Read the Manual First Notes Cautions and Warnings Drawings and Tables Generator Overview Key Generator Features Section 2 Health and Safety 5 General Considerations Plastics Health Notice Electrical Safety Lifting the Equipment Section 3 nstallation 11 Before Installation Unpacking Placement RFI Grounding Connecting Cables Manually Operated Probe System Power Cords Automation Controlled Probe System Section 4 Standard Connections 21 Rear Panel Layout Overview
77. n using J5 1s the HD 26 pin basic thruster connector and J6 is a DB 9 abort switch connector Figures 10 15 and 10 16 identify pin numbers for J6 and J5 respectively the Thruster Control Module in an auto mated system A light curtain or similar safety guarding should be used to prevent The Automation Thruster Control Input J2 pin 9 is used operator injury to control the up and down movement of the thruster If this input is deactivated default the thruster will remain in the up position When the input is activated e o o o O O TA ENE rea 4 50 60Hz 10A Co S Gr C ABORT BASIC THRUSTER 9 i o o eeeeeeeee k 00000 00004 Ww 99000 000g Figure 10 16 HD 26 Connector with Pin Locations J5 inputOutput Pater Signalypes P Sareysgrl Table 10 V Abort Connector Pinout J6 Page 684 Dukane Manual Part No 403 574 01 To enable the thruster Pins 3 and 9 must be shorted together through a safety circuit see Table 10 V during normal operation During anabort or emergency stop condition the connection between Pins 3 and 9 must open to disable movement of the thruster In addition to opening the connection between Pins 3 and 9 Pins 4 and 7 must be shorted together to alert the process controller of the condition The accessory cab
78. nally left blank Page 10 Dukane Manual Part No 403 574 01 Section 3 Installation Installation Before Installation 13 When to Use Lockout Tagout Devices 13 Unpacking WEE 15 Placement PTT 15 RFI Grounding 18 Connecting Cables 19 Manually Operated Probe System 19 Power CONS s oa a s L a uma ET RR A X xd 19 Automation Controlled Probe 5 8 2 222222 20 Dukane Manual Part No 403 574 01 Page 11 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 12 Dukane Manual Part No 403 574 01 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 e Lifting the generator safely See Section 2 Health and Safety P 9 When to Use Lockout Tagout Devices 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 The figure to the right shows the lockout device in the closed locked position Contin
79. nnector Signals J2 System Inputs Signal Descriptions Pin 1 22V This pin can supply 22VDC at up to 250mA to power the user s automation controls Pin 2 Power Gnd Pin 2 is the 22VDC return and is tied to the system chas sis ground 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 set ups with an automation control system This input is also used to select different channels when a Multiple Probe Controller MPC Interface option board is installed Pin 4 Remote Setup Selection Bit 1 Input 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 This input is also used to select different channels when a Multiple Probe Controller MPC Interface option board is in stalled T1 12 18 14 15 Figure 4 5 HD 15M Generator Input Cable Connector Page 26 Dukane Manual Part No 403 574 01 Pin 5 Remote Setup Selection Bit 2 Input Pin 5 is the Remote Setup Selection Bit 2 which is the third least significant bit used to select different weld ing setups with an automation control system This input is also used to select different channels when a Multiple Probe Controller MPC Interface option board is in stalled Pin 6 Remote Setup Selection Bit 3 Input Pin 6 is the Remote Setup Selection Bit 3 which
80. ntrol 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 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 ofthe 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 Dukane Manual Part No 403 574 01 Note that a simple switch closure relay contact connect ed to a control input can not activate the input unless an external power supply is added to power the input However if you don t want to add an additional power supply you can configure switch closure inputs to operate referenced to chassis ground by adding jumper connec tions to the System Inputs connector For detailed wiring diagrams of example applications refer to Application Note AN502 found on
81. o be ultra sonically joined and run a welding cycle 3 Hand Probe The programmed welding time or energy will be processed and then the ultrasound will be shut off Automation System The programmed weld time will be processed and then the ultrasound will shut off Stopping the Ultrasound Output Set mode key 8 to OFFLINE Ultrasound will deactivate System with a User supplied Emergency Stop Switch Press the emergency E Stop switch and the ultrasound signal will deactivate This applies only if Auto Stop is wired to end user E Stop circuits AND Auto Stop is enabled Dukane Manual Part No 403 574 01 Section 7 System Operational Testing NOTE Neither a hand probe or an automa tion system can trigger the generator to produce an ultrasound output if the generator is OFFLINE SYSTEM POWER OUTPUT LEVEL 0 2 40 60 80 100 e SYSTEM OPERATING MODE s OFF LINE L Figure 7 6 Stop Ultrasound Output Page 59 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 60 Dukane Manual Part No 403 574 01 Section 8 Troubleshooting Troubleshooting No Ultrasonic Output 63 0010005 AA MEE 63 Be AA IE PA 63 E VE EEN 63 Operate Input 63 System Power Output Level Red 64 Red Fault Condition iu oec RR E HUE PG ERA hg se 64 Ree AA
82. oller The user can determine which signals are appropriate for each welding application Thesystem monitor outputsignals are analog signals used to monitor ultrasonic amplitude setting and ultrasonic output power levels referenced to the Monitor Common Pin 13 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 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 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 mounted 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 Page 28 System Outputs Connector Pinout The SYSTEM OUTPUTS connector is a DB 25F standard D subminiature 25 circuit female connector Connector pin assignments for this connector are shown in Figure 4 6 The male connector on the cable is a mirror image of the panel mounted c
83. onnector and is shown in Figure 4 7 Table 4 II lists the signal names Detailed descriptions are listed in the System Outputs Signal Descriptions section below To assist with custom automation system wiring and assembly the wire color coding for the system outputs cable is listed in Table 4 I System Outputs Signal Descriptions Pin 1 22V Power Supply This pin can supply 22VDC at up to 250mA to 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 Pin 4 Programmable Status Output 1 Pin 4 is a digital active low status output that can be reprogrammed and assigned to another system status signal from the available selections using the front panel controller 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 using the front panel controller 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 Dukane Manual Part No 403 574 01 Pin 7 Any Fault Status Output Pin 7 is a digital active low status output that activates whenever any fau
84. ormation press ENTER to get this data 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 USA Phone 630 797 4900 E Mail ussales dukane com Fax Main 630 797 4949 Service amp 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 This is our main web address www dukane com us You can locate your local representative at www dukane com us sales intsales htm Dukane Manual Part No 403 574 01 Section 12 Contacting Dukane Page 105 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 106 Dukane Manual Part No 403 574 01 Appendices List of Figures _ 109 List of Tables EE BORD RS ua 110 Guide to iQ Generator Menu Structure 111 127 Dukane Manual Part No 403 574 01 Page 107 iQ Series Ultrasonic Generator Power Supply LS User s Manual This page intentionally left blank Page 108 Dukane Manual Part No 403 574 01 Appendices List of Figures No Description Page 2 1 Example of 220 Volt Grounded 3 prong Receptacle
85. re 10 12 Remote Amplitude Control Module Page 82 Dukane Manual Part No 403 574 01 Section 10 Options Menu Selections With the optional Remote Amplitude Control Module installed the generator detects the module As a result there is an additional menu to consider AMPLITUDE CONTROL AMPLITUDE SETTING AMPLITUDE SETTING RAMP UP DOWN TIME 4 SELECT DIGIT y x a CHANGE VALUE AMPLITUDE SETTING AMPLITUDE CONTROL BY A iQ SYSTEM AUTOMATION l This menu available only with Remote Amplitude J Control option Figure 10 13 Amplitude Control Menu Detail See Figure 10 13 above If IQ SYSTEM is selected the amplitude setting is adjusted with the front panel user interface If AUTOMATION is selected for amplitude control the amplitude setting is adjusted with the 4 20mA current loop Dukane Manual Part No 403 574 01 Page 83 iQ Series Ultrasonic Generator Power Supply LS User s Manual Auto m atio n Th ru ste r Co ntrol the thruster will descend to the down position at a speed that is determined by the pressure regulator setting on the Module front of the thruster Part Number 110 4206 This optional module enables the iQ system to control a Dukane iQ thruster The module is illustrated in Figure NOTE 10 14 Check your thruster operator s manual for cable It is the responsibility of the machine connection information builder to ensure that all appropriate safety regulations are met whe
86. reen as shown here 3 Select PROCESS CONTROL and press ENTER With no option boards installed in the generator you will get a WELD BY choice of iQ SYSTEM or AUTOMATION 4 SelectiQ SYSTEM and press ENTER 5 Select WELD CONTROL 6 Select WELD BY TIME 7 Selectthe digits with the RIGHT and LEFT arrows Use the UP and DOWN arrows to select the value time in seconds of each digit 8 When done with the time entry press ENTER and an ENTRY ACCEPTED message will appear NOTE 1 OPERATE MODE PROCESS SETUP HARDWARE SETUP PROCESS SETUP 4PROCESS CONTROL PROCESS LIMITS UTILITIES AUTOMATED PROBE WELD CONTROL BY 4iQ SYSTEM AUTOMATION 4 WELD CONTROL HOLD CONTROL AFTERBURST CONTROL AMPLITUDE CONTROL 4 WELD BY TIME WELD BY PEAK POWER WELD BY ENERGY gt WELD TIME 0 000 S 4 SELECT DIGIT a SELECT VALUE In the above example we selected Time as the primary method of weld control Next the time of the weld was set in seconds The program will then ask the operator to choose and set a SECONDARY weld control Choices the operator can make Disable a secondary weld control or enable either Peak Power or Energy as the secondary weld control Page 50 Dukane Manual Part No 403 574 01 Section 6 Process Control Settings HOW TO Weld by Energy Available only if generator has energy option 1 OPERATE MODE 1 Press CANCEL until you see the Main Menu screen as E S
87. s AC Line Fault If Power Status indicator in Figure 8 3 below flashes RED at a fast rate of about four flashes per second e Check AC line voltage level either an over under voltage is sensed Do not call service Measure the voltage level at the AC outlet which is probably the source of the problem Call service only if the AC line voltage is within the specified limits DC Bus Fault If Power Status indicator flashes RED at a slow rate of about one flash per second e This is normal for 10 to 15 seconds after power is switched ON If flashing does not stop a DC bus fault is sensed call service Figure 8 3 Power Status Indicator Control Power Supply Fault Power Status indicator doesn t flash but is ON continu ously RED e control power supply fault is sensed call ser vice Dukane Manual Part No 403 574 01 Welding Problems Weak Welds Weak welds or underwelding is caused by insufficient energy being transmitted to the part You can increase the weld pressure increase the weld time or change to a higher gain booster to increase the amplitude to increase the energy delivered to the weld Excess Flash The energy director may be too large You can try to reduce the weld pressure and or weld time The parts may have too much shear interferences or a nonuniform Joint dimension Inconsistent Welds Variations in plastic due to filler ma
88. s LED s that show GREEN normal operation YELLOW warning of potential overload RED warning that an overload condition exists Peak Detect Feature To indicate the maximum peak power achieved during a weld cycle the LED in the bar graph corresponding to the peak level remains on for about one second after the weld cycle has been completed Flash on Overload at 90 The OVERLOAD indicator begins to flash RED when the generator produces 90 of the overload power rating This feature alerts the operator to an impending overload fault condition Dukane Manual Part No 403 574 01 OFF LINE Section 5 Standard System Status and Controls Overload Indicator System Operating Mode 4 line LCD Display Bar Graph Power Scaling Power scaling is related to amplitude At 100 amplitude the whole graph is lit and the generator is operating at 10096 power At 50 amplitude the entire graph is lit and the generator is operating at 50 power If the amplitude setting is lowered the graph rescales automatically according to the revised amplitude Example With a 1200W generator at 50 amplitude if the whole graph is lit that represents 600W System Operating Mode ON LINE ONLINE appears GREEN after AC power has been activated and the generator is operating normally POWER TEST POWER TEST appears RED and will flash for several seconds when AC power is first turned on The generator runs a self test during the
89. s by protecting them from AC power startup transient current surges Multiple Electronic Overload protection circuits prevent instantaneous component failure in the event of extreme output overload conditions The overload power limitis based on the actual true RMS power output level Process Limits include time only time and en ergy and peak power These programmable lim its provide the means to adapt to a wide variety of welding applications Control Board Option Modules The user can select one of the following Multi Probe Control Automation Thruster Control or Remote Ampli tude Control An isolated I O Conversion Module is also available as a DIN rail mounted module CE Certification means that the system meets the required European standards to be sold and used in Europe high line voltage models only ISO 9001 Certification means that this system has been manufactured to high quality standards and assures you of manufacturing excellence Dukane Manual Part No 403 574 01 Section 2 Health amp Safety Health and Safety General Considerations 7 Plastics Health Notice E dci dox a toe AE e E 7 Electrical Safety 8 Domestic Power Grounding 8 International Power Grounding 8 Lifting the Equipment 9 Dukane Manual Part No 403 574 01 Page 5 iQ Series
90. se injury Grounded Electrical Power Operate this equipment only with a properly grounded electrical connection See Electrical Safety Grounding Instructions on the next page Comply with Regulations You may be required to add accessories to bring the system into compliance with ap plicable OSHA regulations for machine guarding and noise exposure Plastics Health Notice Before using any ultrasonic welding system be sure you are familiar with OSHA regulations from the U S De partment of Labor about the particular type of plastic s you are using When plastic materials are being processed they may emit fumes and or gases that could be hazardous Make sure you have adequate ventilation whenever these plas tics are processed Dukane Manual Part No 403 574 01 Page 7 iO Series Ultrasonic Generator Power Supply LS User s Manual 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 Approved 2 pole 3 wire grounding receptacle HUBBELL No 5652 or equivalent to NEMA 6 15R or 6 20R Figure 2 1 Example of 220 240 Volt Grounded 3 Prong Receptacle International Power Grounding The power cable normally provided for international use is compatible with the power outlet used in many Conti
91. start up sequence OFFLINE OFFLINE appears YELLOW indicating that the generator s power output is disabled 4 line LCD Display This is where process control parameters can be set and where process results can be monitored Page 37 iQ Series Ultrasonic Generator Power Supply LS User s Manual Keys Left of Display Keys Right of Display SYSTEM POWER OUTPUT LEVEL oven 2 20 40 60 80 100 SYSTEM OPERATING MODE emm ON POWER OFF LINE TEST LINE 1 PART COUNT WELD TIME POWER ENERGY Figure 5 2 Front Panel Control Detail Ege Navigation Keys 4 Weld Method Time Energy Power Control Keys programmed by the user Keys Left of the Display Time is the default method INFO After the primary weld method has been chosen you can press the INFO key to go directly to the Hot Key screen where frequently used menus can be accessed In the screens shown here Energy is the weld method Screen shown in Setup Mode WELD ENERGY HOTKEY AMPLITUDE 4PROCESS SETUP SYSTEM INFO 4 WELD ENERGY HOTKEY gt AMPLITUDE OPERATE SYSTEM INFO Screen shown in Operate Mode SYSTEM INFO will give the software version model number Use the up and down navigation keys to move the selection indicators 4 P to the desired selection Press ENTER to proceed ON OFF Line The ON OFF LINE key is used to deactivate the ultrasonic signal For example select OFFLINE during
92. t 5 1 05 ees see EE KA EER ER Bee Ak AR Ak ese ee ee 42 541 System Parameter Adjustment Limits u s 43 6 1 Ramp Up Down Times YARAYAR R RAYA RAR NN KG kkk nak 53 8 1 Pop up Status Screens ener 66 10 1 HD15F Example of Customized System Inputs Outputs Connector Signals 75 TON MPC I O Connector Signals EE 77 10 III MPC Setup Bit Inputs Hmmm nnns 77 10 IV Probe Cables a rr 79 10 V Press Base Connector Pinout EE 84 11 1 iQ Generator Weights AE EE OK OE N AR OE EO HE OG ELE DR 99 11 1 AC Power Requirements ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee ee 100 Page 110 Dukane Manual Part No 403 574 01 Appendices Guide to iQ Generator Menu Structure DUKANE DUKANE iQ LS SERIES Menus Page Number Time Only Operate TRES Process Setup Automated Probe 114 Process Setup Hand Probe 115 Process Setup MPC Probe 116 Process Setup Process Limits 117 Process Setup Utilities 118 OPERATE MODE PROCESS DATA Time and Energy 4PROCESS STATISTICS p Operate 119 SYSTEM PARAMETERS Process Setup Automated Probe 120 Process Setup Hand Probe 121 Process Setup MPC Probe 122 Process Setup Process Limits 123 Process Setup Utilities 124 Amplitude Control Hardware Setup Advanced Hardware Setup 1 PART COUNT AUTOMATED PROBE WELD TIME VVELD CONTROL BY POVVER 4iQ SYSTEM ENERGY AUTOMATI
93. t an automation controlled process can not weld any parts if the system is accidentally or otherwise switched to the OFFLINE operating mode Pin 11 Press Top of Stroke Status Output NOT AVAILABLE Pin 12 Current Loop OK Status Output This status output signal will activate only when a Remote Dukane Manual Part No 403 574 01 Section 4 Standard Connections Amplitude Control Board is installed in the system Pin 12 is a digital active low status output that activates when the current loop input to the remote control option board is connected and working normally This output will be an open circuit when the current loop input signal is too low for proper system operation less than 2mA This may be due to a broken wire connection a failed current loop controller or the current loop input wired incorrectly to the input terminal block Pin 13 Analog Monitor Signal Common Pin 13 is the signal common ground connection for all of the analog monitor signals on Pins 14 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 1s connected to the system chassis ground Pin 15 Power Signal Monitor Output Pin 15 is an analog o
94. table for more informa tion about the signals Pin SimaName Connector e Setup Bid input MPC Ready Out J3 Page 25 Table 10 II MPC I O Connector Signals J2 Page 20 MPC Probe Control When the optional MPC Interface and MPC I O connectors are used the generator has the capability of controlling as many as sixteen compatible probes One probe can be turned on at a time while the sequence of probe activation is determined by the user s automation The table below shows how the setup bit inputs correspond to the probes Table 10 III MPC Setup Bit Inputs Dukane Manual Part No 403 574 01 NOTE 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 electri cal 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 The ultrasonic output from this con nector that drives the attached ultrasonic load is a very high AC voltage At high power levels this can exceed 2 amps of current and must be securely terminated via the ultra sound cable for safe operation Use original equipment ultrasound cables for safe and reliable system operation Improperly assembled ultrasound cables can result in high
95. terials and moisture absorption may lead to inconsistent welds Fillers can be especially troublesome if they are not uniformly distributed the content is too high or it contains too much or poor quality regrind or degraded plastic Check the horn and fixture alignment and parallelism Check the alignment of the mating parts shifting during welding or residual mold release on the parts Try welding by energy This eliminates many inconsistencies There should be no unusual or loud noise from the acoustic stack If there is disassemble the stack and reassemble Exchange the probe with another unit to see if the problem disappears If not exchange the generator with another unit to try and isolate the problem The horn amplitude may not be uniform if it has been machined altered or damaged All of these will change the resonant frequency of the horn You can have the horn analyzed Dukane Manual Part No 403 574 01 Section 9 Maintenance Page 65 iQ Series Ultrasonic Generator Power Supply LS User s Manual Pop up Status Screens System Status Signal Status Text Displayed System Status or Fault Explanation Average Overload Peak Overload End of Weld End of Cycle Over Temperature Fault Overload Frequency Overload Frequency 4 20 mA Current Loop Fault System Power Fault Front Panel Locked Empty Setup Table 8 1 Page 66 OVERLOAD AVERAGE AT X XXX SECONDS POWER ABOVE GENERATOR RATING OVERLOAD
96. the Dukane website at http www dukane com us downloads asp type Application 20Notes System Inputs Connector Pinout The SYSTEM INPUTS connector is a HD 15F high den sity D subminiature 15 circuit female connector Connec tor pin assignments for this connector are shown in Figure 4 4 The male connector on the cable is a mirror image of the panel mounted connector and is shown in Figure 4 5 Table 4 I lists the signal names and descriptions with more detailed descriptions that follow The wire color coding for the system input cable is listed in Table 4 1 to assist with custom automation system wiring and assembly Dukane Manual Part No 403 574 01 Section 4 Standard Connections Figure 4 3 System I O Panel standard panel shown NOTE Refer to Section 10 Options for information on optional features Page 25 iQ Series Ultrasonic Generator Power Supply LS User s Manual Pin SignalName Gable Color Code Signal Option Requirements a um ERK LLL 2 Power Ground WE 6 Remote Setup Selection Bit3 Input BLU MPC Option Required 8 UiasoundAcivetonCydeStatimput REDBIK e Automation Thruster Control GRNIBLK Automation Thruster Board Required 16 Front Panel Control Lock input ornek ystemL tn Reset put BUKANA 15 Isolated Common mt BCEE 15 Automation Cycle Stop input swr 1 Table 4 1 System Input Co
97. the four brackets from Dukane s rack mount kit to the generator See Table 3 1 and Figure 3 4 showing a low profile unit below Mount the generator to a 19 inch equipment rack 17 16 1435 8 ALLOW 3 IN BACK FOR CABLES System Type Dukane Part Number High Profile 147 4721 Low Profile 147 4720 Table 3 1 Rack Mount Bracket Part Numbers NOTE The figure shows how a typical jQ generator is rack Gen mounted Your generator s San appearance may be different mons from what is shown here SIDES FOR COOLING 81 20 6 Figure 3 4 Rack Mounting iQ Generator Page 16 25 X 50 SLOT 2 PLCS OPTIONAL RACK IN MOUNT BRACKETS mm 147 4720 400 2251 01 Dukane Manual Part No 403 574 01 Section 3 Installation Benchtop Mounting 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 one side of each L backet to the generator s sheet metal cover 3 Secure the other side of each I bracket to the bench itself 18 84 18 04 458 15 280 HOLE ALLOW 3 IN BACK FOR CABLING NOTE The figure shows how a typi cal iQ generator is bechtop mounted Your generator s appearance may be different 18611 from what is shown here ALLOW 5 BATH ALLOW 5 BOTH 5 FOR COOLING OPTIONAL HOLD DOWN BRACKETS 147 1398 5 19 13
98. to completing these first four Steps com plete Steps 5 and 6 to wire the MPC Control Inputs Status Outputs as described below Details about the various system connectors and their pin assignments are covered below Step 5 MPC I O MPC control input signals and sta tus output signals are carried in the I O cables that should already be connected See Inputs J2 and Outputs J3 in Figure 10 5 Step 6 MPC INTERFACE Attach one end of the MPC Interface cable Dukane 200 1408 XX to the MPC Interface connector on the iQ gen erator panel MPC INTERFACE in Figure 10 5 Connect the other end of the cable to the MPC INTERFACE connector on the right rear of the MPC module NOTE The MPC Interface cable is a separate line item on the iQ generator system order The XX at the end of the cable number speci fies cable length This will vary depending on your MPC installation Inputs lt o I o o 0 LINE VOLTAGE ZC MPG INTERFACE P Q PE S or CE o K Grounding Stud Figure 10 5 Generator Rear View Optional MPC Model MPC Interface See NOTE on the MPC cable above Page 76 Dukane Manual Part No 403 574 01 Section 10 Options MPC VO Connections Signal names and Pin numbers and the comnectors re lated to the MPC option are shown in the table below See the pages referred to in the
99. to modify system parameters Dukane Manual Part No 403 574 01 Page 23 iQ Series Ultrasonic Generator Power Supply LS User s Manual AC Power Inlet Panel 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 120VAC and 3600W 4800W systems include a non detachable power cord 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 Power Switch Circuit Breaker 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 symbol the power OFF posi
100. ued Dukane Manual Part No 403 574 01 Section 3 Installation WARNING 8 Electrical safety hazards H exist inside the generator g chassis Before making g any internal adjustments g to the generator apply a g lockout tagout LOTO g device to the generator H chassis D Am EEN WEN WE WEN HEI EE mm mmm TE K Figure 3 2 Bottom Lockout Device In Closed Position Locked Page 13 iQ Series Ultrasonic Generator Power Supply LS User s Manual Lockout Tagout Continued from previous page Procedure to use BEFORE making any internal adjustments to the generator 1 2 Push the generator s AC power switch breaker to the OFF position Unplug the generator s electrical cord from its source 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 Wait a minimum of five minutes for the generator to discharge its electrical energy 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 cl
101. ukane Manual Part No 403 574 01 Page 99 iQ Series Ultrasonic Generator Power Supply LS User s Manual AC Power Requirements The AC input power requirements depend on the frequency and output power rating of the generator Table 11 II below lists both the AC requirements maximum current drawn before overload and the AC outlet service rating for each model Operating Generator nput i Power Requirements North America Frequency Model Number Ratings 157575 Japan Watts Maximum RMS Current AC Outlet Rating 15kHz 15XX360 2X XX 3600 200 240V 50 60 Hz 25 Amps 15kHz 15XX480 2X XX 4800 200 240V 50 60 Hz 30 Amps 20kHz 20XX120 1X XX 1200 100 120V 50 60 Hz 15 Amps 20kHz 20XX120 2X XX 1200 200 240V 50 60 Hz Q 8 Amps 15 Amps 20kHz 20XX180 2X XX 1800 200 240V 50 60 Hz 12 Amps 20kHz 20XX240 2X XX 2400 200 240V 50 60 Hz 15 Amps 20kHz 20XX360 2X XX 3600 200 240V 50 60 Hz 25 Amps 20kHz 20XX480 2X XX 4800 200 240V 50 60 Hz 30 Amps EE 30kHz 30XX090 1X XX 900 100 120V 50 60 Hz 8 Amps 30kHz 30XX090 2X XX 900 200 240V 50 60 Hz 8 Amps 30kHz 30XX120 1X XX 1200 100 120V 50 60 Hz 15 Amps 30kHz 30XX120 2X XX 1200 200 240V 50 60 Hz 8 Amps 30kHz 30XX180 2X XX 1800 200 240V 50 60 Hz 12 Amps 40kHz 40XX060 1X XX 600 100 120V 50 60 Hz 8 Amps 15 Amps 40kHz 40XX060 2X XX 600 200 240V 50 60 Hz 5 Amps 40kHz 40XX090 1X XX 900 100 120V 50 60 Hz 15 Amps 40k
102. ult detection circuits included in the system This output will be an open circuit when any power related fault is detected in the system Page 30 Figure 4 7 DB 25M Generator Output Cable Connector 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 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 Pin 22 System Ready Status Output 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 offlin
103. utput 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 Watt 0 001 VDC 1mV per Watt Example 20kHz system measures 0 525 VDC on Power Monitor Output 525 Watts Pin 16 Amplitude Monitor Output Pin 16 is an analog output signal used to monitor the system amplitude setting The scaling on this output signal is 10076 amplitude 10 0 VDC or 0 1 VDC per 176 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 1s set to the expected programmed amplitude level Page 29 iQ Series Ultrasonic Generator Power Supply LS User s Manual Pin 17 Amplitude Power Regulation Status Output Contact your sales representative about Power Regulation availability This status signalis mostuseful when the powerregulation 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 In the amplitude regulation mode this signal will be a
104. vailable via PROFIBUS 1 Set weld method to Time Energy or Peak Power Set associated values in seconds joules or watts 2 Set Amplitude Ramp Up Time and Ramp Down Time Enable and set Trigger by Power parameters Enable and set Hold Time Enable and set Afterburst delay and duration Qv pu P7 Ue Enable checking for Suspect Parts Set maximum and minimum values for Time Power and or Energy 7 Enable checking for Bad Parts Set maximum and minimum values for Time Power and or Energy 8 Configure advanced hardware settings including Phase Free Run Frequency Frequency Lock and Hold and Frequency limits Parameters that can be obtained via PROFIBUS All parameters that are configured via PROFIBUS Real time data which includes welder state ultrasound active or not frequency power and amplitude Weld cycle data from previous weld which includes Cycle Count Good Bad and Suspect Part information Process Limit setting exceeded or not reached if Bad or Suspect Part checking is enabled Weld Time Weld Energy Time and Energy option Peak Power For information on how to control and or monitor specific parameters iQ Generator PROFIBUS Communication and Control documentation is available Signing a non disclosure agreement is required to obtain this documentation Bus error activates LED Red N 2
105. x 5000 and Siemens Step 7 PLC projects Contact your local Dukane representative for more information about the iQLinQ options iQLinQ RS 232 Interface Option The RS 232 Interface option allows the iQ generator to connect to a PLC s serial port Each generator requires a dedicated connection to automation so it is not possible to daisy chain or bus multiple generators on a single RS 232 connection Control Parameters Available via RS 232 Time only option 1 Set these parameters Weld Time Amplitude Ramp Up Time and Ramp Down Time 2 Configure advanced hardware settings including Phase Free Run Frequency Frequency Lock and Hold and Frequency Limits Parameters that can be Obtained via RS 232 Time only option 1 All control parameters that are configured via RS 232 2 Real time data that includes welder state ultrasound active or not frequency power and amplitude Dukane Manual Part No 403 574 01 Section 10 Options Control Parameters Available via RS 232 Time and Energy option 1 Set weld method to Time Energy or Peak Power set associated values in seconds joules or watts 2 Set Amplitude Ramp Up Time and Ramp Down Time Enable and set Trigger by Power parameters Enable and set Hold Time Enable and set Afterburst delay and duration N SH ue Enable checking for Suspect Parts Set maximum and minimum values for Time Power and or Energy 7 Enable checking for Bad
106. y 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 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 pro vides consistent system performance regardless of line Page 4 voltage fluctuations It also eliminates the need for bulky external constant voltage transform ers 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 con sistency and reduced weld cycle times 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 world wide operation 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 AC Power Inrush protection reduces electrical stress on the internal component
107. your process setup or to cycle the assembly equipment without ultrasound activated Page 38 Dukane Manual Part No 403 574 01 TEST Hold the TEST key momentarily to activate ultrasound and view system operating parameters The LCD screen will show the real time settings for Amplitude Power does not appear with Time Only generators and Operating Frequency This information is useful in troubleshooting While pushing the TEST key look at the System Power Output Level meter See the illustration to the right There should be at least one green LED segment lit IMPORTANT If more than three LED segments are lit with no load applied to the ultrasonic stack make sure the stack is properly assembled and not damaged During normal operation the peak level LED remains lit approximately 1 second until the next cycle begins Control Keys Right of the Display Navigation Keys Press the left and right navigation keys to move the display s cursor left or right respectively Also use these keys to move up one level in the menu or to move back one level Press the up and down arrow keys to change the value of a selected digit ENTER Press the ENTER key to select a menu item shown by the selection indicators and move to the next level of the menu Think of it as a forward key Press ENTER to confirm and store a selection in memory CANCEL Press the CANCEL key to return to the previous screen or cursor position

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