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Notes - Dukane

1. Weld Mode Time Weld Time Process Setup menu description continues with the oa Weld Method submenu _ Weld Position Primary Position Max Weld Time Weld Method defines when the ultrasound signal is Weld Method 17 Weld Energy ner T terminated after it has been triggered Weld Time Peak P There are two methods of welding NEL Weld Time GuundBetec Max Weld Time Enable Scrub Time Single Single Pressure and Single Scrub Dual Dual Pressure Disabled amp Distance Weld Dist Choosing one method automatically deactivates the Second i dd Position Weld Position other method 9 Energy Weld Energy Peak Power Weld Power Time Weld Time Single Weld Distance Dans Max Weld Time Single Pressure Primary Weld Method 1 is a preset Ramey Weld Position 2 Position pressure applied to the part during the weld process _ eld Energy The pressure conti
2. HH y WARNING Never operate the generator with the cover off This is unsafe practice and may cause injury y J Continued Page 7 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Continued from Previous Page General Considerations Pre trigger Switch Adjustment The pre trigger switch option starts the horn vibrating before contacting the part to be welded To ensure safe operation adjust the pre trigger so the ultrasound signal will not activate if the horn is more than in 7 mm from the part to be welded System Electrical Cabling Electrical power must be off when connecting or disconnecting electrical cables Do Not Wear Loose Clothing or Jewelry They can become caught in moving parts Stay Alert Watch what you are doing at all times Use common sense Do not operate the press when you are tired or distracted from the job at hand Do Not Operate the Equipment Your judgement or reflexes could be impaired while taking prescription medi cations If so do not operate the equipment Be familiar with warning labels and recommended activity restrictions that accompany your prescription medications If you have any doubt do not operate the equipment Plastics Health Notice Certain plastic materials when being processed may emit fumes and or gases that may be hazardous to
3. WARNING Never operate the gen erator with the cover off This is an unsafe prac tice and the high voltage present may cause in jury md peg 115 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 116 Dukane Manual Part No 403 584 00 Section 9 Options Options Power Inlet Options 119 Data 120 Ethemet PONG uus ae 808 dod 120 RS 232 POM JIO eed dS ES RAE 120 Press Interface 122 Dual Pressure 122 P5 Dual Pressure with Distance 122 P6 EPR Load Cell with 122 Dukane Manual No 403 584 00 Page 117 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 118 Dukane Manual Part No 403 584 00 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 up to 1200 Watts 240V Systems Generators with power rat
4. OPTIONAL DISPLAY amp OPERATOR CONTROLS LIGHTED POWER INDICATOR IN mm 11 37 288 80 12 57 319 28 ALLOW 5 BOTH SIDES FOR COOLING 1 k f 9 Gee ULTRASOUND amp SYSTEM I O 1 TT m PRESS CONTROL COMMUNICATION 20 57 2 amp OPTIONS CARDS N x POWER ENTRY 7 3 25 a 0 25 X 0 50 SLOT 82 55 2 PLCS 1 4 9 3 44 87 34 8 8 WEIGHT 20 Ibs 9 kg OPTIONAL RACK MOUNT BRACKETS 147 4720 Figure 11 1 Layout Low Profile 10 Generator Page 129 Dukane Manual Part No 403 584 00 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual ALLOW 6 IN BACK FOR CABLING ULTRASOUND amp SYSTEM 0 5 i 17 64 448 06 14 61 371 09 ALLOW 5 ALLOW 5 EA SIDE FOR EA SIDE FOR COOLING COOLING OPTIONS CARDCAGE PANELS 17 16 AC POWER 435 86 POWER SWITCH ENTRY 1 5 19 5 50 131 83 Cc X P LT Lo OPERATOR OPERATOR COOLING FAN DISPLAY CONTROLS LIGHTED POWER INDICATOR WEIGHT 34 Ibs 15 42 kg mm Layout High Power iQ Generator Figure 11 2 Dukane Manual Part No 403 584 00 Page 130 Section 11 Specifications 17 16 435 86 ALLOW 3 IN BACK FOR CABLES OPTIONAL RACK MOUNTS 147 4721
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6. Figure 5 36 System Status I O Selections Hardware Setup Continued Dukane Manual Part No 403 584 00 Section 5 Operation Hardware Setup Continued from Previous Page Programmable Status Output 2 J3 pin 5 Are you sure you want to Restore Defaults J3 represents the generator s output connector and Pin 5 is programmable It can be programmed to provide Hold Status In Cycle Status or In Cycle no After burst The default setting is Hold Status Output Duration Figure 5 37 Restore System I O Defaults This 1s the duration of the Good Suspect or Bad part output signal Use the Output Duration function to select the length of the output signal Maintained or 100ms Pulse The default setting is Maintained Restore System I O Defaults Choose this function to restore the original system input output defaults Once Restore is chosen a secondary screen is displayed asking the operator to verify the choice Are you sure you want to Restore I O Defaults See Figure 5 37 for the screen view Hardware Setup Continued Dukane Manual Part No 403 584 00 Page 75 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Hardware Setup Continued from Previous Page Additional Hardware Settings The next group of hardware settings following the Serial Port settings and the System Status I O settings deals with a variety of functio
7. EE RM ERN UN 67 5 26 Setup Control Automation Selected esses 68 5 27 Setup Control Choose Setup esses A nennen emen nennen 68 5 28 Select Setup Setup Security Access is 68 5 29 iBreloy Mene 69 5 30 Copy Setup 2 aa aa A aE aa TEA a Ean a aa aaa aA AEEA Eaa ean a EAE ERARA NAER ATERSE 69 5 31 COPY SGUD S T wha EO EE AR NERDE 69 5 32 Erase niren E a E A E aa E 70 5 33 Part Count Settings ENT 70 5 34 71 5 35 Serial Port Selections nennen nennen 72 5 36 System Status 74 5 37 Restore System 75 5 38 Additional Hardware Settings Diagram 76 Continued Page 140 Dukane Manual Part No 403 584 00 Section 12 Appendices Append ix A Continued from Previous Page List of Fig ures No Description Page 5 39 Advanced Process Settings Sume rcp nna en oput dpi 76 5 40 Buzzer Enabled sooo NEIN EINE 79 5 41 Test at Power 8 eren 79 5 42 Trigger Function Basic a
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9. Sd rato dd 135 C 1 What is a 144 C 2 Insertion Sequence Example 9 145 C 3 Sequence Definition nennen 146 D 1 Process Setup Menu Diagram us cues iae oer cc enean ro Resta ut oS tee eee 147 148 D 2 Process Limits Menu Diagram aca saos ocaen autas ne spa barn 149 D 3 U lities Hardware Menu DIAG RAIN vii uec enar sadip p re FaB cag iaa apium 150 Page 142 Dukane Manual Part No 403 584 00 Section 12 Appendices Appendix B List of Tables No Description Page 3 Generator Input Signals J2 evasisse sssini taliabeaiuliute 19 3 11 System Output Communication Signals J3 21 3 111 Power CONUS 28 iQ Generator and Pneumatic Press Thruster Cables 22 222 1 32 5 security Access to Main Menu ifti usua rra tee necati kar 87 7 Default Settings Process 101 7 11 Pounds of Force Comparison Between Dukane Air 105 7 1 Alarm Messages Pneumatic related 109 9 1 Part Data Indexes ucc veretur eere rx ek re eta t ed RR 121 11 1 iQ Generator Weights 132 11 l iQ Generator Ree 132 11 1 Ge
10. Weld 1 Dis ycl 0 2 1 1 Carriage Return and optional Linefeed CR LF Figure 9 1 CSV Output Format Dukane Manual Part No 403 584 00 Number Description o o 6 Average Down Velooty 8 Trigger Delay Time OC 9 TriggerDelay Dist 1 mmeFomatHHMMSS 9 Date gt Formats DD MM YYYY MM DD YYYY YYYY MM DD 50 5 53 53 Error Code gt U Number without the U Table 9 Part Data Indexes Dukane Manual Part No 403 584 00 Section 3 Installation NOTE Individual data records are separated by a comma tab or semicolon The character used is set in the Hardware Settings screen See Page 72 for setting the Output Format character The indexes are printed as 4 characters 0 pad ded and the entire field size is 20 characters including the delimiter The data is right justified with spaces Complete cycle data re cord is terminated by car riage return and optional line feed characters The format is meant to mimic Dukane s DPC generator protocol as closely as possible Page 121 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Press Interface Module This board is also known as the Options Slot 1 as shown in Figure 11 4 Interpreting the Model Number Module location is shown in Figure 3 4 E
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12. Adv Trigger Settings Network Settings Restore Factory Defaults Figure D 3 Utilities Hardware Menu Diagram NOTE The list of available Process Utilities and Hardware items depends on Security ac cess level See Table 5 1 and on system configuration Page 150 Dukane Manual Part No 403 584 00 Index Index Dukane Manual Part No 403 584 00 Page 151 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 152 Dukane Manual Part No 403 584 00 Index A Acoustic Stack 96 Test 96 AC Power Cord 115 AC Power Requirements 133 Advanced Process Settings 59 76 Buzzer 79 Free Run Frequency 76 Frequency Lock Hold 77 Frequency Tracking 77 Ramp Down Time 78 Ramp Up Time 78 Scan Stack 76 System Frequency Limits 77 Test at Power Up 79 Text Keyboard 79 Advanced Trigger Settings 80 Afterburst 56 Agency Compliance 136 CE Marking 136 136 IP International Protection Rating 136 Alarm Messages 108 Alarm Status 63 Appendices 137 A List of Figures 139 List of Tables 143 C Sequencing Notes 144 D Menu Structure Diagrams 147 List of Figures 139 List of Tables 143 Menu Structure Diagrams 147 Sequencing Notes 144 Auto Start Input 74 Auto Stop Input Enabled 74 B Before Installation 13 Buzzer 79 C Chassis Grounding Stud 17 Connect AC Power 33 Connecting Cables 29 Recheck Connections
13. Network Settings Restore Factory Defaults Figure 5 38 Additional Hardware Settings Diagram Are you sure you want to enable Advanced Settings WARNING Improperly modified settings may damage the unit or ultrasonic stack Figure 5 39 Advanced Process Settings Warning Hardware Setup Continued Dukane Manual Part No 403 584 00 Section 5 Operation Hardware Setup Continued from Previous Page Frequency Tracking When Enabled at the end of each cycle the operating frequency is applied to the Free Run ning Frequency setting It s based on a 16 point average Therefore after 16 cycles the actual operating frequency will be the Free Running Frequency setting If the genera tor has not been cycled for a minimum of 5 minutes the generator will request that the stack be scanned in order to verify the optimum Free Running Frequency setting For more information about Frequency Tracking refer to our Application Note 513 on the Dukane website at http www dukane com us DL ApplData asp Frequency Lock Hold When frequency lock and hold is disabled the frequency of the stack is tracked by chang ing the frequency ofthe ultrasound driving pulses to match the actual operating frequency When enabled the frequency of the stack is tracked until lock is achieved Then it is ignored and the ultrasound output remains at a fixed frequency until the end of the weld For more infor
14. 1291 327 91 292 35 12 52 318 01 ALLOW 5 BOTH ALLOW 5 SIDES BOTH FOR SIDE COOLING FOR c 0 12 3 05 i 1 ULTRASOUND amp SYSTEM sol PRESS CONTROL COMMUNICATION amp OPTIONS CARDS 0 203 18 76 DIA 476 50 5 16 0 25 X 0 50 SLOT AC POWER ENTRY E 18 16 m 109 48 d d C OF 2 2 25 4 00 57 15 C DIRE 0 Q 1016 5 50 C 139 70 E 129 79 142 36 07 o Q LJ LJ 0 59 LUT 14 99 OPTIONAL OPERATOR DISPLAY AND CONTROLS LIGHTED POWER INDICATOR WEIGHT 25 Ibs 11 34 kg Figure 11 3 Layout High Profile Generator Page 131 Dukane Manual Part No 403 584 00 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Weights Generator Only Generator Packing Materials Table 11 iQ Generator Weights Dimensions Dimensions in mm Low Profile 3 45 87 6 17 16 435 9 12 55 318 8 High Profile Profile 5 19 131 8 17 16 435 9 12 55 2550088 8 High Power 5 19 131 8 17 16 435 9 14 51 368 6 Table 11 11 Q Generator Dimensions NOTE Add approximately 0 4 10 mm to height when the generator is equipped with factory installed feet Add between 3 and 6 76 152 mm behind the generator and 5 127 mm for air flow and cable connections Operating Environment Operate the equipment within these guideli
15. Pages 87 91 Figure 5 3 Navigating from the Main Menu Administrator Process Engineer Logged In Figure 5 4 Navigating from the Main Menu Setup Logged In Security detail can be fo und on Pages 87 91 Dukane Manual Part No 403 584 00 Page 47 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Setup Ai uto Initiate Mode 4 Manual Latch on Bad Part Disable m Maintained H Max T
16. 4 After enabling the Administrator password the next level to activate is usually Process Engineer Select Process Eng Password None in the list Next Select Process Eng Password with the upper left soft key and the alphanumeric virtual keyboard is displayed Enter a password of up to 15 characters Login Security Screen 06 01 2013 13 31 Password Setup Password Enabled Logout Process Eng Password Enabled Administrator Password Enabled Remote User Timeout Deny Control Press Done when finished 5 After setting the Administrator password and the Pro cess Engineer Password select the line Setup Password None Set a password for Setup repeating the methods already explained Figure 5 61 Security Screen Passwords Enabled Figure 5 61 shows the Security Screen when all three passwords have been enabled Login Security Screen 06 01 2013 13 31 Password Press the Logout key Figure 5 62 shows that the Administrator has logged out Login Password and Done are choices Press the soft key next to Login Password to login Press Done to exit and return to the main menu Figure 5 62 Security Screen Logged Out Continued Dukane Manual Part No 403 584 00 Page 89 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Security Continued from Previous Page After Passwords are Enabled Once passwo
17. Ramp Up Time Ramp Down Time Restore Advanced Process Defaults Figure D 1 Process Setup Menu Diagram 2 of 2 Page 148 Dukane Manual Part No 403 584 00 Appendix D Section 12 Appendices Menu Structure Diagrams Downstroke Time Downstroke Distance Contact Air Pressure Method 1 Weld Time Method 1 Distance Method 1 Weld Energy Method 1 Weld Peak Power Method 1 Weld End Position Method 2 Weld End Position Total Weld Time Show All Show None Total Weld Energy Hold Time Hold Distance Total Cycle Time Total Stroke Distance Total Weld Distance Alarm Status Time Date Setup Figure 0 2 Process Limits Menu Diagram Dukane Manual Part No 403 584 00 OFF Suspect Limits Method 2 Weld Time ON Low Limits High Limits Method 2 Distance OFF Bad Limits Method 2 Weld Energy ON Low Limits High Limits Method 2 Weld Peak Power Display Only NOTE The list of available process character istics depends on Security access level See Table 5 system configur
18. Appendix D Section 12 Appendices Menu Structure Diagrams Process Setup Auto Initiate Mode Weld Mode Figure D 1 Dukane Manual Part No 403 584 00 Process Setup Menu Diagram 1 of 2 4 Manual Latch on Bad Part Disab r Maintained H Max Trigger Time Momentary Max Trigger Time Force Force at Trigger Max Trigger Time When Motion Stops Max Trigger Time Power Trigger Power Max Trigger Time Start Amplitude Position Trig
19. Changing Default Settings From the Main Menu go to Process Setup Each of the items shown in the table above is listed as a Pro cess Setup submenu item and can be customized for your process Refer to Section 5 Operation Pages 48 59 for more information about working with the Process Setup menu Dukane Manual Part No 403 584 00 Page 101 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Charts Trigger Force Weld Time Weld Force The charts that follow can help find starting values for Trigger Force Weld Time and Weld Force Using the Charts 1 Measure the approximate length of the linear weld joint 2 Find the corresponding number on the horizontal axis of each graph 3 Follow that number up into the shaded portion of the chart for the appropriate value EXAMPLE A part with a linear joint of 8 inches would have the following ranges Trigger Setting 2 6 3 2 40 55 pounds Weld Time 0 40 0 65 seconds Weld Force 150 240 pounds Initial Trigger Force Suggested Initial Trigger Force Settings 110 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 10 5 b ul Hun Wi 75 5 o o E b in Wi 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 Linear Weld Joint inches Fig
20. Press Top of Stroke Status Oupa soek Analog Monitor Signal Common E Power Signal monitor Oupa sowar Programmable Status Outputs System Power OK Status Output Bad Part Status upu Good Part Status Output ornen System Ready Status Output Suspect Part Status Output isolated Common Mousa emwekwnur 1 Table 3 System Output Connector Signals J3 6 pee 8 9 19 421 013 NN 15 18 21 22 2 24 7 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 5 2 System Outputs Connector The SYSTEM OUTPUTS connector mounted on the gen erator I O panel includes connections for all of the basic system status and monitor output signals which will typi cally connect to an automated control system The cable attached to this SORS DE all of the aane Fig re 3 9 DB 25F Generator Output Connector 09 system output signals which will be read or monitored by a digital input card or analog inputs on the user supplied automation controller The user can determine which signals are appropriate for each welding application The system monitor output signals are analog signals used to monitor ultrasonic amplitude setting and ultrasonic output
21. Suspect Limits This is also known as Suspect Part Limits Suspect part limits detect out of limit conditions with out ending the weld cycle These limits are used when process characteristics are grouped within a gray area between good and bad Parts can be sorted as good bad and suspect Suspect parts can be inspected manually Suspect limits can also be used as a form of pre control in applications where statistical process control methods are being used When a suspect part limit has not been met or that it was exceeded the operator is notified in these ways One beep is given if buzzer is set to ON See Buzzer Page 79 The iQ ES suspect part output is activated SUSPECT is displayed in the part cycle data In Figure 5 20 the selected characteristic is Method 2 Weld Distance Both Suspect Limits and Bad Limits are ON for which both Low Limits and High Limits need to be entered Part Cycle Data The weld characteristics chosen to be displayed can be seen in real time using the Operate Screen See OPERATE SCREEN on Page 82 Show All Notice that Figure 5 20 indicates there is an active soft key for the selection Show All Press this key to display all process characteristics Show None After pressing the Show All soft key the key designation changes to Show None Press the key so that none of the process characteristics are displayed Suspect Process Limits Limits F Downstroke
22. This is the current date according to the iQ genera tor timer Setup This is the number of the current setup Process Limits Continued Page 63 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Limits Continued from Previous Page Data from Process Characteristics Data from each weld cycle can be monitored through the available process characteristics Programming choices for each characteristic are No Display Display Only Bad Limits and Suspect Limits No Display Figure 5 17 shows that Method 1 Weld Energy is the selected process characteristic and no choices have been made for that characteristic Weld characteristic is not displayed Display Only Figure 5 18 shows Display Only was chosen for the Setup process characteristic That process characteristic 1s displayed during normal op eration using the Operate screen Bad Limits This is also known as Bad Part Limits Figure 5 19 shows that Downstroke Time is the selected characteristic Bad Limits are ON and Low Limits and High Limits need to be set The Bad part limits are used to establish boundaries that de fine unacceptable results for parts that are being processed If a bad limit is either not met or is exceeded the weld cycle is ended immediately and the operator is notified in these ways Two beeps are given if buzzer is set to ON See Buzzer Page 79 The iQ ES bad part
23. This is the distance the press travels while the ultrasound signal is applied to the part during the second weld method Total Weld Time This is available when dual pressure welding is selected It is the total of method 1 and method 2 weld times Total Weld Energy This is the sum of energy drawn from the generator during weld method 1 and weld method 2 Hold Time This is the time the horn maintains pressure on the part after the ultrasound signal has stopped Hold Distance This is the distance the press travels while maintaining pressure during the hold process after the ultrasound signal has stopped Total Cycle Time This is the period from the start of the weld cycle to the end of the weld cycle The start of the cycle is defined as the point the auto input signal begins or when manual operate switches are closed The end of the cycle is defined as the point the head retracts from the part Total Stroke Distance This is the position relative to the reference mark of the mounted distance encoder at the end of the hold process Total Weld Distance This is the sum of the col lapse distances of weld method 1 and weld method 2 Dukane Manual Part No 403 584 00 Process Limits Alarm Status Force Bad Weld Time Distance Weld Energy Peak Power Position Weld Peak Force Hold Time Hold Distance Total Cycle Time Total Stroke Distance Alarm Status Show Back suspec
24. iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Using Security Enabling Passwords for the First Time 1 Press the Security soft key The Security Screen appears as shown in Figure 5 57 The word None means no passwords have been enabled or set In the example that follows three passwords will be set First for the Administrator then for the Process Engi neer and finally for the Setup password 2 Select Administrator Password None in the list The selected phrase is highlighted in green The soft keys Administrator Password and Done are now displayed See Figure 5 57 3 Press the Administrator Password soft key and the alphanumeric virtual keyboard is displayed This is shown in Figure 5 58 Enter a password of up to 15 characters Press Apply Changes when finished The next screen to appear looks like Figure 5 59 Because the screen message says Security Enabled Currently Logged Out the Administrator must enter the Login Password to activate access to security features Once the Administrator password has been entered the screen appears as shown in Figure 5 60 Note the change in the Security Screen from what is seen in Figure 5 58 The Administrator Password has been Enabled Also Administrator Access is followed by Admin showing that the Administrator has current security access Login is complete for the Administrator Page 88 Administrator Password
25. Figure 3 10 DB 25M Generator Output Cable Connector power levels referenced to the Monitor Common Pin 13 Continued Dukane Manual Part No 403 584 00 Page 21 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Continued from Previous Page This is at system chassis ground potential non isolated All of the digital output status signals on this connector are isolated signals are not referenced to generator chassis ground When a status output signal is activated it will sink current 500mA Max sourced by a 24VDC supply to isolated common In automation terms the outputs are NPN sinking and would drive a PNP sourcing input that 1s 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 1s an optional isolated NPN to PNP conversion module that is DIN rail mountable The module converts the standard isolated sinking NPN status output signals to isolated sourcing PNP status output signals Consult your local sales representative for information about the conversion module System Outputs Connector Pinout The SYSTEM OUTPUTS connector is a DB 25F standard D subminiature 25 circuit female connector Connector pin numbers for this connector are shown in Figure 3 9 The male connector on the cable is a mirror image of the panel
26. Position Trigger Position Max Trigger Time Figure 5 42 Trigger Function Basic and Advanced Page 80 Hardware Setup Continued Dukane Manual Part No 403 584 00 Section 5 Operation Hardware Setup Continued from Previous Page Network Settings g DHCP Network Settings Enabled The Network Settings screen as seen in Figure 5 43 has IEEE five elements Enabled Enabled IP Address 172 116 100 111 1 Network Mask 255 255 0 0 Gateway Address 172 16 2 3 DHCP These initials stand for Dynamic Host Config Network Link Down uration Protocol The protocol was established for as 1 signing dynamic IP addresses to devices a network DHCP should be enabled if connecting multiple genera 1 tors when using an Ethernet router or switch Figure 5 43 Network Settings DHCP can be enabled or disabled depending on cus tomer requirements NOTE If the user is directly connecting to a laptop IP Address This Internet Protocol address is a num or PC the PC s IP address should be set ber unique to a piece of equipment acting as an identi to 169 254 0 x x must be 2 255 fier when the equipment is connected to a network The x_ in the computer s IP address can An IP address is specified when a static IP is required not be the same x as in the generator s IP address Network Mask Automatically assigned by the DHCP server Gateway Address Automatically assign
27. Pressure Profile Pressure 2 This is the second pressure profile used during a dual pressure weld cycle Figure 5 14 Pressure Set Profile 1 GENE Enter Pressure for all 10 Segme Enter the 10 values for the profile points and press the DONE soft key Program Notes Pressure profiling relates to how the weld method is Hold Pressure Enter the pressure for the Hold programmed during setup portion of the weld cycle EXAMPLE Ifthe total weld distance 0 010 inch Upstroke Pressure This is the pressure for the final part of the weld cycle as the head retracts Enter the Upstroke Pressure With a 10 step profile each step equals one tenth of the total distance In this example each step 0 001 inch Page 58 Dukane Manual Part No 403 584 00 Process Setup Continued from Previous Page Advanced Process Settings Advanced Process Settings are enabled through the Utilities Hardware menu Please see Hardware Setup Pages 76 81 for information on enabling these settings and for brief descriptions of each Free Run Frequency and Scan Stack Frequency Tracking Frequency Lock and Hold System Frequency Limits Ramp Up and Ramp Down Dukane Manual Part No 403 584 00 Section 5 Operation Process Setup Continued Page 59 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Limits Overview As the weld cycle progresses time distan
28. Virtual 42 L Latch on Bad Part 50 Layout High Power iQ Generator 130 Layout High Profile iQ Generator 131 Layout Low Profile iQ Generator 129 Lifting the Equipment 10 List of Figures 139 List of Tables 143 Lockout Tagout Devices 13 Dukane Manual Part No 403 584 00 M Maintenance 113 115 AC Power Cord 115 Air Ventilation Slots 115 Chassis 115 Cleaning 115 Cover 115 Front and Rear Panels 115 I O Connector 115 Menu Structure Diagrams 147 N Networking 33 Network Settings 81 Notes Cautions and Warnings 3 O Operate Screen 82 Part Number History 82 Operation 45 Current Setup 83 Generator Start up Sequence 45 Graph 84 Hardware Setup 72 Help 86 Overview 45 Process Limits 60 Process Setup 50 Advanced Process Settings 59 Afterburst 56 Control Parameters Single and Dual Pressure Weld ing 54 Hold Method 55 Initiate Mode 50 Pressure 57 Trigger Type 51 Weld Mode 53 Process Setup Menu Diagram 48 Process Utilities 67 Real Time Data 83 Security 87 Start up 45 Stopping the Weld Cycle 46 Using the Menus 47 Options 117 Data Transfer 120 Power Inlet Options 119 Press Interface Board 122 P4 Dual Pressure Only 122 P5 Dual Pressure with Distance 122 Dukane Manual Part No 403 584 00 Index P6 EPR Load Cell with Distance 122 Press Interface Module 122 Output Duration 75 P Plastics Health Notice 8 Power Cords 28 Power Switch Circuit Breaker 17 Press System Overview 4 Key Generator Fe
29. cycle The signal comes from the trigger switch found on presses without an Electronic Pressure Regulator EPR Momentary With a Momentary trigger the trigger switch signal is ignored after it has activated If the trig ger switch opens during the weld portion of the cycle the weld continues normally The signal comes from the trigger switch found on presses without an Electronic Pressure Regulator EPR Force If the ultrasonic press system has an electronic pressure regulator and load cell the trigger type can be Force The load cell takes the place of the mechanical trig ger switch in the press When Motion Stops When the downstroke veloc ity of the thruster reduces to zero the ultrasound signal is triggered Choose this trigger type when the operator wants the ultrasound signal to start as the horn has completely compressed the part to be welded If the maximum trigger time is reached the weld is aborted and the press is returned to top of stroke Dukane Manual Part No 403 584 00 Trigger Type Submenu Diagram NOTE Available trigger types depend on system configuration and primary weld method CAUTION Use extreme caution when using the Momentary trigger type Opening the trigger switch will NOT terminate the weld cycle Guard the horn fixture pinch point to prevent hands or fingers from being crushed by the vibrating horn Process Setup Trigger Type Continued Page 51 iQ Series
30. 4 Rear Panel Expansion Slot 4 RS 232 Serial Configuration Port 4 TUV Certification 4 Wide Line Voltage Operation 4 Generator Outline Drawings 129 Graph 84 H Hardware Setup 72 Advanced Process Settings 76 Advanced Trigger Settings 80 Baud Rate 73 LF after CR 72 Network Settings 81 Restore Factory Defaults 81 Serial Headers 73 Serial Limit Indicators 73 Serial Port 72 System Status 74 Health and Safety 5 Electrical Safety 8 Domestic Power Grounding 9 International Power Grounding 9 General Considerations 7 How to Lift Safely 10 Plastics Health Notice 8 Recommendations 7 Help 86 How to Lift Safely 10 Page 154 I IEC AC Power Inlet Connector 17 Initiate Mode 50 Installation 11 Before Installation 13 When to Use Lockout Tagout Device 13 Cable Connections 29 Configurations 30 Pneumatic Press Ihruster 31 Connect AC Power 33 Connecting Cables 29 Connector Descriptions 26 Networking 33 Power Cords 28 RearPanel 16 AC Power Inlet Panel 17 Chassis Grounding Stud 17 AC Power Inlet Connector 17 Power Switch Circuit Breaker 17 System I O Panel 17 System Inputs Connector 17 Rear Panel Layout Overview 16 AC Power Inlet Panel 17 System I O Panel 17 Recheck Connections 33 RFI Grounding 25 Three Configurations 30 Unpacking 15 Placement 15 Unpacking and Placement 15 When to Use Lockout Tagout Devices 13 Interpreting the Model Number 135 IP International Protection Rating 136 K Keyboard
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32. Connects to the HMI PC LAN port 6 RS 232 Cable J10 Connects to a PC RS 232 port 7 Base Abort Cable J8 Cable 4 Connects to the press base plate connector J35 or an auto mation PLC 8 Connect the AC Power Cords Cable 6 To the HMI Cable 7 To the IEC power inlet connector on the ultrasonic generator Plug the other end s into an approved AC outlet Dukane Manual Part No 403 584 00 Page 29 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Three Configurations The iQ generator ES models are configured in three basic ways 1 With a pneumatic press thruster 2 With a remote controller and a servo press thruster NOTE 3 With a servo press thruster For information about the iQ ES generator for servo systems please refer to Dukane The diagram and table that follow show the pneumatic User s Manual 403 587 00 configuration and list the cables used Page 30 Dukane Manual Part No 403 584 00 Section 3 Installation Pneumatic Press Thruster L Earth Ground de c 9 EX E a 5 Dmm 2 S nm gt 5 x m N m 45 E o o a Figure 3 13 10 Generator and Pneumatic Press Thruster Connecti
33. 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 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 Continen tal European countries Refer to Figure 2 2 However 1f 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 p rc Zn Typical Outlet Provided Cable Figure 2 2 International 220 240V Grounding Dukane Manual Part No 403 584 00 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 elec trician 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 grounding prong or alter the plug in any way
34. Hz 8 Amps Nominal Nominal 20kHz 20HS180 2Q XX XX 1800 200 240V 50 60 Hz 12 Amps 20kHz 20HS240 2Q XX XX 2400 200 240V 50 60 Hz 15 Amps 20kHz 20HS360 2Q XX XX 3600 200 240V 50 60 Hz 25 Amps 1400 VAC 5A 20kHz 20HS480 2Q XX XX 4800 200 240V 50 60 Hz 30 Amps Nominal Nominal 30kHz 30HS090 1Q XX XX 900 100 120V 50 60 Hz 8 Amps 30kHz 30HS090 2Q XX XX 900 200 240V 50 60 Hz 8 Amps 30kHz 30HS120 1Q XX XX 1200 100 120V 50 60 Hz 15 Amps 30kHz 30HS120 2Q XX XX 1200 200 240V 50 60 Hz 8 Amps 30kHz 30HS180 2Q XX XX 1800 200 240V 50 60 Hz 12 Amps 40kHz 40HS060 1Q XX XX 600 100 120V 50 60 Hz 8 Amps 15 Amps e A Nominal Nominal 40kHz 40HS060 2Q XX XX 600 200 240V 50 60 Hz 5 Amps 40kHz 40HS090 1Q XX XX 900 100 120V 50 60 Hz 15 Amps 40kHz 40HS090 2Q XX XX 900 200 240V 50 60 Hz 8 Amps 40kHz 40HS120 1Q XX XX 1200 100 120V 50 60 Hz 15 Amps 40kHz 40HS120 2Q XX XX 1200 200 240V 50 60 Hz 8 Amps Table 11 111 Generator AC Power Requirements mum WARNING 8 NOTES Do not operate machine at voltages lower than 100V Current will exceed rating i causing a shock hazard If the input line voltage is less than 100 the output current will exceed 15 Amps ee E An X used above in the Model Numbers is a wildcard character meaning any valid character code combination Maximum line current requirement is specified at the minimum nomi
35. Power Indicator While the indicator glows GREEN it shows that the gen erator has been powered by the AC current Page 40 0 042 0 500 Bar Graph Figure 4 7 System Power Output Level Bar Graph and Overload Indicator Dukane Manual Part No 403 584 00 Screen Basics Making Selections Figure 4 8 shows there are several ways that an item has been selected word or phrase is bounded by a black border e A black box surrounds the selected item Aline oftext is highlighted The cursor shows what digit is selected Word bounded by black border Process Setup Setup 1 Trigger Type When Motion Stops Weld Mode Single Primary Weld Method 1 Distance Secondary Weld Method 1 Disabled Hold Method Time Latch on Afterburst Disabled Bad Part Weld Amplitude 100 Pressure Main Liat enims Black box surrounds selected item Figure 4 8 Making Selections Interpreting Onscreen Arrows Arrows pointing up down left and right give visual cues that more text is available in the direction the arrow points Two examples are shown below For the screen on the left the up or down navigation keys are used For the screen on the right active soft keys are used See Figure 4 6 Section 4 Control Panel Line of highlighted text Process Setup Setup 1 Type Initiate Mode Manual Max Trigger Weld Mode Single Time Primary Weld Method 1 Distance
36. Time _ Downstroke Distance Contact Air Pressure Bad Limits Method 1 Weld Time 10 0000 in Method 1 Weld Distance Low Limits Method 1 Weld Energy Method 1 Weld Peak Power 0 0000 in High Limits Method 1 Weld End Position High Limits 0 0000 Method 2 Weld Time 9 0000 in Method 2 Weld Distance Method 2 Weld Energy Method 2 Weld Peak Power Show Back suspect limits ON Wead limits ON Blpispisy Only e E Figure 5 20 Process Limits Suspect Limits NOTE Change your mind If you change your mind and decide not to display all of the characteristics press the Show None soft key to turn off the display feature for all of the characteristics Page 65 Dukane Manual Part No 403 584 00 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Utilities Welder Name Setup Name Setup Control Copy Setup Booster Erase Setup Fixture Part Count Settings Manual P2 Hold Notes Dynamic Trigger Language Down Speed Flow Control Base Units Mechanical Stop Date Format HSC Setting Time HSC Start Position Date Pre trigger EOW Flags Figure 5 21 Ultilities Hardwar
37. Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Setup Trigger Type Continued from Previous Page Power Dukane has patented Trigger by Power Go to Dukane s blog Attp usblog dukane com 2010 01 trigger by power feature aids weld 27 html for more information about this feature During the downstroke the ultrasound signal is immedi ately turned on with the Start Amplitude setting When the power level reaches the trigger value the weld amplitude is applied Choose this trigger type when the operator wants the ultrasound signal to start as the horn touches the part to be welded If the maximum trigger time is reached the weld is aborted and the press is returned to top of stroke Position The trigger source is via the distance encoder When the position is reached the ultrasound signal is trig gered Program Notes After selecting the appropriate trigger type the operator enters data where the trigger type calls for it For instance all trigger types call for a Max Trigger Time to be entered Power calls for Trigger Power and Start Amplitude as well For Position Trigger Position is required See Figure 5 7 Trigger Type Submenu Diagram Page 52 Process Setup Continued Dukane Manual Part No 403 584 00 Section 5 Operation Process Setup Continued from Previous Page
38. WARNING blocks as shown here They represent increas ing levels of important information These statements help you to identify and avoid hazards and recognize the conse quences One of three different symbols also accompany the CAUTION and WARNING blocks to indicate whether a the notice pertains to a condition or practice an electrical g safety issue or a operator protection issue i ERN Warning statements T point out conditions or E practi h ld re Drawings and Tables 22 ps A sult in personal injury or The figures and tables are identified by the section num loss of life ber followed by sequence number The sequence num 1 ber begins with one in each section The figures and tables are numbered separately The figures use Arabic sequence numbers e g 1 2 3 while the tables use Roman sequence numerals e g I As an ex ample Figure 3 2 would be the second illustration in sec tion three while Table 3 II would be the second table in Condition Electrical Operator section three or Practice Safety Issue Protection hearing Dukane Manual Part No 403 584 00 Page 3 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Press System Overview An iQ Series Ultrasonic Press System ES consists of these components the iQ generator press with thruster switches controls cables transducer booster ho
39. a separate power supply if de sired Refer to Application Note AN507 Automation Interface Guidelines at Attpz www dukane com us DL ApplDa ta asp for wiring diagrams of example applications System Inputs Connector Pinout The SYSTEM INPUTS connector is a HD 15F high density D subminiature 15 circuit female connector Connector pin numbers for this connector are shown in Figure 3 7 The male connector on the cable is a mirror image of the panel mounted connector and is shown in Figure 3 8 Table 3 I lists the signal names and descrip tions with more detailed descriptions that follow The wire color coding for the system input cable is listed in Table 3 II to assist with custom automation system wir ing and assembly Page 18 Figure 3 6 System I O Panel Standard Panel Shown NOTE Refer to Section 9 Options for information on optional features Continued Dukane Manual Part No 403 584 00 Section 3 Installation Continued from Previous Page Pin Signal Name Cable Color Code Signal Option Requirements 22VDC Power Ground Remote Setup Selection Bit 1 Input Remote Setup Selection Bit 2 Input Remote Setup Selection Bit 3 Input Not Used 0 System Lateh Resetinpt 15 isolated Common 4 womainCydeSupipa o Table 31 Generator Input Signals J2 5 Remote Setup Selection Bit 4 Inp
40. a single pressure weld cycle If welding with dual pressure the iQ generator can be programmed for up to twenty pressure steps NOTE Pressure profiling is only available when the press is equipped with the electronic pres With Pressure Profiling enabled there are three single sure regulator feature pressures to be entered and two pressure profiles to create Figure 5 13 shows the display after Pressure Profiling has been enabled Pressure Process Setup Hold Profilin Setup 1 Pressure Downstroke Pressure This is the pressure for Wownelroke Mai Mua Upstroke P Primary Weld Method 1 Dist P the first part of the weld cycle as the head begins secondary Weld Method Disabied Primary Weld Method 2 Time to travel down Enter the Downstroke Pressure Pressure 4 Secondary Weld Method 2 Disabled Set Hold Method Time value Pressure 2 Pressure Profile Pressure 1 These are the mam Meni pressures used in single pressure welding and it is also the first of two pressure profiles used with Figure 5 13 Pressure Profiling Enabled dual pressure welding Enter the Pressure Profile Pressure 1 values Pressure ieee ou Figure 5 14 shows a Pressure Profile Pressure 1 Segment2 0 0 psi display and the profile points 1 10 Done Enter the 10 values for the profile points and press seamen T psi the DONE soft key eL Segment10 0 0 psi
41. 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 space between 3 6 inches 8 15 cm at the rear of the chassis for cable clearance The amount of space depends on the chassis type and what rear panel connections there are See Section 11 Specifications for generator drawings 17 16 435 86 5 19 131 83 Exhaust Air Outlet Cooling Air Inlet lt lt IN mm Figure 3 3 Generator Front View Typical High Profile NOTE Active Seismic Region Placement If the generator will be put in an active seismic region please refer to Application Note 511 at http www dukane com us DL AppiData asp Dukane Manual Part No 403 584 00 Page 15 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Rear Panel Layout Overview This section provides an overview of the generator rear panel layout which includes panel areas dedicated to var ious standard system functions and options that are avail able Figure 3 4 illustrates a typical panel layout B DUKANE CORP ST CHARLES IL 60174 MADE IN U S A a ULT T012 2010 CSA C22 2 61010 1 12 Ec 61010 2012 WARNING J6 BASEJABORT J5 THRUSTER J11 ENCODER l emm sweweome o P
42. generator can not generate an ultrasound transducer connected Make sure that signal the stack is properly assembled before itis connected to the system The horn The display has a YELLOW background and the word should never come in direct contact with Offline appears in a yellow box in the lower right corner a metal fixture or anvil with ultrasound of the display See Figure 4 3 to the right activated The display has a RED background and the word E STOP appears in a red box in the lower right corner of the display Process Setup Operate Screen Graph Select Setup Current Setup Security Operating Mode Indicator Offline yellow Figure 4 3 Generator in Offline Condition Page 38 Dukane Manual Part No 403 584 00 Navigation Keys Moving the Cursor Press the left and right navi gation keys to move the display s cursor left or right respectively Press the up and down navigation keys to move up one level in the menu or to move back one level Also use the keys to change the value of a selected digit Enable Disable The navigation keys have another function Any of the four keys can be pressed to either enable or disable a particular menu item See Figure 4 4 ENTER Key Press ENTER to confirm and store a selection in memory Example After entering a time value press ENTER CANCEL Key Press the CANCEL key to return to the previous screen or cursor position Think of it as a back key Selecti
43. mounted connector and is shown in Figure 3 10 Table 3 lists the signal names Detailed descriptions are listed in System Outputs Signal Descriptions that fol low To assist with custom automation system wiring and assembly the wire color coding for the system outputs cable is listed in Table 3 Page 22 System Outputs Signal Descriptions Pin 1 22VDC Power Supply This 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 reassigned to other system status signals The output can be assigned to E STOP or Over Temperature The Pin 4 default output E STOP Pin 5 Programmable Status Output 2 Pin 5 is a digital active low status output that can be reassigned to other system status signals The output can be assigned to Hold In Cycle or In Cycle with No Afterburst The Pin 5 default output Hold 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 Pin 7 Any Fault Status Output Pin 7 is a digital active low status output that act
44. on start up and finally turn a steady GREEN This indicates that the system is operational If the power indicator stops flashing but remains RED do not go any further there is a problem with an internal power supply 3 Press the TEST key in ONLINE mode only See TEST Key Figure 6 1 a System Power Output If the power output display remains less than the typical 200 Watts and the horn frequency is within the standard frequen cy range the stack should be operational Ifthe power output exceeds 200 Watts there may be a problem with the stack System Power Output Level Figure 6 1 70 Generator TEST Key Continued Page 96 Dukane Manual Part No 403 584 00 Section 6 System Operational Testing Continued from Previous Page Press the TEST key As long as this key is pressed test data as shown in Figure 6 2 ap pears e Press the GRAPH soft key to display the graph screen e display like the one shown in Figure 6 3 to the right will appear as a graph resulting from the test sequence b If an overload alarm is displayed a mismatch has occurred between the generator s ultrasonic output signal and the stack Refer to the next section Set up Guidelines and Troubleshooting and see the Alarm Message table If all the indicators pass their tests the stack is within the Digi Trac range Typically ultrasonic acoustic stacks operate between 50 200 Watts depending on the gain of the booste
45. quality ven dor 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 certification you must prove to one of the quality system registrar groups that you meet three requirements 1 Leadership 2 Involvement 3 Quality in Line Organizations and Quality System Infrastructure The ISO 9001 standard establishes minimum requirement for these requirements and starts transitioning the company from a traditional inspection oriented quality system to one based on partnership for continuous improve ment This concept is key in that Dukane 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 150 9001 CERTIFIED Dukane products are manufactured in ISO regis tered facilities View the Dukane ISO certificate of compliance at http www dukane com ISORegistrationCertificate pdf Pleas
46. software applica tion 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 J6 Base Abort The Base Abort connector accepts the operate and emergency stop signals from the optical operate switches and abort switch on the base If you are using custom automation you may have separate operate and abort switches but these still connect to this connector on the generator J9 Ethernet This port is used for Ethernet communication between the generator and HMI running iQ Explorer II software J10 RS 232 This port is primarily used for welder diagnostic functions accessible via serial communication to a PC Guidance will be provided by Dukane if the need to use the capability arises J11 Encoder This connector accepts signals from the distance encoder on the press J5 Thruster This connector is used to interface various control signals between the press and generator Dukane Manual Part No 403 584 00 Page 27 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual 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 III Continent of Use Power Cord Part
47. specified level of power to the transducer Peak Power measured in Watts has a 0 1 Watt resolution Peak Power range is dependent on the generator s maximum power rating Ground Detect When Ground Detect is enabled the ultrasonic signal is shut off when the horn touches the isolated metal fixture during the welding process Scrub when enabled extends the weld time generated when the weld portion of the cycle is ended by the ground detect input Typically this is used in cutting applications Often the horn cuts through the material at a single point This activates the ground detect input and ends the weld portion of the cycle There may be an incomplete cut however Scrub time al lows the cut to be completed by keeping the ultrasound signal on for a maximum of 127 milliseconds Page 54 NOTE MAX WELD TIME is a secondary character istic of Distance Position Energy and Peak Power The time forces the weld portion of the cycle to stop even if the specified control parameter is not met NOTE Downstroke Distance Distance the horn travels until the ultrasound trigger point is reached Weld Distance Distance the horn moves during the application of ultrasound to cre ate the weld Hold Distance Distance the horn moves during the hold or cooling portion of the weld cycle Position Downstroke Distance Weld Distance Process Setup Continued Dukane Manual Part No 403 584 00 Sec
48. the display shown in Figure 5 30 appears Erase Setup Part Count Settings Notes Language English Base Units Imperial Setup Choose setups Copy From and Copy To dece cid i Time Date 4 Then press the soft key Press to Figure 5 29 Copy Setup 1 The display will appear as it does in Figure 5 31 Copy Setup Copy Setup from Setup 1 Press Here to Copy Figure 5 30 Copy Setup 2 Copy Setup Select Setup Copy Setup from Setup 1 Copy Setup to Setup 4 Press ee Figure 5 31 Copy Setup 3 Process Utilities Continued Dukane Manual Part No 403 584 00 Page 69 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Erase Setup Setup data can be erased for the current setup or for all setups See Figure 5 32 Part Count Settings This utility permits part count modification through its three submenus See Figure 5 33 Reset Part Count Selecting this sets the part count to zero 0 Preset Part Count Enter a number that starts the part counter Count Bad Parts Enable this to increment the part count if a bad part occurs Language Choice of language displayed by the front panel is made through this utility Base Units Select either Imperial or Metric units with this display utility Date Format The date utility allows for three ways of
49. time shown on the display This tells that the controller has directed the generator to produce the ultrasonic signal for the programmed time Verify that a time for the weld cycle is displayed Verify that a value shows in Weld Peak Power Method 1 Page 106 NOTE The Initiate Mode selection must be set for each setup used This is extremely important in the case of Sequencing and setup selection NOTE If no value displays there is a prob lem For help go to Section 10 Contacting Dukane Page 123 Dukane Manual Part No 403 584 00 The Power up Sequence Stops Under normal conditions power up starts when the genera tor REAR panel AC breaker switch is pushed to the ON position Then the FRONT panel power indicator will flash for a few seconds and finally turn a steady GREEN This indicates that the system is operational If the power indicator stops flashing and remains RED do not go any further there is a problem with an internal power supply Operation of the front panel lighted power indicator Steady Green Generator is ready to cycle Steady Red There is a problem with an internal power supply Dukane Manual Part No 403 584 00 Section 7 Set up Guidelines and Troubleshooting NOTE If troubleshooting does not provide satisfactory results please contact Dukane Corporation see Section 10 Contacting Dukane for servicing The iQ ES generator is serviceable only by Du
50. 0 000 Secondary Weld Method 1 Disabled Hold Method Time Afterburst Disabled Weld Amplitude 100 Pressure Cursor showing selected digit Display arrows point in direction of more text Process Limit San fStroke Distance T feines 1 Weld Time Display ethod 1 Collapse Dist Method 1 Weld Energy Method 1 Weld Peak Power Method 1 Absolute Dist Hold Time Hold Collapse Dist Total Cycle Time Total Stroke Distance larm Status Show Back suspect limits ON Wead limits ON Blpispiay Only Autot Onine Figure 4 9 Arrows Indicate More Text Dukane Manual Part No 403 584 00 Main Menu Page 41 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Virtual Keyboard A virtual keyboard pops up when there is a need to make an entry for the Security and Hardware screens In the example shown below the operator is prompted to choose a Setup Name Setup Name Figure 4 10 Virtual Keyboard Setup Identification Setup identification can be seen in the lower right corner of the screen The example shown in Figure 4 11 illustrates that setup control is by automation Auto and that Setup 1 pro gram has been selected for the generator Setup can also be controlled by iQ System iQ or by se quencing A pair of numbers that resemble a ratio such as 2 3 appears In this example 2 is the number for the seg ment and 3 is the number of the cycle
51. 00 Page 11 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 12 Dukane Manual Part No 403 584 00 Before Installation As you plan for the installation of your generator please consider these important subjects as listed below When to use lockout tagout devices Lifting the generator safely See Section 2 Health and Safety Page 10 When to Use Lockout Tagout Devices Figure 3 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 Dukane Manual Part No 403 584 00 Section 3 Installation Figure 3 2 Bottom Lockout Device In Closed Position Locked WARNING Electrical safety haz ards exist inside the generator chassis Before making any internal ad justments to the generator apply a lockout tagout LOTO device to the generator chassis Continued Page 13 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Continued from Previous Page Lockout Tagout Procedure to use BEFORE making any internal adjustments to the g
52. 33 Connector Dukane Manual Part No 403 584 00 Index Descriptions 26 iQ Generator Connectors 26 Connector Descriptions 26 Control Panel 37 Navigation Keys 39 Overview 37 Screen Basics 41 Interpreting Onscreen Arrows 41 Making Selections 41 Setup Identification 42 Virtual Keyboard 42 System Operating Mode Keys 38 System Power Output Level 40 Current Setup 83 Cycling the System 98 D Digi Trac 95 Drawings and Tables 3 Dukane 95 Address 125 Contacting 123 Contacts 125 Digi Trac 95 796 E mail 125 Fax 125 Intelligent Assembly Solutions 125 Phone 125 Website 125 E Electrical Safety 9 100 120 Volt Systems 9 Domestic Power Grounding 9 International Power Grounding 9 E mail 125 End of Cycle 74 End of Weld 74 F FCC 136 Free Run Frequency 76 Frequency Lock Hold 77 Frequency Tracking 77 G General User Information 3 Drawings and Tables 3 Notes Cautions and Warnings 3 Continued Page 153 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual G Continued Read This ManualFirst 3 Generator Features 4 AC Power Inrush 4 CE Certification 4 Digital Control 4 Digi Trac Tuning 4 Flow Through Cooling Tunnel 4 High Line Voltage Power Supply 4 Interface 4 ISO 9001 Certification 4 Linear Ramp Up Down 4 Line Voltage Regulation 4 Load Regulation 4 Multiple Electronic Overload 4 Process Limits 4 Process Parameters 4 Pulse Width Modulation 4 Rear Panel Expansion
53. 4 Trigger Initial Trigger Force 102 R Ramp Down Time 78 Ramp Up Time 78 Real Time Data 83 Regulatory Agency Compliance 136 CE Marking 136 136 IP Rating 136 UL 136 Restore Factory Defaults 81 Restore System I O Defaults 75 RFI Grounding 25 S ScanStack 76 Screen Basics 41 Scrub 54 Security 87 Page 156 After Passwords are Enabled 90 Enabling Passwords for the First Time 88 Forgotten Password 91 Other Security Prompts 91 Remote User Timeout 87 Sequencing Notes 144 Set up Guidelines 101 Air Cylinder Size and Force 105 Changing Default Settings 101 Initial Trigger Force 102 Initial Weld Force 104 Initial Weld Time 103 Setup Identification 42 Specifications 127 AC Power Requirements 133 Dimensions 132 Interpreting the Model Number 135 Layout Drawings 129 Layout High Power iQ Generator 130 Layout High Profile iQ Generator 131 Layout Low Profile iQ Generator 129 Operating Environment 132 Ultrasonic Pressure 134 Weights 132 Stopping the Weld Cycle 46 System 98 Cycling 98 System Frequency Limits 77 System Inputs Connector 17 System Inputs Connector Pinout 18 System Inputs Signal Descriptions 19 System I O Panel 17 System Inputs Connector 17 System Inputs Connector Pinout 18 System Inputs Signal Descriptions 19 System Outputs Connector 21 System Outputs Connector Pinout 22 System Outputs Signal Descriptions 22 System Operational Testing 93 Cycling the System 98 Test of the Acoustic Stack 96 System Out
54. 8 Dukane Manual Part No 403 584 00 Section 7 Set up Guidelines and Troubleshooting Set up Guidelines and Troubleshooting Set up 101 Default Settings Process 101 Changing Default 5 5 101 Charts Trigger Force Weld Time Weld Force 102 Air Cylinder Size and 105 Troubleshooting 106 The iQ Generator Won t Cycle 106 No Ultrasound 106 The Power up Sequence 107 Alarm 108 Dukane Manual Part No 403 584 00 Page 99 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 100 Dukane Manual Part No 403 584 00 Section 7 Set up Guidelines and Troubleshooting Set up Guidelines The iQ Series ES generator is shipped from the fac tory with a few default settings See the table below for those values Default Settings Process Setup iQ Series Generator ES Pneumatic Initiate Settings Initiate Mode Manual Latch on Bad Part Trigger Type Max Trigger Time Advanced Trigger Settings Weld Mode Downstroke Primary Method 1 Max Weld Time 1 Secondary Method 1 Weld Pressure 1 Weld Amplitude Hold Method Hold Pressure 0 00ps 0 00 Afterburst Table 7 Default Settings Process Setup
55. DUKANE Intelligent Assembly Solutions Series ULTRASONIC GENERATOR POWER SUPPLY Pneumatic Systems OLOJO AUTOMATED HAND PROBE PRESS User s Manual Dukane Part No 403 584 00 Dukane Intelligent Assembly Solutions 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949 150 9001 Dukane products are manufactured in ISO registered facilities www dukane com us iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Copyright 2013 Dukane Intelligent Assembly Solutions 2900 Dukane Drive St Charles IL 60174 USA Notice of Rights All rights reserved No part of this manual including the interior design cover design and icons may be reproduced transmitted or utilized in any form or by any means electronic mechanical photocopying recording or by any information storage and retrieval system without written permission from Dukane Corporation Notice of Liability The information contained in this manual is distributed on an As is basis without warranty While every precaution has been taken in the preparation of this manual Dukane Corporation 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 subject to change witho
56. Diagrams 147 Ji 151 Dukane Manual Part 403 584 00 Section 1 Introduction Introduction General User Information 3 Press System Overview Key Generator Features Dukane Manual Part No 403 584 00 Page 1 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 2 Dukane Manual Part No 403 584 00 Section 1 Introduction General User Information Read this Manual First Before operating your ultrasonic system read this User s Manual to become familiar with the equipment This will ensure correct and safe operation The manual is organized to allow you to learn how to safely operate this equipment The examples given are chosen for their simplicity to il lustrate basic operation concepts This manual provides information to set up operate and interface this generator power supply as an integral part of NOTE Dukane s iQ Series ES press system Note statements provide additional Particular models are listed in Section 11 Specifications information or highlight procedures Notes Cautions and Warnings Throughout this manual we use NOTES to provide infor mation that is important for the successful application and understanding of the product A NOTE block is shown to the right In addition we use special notices to make you aware of safety considerations These are the CAUTION and
57. FF 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 Dukane Manual Part No 403 584 00 Section 3 Installation 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 that is common in an industrial en vironment The chassis ground stud is C in Figure 3 5 Proper system grounding is discussed on Page 9 DUKANE CORP ST CHARLES IL 60174 MADE IN U S A LINE VOLTAGE 200 240 Vac 50 60Hz 10 WARNING POWER LINE OUTLET MUST BE GROUNDED DISCONNECT LINE POWER BEFORE REMOVING COVER U S PATENTS 7 475 801 7 819 158 AND 7 225 965 C Figure 3 5 IEC AC Power Inlet Connector System I O Panel The standard system I O panel is described in this sec tion See Figure 3 6 on the next page System Inputs Connector The SYSTEM INPUTS connector mounted on the sys tem I O panel includes connections for all of the basic sys
58. If an exten sion cord is needed use a three wire cord that is in good condition The cord should have an adequate power rating to do the job safely It must be plugged into a grounded receptacle Do not use a two wire extension cord with this product 100 120 Volt AC Systems North America or Japan The power cord including strain relief supplied with the 100 120VAC systems is permanently attached to the rear of the generator Units with this power cord are for use in North America or Japan 240V Systems High power generators with power ratings above 2400W also use permanently attached power cords Page 9 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Lifting the Equipment How to Lift Safely Before lifting take a moment to think about what you re about to do Examine the object for sharp corners slippery spots or other potential hazards Know your limit and don t try to exceed it e Ask for help if needed or if possible divide the load to make it lighter e 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 1 Page 10 Stand close to the load with your feet spread apart about shoulder width with one foot slightly in front of the other for balance Squat down bending at the knees not your waist Tuck your chin while keeping your back as vertical as possible Get a firm grasp of the o
59. Number 200 1110 240V 15A North America 200 1541 240V 10A 200 1111 240V 16A Continental Europe 200 1542 240V 10A Table 3 Power Cords Page 28 Dukane Manual Part No 403 584 00 Section 3 Installation Cable Connections Reference Cable numbers correspond with those used in Figure 3 13 and Table 3 IV 1 Grounding Thruster and Press Base Cables 8 and 9 respectively Generator Chassis Cable 10 A supplied 14 Gauge wire to be attached to the grounding stud See Figure 3 5 for stud 2 Ultrasound J1 Cable3 This output connects the Ultrasound Output ofthe iQ Series generator to the transducer through a coaxial cable The electrical welding signal 1s transmitted through this cable 3 Operational Control J201 Cable 1 This cable runs from J201 on the thruster to the generator s Thruster connector J5 The gen erator provides controls for triggering the weld operating the thruster s pneumatic system and providing 24 VDC operating voltage through this cable The press driver card in the generator also NOTE provides monitoring for these functions Some connectors have a pair of 4 Encoder J11 Optional Cable 2 The pur threaded jack screws to secure the pose of the encoder cable is to connect the dis connector Make sure the screws are tance encoder option to the generator s Encoder snug but do not overtighten them Port 111 5 Ethernet Cable J9 Cable 5
60. OSF BE GROUNDED ace e J9 ETHERNET J10 RS 232 AE Figure 3 4 Generator Rear Panel Pneumatic Press Thruster AC Power Inlet Panel A IEC Power Inlet Connector Attaches to an IEC style power cord B Power Switch Circuit Breaker Used to switch sys tem power ON and OFF C Chassis Grounding Stud Chassis connection for a protective earth ground The System I O Panel D System Input Connector J2 Connections for sys tem control input signals E System Output Connector J3 Connections for sys tem status output signals F Ultrasound Output Connector J1 Coaxial high volt age connection to ultrasonic stack G Configuration Port Connector J4 Digital control port to modify system parameters Page 16 Options Module Panel H Communications Board See NOTE below Shown in the example above are these ports J9 Ethernet J10 Serial RS 232 K Press Interface Module See NOTE below Shown in the example above are these ports J6 Base Abort J5 Thruster J11 Encoder NOTE The press interface board is available in several different configurations See Section 9 Options for more infor mation about Data Transfer using the Communications Board and more about the Press Interface Module Dukane Manual Part No 403 584 00 AC Power Inlet Panel The standard AC power inlet panel is described in this sec tion IEC AC Power Inlet Conne
61. Operation Process Limits Continued from Previous Page Downstroke Time Downstroke Distance Contact Air Pressure Method 1 Weld Time Method 1 Distance Method 1 Weld Energy Method 1 Weld Peak Power Method 1 Weld End Position OFF Suspect Limits KT Method 2 Weld Time ON Low Limits High Limits Method 2 Distance OFF Bad Limits K E Method 2 Weld Energy ON Low Limits High Limits Method 2 Weld Peak Power Display Only Method 2 Weld End Position Total Weld Time Show All Show None NOTE Total Weld Energy 2 2 The list of available process character eee istics depends on Security access level Hold Distance See Table 5 1 system configuration Total Cycle Time and on the chosen weld mode Total Stroke Distance Single Weld mode a list of 15 character istics would be shown Total Weld Distance Dual Weld mode list of 23 character istics appears That list includes the Single Weld 15 plus eight more charac Date teristics shown in shaded boxes in the diagram to the left Alarm Status Time Setup Figure 5 15 Process Limits M
62. Power Max Weld Time Max Weld Time Scrub Ti Ground Detect Scrub Enable as Disable ri Disabled Secondary H Distance Weld Distance Weld Method 1 Position Weld Position H Energy Weld Energy Peak Power Weld Power Process Setup Continued Page 147 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Appendix D Menu Structure Diagrams Process Setup Continued from Previous Page Process Setup Disabled Time Hold Time Hold Method Distance Hold Distance Max Hold Time Until Motion Stops 4 Max Hold Time Enabled Afterburst Delay Time Afterburst Duration Afterburst Amplitude Afterburst Disabled Weld Amplitude Enabled Pressure 1 Set Profile Pressure 2 Set Profile Pressure Profiling Disabled Pressure E Downstroke Pressure Hold Pressure Upstroke Pressure Weld Pressure 1 Weld Pressure 2 Run Frequency Scan Stack Scan Stack Enable Frequency Tracking Disable Enable Frequency Lock and Hold Disable Wide Advanced Process Settings Normal System Frequency Limits Narrow Manual
63. Security Screen 07 01 2013 13 31 Administrator Access Default Setup Password None Process Eng Password None Remote User Timeout Deny Control Figure 5 57 Security Screen Administrator Password Selected Security Screen 06 01 2013 13 31 Password _ IPLE Security Screen 06 01 2013 13 31 Password Setup Password None Process Eng Password None Administrator Password Enabled Remote User Timeout Deny Control Figure 5 60 Security Screen Administrator Access Enabled Continued Dukane Manual Part No 403 584 00 Section 5 Operation Security Continued from Previous Page At this point the Administrator typically has four options Logout Press the soft key next to Logout and the Administrator will be logged out None of the security levels will be active Done Press the soft key next to Done to exit and return to the main menu Erase Select Administrator Password En abled in the list Press the Erase soft key and the password will be erased or Continue enabling passwords NOTE If the Login Password soft key is pressed For additional passwords complete Steps 4 and 5 and a wrong password is entered a screen prompt indicates an incorrect Also please read the NOTE to the right gt password has been entered The next screen shows that the person has been logged out Restart the login process to activate the security features
64. ach option is described in general terms P4 Dual Pressure Only P N 110 4426 Dual pressure is a feature that is exclusive to Dukane press systems It increases clamp force to improve the plastic melt and flow during the weld portion of a cycle and as sures tight assembly during the hold portion by welding parts at one pressure and holding them together at a second pressure Dual pressure can also be used to begin a weld at one pressure finish the weld at a second pressure then hold the assembly together at the second pressure P5 Dual Pressure with Distance P N 110 4427 Dual pressure is a feature that is exclusive to Dukane press systems See the P4 description above Weld by distance mode controls the melt collapse distance to ensure that the same volume of material melts on each part The result finished joint strength is consistent All distance parameters downstroke trigger delay weld hold absolute weld total weld and total stroke distance are monitored to show upper and lower limits for bad and suspect parts This will verify part quality and uniformity Dukane s linear optical encoder has a one micron resolu tion to insure exceptional precision and repeatability P6 EPR Load Cell with Distance P N 110 4428 This option offers programmable pressure profiling and force by interfacing with the EPR electronic pressure regulator pressure transducer and load cell Increased control repeatability and consistenc
65. 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 Here is the address for the main website www dukane com us You can locate your local representative at www dukane com us sales intsales htm Dukane Manual Part No 403 584 00 Section 10 Contacting Dukane Page 125 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 126 Dukane Manual Part No 403 584 00 Section 11 Specifications Specifications Generator Outline 5 129 Weights Dimensions Operating Environment 192 AC Power Requirements 132 Ultrasonic Pressure 134 Interpreting the Model Number 135 Regulatory Agency Compliance 136 Dukane Manual Part No 403 584 00 Page 127 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 128 Dukane Manual Part No 403 584 00 Section 11 Specifications 12 99 329 95 ALLOW 5 BOTH SIDES FOR COOLING 0 12 3 05 17 16 435 86 ALLOW 3 IN BACK FOR CABLES 18 76 476 50 18 16 461 26 3 82 97 03 e
66. aner directly on the generator e Apply a small amount of cleaner on a soft clean cloth first Then clean the panel with the moistened cloth Power Button The button responds well to firm gentle finger pressure Do not use sharply pointed tools or other objects that could damage the button Chassis Sheet Metal Cover The cover is preformed to fit over the chassis and has pro tective grills over the cooling air vents Keep the cover on at all times because there are high voltages present which could cause injury The internal case also contains capaci tors which continue to hold a high electrical charge even after the power is shut off Air Ventilation Slots Keep the ventilation slots free from obstructions If exces sive dust or dirt collects on the slots wipe or vacuum them clean Do not use compressed air to clean them as this may force the dirt inside the chassis Allow 5 inches 127 mm of clearance outside each ventila tion slot The air intake is on the right and the exhaust is on the left This is shown in Figure 3 3 Page 15 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 Dukane Manual Part No 403 584 00 Section 8 Maintenance 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
67. ardware Setup Current Setup O Access X No Access Select Setup is available Table 5 Security Access to Main Menu Item Remote User Timeout The purpose of this option of the Security menu is to yield allow or deny access to the programming features of the iQ generator under certain conditions This feature is most useful when a remote user using iQ Explorer II software and a user at the generator might both want to control the generator A request for control by either user shows on the generator display and on the remote computer display If no response is given by either user to this request within 30 seconds then in whatever state the generator had been left Deny Control or Yield Control before the request for control that is the state in which the generator will continue to operate Example A remote user requests control of the genera tor and no one is at the generator to respond to the request If the generator had been programmed to yield control then after 30 seconds the remote user would have control Dukane Manual Part No 403 584 00 Access to program the generator is assigned to the Administrator as a default setting if no passwords have been set Security Screen 07 01 2013 13 31 Setup Password None Process Eng Password None Administrator Password None Remote User Timeout Deny Control TII Figure 5 56 Security Screen No Passwords Set Continued Page 87
68. asonic RFI from being fed back into the AC power line If you experience problems with RFI from the press run an additional grounding wire from the press base ground ing stud to the nearest grounded metal pipe or equivalent earth ground by means of a ground clamp Use at least 14 AWG wire for the connection to the press base Dukane Manual Part No 403 584 00 Section 3 Installation Page 25 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Connector Descriptions iQ Generator Connectors J1 Ultrasound Output Connector The ultrasound output connector used with all stan dard generators is a high voltage 5000V coaxial style SHV BNC connector This connector provides supe rior shielding of electrical noise compared to other types ofconnectors The ultrasound output connector mates with fully shielded coaxial ultrasound cables that are secured with a simple and reliable quarter turn bayonet style attachment mechanism Figure 3 11 Ultrasound Output Connector J2 System Inputs Connector The SYSTEM INPUTS connector includes connec tions for all of the basic system control input signals that will typically come from an automated control system The cable attached to this connector includes all ofthe available system control 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 wel
69. assword Hone Process Eng Password Hone Remote User Timeout Deny Control 1 I Erase 4 Figure 4 5 Active Soft Keys Example 1 Active Key Part 4 Total Weld Total Weld Setup Time Distance in iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual System Power Output Level Bar Graph A bar graph displays the percentage of ultrasonic power being drawn by the load The display uses 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 1n 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 Bar Graph Power Scaling Power scaling is related to amplitude At 100 amplitude the whole graph is lit and the generator is operating at 100 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 Lighted
70. ation and on the chosen weld mode Single Weld mode a list of 15 character istics would be shown Dual Weld mode a list of 23 character istics appears That list includes the Single Weld 15 characteristics plus eight more characteristics shown in shaded boxes in the diagram to the left Page 149 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Appendix D Menu Structure Diagrams UNES Process Utilities Hardware Setup Welder Name Serial Port Setup N Setup Control Su ose Horn Output Format Copy Setu pm H LF After CR Erase Setup Fixture Output Mode Part Count Settings anua Baud Rate Manual P2 Hold Notes Dynamic Trigger Serial Limit Indicators Language Down Speed Flow Control Serial Headers Base Units Mechanical Stop Date Foma HSC Setting System Status 1 Time HSC Start Position Auto Start Input Pre trigger EOW Flags Date t Auto Stop Input Enabled J3 pin 4 J3 pin 5 Output Duration Restore System I O Defaults Adv Process Settings Buzzer Text Keyboard Test at Power Up
71. ators are characters that appear in front of dis played or printed part data indicating whether the data has reached or exceeded an upper or lower limit The greater than sign 7 means that an upper limit Suspect value has been exceeded Two greater than signs gt gt mean that an upper limit Bad value has been exceeded The ess than sign means that a lower limit Suspect value has not been reached Two less than signs mean that a lower limit Bad value has been exceeded Select Disable if the limit indicator might confuse a pro gram that is running an SPC or data collection application Select Enable to allow use of the limit indicators Serial Headers At the end of every cycle the cycle data also gets sent out via the serial port The user can send print this data each time the Print soft key is pressed Dukane Manual Part No 403 584 00 NOTE Baud rate settings on both the sending unit iQ generator and the receiving unit computer must be the same for com munication between the devices to work properly Hardware Setup Continued Page 73 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Hardware Setup Continued from Previous Page System Status I O The next group of hardware settings following the Serial Port settings deals with the generator s System Status I O These six selections enable customization of some of the iQ generator s input and
72. atures 4 Pressure 57 Downstroke Pressure 57 Hold Pressure 57 Pressure Profiling 58 Upstroke Pressure 57 Weld Pressure 1 57 Weld Pressure 2 57 Process Characteristics 62 Contact Air Pressure 62 Downstroke Distance 62 Downstroke Time 62 Hold Distance 63 Hold Time 63 Method 1 Distance 62 Method 1 Position 62 Method 1 Weld Energy 62 Method 1 Weld Peak Power 62 Method 1 Weld Time 62 Method 2 Distance 62 263 Method 2 Weld Energy 63 Method 2 Weld Peak Powe 63 Method 2 Weld Time 62 Total Cycle Time 63 Total Stroke Distance 63 Total Weld Distance 63 Total Weld Energy 63 Total Weld Tim 63 Weld Distance 62 Process Limits 60 Alarm Status 63 Bad Limits 64 Date 63 Display Only 64 No Display 64 Part Cycle Data 65 Process Characteristics Defined 62 Process Limits List 83 Setup 63 Show All 65 Show None 65 Suspect Limits 65 Time 63 Continued Page 155 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual P Continued Process Limits Menu Diagram 61 Process Setup 50 Advanced Process Settings 59 Initiate Mode 50 Process Utilities 67 Base Units 70 Choose Setup 68 Setup 69 Date 70 Date Format 70 EraseSetup 70 Language 70 Notes 71 Part Count Settings 70 Setup Control 67 Time 70 Welder Name 67 Programmable Status Output 1 74 Programmable Status Output 2 J3 pin5 75 Q Quick Start Pneumatic Welder Process Settings Initial Weld Time 103 Pressure Initial Weld Force 10
73. avigation Keys System Power Output Level Screen Basics Contents Continued Page v iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Page vi Continued from Previous Page Contents Section 5 43 OVGIVIEW e ss scien e bg RE e de De E c 45 Generator Start up Sequence 45 Stopping the Weld Cycle 46 Using the 47 Section 6 System Operational Testing 93 Section 7 Set up Guidelines and Troubleshooting 99 Section 8 Maintenance 113 Section 9 5 117 Section 10 Contacting Dukane 123 Section 11 Specifications 127 Outline 129 Weights Dimensions Operating Environment 132 AC Power 5 133 Ultrasonic 134 Interpreting the Model Number 135 Regulatory Agency 136 Section 12 Appendices 137 Appendix A List of 5 139 Appendix B List of Tables 143 Appendix C Sequencing 5 144 Appendix D Menu Structure
74. bject before begin ning the lift Begin slowly lifting with your LEGS by straightening them Never twist your body during this step 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 If you must turn while carrying the load turn using your feet not your torso To place the object below the level of your waist fol low the same procedures in reverse order Remember keep your back as vertical as possible and bend at the knees NOTE For equipment weights see Page 132 Table 11 1 in Section 11 Specifications Dukane Manual Part No 403 584 00 Section 3 Installation Installation Before Installation 13 When to Use Lockout Tagout Devices 13 15 Placement 15 Rear Panel Layout Overview 16 AC Power Inlet Panel 17 System I O 17 RFI Grounding PT 25 Connector Descriptions 26 Power 5 28 Cable 5 29 33 Recheck Connections 33 Connect AC 33 Dukane Manual Part No 403 584
75. c Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 34 Dukane Manual Part No 403 584 00 Section 4 Control Panel Control Panel 37 System Operating Mode Keys 38 Navigation 39 System Power Output Level 40 Screen 5 41 Dukane Manual Part No 403 584 00 Page 35 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 36 Dukane Manual Part No 403 584 00 Overview This section introduces the iQ Series ultrasonic generator ES control panel and color display with this information Functions of the panel components shown in Figure 4 below are discussed Some screen basics are introduced Making selections nterpreting onscreen arrows Using the virtual keyboard feature and Taking a look at setup identification Color Display Soft Keys 8 Section 4 Control Panel NOTE Do not touch the display Touch only the System Operating Mode Keys the Navigation Keys and the Soft Keys to the left and right of the display Cleaning If the display is dirty clean it by first putting a mild cleaning solution on a clean soft cloth Then gently wipe the cloth over the screen Navigation Keys 4 Lighted Pow
76. ce power and energy data are kept for each portion of the cycle These measurements also called process characteristics cre ate a process record for each part Records analysis can establish parts limits which then can be used to determine if the current process is in control The iQ generator can report the process characteristics as Bad or Suspect The characteristics can also be displayed or printed without evaluation Limits are set using either statistical methods or physical system constraints Statistical methods can be applied to pre production parts that were evaluated for physical characteristics of quality e g strength appearance Results of this evaluation are correlated to the process characteristics Limits for the characteristics related to part quality are calculated Other limits are determined by the system itself For instance Total Cycle Time limits may be established to end the cycle before an index table moves Downstroke Distance may be set to detect a misload or incomplete assembly Available Process Characteristics The list of available process characteristics is shown in Figure 5 15 the following page This is followed by brief descriptions of each characteristic Page 60 NOTE Of the available process characteristics the ones that apply to a particular part de pend on the current iQ setup for that part Process Limits Continued Dukane Manual Part No 403 584 00 Section 5
77. ch is the most significant bit used to select different welding setups with an automation control system Pin 8 Ultrasound Activation Cycle Start Input Pin 8 is used to activate the generator ultrasound output Activation ofthis control input will switch the ultrasound output ON and deactivating this signal will switch ultra sound OFF This input signal will also function as a cycle start input where the ultrasound activation and timing are completely under the control of the process controller Depending on the welding process controller setup this input signal could be activated momentarily minimum of 50 ms to start a welding cycle Pin 9 Not Used Pin 10 Not Used Pin 11 Press Inhibit for Hand Probes Pin 11 is used to disconnect power applied to a press or thruster if a hand probe is connected to the system input connector for safety considerations The hand probe acti vation switch could unexpectedly start a welding cycle that activates a press or thruster to the down position The hand probe cable connector is wired to apply chassis ground to this pin when it is attached to the system which activates a press inhibit relay that disconnects power from the pneu matic press valves This pin must be left open whenever a press control board is installed Connecting this pin to chassis ground will inhibit press operation Page 20 Pin 12 System Latch Reset Input Pin 12 is used to reset the Any Fault or System Overloa
78. cond part of the sequence is Setup 02 which will process four 2 inserts Segment deals with insert 1 and Segment 2 deals with insert 2 Each segment has four cycles When the cycles are finished the sequence is reset to begin processing another part The figure below gives a graphic representation of what this sequence might look like on an X Y table Setup 01 Cycle 4 Setup 01 Cycle 3 Setup 02 Cycle 2 Setup 02 Cycle 1 Setup 02 Setup 02 Cycle 4 Start Point Stop Point Setup 01 Cycle 1 Setup 01 Cycle 2 Figure C 2 Insertion Sequence Example Continued Dukane Manual Part No 403 584 00 Page 145 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual AppendxC Sequencing Notes Sequence Definition Figure C 3 illustrates that when defining a sequence there are five parts of the definition to consider Sequence Length Choose 1 8 Segments Define Part as Cycle or Sequence Current Cycle Choose 1 8 Current Segment Choose 1 8 Process Cycles for a Given Segment Choose 1 255 Sequence Length 1 8 Segments Cycle or Sequence Current Cycle 1 8 equence Define Sequence Define Part As Sequence Current Segment 1 Current Cycle 1 Current Segment Segment 1Setup 1 Segment 2 Setup 1 Segment 3 Setup 1 Segment 4 Setup 1 Process Cycles for a Given Segment 1 255 Figure C 3 Sequence Definition Page 146 Dukane Manual Part No 403 584 00
79. ct goggles Acoustic Stack Hazard When an acoustic stack trans ducer booster horn and tip is energized by the ultrasound signal it presents a potential hazard Stay clear of an energized stack System E STOP abort Switch Install a system E STOP abort switch at each operator station when ultra sonic plastic assembly equipment is used with automatic material handling equipment in an automated system Foot Switch Do not use a foot switch Using a foot switch in place of the optical touch finger switches oper ate switches violates OSHA regulations Dukane Manual Part No 403 584 00 Section 2 Health and Safety NOTE These recommendations apply to the welding system System in this manual refers to a complete group of components associated with the welding of parts also known as an ultrasonic assembly system A typical iQ Series System consists of the iQ generator a press with thruster switch es controls cables transducer booster horn fixture and iQ Explorer II software SE BEB ee WARNING Any fixture manufactured by a third party must comply with all OSHA and ANSI re quirements All fixtures must be guarded as necessary Dukane Corporation does not assume any responsibility or li ability for fixtures manufactured by the customer or any third party manufacturer mm EE NE EE E EO
80. ctive for the time the ultrasound is at the programmed amplitude setting The output can only be assigned to Amplitude Regulation Status Pin 18 Not Used Pin 19 System Power OK Status Output Pin 19 is a digital active low status output that activates when no fault conditions are detected by any ofthe power fault detection circuits included in the system This output will be an open circuit when any power related fault is detected in the system Pin 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 Page 24 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
81. ctor The IEC AC power inlet connector mounted on the system AC power inlet panel requires a properly configured IEC compliant power cord which enables worldwide system operation by simply changing the power cord Low profile systems are equipped with a 10 amp rated IEC inlet connector The high profile systems include a 16 20 amp rated IEC inlet connector 120 VAC and 3600 4800W systems include a non detachable power cord 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 180V 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 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 O
82. d status outputs See Status Output descriptions If a fault occurs during a weld cycle these outputs will normally remain active until the next weld cycle is initiated Activat ing this input will reset the status output faults and may simplify automation programming NOTE Refer to Latch on Bad Part on Page 50 for more information 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 volt age 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 Dukane Manual Part No 403 584 00 Section 3 Installation zac KP j 2avocPowerGrund Ro Programmable Status Outpt cen Programmable Status Outut2 on Utrasound Active Status Output Any Fault Status Outpt Press Trigger Status oup System Overload Status Output System Onine Status Output ons
83. ding application but there must be at least one connection to this connector in order to activate the ultrasound output J3 System Outputs Connector The SYSTEM OUTPUTS connector includes con nections for all ofthe 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 au tomation controller The user can determine which signals are appropriate for each welding application NOTE For details on integrating the welder with automation refer to Application Note AN507 Automation Interface Guidelines at www dukane com us gt DL AppiData asp Continued Page 26 Dukane Manual Part No 403 584 00 Section 3 Installation Continued from Previous Page J4 Configuration Port Connector The configuration port connector is a DB 9M stan dard D subminiature 9 circuit male typically used for RS 232 serial communications This serial port DTE connects to a serial port DCE on a computer via a standard 9 pin serial cable If the computer does not have a serial port you may use a USB to serial conversion cable This port is used for field updates to the generator Figure 3 12 Configuration Port Connector firmware without removing the enclosure cover This port can also be used with a
84. displaying the date MM DD YYYY DD MM YYYY or YYYY MM DD Time This utility is used to set the time in the 24 hour format Date Entering the current date will be done in the date format already chosen Page 70 Figure 5 32 Preset Part Count Count Bad Parts Clear Bad Part Process Utilities Welder Name Welder2 Setup Control iQ System Copy Setu Part Count Settings Notes Language English Base Units Imperial Date Format MM DD YYYY Time Date Erase Setup Process Utilities Welder Name Welder2 Setup Control iQ System Copy Setup Erase Setup Notes Language English Base Units Imperial Date Format MM DD YYYY Time Date Figure 5 33 Part Count Settings Dukane Manual Part No 403 584 00 Section 5 Operation Process Utilities Continued from Previous Page Notes It is important to document information about your process With the dozen components or fields that make up Notes for one setup a customized record can be invaluable See Figure 5 34 below Program Notes EXAMPLE Why use Notes With a manual press pressure values for P1 and P2 are This utility makes it easy to name or identify each of not part of the Setup file itself the fields using the virtual keyboard However to record those values using the Notes fea The Erase Name option also makes it easy to quick ture will allow for those pressures to be recalled ly remove a name Use the Manua
85. e Menu Diagram Page 66 Hardware Setup Serial Port Output Format LF After CR Output Mode __ Baud Rate Serial Limit Indicators Serial Headers System Status I O Auto Start Input Auto Stop Input Enabled J3 pin 4 H J3 pin 5 Output Duration Restore System I O Defaults Adv Process Settings Buzzer Text Keyboard Test at Power Up Adv Trigger Settings Network Settings Restore Factory Defaults NOTE The list of available Process Utilities and Hardware items depends on Security ac cess level See Table 5 and on system configuration Process Utilities Continued Dukane Manual Part No 403 584 00 Section 5 Operation Process Utilities Continued from Previous Page Process Utilities Overview Process Utilities provides setup management and part track ing tools Notes are included to allow unique names to be given to many setup components Setups and their components can be identified This infor mation can be used to recall setup conditions Figure 5 22 shows that with the exception of Notes there are 10 utilities to consider Review the brief descriptions of these utilities below Welder Name Use the virtual keyboard to give the welde
86. e Setup Part Count Settings Notes Language English Base Units Imperial Date Format MM DD YYYY Time Date Hardware Setup Define Sequence TTT Main Menu ier Figure 5 24 Setup Control Sequencing Chosen SRQUERCS Define Sequence Length Define Part As Sequence Current Segment 1 Current Cycle 1 Segment 1Setup 1 Segment 2 Setup 1 Segment 3 Setup 1 Segment 4 Setup 1 1 1 1 1 uua Figure 5 25 Defining the Sequence Process Utilities Setup Control Continued Page 67 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Utilities Setup Control Continued from Previous Page Choose a Setup Choosing a setup depends on two factors Setup Control and Security Access Setup Control Using Setup Control through the Process Utilities menu the three types of control deal with setup selection in these ways iQ System Press the Select Setup soft key See Figure 5 22 Sequencing Press the Edit Setup soft key See Figure 5 24 Automation Press the Edit Setup soft key See Figure 5 26 After pressing the Select Setup or Edit Setup key a Choose Setup screen like the one shown in Figure 5 27 is displayed Then highlight a setup from the setup number list Next press the Choose Setup soft key to confirm the choice Security Access If Security access has been establi
87. e refer to our website at www dukane com us sales intsales htm to locate your local representative Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Part No 403 584 00 m Printed in the United States of America www dukane com us Dukane Intelligent Assembly Solutions 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949
88. ed by the NOTE DHCP server Network Settings are maintained even after Restore Factory Defaults Network Link This shows the status of the connec tion to a network Are you sure you want to Restore Factory Defaults Linked This displays the speed of the network connection Not Linked Down Restore Factory Defaults Choose Restore Factory Defaults when restoring the generator software to the factory default settings uU NN Figure 5 44 Restore Factory Defaults Before this is allowed however an intermediate screen questioning the action appears See Figure 5 44 NOTE Performing a Restore Factory Defaults can not be reversed Dukane Manual Part No 403 584 00 Page 81 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Operate Screen The Operate screen displays weld cycle data in real time Figure 5 45 shows the main Operate screen Process characteristics listed below the setup name are the ones chosen as process limits to be displayed or programmed Part in the upper left corner of the Operate screen records the running total of processed parts When a minimum of 10 parts have been processed press the soft key next to the total number of parts box The next screen Search Part History appears and allows searches by Part Number Time Date Previous Bad Previous Sus pect and Previous Alarm Part Number History Search by Part Press t
89. enerator 1 Push the generator s AC power switch breaker to the OFF position 2 Unplug the generator s electrical cord from its source 3 Authorized personnel apply a lockout tagout LOTO device to the plug end of the generator s electrical cord Using a typical clam shell type LOTO device 1 Open the clam shell 2 Place the electrical cord plug end inside the shell 3 Close the shell 4 Secure the shell with its lock and lock it 4 Wait a minimum of five minutes for the generator to discharge its electrical energy 5 After taking these steps make the necessary adjustments to the generator Assuming the generator is being put back into service Procedure to use AFTER making any internal adjustments to the generator 1 Authorized personnel remove the lockout tagout device from the plug end of the generator s electrical cord Using a typical clam shell type LOTO device 1 Unlock the protective shell 2 Open the shell exposing the electrical cord end 3 Remove the LOTO device and set it aside 2 Plug the generator s electrical cord into its AC power source 3 Push the generator s AC power switch breaker to the ON position Page 14 Dukane Manual Part No 403 584 00 Section 3 Installation Unpacking Carefully open your shipping container and make sure It contains the items shown on the shipping documents Inspect all items and report any damage immediately Placement Generator placement and
90. enu Diagram Process Limits Continued Dukane Manual Part No 403 584 00 Page 61 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Limits Continued from Previous Page Process Characteristics Defined Downstroke Time This is the time from the start ofthe welding cycle to the trigger point Downstroke Distance Distance Encoder Systems Only This is the distance from the distance encoder reference mark to the trigger point Contact Air Pressure Electronic Pressure Regulator Systems Only This is a measurement of the line pres sure at the trigger point Method 1 Weld Time This is the length of time the ultrasound is applied to the part while Pressure 1 is ap plied to the part Method 1 Distance Distance Encoder Systems Only This is the distance the press travels while the ultrasound signal is applied to the part during the first weld method Method 1 Weld Energy This is the amount of energy drawn from the generator while the ultrasound signal is applied to the part under Pressure 1 Method 1 Weld Peak Power This is the highest in stantaneous power delivered to the transducer during the Pressure 1 portion of the weld cycle Method 1 Position This is the position relative to the reference mark of the mounted distance encoder at the instant of the end of weld method 1 Method 2 Weld Time This is the length of time the ultrasound is applied to the part w
91. er Grounding 9 International Power 9 Lifting the 10 Dukane Manual Part No 403 584 00 Page 5 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 6 Dukane Manual Part No 403 584 00 General Considerations Please observe these health and safety recommenda tions for safe efficient and injury free operation of your equipment Proper Installation Operate system components only after they are properly installed No Unauthorized Modifications Do not modify your system in any way unless authorized to do so by Dukane Corporation Unauthorized modifications could cause equipment damage and or injury to the operator In ad dition unauthorized modifications will void equipment warranty Keep the Cover On Do not remove any equipment cover unless directed to do so by Dukane Corporation The generator produces hazardous electrical voltages which could cause injury Grounded Electrical Power Operate this equipment only with a grounded electrical connection See Electrical Safety for grounding instructions Page 9 Comply with Regulations You may be required to add accessories to bring the system into compliance with applicable regulations OSHA in the USA for machine guarding and noise exposure Use Eye Protection Wear ANSI approved safety impa
92. er Indicator System Operating Mode Keys 3 CANCEL Key Figure 4 1 10 Generator Display and Control Keys Dukane Manual Part No 403 584 00 ENTER Key Page 37 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual System Operating Mode Keys ONLINE After AC power has been activated and the generator is operating normally ONLINE is the normal operating mode The generator can produce ultrasound signals in this mode The display has a WHITE background and the word Online appears in a GREEN box in the lower right corner of the display Main Menu TEST After AC power has been activated and the gen erator is operating normally in the ONLINE mode the TEST key can be pushed Online green Offline yellow or E STOP red Operating Mode Indicator This activates a momentary ultrasound pulse allowing Figure 4 2 Display Detail Operating Mode Indicator the operator to test system function The display will show the real time settings for Amplitude Power and Operating Frequency CAUTION This information is useful in troubleshooting If a transducer is not connected to the ultrasound output con OFFLINE After AC power has been activated and the nector the system should be generator is operating normally the OFFLINE key may set to the OFFLINE mode Do not ac be pressed to put the generator into the offline mode In tivate the ultrasound output without a this mode the
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94. for Heavy Industrial EN 61000 6 4 2001 EN 55011 2003 EN 61000 6 2 2005 61000 4 2 61000 4 3 61000 4 4 61000 4 5 61000 4 6 EN61000 4 8 EN61000 4 11 The Low Voltage Directive 2006 95 EC e Machinery Directive 2006 42 EC EN 60204 2006 Safety of Machinery Electrical Equipment of Machines Part 1 General Requirements IP Rating The iQ generator has an IP International Protection rating from the IEC International Electrotechnical Commission The rating 1s IP2X in compliance with finger safe industry standards Page 136 UL The iQ generator complies with these standards Underwriters Laboratories UL 1012 2010 UL 61010 1 2012 and National Standards of Canada CAN CSA C22 2 No 61010 1 12 2012 as verified by T V Rheinland A TUVRheinland Dukane Manual Part No 403 584 00 Section 12 Appendices Appendices Appendix A List of Figures 139 Appendix B List of 143 Appendix C Sequencing Notes 144 Appendix D Menu Structure Diagrams 147 Dukane Manual Part No 403 584 00 Page 137 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 138 Dukane Manual Part No 403 584 00 Section 12 Appendices Appendix A List of Figures No Description Page 2 1 Example of 220 240 Volt Grounded 3 P
95. ger Position Max Trigger Time Time Weld Time D NOTE Weld Distance Distance See Page 80 for Advanced Weld Position Trigger features not shown _ Primary Max Weld Time p Weld Method 1 Weld Energy here but illustrated in Figure Energy Max Weld Time 5 42 Beare Weld Power ean rower Max Weld Time Single Max Weld Time Enable Scrub Time Ground Detect Scrub Disable Disabled Distance Weld Distance Secondary it Weld Position Weld Method 1 99 9n NOTE Energy Weld Energy Peak Power Weld Power Available weld choices depend Time Weld Time x Weld Distance on Security access level See Distance 3 Max Weld Time Table 5 system configura Weld Position 1 Primary T tion and primary weld method Weld Method 1 LPosition Max Weld Time on and primary weld method Weld Energy Energy Max Weld Time Weld Power Peak Power Max Weld Time Max Weld Time Ground Detect Enable Scrub Time Disable Disabled Distance Weld Distance 7 Position Weld Position eld Metho lt n Energy Weld Energy The Secondary Weld Method ua Peak Power Weld m choices are based on the ri Time Weld Time Weld Distance selection of the Primary Weld Distance Max Weld Time Method Weld Position 5 L Position Wax Weld Time These selections are based on Weld Method 2 Energy Weld Energy the Primary Weld Method being Weld Time Weld Power Distance Peak
96. given pressure Table 7 1 Pounds of Force Comparison between Dukane Air Cylinders Dukane Manual Part No 403 584 00 Section 7 Set up Guidelines and Troubleshooting Page 105 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Troubleshooting The iQ Generator Won t Cycle Just before weld cycle starts the iQ generator waits for an initiating signal If an initiating signal 1s applied and the system does not begin to cycle check the following Make sure the iQ generator s Initiate Mode in the Process Control menu is set to the appropriate setting Manual if using operate switches Auto ifthe system is configured for use with an automated system Remove all inhibiting inputs and check that no Cycle Start error messages are displayed Ensure that cabling is connected properly and that user interface circuitry is operating No Ultrasound To verify that the generator is producing an ultrasonic signal use the acoustic stack test procedure described in Section 6 System Operational Testing Verify on the front panel that the generator 1s in the ONLINE mode Verify pressure settings Review the program There should be a Weld Time P1 and Weld Time P2 if dual pressure is used Set the weld characteristic to Display using the genera tor s front panel Process Limits screen From the Main Menu screen select the Operate Screen key Start the weld cycle and view the re ported weld
97. h situations the Digi Trac circuit compensates for the unique vibrational characteristics of each stack due to differences caused by aging loading temperature changes and differences in horn configurations Dukane Manual Part No 403 584 00 Section 6 System Operational Testing Page 95 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Operational Test of the Acoustic Stack The following test procedure is suggested before starting the generator to verify that the vibrational characteristics of the stack fall within the range of the Digi Trac All Dukane stack components are manufactured to tolerance specifications within this range A non Dukane horn an improperly assembled stack or a stack component that is worn or damaged can result in vibrational char acteristics outside these specifications and will require some adjustment This test reveals the existence of any problems and directs you to corrective action 1 Check the following a Make sure that the correct booster and horn for the application are installed in the thruster b Check the iQ Series system components for proper grounding c Check the ultrasound cable connections on the generator and thruster for proper seating and security d Verify that the horn is not under load not in contact with a fixture or part 2 Push the generator REAR panel AC breaker switch to ON Then the FRONT panel power indicator will flash
98. he Primary Weld _ H Max Weld Time Method _ Weld Position Th ti b d An H Position H e Weld Time ese selections are based on Weld Method 2 Weld Energy the Primary Weld Method being L Energy H Weld Time Power Distance LPeakPower fax Weld Time Max Weld Time 7 Ground Dete U Enable HScrub Time Scrub Disable ri Disabled Secondary H Distance Weld Distance Weld Method 1 Position Weld Position y H Energy Weld Energy Peak Power Weld Power Figure 5 5 Process Setup Menu Diagram 1 of 2 Process Setup Continued Page 48 Dukane Manual Part No 403 584 00 Section 5 Operation Process Setup Continued from Previous Page Process Setup Disabled Time r Hold Time Hold Method Distance Hold Distance Max Hold Time Until Motion Stops Max Hold Time Enabled Afterburst Delay Time Afterburst Duration Afterburst Amplitude Afterburst KG Disabled Weld Amplitude Enabled Pressure 1 Set Profile Pressure 2 Set Profile r Pressure Profiling Disabled Press
99. hile Pressure 2 is on the part Method 2 Distance This is the distance the press travels while the ultrasound signal is applied to the part during the second weld method Weld Distance Distance Encoder Systems Only This is the distance the press travels while the ultrasound signal is applied to the part under pressure Trigger Delay Time The ultrasound signal can be delayed by a specified amount of time after the trigger switch has closed This char acteristic is set in milliseconds Trigger Delay Distance The ultrasound signal can be delayed until the press travels a specific distance beyond the trigger point This characteristic is set in inches Total Weld Distance Distance Encoder Sys tems Only This is available when dual pres sure welding is selected It is the total of P1 and P2 weld distances Total Weld Energy This is available when dual pressure welding is selected It is the total of P1 and P2 weld energies Process Limits Continued Page 62 Dukane Manual Part No 403 584 00 Section 5 Operation Process Limits Continued from Previous Page Method 2 Weld Energy This is the amount of energy drawn from the generator while the ultrasound signal is applied to the part under Pressure 2 Method 2 Weld Peak Power This is the highest in stantaneous power delivered to the transducer during the Pressure 2 portion of the weld cycle Method 2 Distance Distance Encoder Systems Only
100. his soft key to search for a specific part number in the cycle data Pressing the Part soft key displays a search screen after a minimum of 10 parts are in the cycle data Search by Time Press this soft key to search for a part know to have been welded at a specific time in the cycle data Search by Date Press this soft key to search for a specific part welded on a specific date in the cycle data Previous Bad Press this soft key to search for a previously welded bad part in the cycle data Pressing the soft key again will continue searching for the next previously welded bad part Previous Suspect Press this soft key to search for a previously welded suspect part in the cycle data Pressing the soft key again will continue searching for the next previously welded suspect part Previous Alarm Press this soft key to search for a previously part that had an alarm in the cycle data Pressing the soft key again will continue searching for the next previous part that had an alarm Direction Press this soft key to change the direction of the search from previous cycle data parts to next cycle data parts Page 82 Process Total Parts Characteristic Processed Setup Name m q Setup 1 Part Methodi Method 2 Method2 Total Weld Weld Weld Weld Peak Time Energy Power J 5 7 w s unum Figure 5 45 Main Operate Screen Dukane Manual Part No 403 584 00 Current Setup While viewing the O
101. in that segment See Page 67 for more on Setup Page 42 Figure 4 11 Main Menu Detail Setup Identification Dukane Manual Part No 403 584 00 Generator Start up Sequence Stopping the Weld Cycle Using the Menus Process 5 Process Limits Process Utilities Hardware Setup Operate Screen Dukane Manual Part No 403 584 00 Section 5 Operation Operation Page 43 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 44 Dukane Manual Part No 403 584 00 Section 5 Operation Overview NOTE The iQ Series generator model ES is typically part of a system Major system components would be Press acoustic stack and tooling will require their own individual adjustments as those components are integrated into your particular system iQ generator e iQ Explorer II software User Interface HMI or computer user supplied and 10 Press System Helpful information on a wide variety of assembly equipment processes and With this type of system the user controls nearly all aspects techniques can be found at the Dukane of the welding process and has several choices of how best website to accomplish this http www dukane com us PPL_upa htm Control can be done through the color front pa
102. ings above 2400 Watts also have fixed power cords See Table 11 II in Section 11 Specifications Dukane Manual Part No 403 584 00 Section 9 Options NOTE Refer to Section 2 Health and Safety Pages 8 and 9 for information about Elec trical Safety including grounding Page 119 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Data Transfer Board and port locations are shown in Figure 3 4 Ethernet Port J9 J9 is the generator s Ethernet port A cable connects J9 to the HMI Ethernet port RS 232 Port J10 Cycle data can be sent from this serial RS 232 port Typi cally the data is sent to a PC where it can be stored or manipulated to suit the user Probe When using a probe with the generator cycle data can be sent at predetermined intervals Press When using a press with the generator cycle data is sent following each cycle Output Format The Comma Separated Value CSV format is used With this format each characteristic value is output along with an additional part data index unique to a particular characteristic This allows a program to identify each characteristic and store it in an appropriate file regardless of the order in which the characteristic is received Figure 9 1 shows an example of this output format and Table 9 I on the next page gives the Part Data Index num bers and descriptions Page 120 Part Number 417 ownstroke Time 0
103. ir pressure Enter the Weld Pressure 1 value Figure 5 11 Pressure Submenu Diagram Weld Pressure 2 This is the second pressure used during a dual pressure weld cycle In presses with an electronic pressure regulator this setting controls the air pressure Enter the Weld Pressure 2 value Process Setup Pressure Hold Weld Amplitude 100 amount of the Hold portion of the weld Weld Pressure 2 Main Menu 0 0 psi Profilin Setup 1 Pressure g Hold Pressure Enter the pressure for the Hold Disabled rigger Type en otion ops 1 D troke Weld Mode Dual Upstrok portion of the weld cycle Eo Primary Weld Method 1Distance Pressure 1 9 0 psi Secondary Weld Method 1 Disabled 9 0 psi Primary Weld Method 2 Time In presses without an electronic pressure regulator ened Pressure 1 D Ale Help the manual regulator setting controls the air pressure ey 2 Upstroke Pressure This is the pressure for the final part of the weld cycle as the head retracts Enter the Upstroke Pressure Figure 5 12 Pressure Profiling Disabled Process Setup Pressure Continued Dukane Manual Part No 403 584 00 Page 57 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Setup Pressure Continued from Previous Page Pressure Profiling Up to ten different pressures can be programmed to occur during
104. is completed and the welding process control system is ready to start the next welding cycle This output will be an open circuit when the welding process controller determines that the next welding cycle cannot be started This includes system faults or off line active but not a process fault like Overload Pin 23 Suspect Part Status Output Pin 23 is a digital active low status output that activates ei ther momentarily or until the start ofthe 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 Dukane Manual Part No 403 584 00 RFI Grounding The iQ Series generator provides the operating power and power returns Make sure the generator is grounded properly In addition to the safety considerations proper grounding is essential for the effective suppression of RFI Radio Frequency Interference Every generator contains a RFI filter which blocks noise on the AC power line from enter ing the generator control circuitry This filter also prevents ultr
105. ith electronic pressure regulation NOTE Manual Pressure Regulation For systems without electronic pressure regulation pres sure adjustments are made with manual Pressure selections begin with a choice about Pressure Profiling If Enabled Pressure Profiling is explained on 838 regulators on the front of the thruster Pressure Profiling Disabled With Pressure Profiling The weld pressure values 1 and 2 can be disabled there are five pressures to be entered added to the setup using the Notes feature found in the Utilities screen See Figure 5 12 to the right Downstroke Pressure This is the pressure for the first part of the weld cycle as the head begins to travel down towards the part to be welded This is also the pressure responsible for triggering the ultrasound signal When using force more pressure Pressure 1 Set Segments mplish this Enabled may be agen pais Pressure 2 Set Segments Enter the Downstroke Pressure value Pressure Profiling Weld Pressure 1 Pressure Disabled e Weld Pressure 2 Weld Pressure 1 This is the pressure used in single Downstroke Pressure pressure welding and it is also the first of two pres Hold Pressure sures used with dual pressure welding In presses Upsiroke Pressure with an electronic pressure regulator this setting controls the a
106. ivates whenever any fault condition is detected that inhibits ultrasound output and normal system operation This output will be an open circuit when no system fault conditions are detected Generator faults that will activate the Any Fault output Overload Average Peak or Frequency Overtemperature Fault System Power Fault Continued Dukane Manual Part No 403 584 00 Section 3 Installation Continued from Previous Page Pin 8 Press Trigger Status Output Pin 8 is a digital active low status output that activates when the specified trigger type has occurred It will re main active until the thruster head raises to the top of the stroke This output will be an open circuit when a trigger condition hasn t been detected 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 overload a positive peak overload or a negative peak overload condition After the overload status output activates it will remain active until the next ultrasound activation cycle begins and this output will automatically reset This output will be an open circuit when no overload conditions have been detected Pin 10 System On Line Status Output Pin 10 is a digital active low status output that activates when the system is in the ON LINE operating mode which enables the activa
107. kane personnel Unauthorized at tempts to service this product will void any warranty Page 107 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Alarm Messages The following table lists alarms that may appear for the pneumatic systems containing a generator with a color front panel display Q Series or iQ Explorer II software Information on particular alarms may also be obtained on the Dukane Alarm web page Attp www dukane com us DL EasyAlarm asp Continued Page 108 Dukane Manual Part No 403 584 00 Section 7 Set up Guidelines and Troubleshooting Continued from Previous Page eueynqg joejuoo ojeJeueB eu JO uonipuoo e si 3141 104 Y29049 epnyjduue uonoeuuoo Y09949 sseJd ones e uo peeds y 10 559 0 oneuuneud e oj Buraq 9910 eu eonpes poeu1oo 195 ase sBunjes 6 6 sJojeJeuoB O 99 JI 2949 8S00 51 sjueuoduJoo oejs BU JO auo JI Y09949 51 sjueuoduioo 5 eu Jo euo 499u2 poeu1oo 195 sBunjes 6 6 sJojeJeuoB O 99 JI 499u2 8S00 51 sjueuoduJoo oejs BU JO auo JI Y09949 51 sjueuoduioo x9e s eu Jo euo 499u2 eseq pue eJnjxi ejnjxiy pue eui YJOD JO BUODI IS Jo jeeus e se
108. l P1 and Manual P2 Hold fields to record the information Notes become part of the setup so a major benefit is that future setup time will be much shorter when try ing to create the same or similar setup Setup Name Horn Booster Fixture Manual P1 Manual P2 Hold Dynamic Trigger Down Speed Flow Control Mechanical Stop HSC Setting HSC Hydraulic Speed Control HSC Start Position Pre trigger EOW Flags EOW End of Weld Figure 5 34 Notes Process Utilities Continued Dukane Manual Part No 403 584 00 Page 71 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Utilities Continued from Previous Page Hardware Setup Hardware Setup and its submenus can be used before start up or during normal operation Typically Process Utilities have been set before Hard ware Setup is completed Time Date Base Units Setup Control and the other utilities have usually already been established before Hardware Setup is programmed Serial Port The first group of hardware settings deals with the serial port on the generator These selections configure the iQ generator s port to transfer cycle data to a separate com puter See Figure 5 35 Output Format Use the Output Format function to choose one of three keyboard characters as the delimiter Comma Tab Semicolon Most database and
109. le will start P e t Setup Control iQ System The next cycle will not activate until the latch is cleared There are two ways the latch can be cleared dia Parte Enabled Base Units Imperial Date Format Remove the LATCHED Message from the Display Time Bad Part Date 1 Go to the Main Menu 2 Goto Utilities and then to Part Count Settings Figure 5 6 Enable Clear Bad Part 3 Enable Clear Bad Part See Figure 5 6 to the right When these three steps are completed the operator can press the ENTER key to clear the latch or NOTE What is a bad part Bad part limits de fine what is considered to be a bad part If the UPPER limit of a selected character istic is reached during its phase of the weld cycle the weld process is stopped and the part is identified as a bad part Activate the System Latch Reset Input The System Latch Reset Input signal Pin 12 of J2 the System Inputs connector can be activated See Page 20 for information about Pin 12 of the System Inputs J2 connector The pin can be used for latch reset If the LOWER limit of a selected parameter Auto is not reached by the end of its phase of The AUTO mode requires a voltage signal applied to the weld cycle the assembly process is J2 pin 8 The applied voltage level either ground or stopped and the part is identified as a 22VDC must be the opposite of the voltage level bad part applied
110. line COPIED sassis guttis MM SES 38 4 4 Navigation Keys 4 with Enter and 39 4 5 Active Soft Keys Example 1 39 4 6 Active Soft Keys Example 2 Ua EROR UN KU RAN MERGER 39 4 7 System Power Output Level Bar Graph and Overload 40 4 8 dubiae oom N 41 4 9 Arrows Indicate More 41 4 10 eicere 42 4 11 Main Menu Detail Setup 9 42 5 1 Front Panels Lighted Power 45 5 2 Main VR ERREUR O reg Y Ye VR a 45 5 3 Navigating from the Main Menu Administrator Process Engineer Logged In 47 5 4 Navigating from the Main Menu Setup Logged 47 5 5 Process Setup Menu Diagram 2 ttn xao nta barba asi 48 49 Continued Dukane Manual Part No 403 584 00 Page 139 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Appendix A Continued from Previous Page List of Figures No Description Page 5 6 Enable Clear Bad 50 5 7 Trigger DIEGO uc bo
111. mV per Watt 50kHz and higher systems 1 Watt 0 010 VDC 10mV per Watt Examples 20kHz system measures 0 525 VDC on Power Monitor Output 525 Watts 50kHz system measures 0 525 VDC on Power Monitor Output 52 5 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 sig nal is 100 amplitude 10 0 VDC or 0 1 VDC per 1 amplitude This monitor signal output would typically be used when a remote control option board is installed in the system The automation control system will adjust the system s amplitude setting remotely using a 4 20mA current loop attached to the input of the remote control board Using this monitor output the control system can verify that the amplitude is set to the expected programmed amplitude level Continued Page 23 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Continued from Previous Page Pin 17 Programmable Status Output 3 Pin 17 is a digital active low status output that activates when the system is regulating the amplitude level correctly This output becomes an open circuit when the system falls out of regulation When that happens it can not adjust the system output to the output level that was programmed as the regulation set point This signal will be activated at the end of the ramp up time until the beginning of the ramp down time This status signal will be a
112. mation about Frequency Lock Hold refer to our Application Note 505 on the Dukane website at http www dukane com us DL ApplData asp System Frequency Limits Wide In wide mode the upper and lower frequency limits are set to the maximum and minimum allowed frequencies for the generator These values are depen dent on the system frequency of the generator Normal In Normal mode the upper and lower fre quency limits equal the free run frequency 500Hz Narrow In Narrow mode the upper and lower fre quency limits equal the free run frequency 200Hz Manual In Manual mode the user sets the upper and lower frequency limits To be valid the settings must be within the maximum and minimum values for the generator and at least 25Hz greater than the upper free run frequency and 25Hz less than lower free run frequency Dukane Manual Part No 403 584 00 NOTE Why System Frequency Limits Modes Might be Chosen Wide This mode is primarily used for testing bare transducers no booster or horn attached Normal This mode is the one most often used covering a wide variety of horns Narrow This mode is used when the acoustic stack has known unwanted fre quencies that are close to the main oper ating frequency Manual This mode allows for a fre quency range to include only frequencies that are wanted and excluding unwanted frequencies Hardware Setup Continued Page 77 iQ Series Ultrasonic Generat
113. mezijeniuir O pejoejeq jeuBis pjeM Jo pu3 pepeeo X3 Je58u XEN XEN Wed uMopinus 0197 01195 XEN 0197 01195 PIIM 0197 01195 SOUEISIG 0197 01195 097 JOS 0197 01195 SUL uoneJedo sno nunuoo syw pleA JON 559 10 JojeJeuec JO Wes pessald Z YMS ejejedo Wes eq YAMS ejejedo oorn coen LOEN ooen abesse uey ep0 uuely Continued Table 7 1 Alarm Message Screens Page of 3 Page 111 Dukane Manual Part No 403 584 00 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 112 Dukane Manual Part No 403 584 00 Section 8 Maintenance Maintenance Dukane Manual Part No 403 584 00 Page 113 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 114 Dukane Manual Part No 403 584 00 Front and Rear Panels Cleaning Do not use any solvents or abrasive cleaners to clean any of the panels Donotspray or apply cle
114. n the internal components 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 limit is based on the actual true RMS power output level Process Limits include distance time only time and energy and peak power These programmable limits provide the means to adapt to a wide variety of weld ing applications Rear Panel Expansion Slot is available to allow for custom configurations for OEM and cost effective so lutions RS 232 Serial Configuration Port is used for field software upgrades troubleshooting and advanced hardware setup with optional PC based configurator 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 as sures you of manufacturing excellence TUV Certification T V Rheinland certifies Du kane products comply with applicable UL Under writers Laboratories and CSA Canadian Standards Association requirements Dukane Manual Part No 403 584 00 Section 2 Health and Safety Health and Safety General Considerations 7 Plastics Health 8 Electrical Safety 8 Domestic Pow
115. nal AC line voltage and the rated power level Page 133 Dukane Manual Part No 403 584 00 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Ultrasonic Pressure Ultrasonic Pressure iQ Generator Models kHz Useful Beam 360 degrees Ultrasonic Pressure Operator s Position dB Ultrasonic Pressure 1 m from the Equipment dB Table 11 IV 10 Generator Ultrasonic Pressure NOTE All measurements taken with Data Physics Dynamic 4 Channel Signal Analyzer with calibrated 377C01 Microphone and 426B02 Preamplifier Page 134 Dukane Manual Part No 403 584 00 Section 11 Specifications Interpreting the Model Number Nominal U S Frequency HS Horizontal Bench Chassis iQ Generator Model Number Codes 2 0 5 24 0 2 P6 Power Level System Process Controls 480 4800 Watts Press System 360 3600 Watts Q ES Graphics Color LCD w Press Card 240 2400 Watts K ES Graphics Color LDC Probe 180 1800 Watts w o Press Card 120 1200 Watts Both Generator Models Support the iQ Explorer II 060 600 Watts Safire 090 900 Watts 024 240 Watts 018 180 Watts 012 120 Watts 15 15kHz 20 20kHz 30 30kHz 40 40kHz 50 50kHz 70 70 kHz Chassis Style Line Input Options Slot 1 2 200 240V for 5 25 Tall chassis ES Se
116. nd 2 80 5 43 Network SUNOS mee 81 5 44 Restore Factory Defaults 2 T aiina 81 5 45 Main Operate SCree N DEES 82 5 46 Current Setup 83 5 47 AProcess Limits BIN PH 83 5 48 Real Time emmnmmnnnernnnnn nennen nene seen nne EEE senes 83 5 49 GAP SCLSS C ER 84 5 50 Graph Axis Setup Screen 84 5 51 Start Graph at Setup onini Dec roa ca o sth tha cena aat da e utu v RUN DU 84 5 52 End e EE Re RE NER RR e E KR 84 5 53 Example Graph Following 5 ues cotta chm Mutui 85 5 54 Locating Help on the Main 86 5 55 Help Screen eem ennemis 86 5 56 Security Screen No Passwords 87 5 57 Password Screen Administrator Password Selected 88 5 58 Virtual Keyboard 88 5 59 Security Screen Currently Logged Qut eese nhe nnn 88 5 60 Security Screen Administrator Access Enabled 88 5 61 Security Screen Passwords Enabled sse 89 5 62 Securi
117. nel of the See Downloads for these User s Manuals iQ Explorer Part No 403 585 00 iQ Press System ES Part No 403 569 00 iQ ES generator System control can also be done with the User Interface HMI or a computer user supplied using iQ Explorer Generator Start up Sequence 1 Press the rear panel AC breaker switch to OFF 2 The front panel lighted power indicator flashes during the start up sequence then turns a steady GREEN See Figure 5 1 when the generator is activated 3 After the generator is activated the LCD displays an Lighted Power Indicator image that identifies the Dukane iQ Series type The sequence ends when the Main Menu screen is displayed as shown in Figure 5 2 Figure 5 1 Front Panel s Lighted Power Indicator 1 Process Setup Operate Screen 1 Process Limits Graph Utilities Hardware Help u 1 Current Setup Security Figure 5 2 Main Menu Screen Dukane Manual Part No 403 584 00 Page 45 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Stopping the Weld Cycle Normal Conditions The cycle stops when the programmed welding cycle ends or when the rear panel s Cycle Stop input is activated NOTE Emergency Conditions Automated System External Controls Customer supplied external controls pro Push the power switch on the generator s rear panel to
118. nerator AC Power Requirements 133 11 IV iQ Generator Ultrasonic 134 Dukane Manual Part No 403 584 00 Page 143 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Appendix C Sequencing Notes Sequencing is typically used for operations where parts must be staked or inserted and need more than one processing step or more than one set of process parameters To use the sequencing feature the operations performed on NOTE a part must be grouped according to a setup number Once the setup parameters have been established for each group See Page 67 Process determine the order in which the groups are to be processed Utilities Setup Control This order of operations determines the order ofthe segments in the sequence definition See Sequence Definition Page 146 The figure below gives a graphic representation of a se quence The figure shows that a sequence is a process having from 1 to 8 seg ments and each of those segments has from 1 to 255 cycles Sequence Figure C 1 What is a Sequence Continued Page 144 Dukane Manual Part No 403 584 00 Section 12 Appendices Appendix C Sequencing Notes In this example a sequence to be used in an insert ap plication has two segments The first part of the sequence is known as Setup 01 which will process four 1 inserts The se
119. nes Temperature 40 F to 100 F 5 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 for deactivated equipment Temperature 4 F to 158 F 20 C to 70 C Air Particulates Keep the equipment dry Minimize exposure to moisture dust dirt smoke and mold Humidity 5 to 95 Non condensing 0 C to 30 C Page 132 Dukane Manual Part No 403 584 00 Section 11 Specifications AC Power Requirements Generator The AC line voltage and current needed depend on whichever generator has been chosen for your system See the table below 4 beri Input AC Power Requirements North America Output Output en id NE E Ratings Nominal AC Volt Japan Voltage Current Watts Maximum RMS Current AC Outlet Rating Max Max 15kHz 15HS360 2Q XX XX 3600 200 240V 50 60 Hz 25 Amps 1400 VAC 5A 15kHz 15HS480 2Q XX XX 4800 200 240V 50 60 Hz 30 Amps PUE Nominal Nominal 20kHz 20HS060 1Q XX XX 600 100 120V 50 60 Hz 8 Amps 20kHz 20HS060 2Q XX XX 600 200 240V 50 60 Hz 5 Amps 20kHz 20HS090 1Q XX XX 900 100 120V 50 60 Hz 15 Amps 20kHz 20HS090 2Q XX XX 900 200 240V 50 60 Hz 8 Amps 20kHz 20HS120 1Q XX XX 1200 100 120V 50 60 Hz 15 Amps 700 1300 VAC 1 5 3A 20kHz 20HS120 2Q XX XX 1200 200 240V 50 60
120. no n acces 51 5 8 Weld Mode Submenu Diagram iui 53 5 9 Hold Method Submenu NAGAI rt 55 5 10 Afterburst Submenu UR ME 56 5 11 Pressure Submeni qa din 57 5 12 Pressure Profiling Disabled nop 57 5 13 Pressure Profiling A coE 58 5 14 Pressure Set Profile 1 58 5 15 Process Limits Men Diagtaii Pega dna 61 5 16 Process Limits Alarm Status 63 5 17 Process Limits CHOC esset eder eed rb a n e aad 64 5 18 Process Limits Display rus a 64 5 19 Process Limits Bad 64 5 20 Process Limits Suspect Limits 65 5 21 Utiliaes Mardware Menu 2 22 oerte ntn nnt au nn ha eines 66 5 22 rH M M 67 5 23 Setup Control Select a Method 67 5 24 Setup Control Sequencing Chosen sse 67 5 25 Defining the SegaeriDe succo stus
121. ns These six selections provide further customization of the iQ generator Figure 5 38 diagrams these selections Advanced Process Settings Enabling Advanced Process Settings allows for ad justment of several advanced process settings within the Process Setup menu Brief descriptions of these settings are given below Free Run Frequency and Scan Stack Frequency Tracking Frequency Lock and Hold System Frequency Limits Ramp Up and Ramp Down Free Run Frequency Free run is the frequency at which the generator drives the ultrasound output pulses until the actual operating frequency is detected Typically this value should be 50 100 Hz below the operating fre quency of the stack Scan Stack With Advanced Process Settings en abled Run the scan Return to the Main Menu Select the Process Setup soft key to display the Process Setup screen Scroll to Adv Process Settings in the list and select the Adv Process Settings soft key Scroll to Free Run Frequency in the displayed list and select the Scan Stack soft key Follow the displayed instructions For more detail on the Scan Stack feature please refer to our website to download Application Note 512 at http www dukane com us DL ApplData asp Page 76 Hardware Setup Serial Port System Status I O Adv Process Settings Buzzer Text Keyboard Test at Power Up Adv Trigger Settings
122. nues until the control parameter Energy Max Weld Time 5 gt ps Weld Power Time Distance Position Energy or Peak Power Peak Power Max Weld Time specified under the Weld Method submenu is reached Disabled Distance Weld Distance Secondary Position Weld Position Weld Meinod 1 Energy Weld Energy Peak Power Weld Power Dual 6 Time Weld Time 5 Weld Distance When Dual Pressure is chosen two separate pressures Distance Weld Time 5 Weld Positi are applied to the part Primary Weld Method 1 Position a rimary Se Se and Primary Weld Method 2 while the ultrasound Weld Method 2 Ecc ern dE ax ime signal is on When the control parameter is reached Weld Power Max Weld Time for P1 the pressure changes to Pressure 2 The weld Max WeldTime Te 5 Ground Detect Scrub continues until the control parameter for P2 is reached Disable Isable or a process characteristic moves outside its process ENT Diane Weld Distance limits Control parameter limits set for the parameters Weld Method 1 Position Weld Position are specific to each pressure Energy Weld Energy Peak Power Weld Power Figure 5 8 Weld Mode Submenu Diagram Program Notes After selecting the appropriate weld mode the op erator enters data where the weld mode calls for it Figure 5 8 illustrates the weld mode submenu structure Process Setup Weld Mode Continued Dukane Manual Part N
123. o 403 584 00 Page 53 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Setup Weld Mode Continued from Previous Page Control Parameters Single and Dual Pressure Welding Time Welding by time means that the generator applies the ultra sound signal for a user specified period The range is from 0 to 99 999 seconds with a 001 second increment Distance For Systems with Distance Encoder Only Welding by distance means that the generator applies the ultrasound signal until the press travels a user defined dis tance from the trigger point The range is from 0 to 7 0000 inches 0 to 177 800 mm with a 0 0001 inch 0 001 mm increment Position For Systems with Distance Encoder Only Welding by position means the generator turns off the ultra sound signal after the horn travels a user defined distance from the distance encoder reference mark This is inde pendent of when the horn touches the part to be welded Position terminates the ultrasound signal at the specified programmed distance Energy With Energy as the selected weld control parameter the system welds until the generator delivers a specified level of energy to the transducer while the horn is in contact with the part Energy measured in joules has a range of 0 to 100000 0 and has a 0 1 joule resolution Peak Power With Peak Power as the selected weld control parameter the system welds until the generator delivers a
124. on is not stored in memory Soft Keys Bordering the Display 8 Use the eight keys that border the display to make selec tions from the choices shown on the display Not all keys will be active on any given screen Example I For the display shown on the right three of the eight soft keys are active Administrator Password Erase and Done Example 2 At times the soft keys act like navigation keys to help move from screen to screen In the example shown to the right the two keys nearest the arrow on either side of the display will respond to an operator s touch The arrows indicate more information is available either left or right In the example shown in the figure to the right pressing the active soft key s will display more real time data If the lower active keys are pressed they will display the Operate screen left or the Main Menu right Dukane Manual Part No 403 584 00 Section 4 Control Panel Navigation Key 4 Welder Name Setup Control iQ Syst Copy Setup Erase Setup Press one of the navigation keys to Enable the func tion Bad Parts Enabled Notes Language English Base Units Imperial Date Format MM DD Y Clear Time Bad Part Date Disabled Press again to Disable the func tion once more Figure 4 4 Navigation Keys 4 with Enter and Cancel Active Key Administrator Security Screen 08 01 2011 02 41 Password y Administrator Access Admin Setup P
125. onfiguration Unique IP Address and Connection to Local Area Network Recheck Connections Recheck all cabling connections for the e iQ ES Generator Press Thruster Connections to Local Area Network Connect AC Power When all cabling connections have been made and they have been systematically rechecked connect AC line power to your system Dukane Manual Part No 403 584 00 Section 3 Installation WARNING Any modifications to the Activation Switch also known as the Operate Switch circuit must comply with all OSHA and ANSI requirements Compliance with all local building and electrical codes is also required Dukane Corporation does not as sume any responsibility or liability for circuitry modifications made by the customer or by any third party manufacturer Am NE EN ENS ES ee WARNING Any modifications to the Emergency Stop Switch also known as the E STOP or Abort Switch circuit must comply with all OSHA and ANSI requirements Compliance with all local building and electrical codes is also required Dukane Corporation does not assume any responsibility or liability for circuit ry modifications made by the customer or by any third party manufacturer Am EE EE 33 iQ Series Ultrasoni
126. ons Diagram Continued Dukane Manual Part No 403 584 00 Page 31 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Continued from Previous Page Pneumatic Press Thruster INXX L8 1 002 WXX 08 L 00 X 754002 L 2551 002 YOL OWA 092 291 002 YOL OWA dic 2791 002 SN VOL OWA 191 006 iid epul WSL OWA 291 002 edoun3 OWA OFZ 1111 00 SN WSL OWA OFZ OLLL 00Z y JO SUE OWA 021 929 002 epul VOL OWA 7291 002 OV vc edoun3 VOL OWA OFZ 791 008 SN VOL OWA OFZ 51 002 jo euo ijw3di3 e x KES sr sea __ XX Z9 627 002 5 seg 5 ie Suonoeuuo5 ch Ob 2 S ON Continued Table 3 IV iQ Generator and Pneumatic Press Thruster Cables Dukane Manual Part No 403 584 00 Page 32 Networking Where several welders are connected please refer to the iQ Explorer User s Manual 403 585 00 Refer to the Section on networking Among other things there is information about connection through Simple Stand alone C
127. or Power Supply Pneumatic Systems ES User s Manual Hardware Setup Continued from Previous Page Ramp Up Time Although the Ramp Up time is fac tory set it is variable and can be adjusted to account for starting characteristics of a particular stack The Ramp Up setting depends on the generator load at the start of a cycle The Ramp Up time increases the amplitude inearly in the programmed time period at the start of the weld from zero to the programmed amplitude level The stack is brought up to the operating amplitude smoothly with out shock stress Ramp Down Time Although the Ramp Down time is factory set it is variable and can be adjusted to ac count for characteristics of a particular stack Ramp Down Time decreases the amplitude linearly to zero in the programmed time period following the end of the weld when ultrasound is shutting off The stack is brought down from its weld amplitude reducing shock stress Restore Advance Process Defaults Enable this feature by pressing the Restore Defaults soft key A screen appears with the question Are you sure you want to Restore Advance Process Defaults Select YES to restore all of the advanced process set tings to their factory defaults NOTE Ramp Down Time Ramp Down Time extends the service life of complex acoustic stacks by minimizing stresses encountered during the process of shutting off the ultrasound It is espe cially recommended for ve
128. otal Weld Total Weld Setup Time Distance s in Current Setup Page 1 Setup 1 Downstroke Pressure suspect limits ON 4 limits ON Only Onine Figure 5 47 Process Limits List Section 5 Operation 9 0 psi Page2 Bad Limits m ORR Back BEBE Figure 5 48 Real Time Data Page 83 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Graph The generator is factory programmed to provide graphs with amplitude and power as the vertical axes Figure 5 49 shows the graph screen Graph Setup Figure 5 50 shows the graph setup screen used when se lecting parameters for the two vertical axes of the graph The horizontal axis represents time Select from these parameters Amplitude Power Frequency Energy Distance Speed Pressure Force 1 Red Axis Press one active soft key representing the parameter for the vertical red axis This axis is on the left side of the graph 2 Blue Axis Press one active soft key representing the parameter for the vertical blue axis This axis is on the right side of the graph Figure 5 51 shows the graph setup screen used to choose a starting point for the graph 3 Choose one of the active soft keys representing the event that starts the graphing procedure The events are Cycle Start Trigger or Weld Start Figure 5 52 shows the graph setu
129. output is activated BAD is displayed in the part cycle data Page 64 Figure 5 17 Process Limits No Choice Suspect Process Limits Limits OFF Downstroke Time Downstroke Distance Contact Air Pressure Method 1 Weld Time Method 1 Weld Distance Display Method 1 Weld Peak Power Method 1 Weld End Position Method 2 Weld Time Method 2 Weld Distance ls 2 Weld Energy Method 2 Weld Peak Power Show AI suspect limits ON Wead limits ON Blpispiay Only Process Limits Method 2 Weld End Position Total Weld Time Total Weld Energy Hold Time Hold Distance Total Cycle Time Total Stroke Distance Total Weld Distance Alarm Status Time Date suspect limits ON Wead limits ON Blpispiay Only Display Onl Bad Limits m OFF Figure 5 18 Process Limits Display Only Suspect Process Limits Limits or 779 Downstroke Distance Contact Air Pressure Method 1 Weld Time Method 1 Weld Distance Method 1 Weld Energy Method 1 Weld Peak Power Method 1 Weld End Position Method 2 Weld Time Method 2 Weld Distance l Method 2 Weld Energy Method 2 Weld Peak Power suspect limits ON Wead limits ON Only Bad Limits ONT Low Limits 0 0005 High Limits Figure 5 19 Process Limits Bad Limits Process Limits Continued Dukane Manual Part No 403 584 00 Section 5 Operation Process Limits Continued from Previous Page
130. output signals Figure 5 36 shows these functions Auto Start Input Use the Auto Start Input function to choose one of two types of input that can originate the Auto Start signal Solid State or Mechanical Choosing Mechanical presents another choice That is Switch Debounce Time choose 5ms 10ms or 25ms Switch debounce time is typically used when using a relay to activate the Auto Start input Auto Stop Input Enabled This function can be disabled or enabled The default set ting is Enabled and set to End of Cycle When the Auto Stop Input is enabled the operator se lects either End of Weld or End of Cycle End of Weld When Auto Stop is set to End of Weld the auto stop input signal terminates the weld but not the complete weld cycle If hold is enabled it begins at the trigger of this signal End of Cycle When Auto Stop is set to End of Cycle the auto stop input signal terminates the complete weld cycle hold is not executed even if enabled Programmable Status Output 1 J3 pin 4 J3 represents the generator s output connector and Pin 4 is programmable It can be programmed to provide E Stop Status or Overtemp Status The default setting is E Stop Page 74 Hardware Setup Serial Port System Status I O Auto Start Input Auto Stop Input Enabled J3 pin 4 J3 pin 5 J3 pin 17 Output Duration Restore System I O Defaults
131. p screen used to select the end point for the graph 4 Choose one of the active soft keys representing one of two events that after they have finished the graphing procedure will come to an end The events are Weld End Hold End NOTE As the graph is being designed with these setup screens press ENTER to display the graph Amplitude Start graph at Cycle Start End graph after Hold End Graph Setup Blue Axis Power Start graph at Cycle Start End graph after Weld End Graph Setup Red Axis Amplitude Blue Axis Power g Trigger _ End graph after Hold End Press EHTER to display graph Figure 5 51 Start Graph at Setup Graph Setup Red Axis Amplitude Blue Axis Power Start graph at Cycle Start augu Press EHTER to display graph Figure 5 52 End Graph at Setup Continued Page 84 Dukane Manual Part No 403 584 00 Section 5 Operation Graph Continued from Previous Page Completed Graph The figure below shows a completed graph This particular image resulted after pressing the TEST key See Figure 5 53 below Red Vertical Axis Blue Vertical Axis Horizontal Axis Power Time Frequency 250 500 1750 1000 Power Start graph at Test Frequency End graph after Test LIT Figure 5 53 Example Graph Following Test Dukane Manual Part No 403 584 00 Page 85 iQ Series Ultrasonic Generator Power Supply Pneumatic Sy
132. perate screen or from the Main Menu press the soft key next to Current Setup and a view similar to the one shown in Figure 5 46 will appear This is usually a multiple page display list of the main parameters that were set for the current setup Process Limits Press the soft key next to Process Limits and the process limits list similar to the one shown in Figure 5 47 1s dis played Adjustments to the list of process characteristics can be made easily Press Back when finished making adjustments to the list of process characteristics and once again the main Operate screen will be shown Real Time Data See Figure 5 48 Press the soft key next to Real Time Data and the display changes to show press characteristics for the current setup and weld cycle The possible characteristics are Pressure Force Dis tance Power and Frequency Characteristics displayed depend on system configuration Dukane Manual Part No 403 584 00 Weld Amplitude Weld Method 1 Collapse Dist 9 0000 in Weld Pressure 1 0 0 psi Weld Pressure 2 0 0 psi errr Figure 5 46 Current Setup Suspect Process Limits Limits a Display Downstroke Time Downstroke Distance Contact Pressure Method 1 Weld Time Method 1 Collapse Dist Method 1 Weld Peak Power Method 1 Absolute Dist Method 2 Weld Time Method 2 Collapse Dist ls 2 Weld Energy Method 2 Weld Peak Power Show an Part T
133. perating amplitude smoothly minimizing start up surges and undue stress to stack and generator This circuitry also allows decreases to amplitude as the weld cycle ends The stack is brought down from its maximum operating amplitude smooth ly reducing shock stress Digi Trac Tuning tracks the resonant frequency of the acoustic stack horn booster and 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 Page 4 Line Voltage Regulation automatically maintains constant amplitude regardless of line voltage devia tion The available output power is maintained with any voltage input within the specified range This provides consistent system performance regardless of line voltage fluctuations It also eliminates the need for bulky external constant voltage transformers Load Regulation provides constant ultrasound am plitude automatically regardless of power draw The ultrasonic output amplitude level is held to within 1 to provide weld process consistency and reduced weld cycle times Wide Line Voltage Operation means that standard systems will operate worldwide within their standard AC voltage ranges Flow Through Cooling Tunnel with a matched high performance heatsink and thermostatically controlled fan reduces thermal gradients and increases compo nent life AC Power Inrush protection reduces electrical stress o
134. puts Connector 21 System Outputs Connector Pinout 22 System Outputs Signal Descriptions 22 System Power Output 96 System Status I O 74 Auto Start Input 74 Auto Stop Input Enabled 74 Output Duration 75 Programmable Status Output 1 J3 pin 4 74 Programmable Status Output 2 J3 pin 5 75 Restore System I O Defaults 75 Dukane Manual Part No 403 584 00 T Test at Power Up 79 Testing Acoustic Stack 96 System Power Output 96 TEST Key 96 Text Keyboard 79 Troubleshooting 99 7106 Alarm Messages 108 iQ Generator Won t Cycle 106 107 No Ultrasound 106 The iQ Generator Won t Cycle 106 The Power up Sequence Stops 107 U User Information 3 Drawings and Tables 3 Notes Cautions and Warnings 3 Read this Manual First 3 Using the Menus 47 Utilities Hardware Menu Diagram 66 W Weld Amplitude 56 Distance 54 262 Energy 62 Initial Weld Force 104 Initial Weld Time 103 Max Weld Time 54 Method 53 Dual 53 Single 53 Mode 53 Peak Power 62 Pressure 57 Time 62 Total Cycle Time 63 Total Weld Distance 63 Total Weld Time 63 Trigger Force 102 Welder Name 67 Dukane Manual Part No 403 584 00 Index Page 157 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 158 Dukane Manual Part No 403 584 00 50 ISO CERTIFICATION Dukane chose to become ISO 9001 certified in order to demonstrate to our customers our continuing commitment to being a
135. r horn The vibration amplitude of the horn and booster and the mass of the horn determine the amount of power needed to vibrate the stack e Ifthe system passes the tests of these four steps proceed to Cycling the System on the next page e If one or more of these tests have failed go to the next step Turn the generator OFF Check the stack for proper as sembly damaged components or dirty mating surfaces Recheck the ultrasound cable for proper connections Repeat Steps 1 through 4 If the test still fails go to the next step Dukane Manual Part No 403 584 00 Amplitude 100 96 Power 62 9 W Frequency 19990 Hz Figure 6 2 TEST Screen Display 250 500 750 hooo Power Start graph at Test Frequency End graph after Test 1 Graph Setup monu Figure 6 3 TEST Graph Display NEN NOTE Note the Frequency and Power values in the graph above If using iQ Explorer IT software to control the process you have the option of sav ing the test data for future reference Continued Page 97 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Continued from Previous Page Acoustic Stack Test 6 Turn the generator OFF remove the stack from the thruster and remove the horn from the stack Reinstall the transducer booster assembly in the thruster and turn the generator ON Repeat Steps 2 through 4 Ifthe assembly pa
136. r its own iden tification Setup Control Setup Control defines where control for setup originates with the iQ System with Automation or with Sequenc ing Select a Method of Control When the soft key Change Method is pressed an image like the one shown in Figure 5 23 appears Choose from three methods that define where control for a particular setup originates iQ System Control originates through the iQ generator and its program Sequencing Control originates through the sequence definition as programmed through the iQ generator See more on Sequencing in Appendix C Automation Control originates with equipment external to but in communication with the iQ generator If Sequencing is selected then the screen shown in Figure 5 25 appears Typically Define Sequence would be chosen Defining the sequence involves entering the information suggested by Figure 5 25 Sequence Length etc For more on Sequencing go to Appendix C Dukane Manual Part No 403 584 00 Process Utilities Change Method Welder Name Select Setup Copy Setup Erase Setup Part Count Settings Notes Language English Base Units Imperial Date Format MM DD YYYY Hardware Setup Time Date Figure 5 22 Setup Control Setup Control System Sequencing Automation Figure 5 23 Setup Control Select a Method Process Utilities Change Method Welder Name Copy Setup Eras
137. rasonic assembly system the ultrasound signal from the generator must match the frequency vibrational characteristics of the stack that is being driven Each stack has unique vibra tional characteristics dependent on the combination of stack components In addition the characteristics of a particular stack may vary slightly during operation because of temperature and loading factors To match the generator output signal with the character istics of a particular stack the generator output frequency is adjusted by Dukane s patented phase locked loop Digi Trac pulse width modulation circuitry The Digi Trac feature automatically adjusts the ultrasound signal to match the vibrational characteristics of the stack being driven When the ultrasound turns on during each operating sequence the Digi Trac circuit monitors the motion of the stack on a frequency cycle by cycle basis and adjusts the ultrasound signal for the optimum setting Because the Digi Trac continuously monitors each oper ating sequence it compensates for vibrational changes that occur during repeated operations due to heating of the stack components It also compensates for changes that occur over longer time periods due to aging of the piezoelectric crystals in the transducer or possible wear of the ultrasonic horn The Digi Trac feature excels in environments hostile to reliable operation such as high duty cycles or high stress and continuous duty applications In suc
138. ration Maintained Restore System 1 0 Defaults Adv Process Settings Disabled of Stroke Buzzer at Trigger Buzzer Enabled Disabiea Text Keyboard Enabled Adv Trigger Settings Disabled Network Settings System Restore Figure 5 40 Buzzer Enabled Figure 5 41 Test at Power Up Hardware Setup Continued Page 79 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Hardware Setup Continued from Previous Page Advanced Trigger Settings When Advanced Trigger Settings are enabled basic trigger settings are enhanced For example in the Process Setup menu when Force is the Trigger Type Sensing Start Position is added to refine the Force selection See the figure below where basic and advanced trigger functions are illustrated Maintained Max Trigger Time Momentary 7 Max Trigger Time Trigger Type Enabled Not a choice if Pre trigger is Enabled Enabled Force at Trigger Max Trigger Time When Motion Stops Max Trigger Time Key to Trigger Function Basic Trigger Function Not a choice if Pre trigger is Enabled Not a choice if Pre trigger is Enabled Enabled Not a choice if Pre trigger is Enabled Power Trigger Power Max Trigger Time Start Amplitude
139. rds have been enabled as described above generator menu access is controlled For each person assigned a password please use the four steps detailed below for the login logout procedure 1 Press the soft key for Security The Security Screen appears as shown in Figure 5 63 The previous user has logged out 2 Any of the three passwords Setup Process Eng or Admin that were already enabled can be entered In this case the Setup password will be entered and the screen then will resemble what is shown in Figure 5 64 The Security Screen indicates that Setup Eng controls access to the generator 3 Press Done to continue working with the available menus Available menus for Setup Eng are Select Setup Operate Screen Graph Help and Security 4 When finished working with the generator press Security to getto the Security Screen again Then press the soft key next to Logout to quit 5 Finally press Done so that the main menu screen is displayed when the session is complete Page 90 NOTE When using the Security feature only one person can be logged in at a time Each login session must end with a logout Login Security Screen 06 01 2013 13 31 Password Figure 5 63 Security Screen Logged Out Security Screen 06 01 2013 13 31 Password Setup Password Enabled Figure 5 64 Security Screen Setup is Logged In NOTE Refer to Table 5 1 for a guide to the levels of access that a
140. re possible when using the Security function Continued Dukane Manual Part No 403 584 00 Section 5 Operation Security Continued from Previous Page Other Security Prompts With login passwords in use the levels of access to the generator are established Security prompts like the samples seen in Figures 5 65 and 5 66 to the right are displayed when access to menu features has been limited Figure 5 65 Security Prompt for Process Engineer Forgotten Password Access Contact Dukane if the password has been forgotten See Section 10 Contacting Dukane 3 Figure 5 66 Security Prompt Setup Access Dukane Manual Part No 403 584 00 Page 91 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 92 Dukane Manual Part No 403 584 00 Section 6 System Operational Testing System Operational Testing e ds 95 Operational Test of the Acoustic Stack 96 Cycling the 98 Dukane Manual Part No 403 584 00 Page 93 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 94 Dukane Manual Part No 403 584 00 Overview An iQ Series generator must be operating and connected to the press thruster in order to test the system For efficient operation of a Dukane ult
141. ries Options 1800W and 2400 W only P4 Press Interface Board 2 200 240V for 3 5 Short chassis P5 Press Interface Board w Distance 1200W and below P6 Press Interface Board w Distance amp 1 100 120V for 5 25 Tall chassis Press Options 1200W and below fixed power cord Example System Number shown above 20HS240 2Q P6 System Assembly Detailed Description 20kHz 2400 Watt Bench System in a 5 25 Tall chassis that operates on a 200 240V AC Line for a Pneumatic thruster and a Color LCD System power cord if needed is listed as a separate line item on the sales order matching user s AC line power outlet configuration Figure 11 4 Interpreting the Model Number Page 135 Dukane Manual Part No 403 584 00 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Regulatory Agency Compliance FCC The generator complies with the following Federal Com munications Commission regulations The limits for FCC measurement procedure MP 5 Methods of Measurement of Radio Noise Emissions from ISM Equipment pursuant to FCC Title 47 Part 18 for Ultrasonic Equipment CE Marking This mark on your equipment certifies that it meets the requirements of the EU European Union concerning interference causing equipment regulations CE stands for Conformit Europe ne European Conformity The equipment complies with the following CE requirements The EMC Directive 2004 108 EC
142. rigger Time Momentary Max Trigger Time Force Force at Trigger Max Trigger Time Trigger Type When Motion Stops H Max Trigger Time Power Trigger Power Max Trigger Time Start Amplitude Position Trigger Position Max Trigger Time i i NOTE See NOTE Weld Distance Distance Wald Time See Page 80 for Advanced Weld Position Trigger features not shown _ Primary Position Max Weld Time Weld Method 1 Weld Energy here but illustrated in Figure Energy H Weld Time 5 42 Weld Power PeakPower Weld Time Single Max Weld Time Enable HScrub Time Ground Detect H Scrub Disable Disabled Distance Weld Distance Secondary m m Posit Weld Position Weld Method 1 osmon NOTE Energy H Weld Energy Peak Power Weld Power Available weld choices depend Time Weld Time Weld Distance on Security access level See p_Distance ____ Max Weld Time Table 5 system configura lode m Weld Position 1 1 _ Primary m Primary Position rue we Toe tion and primary weld method Weld Energy Energy H Weld Time Weld Power Peak Power Wax Weld Time Max Weld Time i Ground Detect H Enable Scrub Time Disable Disabled Distance Weld Distance NOTE Secondary Position Weld Position Weld Method 1 Dai Energy H_Weld Energy The Secondary Weld Method Peak Power Weld Power choices are based on the ri Time Weld Time Wad DSGRSS selection of t
143. rn and fixture and iQ Explorer IT software The software allows the operator to control the system either remotely or at the press location The iQ Series ES generator has rugged internal ultrasonic circuitry and ensures a continuous resonant frequency lock at the start of each weld The generator s compact size allows multiple units to be placed into an industrial equipment cabinet This genera tor will operate at the same international line voltage input specifications as the other generators of this product fam ily unless the 120V option is installed It also includes an RFI line filter that passes FCC CE UL and CSA testing for global applications Key Generator Features Generator Interface has a 5 LCD color display and soft keys to ease the intuitive menu navigation Digital Control of all power supply functions includ ing digital frequency synthesis and parameters allows for unique configurations and allows for future up grades e Process Parameters such as frequency amplitude and power are all updated at a 0 5 ms rate e Pulse Width Modulation incorporates patented circuitry giving the power supply the ability to efficiently change and maintain the output amplitude This makes it possible to start large horns with reduced power It also provides more power efficient switch mode generator operation and increased reliability Linear Ramp Up Down circuitry allows the acoustic stack to be brought to o
144. rong Receptacle esses 9 2 2 International 220 240 Volt CODI usu cda cosa eta qui ba berba cama aA R Cops 9 3 1 Lockout Device in Open Position Unlocked 2 404404 000 0000 13 3 2 Bottom Lockout Device in Closed Position 222 21 4 13 3 3 Generator Front View Typical High 2 44 15 3 4 Generator Rear Panel Pneumatic Press Thruster 16 3 5 IEG AC Power i i ei 17 3 6 System I O Panel Standard Panel Shown 18 3 7 HD 15F Generator Input Connector 0 1 0000 nennen nnns 19 3 8 HD 15M Generator Input Cable 8 19 3 9 DB 25F Generator Output Connector sx udi uta aeo dis 21 3 10 DB 25M Generator Output Cable Connector 799 21 3 11 Ultrasound Output 8 99 26 3 12 ompem isp zebs e ne nee er re ae acre er er eee ene Se 27 3 13 iQ Generator and Pneumatic Press Thruster Connections Diagram 31 4 1 iQ Generator Display and Control KeyS vast Eso Fr ME Seba Re 37 4 2 Display Detail Operating Mode 38 4 3 Generator in Off
145. ry large horns or when the ultrasound is shut off in air Hardware Setup Continued Page 78 Dukane Manual Part No 403 584 00 Section 5 Operation Hardware Setup Continued from Previous Page Buzzer Use the Buzzer function to turn the internal generator buzzer on or off Disabled The buzzer will not sound Enabled The buzzer can signal two different events See Figure 5 40 to the right Buzzer Top of Stroke When enabled buzzer sounds when top of stroke is reached Buzzer at Trigger When enabled buzzer sounds when the trigger point is reached Parts Alert The buzzer when enabled beeps once when a suspect part is detected and it beeps twice when a bad part is detected Text Keyboard The virtual keyboard is enabled by default and it pops up when required When disabled the virtual keyboard will not appear Test at Power Up Each time the generator is powered On the operator will be prompted to execute a TEST of the ultrasonics stack The TEST can also be cancelled The feature can be disabled from the Hardware Settings screen Test at Power Up is Enabled by default See Figure 5 41 The Test at Power Up feature can also be cancelled by activating the System Latch Reset input J2 12 Dukane Manual Part No 403 584 00 Hardware Settings Auto Start Input Mechanical Auto Stop Input Enabled Enabled Buzzer Top J3 pin 4 E Stop Status J3 pin 5 InCycle Ho Afterburst Output Du
146. shed then menu access can be limited depending on what Secu rity access level is active Ifthe Setup Security is active then the main screen would look like it does in Figure 5 28 to the right To choose a setup in this case press the Select Setup soft key As with System Control a list of setups is displayed Highlight a setup from the list and press Choose Setup Page 68 Change Method Process Utilities Welder Name Copy Setup Erase Setup Part Count Settings Notes Language English Base Units Imperial Date Format MM DD YYYY Time Date _ Figure 5 26 Setup Control Automation Selected Choose Setup Choose Setup Setup Setup Setup Setup Setup Setup Setup Setup Setup 10 Setup 11 Setup 12 Ov da UI Figure 5 27 Setup Control Choose Setup NOTE uu DE Read the Security material starting on Page 84 for more information Process Setup Current Setup Operate Screen Figure 5 28 Select Setup When Setup Security Access is Active Process Utilities Continued Dukane Manual Part No 403 584 00 Section 5 Operation Process Utilities Continued from Previous Page Copy Setup This feature allows data from one setup to be copied to another setup In Figure 5 29 to the right Copy Setup is selected from the Process Utilities list Process Utilities Welder Name Setup Control Automation Press the Copy Setup soft key and
147. spreadsheet programs are able to read or save data in a delimited format See Page 120 for more detailed information about the serial data format LF after CR Each line of output ends with a carriage return CR Some devices automatically insert a ine feed LF to advance the paper while others do not Enabling the LF After CR function makes it possible to insert a line feed at the end of an output string Output Mode Use Output Mode to determine the type of data that will appear in the part record Selections are defined below All All parts are sent to the output device immediately after the weld cycle None No parts are sent to the output device Good Only good parts are sent to the output device Bad Only bad parts are sent to the output device Suspect Only suspect parts are sent to the output device Bad and Suspect All bad and suspect parts are sent to the output device Page 72 Hardware Setup Serial Port Output Format LF After CR Output Mode Baud Rate Serial Limit Indicators Serial Headers Figure 5 35 Serial Port Selections Hardware Setup Continued Dukane Manual Part No 403 584 00 Section 5 Operation Hardware Setup Continued from Previous Page Baud Rate Baud rate is the serial port output speed in bits per second Choose a baud rate appropriate for your output device Serial Limit Indicators Limit indic
148. sses with the horn removed the horn is outside the specifications required for operation with the Digi Trac preset range Reassemble the horn to the stack If any failure indications are present with the horn removed check the booster and the transducer for the following visible damage Loose or cracked stud e Pitted or dirty mating surfaces Make any necessary repairs or adjustments Go to Step 7 7 Repeat Steps 1 through 6 e Ifthe failure indications disappear reassemble the horn to the stack and repeat Steps 2 through 4 e If any failure indications are still present do not run this stack Return the transducer and booster to Dukane for analysis Cycling the System Check that you have correctly performed the NOTE For more information about stacks see this following article a Installed the stack in the thruster and have closed www dukane com us SE stackarticle htm the stack access cover securely b Secured the fixture in place c Performed the Operational Test of the Acoustic Stack as detailed on Page 96 of this section 2 Verify that all controls on the Press Thruster and the generator are set as required for this operation Place a part in the fixture 4 Manually cycle the system Activate both operate switches at the same time to start the system and hold fingers in place until the ultra sound starts Releasing the fingers before ultrasound starts will abort the cycle Page 9
149. stems ES User s Manual Help From the main screen Figure 5 54 to the right press the soft key next to Help Process Setup Operate Screen Process Limits This will produce a screen that gives information about your generator including model and serial numbers An example of this screen is seen in Figure 5 55 Security Figure 5 54 Locating Help on the Main Menu Color Front Panel app v1 11 00 Aug 16 2013 08 43 09 boot v1 03 Sep 20 2012 11 04 37 Motherboard app v3 11 02 Aug 9 2013 11 20 24 boot v1 04 Sep 20 2012 08 48 10 Model 20HS2402QP6 Serial 229180 Figure 5 55 Help Screen Example Page 86 Dukane Manual Part No 403 584 00 Security The Security menu choices control access to the program ming menus by using individual logins for three levels Administrator Process Engineer and Setup The table below shows what access each security level has In addition the Operator column shows the access a generator operator would have when the three levels of control are in use Section 5 Operation NOTE Operator Usually the operator does not need to use the Security feature Typically an operator only monitors the weld cycle using the Operate and Graph screens Persons needing an individual login Main Menu Item Process Operator Administrator Engineer Graph Screen Operate Screen Process Setup Process Limits Process Utilities H
150. t limits ON imis Figure 5 16 Process Limits Alarm Status Alarm Status See Figure 5 16 This feature is included with the Part Limits menu to compliment part cycle data It does this to show that a system alarm www dukane com us DL EasyAlarm asp was active during the weld cycle for a particular part There are four options with Alarm Status one that disables the feature and three other options that allow for the part record to show that an alarm was active Options 1 Disabled Alarm Status is off If an alarm Occurs no signal will be generated for the welded part record 2 and 3 Force Bad or Force Suspect The ultrasonic generator will provide a signal when a system alarm activates The operator chooses whether to categorize the part under this circumstance as Suspect or as Bad Whatever designation is given to the part it will be carried on to become an item in the part record Figure 5 16 above shows with the red square symbol that Force Bad has been chosen as the option for Alarm Status 4 Display Whenever a system alarm happens the ultrasonic generator indicates this on the display s Operate screen A square green indicator appears alongside the term Alarm Status This is a visual cue to the operator The part record will not have this information Time This is the current time of day according to the iQ generator timer Date
151. tem control input signals that will typically come from an automated control system The cable attached to this connector includes all of the available system con trol signals which will be controlled by an output card or output port on the automation controller 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 Continued Page 17 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Continued from Previous Page Note that a simple switch closure relay contact con nected to a control input can not activate the input with out adding an external power supply to power the input Adding jumper connections to pins available on the Sys tem Inputs connector can configure switch closure inputs to operate referenced to generator chassis ground non isolated without adding
152. the operator s health Proper ventilation of the work station should be provided where such materials are processed Inquiries should be made to the U S Department of Labor concerning OSHA regulations for a particular plastic prior to processing with Dukane ultrasonic equipment Electrical Safety The iQ Series generator provides the operating power and power returns Make sure the generator is grounded properly In addition to the safety considerations proper grounding is essential for the effective suppression of RFI Radio Frequency Interference Every generator contains a RFI filter which blocks noise on the AC power line from enter ing the generator control circuitry This filter also prevents ultrasonic RFI from being fed back into the AC power line If you experience problems with RFI from the press run an additional grounding wire from the press base ground ing stud to the nearest grounded metal pipe or equivalent earth ground by means of a ground clamp Use at least 14 AWG wire for the connection to the press base Page 8 WARNING Keep head hands limbs and body at least six inches 152 mm away from an operating press thruster A vibrating descending horn can cause burns and or crushing injuries Continued Dukane Manual Part No 403 584 00 Section 2 Health and Safety Continued from Previous Page Electrical Safety Domestic Power
153. the vide the means to stop the cycle for an OFF position The front panel lighted power indicator goes out showing that power has been turned off automated system An auxiliary cable connects these external controls to the iQ generator at connector Manual System J2 Do either of these things Activating the System Input called Automa 1 Press OFFLINE to stop the ultrasound signal This tion Cycle Stop will stop the weld may be done under any condition OR or the complete cycle depending on if it s configured for End of Weld or End of Cycle See Page 20 for a description of Automation Cycle Stop Input 2 Pushthe power switch on the generator s rear panel to the OFF position Page 46 Dukane Manual Part No 403 584 00 Using the Menus Navigation through the menus typically begins at the Main Menu This menu can take two forms as shown below If either the Administrator or Process Eng Process En gineer has logged in the screen looks like that shown in Figure 5 3 If Setup has logged in the screen looks like that shown in Figure 5 4 The screens look identical with one exception The Administrator Process Engineer screen has Utilities Hardware while the Setup screen has Select Setup Go to the pages referenced for more detail about each sub menu Pages 48 59 Pages 60 65 Pages 66 81 Page 83 Page 68 Current Setup Security Section 5 Operation Page 82 Page 84 85 v e
154. tion 5 Operation Process Setup Continued from Previous Page Hold Method The Hold Method determines in what way pressure on the part is held after the ultrasound signal has ended Holding allows the material to solidify under pressure before the press head retracts Hold Method choices are Disabled Disabled Isable Time Time Hold Method Distance Distance and Until Motion Stops Until Motion Stops See Figure 5 9 Figure 5 9 Hold Method Submenu Diagram Disabled Choose Disabled when no hold method is needed Time The iQ generator will keep pressure on the part for the time period specified Distance For Systems with Distance Encoders Only Holding by collapse distance involves keeping pressure on the part until a specified distance from the start of hold is reached As with the weld methods to prevent the press from staying on the part indefinitely if the hold distance is not reached a MAX HOLD TIME must be entered with this option Until Motion Stops For Systems with Distance Encoders Only Pressure will be kept on the part until the speed of the press drops to zero Like the weld methods a user specified maximum time prevents infinite holding due to an unreachable distance Process Setup Continued Dukane Manual Part No 403 584 00 Page 55 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Se
155. tion ofthe ultrasonic output This output will be an open circuit if the system is switched to the OFF LINE operating mode which will prevent the start of a welding cycle or activation ofthe ultrasound output Note that an automation controlled process can not weld any parts if the system is accidentally or otherwise switched to the OFF LINE operating mode Pin 11 Press Top of Stroke Status Output Pin 11 is a digital active low status output that activates when the press thruster head is in the top of stroke posi tion This output will be an open circuit when the press thruster head is not at the top of stroke position Pin 12 Not Used Pin 13 Analog Monitor Signal Common Pin 13 1s the signal common ground connection for all of the analog monitor signals on Pins 15 and 16 This signal common pin is connected to system chassis ground and is not isolated from the generator chassis This is an analog signal ground connection Do not connect anything to this ground connection except the wiring to the inputs ofthe analog instrumentation devices used to measure the monitor output signals Dukane Manual Part No 403 584 00 Pin 14 Not Used Pin 14 1s connected to the system chassis ground Pin 15 Power Signal Monitor Output Pin 15 is an analog output signal used to monitor the power output from the welding system The scaling on this output signal is as shown below 15kHz 20kHz 30kHz and 40kHz systems 1 Watt 0 001 VDC 1
156. to J2 pin 13 See Pages 19 and 20 for additional See Page 64 information Apply the auto input signal for a minimum of 50 millisec onds to ensure that the cycle has been started Process Setup Continued Page 50 Dukane Manual Part No 403 584 00 Section 5 Operation Process Setup Continued from Previous Page Trigger Type Trigger Type is the next Process Setup submenu See Figure 5 7 Trigger defines the type of event that turns on the ultra sound signal This event can be a contact closure from the trigger switch in the press an absolute encoder position as in the case of pre trig gering a velocity reached by the press NOTE Pre trigger and Trigger Delay information can be found on Page 80 NOTE Available trigger types depend on sys tem configuration and primary weld method Max Trigger Time Max Trigger Time Types can be Maintained Maintained Momentary Momentary Force Trigger Type Force at Trigger Max Trigger Time When Motion Stops Max Trigger Time When Motion Stops Power Trigger Power Start Amplitude Max Trigger Time Power Position Trigger Position Max Trigger Time Position Figure 5 7 Maintained A Maintained trigger means that the trig ger switch signal is active for the entire weld portion of the
157. tup Continued from Previous Page Afterburst In some applications the horn can stick to the part being welded as the head of the press retracts Afterburst dis Afterburst Delay Time lodges the part by sending a short burst of ultrasound on the upstroke Afterburst Duration Enabled Afterburst lt Afterburst Amplitude Afterburst is defined by three values the delay time the Disabled E duration of the afterburst and by the amplitude See Figure 5 10 Delay is the time from the start of the upstroke until the start of the afterburst Figure 5 10 Afterburst Submenu Diagram Duration is how long the afterburst ultrasound signal is on Amplitude defines the amplitude of the afterburst ultra sound signal The afterburst feature can be turned off by choosing DIS ABLE or it can be turned on by choosing ENABLE When enabled the delay and duration times and the ampli tude are then entered Weld Amplitude The last parameter to enter is Weld Amplitude Amplitude refers to the peak to peak excursion ofthe horn at its workface Amplitude settings are given as a percent of the horn s nominal amplitude in the range of 20 100 Process Setup Continued Page 56 Dukane Manual Part No 403 584 00 Section 5 Operation Process Setup Continued from Previous Page Pressure Figure 5 11 to the right diagrams the basic pressure sub menu for systems w
158. ty Screen Logged UE cie tuve andere ndn ba UR ud bend M 89 5 63 Security Screen Logged 90 5 64 Security Screen Setup IS Logged ase ae 90 5 65 Security Prompt for Process Engineer ACCBSS eux sp pua ca 91 5 66 Security Prompt for Setup 91 Continued Dukane Manual Part No 403 584 00 Page 141 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Continued Previous P iiis List of Figures No Description Page 6 1 iQ Generator TESI d eec TEN 96 6 2 TEST Screen Display vasi nxor rax aep eR RE ODE RE ER anteaters 97 6 3 TEST GraphiDIsplady sisssssiese 97 7 1 Suggested Initial Trigger FOTCE ion esi pese pae 102 7 2 Suggested Initial Weld er v 103 7 3 Suggested Initial Weld Pott 104 9 1 CSV OUutpit FORM At a a ata assess 120 11 1 Layout Low Profile IQ Genel alor iusti daba terse be dai ess uab dob Rb URN ME UEM UU 129 11 2 Layout High Power 130 11 3 Layout High Profile IQ Generator ciui iain aai tef sns caa radi Get nb a ds 131 11 4 Interpreting the Model
159. ure Downstroke Pressure Hold Pressure Upstroke Pressure Weld Pressure 1 Weld Pressure 2 Free Run Frequency Scan Stack Scan Stack Enable Frequency Tracking K Disable Enable Frequency Lock and Hold Disable Advanced Process Settings FEES System Frequency Limits Manual Ramp Up Time Ramp Down Time Y Restore Advanced Process Defaults Figure 5 5 Process Setup Menu Diagram 2 of 2 Process Setup Continued Dukane Manual Part No 403 584 00 Page 49 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Process Setup To gain a better understanding of Process Setup please read this material The first of the Process Setup submenus is Initiate Mode Initiate Mode controls the way a cycle is started using either of two modes Manual or Auto Manual The cycle is started by depressing both operate switches on the press base Operate Switch 1 and Operate Switch 2 within 0 35 seconds of each other Depress the operate switches continuously until the trigger switch on the press has activated or until the ultrasonic signal is applied Latch on Bad Part When this feature is active It is available only with the Manual Initiate mode the cycle stops when a bad part is detected and SYSTEM LOCKED Bad Part Limit Exceeded LATCHED appears on the iQ display The operator must deal with the LATCHED message before Process Utilities Welder Name anew cyc
160. ure 7 1 Suggested Initial Trigger Force Continued Page 102 Dukane Manual Part No 403 584 00 Section 7 Set up Guidelines and Troubleshooting Continued from Previous Page Initial Weld Time Suggested Initial Weld Time 1 4 14 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 10 Time seconds 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 Linear Weld Joint inches Figure 7 2 Suggested Initial Weld Time Continued Dukane Manual Part No 403 584 00 Page 103 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Continued from Previous Page Initial Weld Force NOTE Downstroke pressure must be pro grammed so that enough force will be available to achieve the programmed Trigger Force If there is not enough downstroke pressure it may cause the system to fault at Max Trigger Time Suggested Initial Weld Force Force pounds LIN 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 Linear Weld Joint inches Figure 7 3 Suggested Initial Weld Force Page 104 Dukane Manual Part No 403 584 00 Air Cylinder Size and Force Verify the size of your air cylinder diameter Use Table 7 below to determine actual force at a
161. ut WHT BLK 8 Ultrasound Activation Cycle Start Input RED BLK 1 System Inputs Signal Descriptions Pin 1 22VDC Power Supply This pin can supply 22VDC at up to 250mA to power the user s automation controls Pin 2 22VDC Power Ground 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 1s the 12345 least significant bit used to select different welding setups 4 with an automation control system Pin 4 Remote Setup Selection Bit 1 Input 11 12 13 14 15 Pin 4 is the Remote Setup Selection Bit 1 which 1s the second least significant bit used to select different welding Figure 3 8 2 input able setups with an automation control system Continued Dukane Manual Part No 403 584 00 Page 19 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual Continued from Previous Page 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 welding setups with an automation control system Pin 6 Remote Setup Selection Bit 3 Input Pin 6 is the Remote Setup Selection Bit 3 which is the second most significant bit used to select different weld ing setups with an automation control system Pin 7 Remote Setup Selection Bit 4 Input Pin 7 is the Remote Setup Selection Bit 4 whi
162. ut notice This user s manual documents product features hardware and controls software available at the time this user s manual was published Printed in the United States of America Dukane Part Number 403 584 00 Dukane ultrasonic equipment is manufactured under one or more of the following U S Patents Inactive 3 780 926 4 131 505 4 277 710 5 798 599 5 880 580 6 984 921 7 225 965 7 475 801 7 819 158 and 8 052 816 Page ii Dukane Manual Part No 403 584 00 Revision History Revision Revision Number Summary Date 00 Original release December 6 2013 Dukane Manual Part No 403 584 00 Page iii iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page iv Dukane Manual Part No 403 584 00 Section 1 Introduction General User Information Press System Overview Key Generator Features Section 2 Health and Safety General Considerations Plastics Health Notice Section 3 Installation Dukane Manual Part No 403 584 00 Electrical Safety Lifting the Equipment Before Installation Unpacking exe d x Rear Panel Layout Overview Grounding Connector Descriptions Power Cords Cable Connections Networking Recheck Connections Connect AC Power Section 4 Control Panel System Operating Mode Keys N
163. y are benefits The electronic pressure regulator and pressure transducer are components of the same system The electronic pressure regulator accepts commands from the generator and sets the air pressure to the user selected value The pressure transducer senses the pressure and transmits it to the generator via a 4 20 mA current loop The force transducer load cell senses force exerted on the part and controls when the ultrasound signal is applied See P5 for more information on distance Page 122 Dukane Manual Part No 403 584 00 Section 10 Contacting Dukane Contacting Dukane Dukane Manual Part No 403 584 00 Page 123 iQ Series Ultrasonic Generator Power Supply Pneumatic Systems ES User s Manual This page intentionally left blank Page 124 Dukane Manual Part No 403 584 00 Contacting Dukane Identify Equipment When contacting Dukane about a service related problem be prepared to give the following information Model number and serial number Alarm indicators from the generator or displayed by iQ Explorer IT Software version Problem description and steps taken to resolve it Many problems can be solved over the telephone so it is best to call from a telephone located near the equipment Intelligent Assembly Solutions Mailing Address Dukane Ultrasonics 2900 Dukane Drive St Charles IL 60174 US Phone 630 797 4900 E mail ussales dukane com Fax Main 630 797 4949 Service

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