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iQ Explorer II User`s Manual

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1. Organize System properties Uninstall or change a program gt gt a Favorites 4 Hard Disk Drives 1 W Desktop Local Disk C Ji Downloads gt E Recent Places 258 GB free of 297 GB 4 Devices with Removable Storage 1 409 Libraries E Documents DVD RW Drive D D y Music gt E Pictures 4 Network Location 11 ____apps f roosevelt F m 098 TB free of 1 00 TB useng sh roosevelt H gt mm Memory 8 00 GB Open in new window Map network drive Disconnect network drive Add a network location Delete Rename Dang CONG Submenu Figure 2 9 Computer Right Click Displays Submenu Windows 7 4 From the Computer submenu click on Properties to view computer details about your computer A sample view is shown below in Figure 2 10 f s l El Control Panel System and Security System 49 Search Control Panel 9 Pe Control Pama Control Panel He a PEN Jo nena Noa View basic information about your computer 19 Device Manager Windows edition 9 Remote settings Windows 7 Professional System protection Copyright 2009 Microsoft Corporation All rights reserved Advanced system settings Service Pack1 Get more features with a new edition of Windows 7 System Manufacturer Dell Rating n Windows Experience Index Processor Intel R Core TM i5 2450M CPU 2 50GHz 2 50 GHz Installed memory RAM 8 00 GB 7 90 GB usable System t
2. 73 Network Settings nananana aana 74 Direct CONNECIION co 2x 4 ees tens ow dee ee eee eee ee Kee 74 DHCP Enabled aa on oe bude oe tes on ease eee eee ees KEN 74 DHCP Disabled on the HM sa aaa ae kd wa cud kWh GHANA AA chs 74 DHCP Disabled on the iQ ES Generator 74 HMI Directly Connected to a Single Generator 15 Connection through a Stand alone Network 77 Connection to a Local Area Network 78 Dukane User s Manual Part No 403 585 00 Page 71 iQ Explorer II User s Manual This page intentionally left blank Page 72 Dukane User s Manual Part No 403 585 00 Section 5 Networking Introduction iQ Explorer IT is designed to connect to one or more ES model iQ welders via Ethernet using TCP IP protocol Configuration of the network depends on the user s needs This section offers various options regarding the configuration of your network of iQ products DHCP ES Model iQ welders are capable of DHCP support All Windows PCs that are capable of using TCP IP protocol support DHCP as well DHCP enabled is the default setting in both cases DHCP is a TCP IP standard that reduces the complexity and administrative overhead of managing network client IP addresses A DHCP server available on a network supplies IP addresses to DHCP clients Once a DHCP client obtains an IP address from the DHCP server then that client will obtain the same IP address as lon
3. Select Lower Bad Lower Suspect Downstroke Time Display y Position at Trigger Display Trigger Delay Time Lole Trigger Delay Distance Force at Trigger Weld Time Display Weld Distance Display Weld Energy Display Weld Peak Power Display Weld End Position Display Weld Peak Force Display Hold Time Display Hold Distance Display Total Cycle Time Display Total Stroke Distance Display Alarm Status Display Process Limit Helper i Y Not enough cycles to perform operation Leet bet bebe be KA KA be te el Cycle Data Upper Suspect Upper Bad Process Limit Helper Figure 4 34 Setup Process Limits Helper When Not Enough Data Dukane User s Manual Part No 403 585 00 Thursday November 08 2012 11 2253AM Continued Page 51 iQ Explorer II User s Manual Continued from Previous Page Basic Setup 7 If the user has more information to associate with a setup click the Notes tab A sample display is shown in Figure 4 35 below Several text entry boxes appear Whatever text is entered is stored within the setup iQ Explorer II Welder 1 Seryo1 FO Ble Tools Window Help CA oe E oe NG ae e el 8 9 8 HH g O welderz O Welder H Operation Summary Process Settings Process Limits Notes Cycle Data Graph Production Utilities System Hardware General notes Used lab horn and customer s fix
4. Print Screen Select this action to make copy of the screen The user can save this image to file or immediately print it to a connected printer Print Graph Data Select this action to print the current graph data to a connected printer This option is available from the Graph Data tab when there is available data Print Cycle Data Select this action to print the current cycle data to a connected printer This option is available from the Cycle Data tab when there is available data Print Setup Select this action to populate a report with the current setup on display The user can save this image to file or immediately print it to a connected printer Exit Select this action to exit iQ Explorer II Continued Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page Tools See Figure 4 2 to the right for the Tools menu Tools submenu items are detailed below Options See Figure 4 3 to the right This is the window that appears after Options has been activated Communications This group contains features related to how iQ Explorer II connects to iQ generators on the network Security This option contains the features used to enable access limitations to iQ Explorer II and any connected iQ generators PLC Interface Enabling this feature allows the user to configure a machine interface screen related to controls associated with a Dukane Lean Work Cell This feat
5. Help File Organization A Contents tab and an Index tab are two entry points to the Help file information Contents groups the Help file information into these eight main categories Hardware Process Control Process Limits Notes Graph Utilities System and Options The Index is an alphabetical list of words and phrases found in the Help file The figures on the next page illustrate that the term Cycle Data Storage was found through both Index and Contents Using the F1 Key The F1 key can be tapped to activate Help when 1 the cursor is positioned in an item that can be edited such as a text box drop down list or check box and 2 that item is linked to Help Dukane User s Manual Part No 403 585 00 Section 4 Operation iQ Explorer II 20 kHz Thermo Cup Se Tools Window Help toga o About iQ Explorer II EH Operation Summary Process Settings Process Limits Notes C Initiate Mode un Z Oo 5 par o wo Figure 4 51 Help File Access from Top Menu Bar Continued Page 67 iQ Explorer II User s Manual Continued from Previous Page Using the Index Tab and the Contents Tab The figures below illustrate that the term Cycle Data Storage was found through both the Index and Contents tabs of the Help file Index Tab doo amp e k Hide Back Print Options Contents Index Type in the keyword to find Cycle Data Storage Automation W
6. Force Frequency Pressure Amplitude Iv Cancel Figure 4 20 Options Graph Display Tab Continued Page 43 iQ Explorer Il User s Manual Continued from Previous Page Cycle Data Files Tab Cycle data can be stored in three directories at Shifts Graph Data Cycle Data Setup Barcode Force Appearance Diagnostics Files Oth the same time Bata 3 4 Save cycle data from multiple welders to one file With this feature the user can store data on a network or Save Cycle Data Directories ai A XML Directory 1 CAD ts and Settings All Users Application Data Dukane C on a USB flash drive while saving data on the PC itself S SaaS ai N R a KA See Figure 4 21 to the right T CSV Directory If no directory is selected no cycle data is saved to file Data from Multiple Welders when iQ Explorer IT is connected to several welders on a network this option can be enabled so that cycle data will be saved to a single file Figure 4 21 Options Cycle Data Tab Files Other Tab When Display Only Most Recently Welded is checked only the most recent cycle data will Communications Security PLC Interface Shifts Graph Data Cycle Data Setup Barcode Fon 4 gt Files Other be shown in the Cycle Data tab pg Display only most recently welded cycle 5 parts data See Figure 4 22 to the right F7 Limit the file size of XML cycle datafiles 5000 Kb
7. Page 41 iQ Explorer II User s Manual Continued from Previous Page PLC Interface This feature provides a PLC configuration enhancement and a custom HMI user interface using iQ Explorer II Enable the feature to interface to a Dukane Lean Work Cell See Figure 4 17 to the right User levels must be enabled with the Security tab so this PLC interface can be used Shifts When this option is enabled the user can define up to three shifts Cycle data related to each shift will be saved to unique files The display will be reset automatically during a change of shift See Figure 4 18 to the right Page 42 NOTE Please contact a Dukane custom applica tions specialist before enabling the PLC Interface feature PLC Interface Shifts Force Graph Data Cycle Data Setup Appearance 4 Enable interface to a Dukane Lean Work Cell r Dis pate TA T At startup ja Cancel Figure 4 17 Options PLC Interface Tab PLC Interface Shifts Force Graph Data Cycle Data Setup Appearance 4 gt Enable saving cycle data in shifts Shift Management Enable shift 1 Enable shift 2 Enable shift 3 1 Start time Start time Start time Name Morning Name Second Name Cancel Figure 4 18 Options Shifts Tab Continued Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page
8. eee eee 64 Save and Restore Graph Data ooooooooooo 66 Using the Help System 0 0 00 cee ee eee 67 Software Prompts ev gig exerts A bese os eee aca 69 Dukane User s Manual Part No 403 585 00 Page 21 iQ Explorer Il User s Manual This page intentionally left blank Page 22 Dukane User s Manual Part No 403 585 00 Main Menu This section gives an overview of the top of screen menu bar and the submenus that flow from it File See Figure 4 1 to the right for the File menu File submenu items are detailed below Select Active Setup A pop up window displays the list of setups currently loaded in the welder The user can select a different active setup in the welder Open Cycle Data A pop up window displays the current month s list of stored cycle data files This pop up window can be used to navigate to a directory other than the one defined in the Options The user can select a file and load the contents into a separate window of iQ Explorer IT Open Graph Data A pop up window displays the current month s list of stored graph data files This pop up window can be used to navigate to a directory other than the one defined in the Options The user can select a file and load the contents into a separate window of iQ Explorer II Open Setup from Disk A pop up window displays the list of stored setup files This pop up window can be used to navigate to a directory other than the one defined in
9. 2 The user interface on the generator prompts the user Yield control to remote user iQ Explorer II will display the status message Welder is in use Please wait while requesting access to welder If the user at the generator denies control iQ Explorer II will display the parameter settings but will also remain in read only mode 3 Ifthe user at the generator permits the handoff of control iQ Explorer II will display the parameter settings and then the one who is using iQ Explorer IT will be permitted to modify any parameter 4 After yielding control the user at the generator will not be permitted to access the parameter screens until that user reacquires access permission from the user at iQ Explorer II The user at the generator may still view the Operator Screen initiate tests and turn the system offline and online Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued Page 35 iQ Explorer II User s Manual Continued from Previous Page When the user at the generator requires parameter access that person has to use the Security screen and press the Request Control button to reacquire access Timeout When either user interface at the generator or with iQ Explorer IT is prompted there is a chance that no one will be present to respond to the request to yield control Both interfaces give the user fifteen seconds to respond to the request After the fifteen seconds has elapsed the decisi
10. Force Graph Data Cycle 4 r Default Yes response to automatically yield access to welder w Enable user level access Setup Users Custom Levels Show keyboard on password entry for touchscreens T Enable automatic log off timeo 15 minutes C Documents and Settings All Users Application Data Dukane Corpi _ Cancel Figure 4 16 Options Security Tab Enable Auto Timeout and Enable Auditing NOTE An iQ Explorer IT connection is re quired to execute a weld on an iQ ES generator with Part 11 active Continued Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page Audit Trail Introduction When auditing is enabled in iQ Explorer I all modifications to active setups on the iQ generator are tracked in a file and stored in a user defined directory All weld cycles and loading of active setups are tracked as well This feature complies with the DFA 21CFR Part 11 standard When referencing this standard it will simply be referred to as Part 11 Fundamental requirements for this standard are associating a user with every action that occurs at the welder Password Protection Part 11 Requirements Part 11 requirements regarding password protection include a user ID and a password iQ Explorer II hides user IDs and passwords on the PC on which it runs There are no limits to the number of users that can be added to iQ Explorer IT Exporting
11. Graph Data Files Tab When Automatically Save Graph Data is enabled graph data for each weld is saved with its own name in the directory specified If no directory is named data is saved in the default GraphData subdirectory See Figure 4 19 to the right Reference graph data can be filed in a user defined directory If no directory exists for reference graph data it will be filed in the default RefGraph directory Display Tab When Show Graph in Cycle Data Screen is checked a smaller copy of the graph is displayed on the Cycle Data tab See Figure 4 20 to the right Data Types All graphs are displayed with one millisecond resolution of the complete weld cycle Storage of all graph types may take up a lot of disk space so the user may want to disable graph types that are not essential Dukane User s Manual Part No 403 585 00 EZ Options Communications Security PLC Interface Shifts Graph Data Cycle Data Setup Barcode Fon 4 gt Files Display F Automatically save graph data Save Graph Data Directories Main U Reference C Documents and Settings All Users Application Data Dukane Cor Cancel Figure 4 19 Options Graph Files Tab HZ Options Communications Security PLC Interface Shifts Graph Data Cycle Data Setup Barcode Fon 4 gt Files Display W Show graph in cycle data screen r Show Graph Data Types Distance Speed lv Power Y Energy
12. Operation Summary Process Settings Process Limits Notes Cycle Data Graph Production Utilities System Hardware O lelder Name Welder 1 O Time 12 3 2012 2 20 PM Do Number 9765432 O Set Welder Date Time O etup File Name 16 Servo1 pi O ename Setup File Rename E E Setup File Image C Program Files Dukane Corporation iQ Explorer IINQEII Default jpg Installed Hardware O O Address 172 16 25 119 iQ Motherboard Version u3 10 iQ Front Panel Version u1 10 Press Controller Version u22 13 Model Number 20HS120 10 P7 Servo with Load Cell 625 15 System Frequency 20 KHz Power Level 120 W Monday December 03 2012 220 10PM On line When Green Generator E Stop When Red Emergency can enable an Stop is active ultrasound signal The generator will not be Off line When Yellow A cycle able to start a cycle can be run but no ultrasound is signaled Figure 4 31 Setup Hardware Continued Page 48 Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page Basic Setup 4 To configure a setup to execute a weld click on the Process Settings tab and modify the settings listed below and shown in Figure 4 32 O Initiate Mode Top of Stroke for iQ servo O Settings before and at trigger Settings to monitor the weld O Enable Melt Detect patented iQ servo setting G iQ servo Motion Control
13. a Welder 47 Show Welders 47 System Buzzer Status 62 Modify Hardware Settings 61 Serial Communications 62 Servo Press 62 System I O 62 Utilities 59 Alarm History 59 Part Count 59 Setup Utilities 59 Sonics Test 59 View Real Time Data 59 Buzzer Status 62 Dukane User s Manual Part No 403 585 00 Index C Computer Requirements 7 Cycle Data 53 D Data Data from Multiple Welders 64 Data Storage 64 DHCP 73 Diagnostics 46 Dukane Address 83 Contacting 83 E mail 83 Fax 83 Intelligent Assembly Solutions 83 Address 83 E mail 83 Fax 83 Phone 83 Phone 83 Website 83 www dukane com us 83 www dukane com us sales intsales htm 83 E E mail 83 F FDA 21 CFR Part 11 Compliance 40 G General User Information 3 Drawings and Tables 3 Notes Cautions and Warnings 3 Graph 54 Interaction 57 Save and Restore Graph Data 66 Save as Reference 56 Show Reference 56 Transition Point 56 Graph Display 55 Graph Setup 63 Continued Page 95 iQ Explorer II User s Manual H Hardware Modification 61 Hardware Tab 48 Help System 67 Fl Key 67 Top Menu Bar Using the Fl Key 67 Hold 49 I Icons 28 Index 93 Initiate Mode 49 Installation Installing 17 Launching the Software 18 Unpacking 17 IP Address 48 Modify the Permitted IP Address List 79 iQ Explorer II Key Features 4 Overview 4 iQ System Requirements 14 K Keyboard and Mouse 31 Key Features 4 L LAN 78 Latch on Bad Part 50 Launching the Software 1
14. confirm your selection Type in the changes and press the ENTER key If the user requires help with a specific setting press the F1 key while the box is flashing Touch Screen 1 Touch the box in which the user would like to make changes Press either the numeric keypad or the keyboard icons on the toolbar to use in making the changes Double touching any box in iQ Explorer II will also bring up either the numeric keypad or the keyboard Tap the ENTER key on either the numeric keypad or the keyboard to apply the entry Dukane User s Manual Part No 403 585 00 Section 4 Operation NOTE Entry box prompts There may be a flashing vertical bar or the entire entry box might be filled with a flashing color Continued Page 31 iQ Explorer II User s Manual Options This feature helps you manage the welding process with the settings offered through the options listed below e Communications e Security e PLC Interface NOTE e Shifts The Help file of iQ Explorer IT is a good source of information e Force aut for reviewing the purpose of e Graph Data particular features e Cycle Data e Setup e Appearance and e Diagnostics Table 4 I on the next page gives an overview of each option The pages that follow the table explain these options in more detail Continued Page 32 Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page What the Operator Can
15. edit controls will always pop up the keyboard otherwise This is handy if you have an HMI touch screen without a physical keyboard See Figure 4 16 to the right Enable Automatic Log Off Timeout Another security option for the Administrator is the Automatic Log Off Timeout as see in Figure 4 16 to the right When enabled this will automatically log off a user when no activity is detected after the amount of time set in the entry box has passed Enable Auditing to Support FDA 21 CFR Part 11 Compliance In addition to standard password protection iQ Explorer I offers a feature that complies with FDA 21 CFR Part 11 To support Part 11 O Explorer II attaches a user ID to every cycle alarm setup modification and other events iQ Explorer IT has the option for the user to define a target directory to host the audit file s that track all events To ensure Part 11 compliance no user is permitted to log into the iQ ES system since fully recording all modifications is not possible Therefore the user may not have password protection on the ES generator in conjunction with Part 11 Only operator access is permitted Page 40 Manage Custom Security Levels Name Custom Level Custom security 3 4 Custom 1 Custom security c 2 Custom 2 Permit Read Only Amplitude Bose Hold Ze Pressure 3 Exit Figure 4 15 Options Security Custom Security Levels Options Communications Security PLC Interface Shifts
16. iaa 19 4 1 Main Mente FE iii aa N 23 4 2 Man Menu 100 S resucita 25 4 3 Main Menu Tools gt Options Window maana 25 4 4 Main Menu WING OW vesciniccssdcosascsanducsteaveredccanacssedavsnasenncauvanea devadveetadvenascnetavveusanevedieataves 27 4 5 Main MG AU s H el Disses ismene nen e andas 27 4 6 Maim sa PON COs nesr a PAA o 5 Io 28 4 7 Icon and FUNCOM a 29 4 8 Options Communications Tab eskerren e EE A E 34 4 9 Options UA ia a aaie aaa E Ta Raa aoe a ESER 37 4 10 Options Enable Administrator Password ooooooccccccocococoncooonooononononononononononnnnnnnnrnnnnnnnnnnos 37 4 11 Options Set PassWord univirne idad ii 37 4 12 Options Security Setup Users usssssiie se iin aiaei aa a EE a ENEE 39 4 13 Options Security Add New Us Ts cocoa tt 39 4 14 Options Security Create User Profiles ona 39 4 15 Options Security Custom Security Levels cusco 40 4 16 Options Security Tab Enable Auto Timeout and Enable Auditing 40 4 17 Options PEC Interface Tai li 42 Continued Dukane User s Manual Part No 403 585 00 Page 87 iQ Explorer II User s Manual Continued from Previous Page Appendix A List of Figures No Description Page 4 18 Options Shits laba AN AA acne stout ce eee 42 4 19 Options Graph Files TaD ooooonconinicicinnnncoccocccononononoono nono nono nono nnnonnnonn nono nnnnnnnnnnnnnnnnnnnnnos 43 4 20 Options Graph Display Tab 0ooooooocccccccccococococonononncoononnnnn
17. power relative to standard laptops and desktops available today Factoring in the likely requirements for anti virus software and other software that is required for PCs on a company LAN the HMI is not the best host for iQ Explorer IT in this configuration iQ Explorer II can run on any Windows operating system available at the time of the writing of this manual so we recommend using a PC supplied by the user s IT department in this type of network configuration To desktop PC NOTE If any installed HMI has a one to one rela tionship with its welder as shown in Figure 5 7 then the welder IP address should be added to its Permitted IP Address List The DHCP server assigns an IP address to the welder and that IP address is what should be added to the Permitted IP Address List NOTE A desktop PC with iQ Explorer IT does not need any IP configuration It automatically finds the generators on the network as long as a firewall or router permits UDP broad cast packets Local Area Network LAN Connection to Local Area Network Figure 5 7 Continued Page 78 Dukane User s Manual Part No 403 585 00 Section 5 Networking Continued from Previous Page Modify the Permitted IP Address List 1 Click the Options icon BG ae NOTE A eer Dukane recommends Add the list of gen 3 See Figure 5 8 for a view of this tab erator IP addresses to the Permitted IP Auto Display Welder Contents Address List of iQ Explorer II
18. where a change needs to be made 2210 Explorer II Welder 1 Servo1 GO Ee Tools Window Hep fa 8 je ka E Operation Summary Process Settings Process Limits Notes Cycle Qae fGraph Production Utilities System Hardware Initiate Mode Amplitude and Power Regulatio Enable Advanced Settings op of Stroke Weld Amplitude 60 Manual 1 0000 in Teach T Power Regulation Advanced Trigger Sensing Btart Type Max Trigger Time Sensing Speed Parameter Conflict boo E 0 0900 ims in Teach explanation sa gespoeti Advanced Note the warning Weld symbol and the Primary Method yellow background gt for the message Enable Melt Detect Advanced Servo 1 Weld Motion Control Weld Profile itself Speed Constant 0 0100 in s Post Weld Dynamic Hold Method Hold Distance Speed Max Time Travel Limit Distance 0 0010 in 000100 ins 5 000 s 0 0000 in Static Hold Method Hold Time Time 0 100 s T Afterburst Baa Paste Coria Monday December 03 2012 42612FM Yellow background indicates a problem In this example with the Process Settings tab displayed there is a Parameter Conflict Figure 4 55 Parameter Conflict Display Page 70 Dukane User s Manual Part No 403 585 00 Section 5 Networking Networking Introduction 20262 atorado a as KA 73 De orcos creada rara 73 Network Settings on the iQ ES Generator
19. 000 4 8 EN61000 4 11 e The Low Voltage Directive 2006 95 EC e The Machinery Directive 2006 42 EC EN 60204 2006 Safety of Machinery Electrical Equipment of Machines Part 1 General Requirements IP International Protection Rating The iQ generator as well as all models of the servo press and remote controller have an IP rating from the IEC In ternational Electrotechnical Commission The rating is IP2X in compliance with finger safe industry standards Dukane User s Manual Part No 403 585 00 Section 7 Appendices Appendix C Page 91 iQ Explorer II User s Manual This page intentionally left blank Page 92 Dukane User s Manual Part No 403 585 00 Index Dukane User s Manual Part No 403 585 00 Page 93 iQ Explorer II User s Manual This page intentionally left blank Page 94 Dukane User s Manual Part No 403 585 00 Index A Advanced Settings 49 Afterburst 49 Alarm History 59 Amplitude 49 Appearance 46 Appendices List of Figures 87 List of Tables 90 Regulatory Agency Compliance 91 B Barcode 45 Basic Setup 47 Cycle Data 53 Graph 54 Graph Display 55 Hardware 48 Name the Welder 48 Notes 52 Operation Summary 63 Graph Setup 63 View Live Data 63 Process Limits 50 Process Limits Helper 51 Process Settings 49 Advanced Servo Settings 49 Advanced Settings 49 Afterburst 49 Amplitude 49 Enable Melt Detect 49 Hold 49 Initiate Mode 49 Power Regulation 49 Production 58 Select
20. 03 585 00 Page 49 iQ Explorer II User s Manual Continued from Previous Page Basic Setup Cycle data for all process characteristics are always saved The user determines whether these are shown 5 To weld a part successfully some users require a Ai in the cycle data display process limits for specific process characteristics These settings determine whether a cycle is good bad or suspect The user may also mark a cycle as bad when an alarm is detected Latch on Bad Part Only available when Initiate Mode is Manual KB iQ Explorer II Welder 1 Seryo1 aaa O fle Tools Window Help r G 7 y o 9 i a Operation Summary Pybcess Settings Process Limits Notes Cycle Data Graph Production Utilities System Hardware Select Lower Bad Lower Suspect Cycle Data Upper Suspect Upper Bad Display slapjan PIH Lolle Position at Trigger Display Trigger Delay Time Process Limit Helper Trigger Delay Distance Force at Trigger Display Weld Time Display Weld Distance Bad Suspect Weld Energy Display Weld Peak Power Weld End Position Display Weld Peak Force Bad Hold Time Suspect Hold Distance Display Total Cycle Time Total Stroke Distance Alarm Status Display Lola Le Le be Ls la bel vel bel vel bed te Removes ma PAG BAGO paid Adds the limit s to the weld cycle from the weld data display and to the appropr
21. 58 System 61 Utilities 59 Operation Summary 63 Options 32 Appearance 46 Barcode 45 Communications 34 Cycle Data 44 Diagnostics 46 Force 45 Graph Data 43 PLC Interface 42 Security Creating Custom Level User Profiles 40 Enable Auditing to Support FDA 21 CFR Part 11 Com pliance 40 Setup Users 39 User Access Levels 38 Shifts 42 P Parameter Conflict Example 70 Power Regulation 49 Process Limit Helper 51 Process Settings 49 Production 58 R Regulatory Agency Compliance 91 S Save and Restore Graph Data 66 Save and Retrieve Cycle Data 64 Save and Retrieve Part Data 64 Save and Retrieve Setup Files 64 Security Key 9 17 Dukane User s Manual Part No 403 585 00 Serial Communications 62 Servo Press 62 Servo Settings Advanced 49 Software Prompts 69 Software Requirements NET Framework 14 Windows 10 Sonics Test Test Display 60 System 61 System I O 62 System Requirements 5 Computer Requirements 7 CD ROM Drive 9 Communication Ports 9 Ethernet Port 9 Security Key 9 USB Port 9 Hard Disk Space 9 Memory 7 Processor 7 Software Requirements 10 Video Display 7 iQ System Requirements 14 T Tables 90 Testing Ultrasonics 59 Time 48 Touch Screen 4 31 40 59 U Using the Help System Using the Index Tab and the Contents Tab 68 Utilities 59 Utilities Sonics Test 60 Vv View Live Data 63 View real time data 59 W Windows Windows 7 12 Windows XP 10 Page 97 iQ Explorer Il User s Manu
22. 6 5 4 Show Welders lis 76 5 5 Show Welders 72 iaa it dene ee ade ete as 76 5 6 Simple Stand alone Network Configuration caviar a ata 77 5 7 Connection to Local Area Network cccceecceeeeeeeeeeeeeeceeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeeeees 78 5 8 Options Modify Permitted IP Address List 2 cecceseessssececeeeeeeeseesseeceeeeeeneneeees 79 Dukane User s Manual Part No 403 585 00 Page 89 iQ Explorer II User s Manual Appendix B List of Tables No Description Page 4 Options Choices for the Operator oooooooooocccoocconcconcnoncnonnnncnoncnonononononcnnnnnnnnnnnnnnncnnnnnnnnnss 33 Page 90 Dukane User s Manual Part No 403 585 00 Regulatory Agency Compliance FCC The generator complies with the following Federal Com munications Commission regulations e The limits for FCC measurement procedure MP 5 Methods of Measurement of Radio Noise Emissions from ISM Equipment pursuant to FCC Title 47 Part 18 for Ultrasonic Equipment CE Marking This mark on your equipment 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 e The EMC Directive 2004 108 EC for Heavy Industrial EN 61000 6 4 2001 EN 55011 2003 EN 61000 6 2 2005 EN61000 4 2 EN61000 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN61
23. 8 Change Autoboot 18 Click Icon 18 List of Figures 87 List of Tables 90 M Main Screen Icons 28 Melt Detect 49 Menu Icons 23 Microsoft NET Framework 17 Modify Hardware Settings 61 Multiple Welders 64 Page 96 Continued from Previous Page N Networking 71 Connection through a Stand alone Network 77 Connection to a Local Area Network 78 DHCP 73 HMI Directly Connected to a Single Generator 75 Network Settings 74 DHCP Disabled on the HMI 74 DHCP Disabled on the iQ ES Generator 74 DHCP Enabled 74 Direct Connection 74 Network Settings on the 1Q ES Generator 73 Notes 52 O Operation Basic Setup 47 Icons 28 Icon Detail 29 Main Menu 23 File 23 Copy Setup to Welder 24 Delete Setup File from Disk 24 Erase Setup From Welder 24 Exit 24 Load Setup from Disk 23 New Setup File Offline 24 Open Cycle Data 23 Open Graph Data 23 Open Setup from Disk 23 Print Cycle Data 24 Print Graph Data 24 Print Screen 24 Print Setup 24 Save Current Setup File 24 Save Current Setup File As 24 Save Cycle Data As 24 Save Graph Data As 24 Select Active Setup 23 Tools Help 27 Language 26 Options 25 Window 27 Making an Entry 31 Keyboard and Mouse 31 Touch Screen 31 Continued Dukane User s Manual Part No 403 585 00 Index Continued from Previous Page O Options 32 Appearance 33 Communications 33 Graph Data 33 Shifts 33 Supervisor 33 Setup 47 Cycle Data 53 Graph 54 Graph Display 55 Process Settings 49 Production
24. 9 Graph Display Detail Continued Page 56 Dukane User s Manual Part No 403 585 00 Graph Features Interaction Check the Interaction box to activate interactive features that use the left button of the computer mouse Continued from Previous Page These features Zoom Scale and Translate are shown at in Figure 4 40 below EE iQ Explorer II Graph_SN240488_ 7_20121114_162722 0 Ele r G E y ha Tools Window Help 5 Hi Section 4 Operation Graph slapjam moys Time Force Energy O 0 566 12 115 76 515 Y Value 0 652 0 000 Restore Interaction T Show Reference Part Count 7 14 Nov 2012 Welder8 Save as Reference Graph Setup 0 Sensing Start Position Ir A5s0u3 04 Time s O Zoom ALT LMouse Scale CTRL LMouse Translate SHIFT LMouse Monday November 19 2012 1 53 53 PM Figure 4 40 Setup Interaction Points highlights a transition point in the weld cycle The name of the transition point appears when the cursor rolls over that place on the graph Dukane User s Manual Part No 403 585 00 Continued Page 57 iQ Explorer Il User s Manual Continued from Previous Page Basic Setup 11 Click on the Production tab This page provides a graphic analysis of parts produced the good the suspect and the bad See Figure 4 41 below for a sample of this type of grap
25. Do with the Option Turn Feature Enter Data Make a Selection On or Off IP Address List Enter permitted IP addresses Automatically display Communications welder access window when discovered Enable security Enable auto log off timeout 4 e Enable auditing to support FDA 21 CFR Part 11 Default response to yield access rights Show keyboard on password entry Enable interface to Dukane Lean Work Cell e Disable outputs to operators PLC Interface At startup navigate directly to machine interface Prevent unspecified user to log on as operator Enable saving Cycle Data in shifts Files Automatically save graph data to file Show graph in cycle data Display screen Show graph data types Distance Velocity Power Energy etc e Save cycle data from multiple welders to one file Directories to save cycle data Security Graph Data Display only most recently welded cycle data Limit the file size of SML cycle data files Limit the number of cycle data to a single file Enable barcode scan Barcode Enter Force instead of Force Pressure Ey passwords e Configure PLCs times Add users with access Directory to store FDA 21 CFR Part 11 audit file Name the shift and enter Enable shift s e Directories to save graph data to file Interval Save cycle data minutes to file e Directories to save cycle data to file
26. Enable this feature to always display the user interface That reduces the impact of handling net immediately following the detection of the welder This work overhead for the HMI is best used when iQ Explorer IT is directly connected to a single generator Permitted IP Addresses Add IP addresses of iQ generators to this list to limit the iQ Explorer I interface to only those on the permitted list This is best used when many iQ generators are present on a single network and iQ Explorer IT is dedicated to a subset of the generators on that network Edit Permitted IP Address List iQ Advanced IP Address 176 17 5 102 Add 176 17 5 100 Remove Options Communications Security PLC ace Shifts Force Graph Data en 4 O Automatically display vee rages ee when covered ANG na Ka O Permitted IP Addrg sL SG om Modify List amp Figure 5 8 Options Modify Permitted IP Address List Dukane User s Manual Part No 403 585 00 Page 79 iQ Explorer Il User s Manual This page intentionally left blank Page 80 Dukane User s Manual Part No 403 585 00 Section 6 Contacting Dukane Contacting Dukane Dukane User s Manual Part No 403 585 00 Page 81 iQ Explorer II User s Manual This page intentionally left blank Page 82 Dukane User s Manual Part No 403 585 00 Contacting Dukane Identify Equipment When contacting Dukane about a service related problem be prepared to give th
27. Help submenu items are detailed below Help Select this menu item to open the help file to assist you on how to use weld parameters and more details on features of iQ Explorer IT About iQ Explorer IT iQ Explorer II version information is available here Dukane User s Manual Part No 403 585 00 Hig Explorer Il Welder8 Setup 1 Window Help SJBp an MOYS 4rrange Icons Cascade Close All Windows Tile Horizontally s Proce Tile vertically Minimize All Windows 1 Welder Setup 1 Figure 4 4 Main Menu Window Hig Explorer Il Welder8 Setup 1 je File Tools Window Help LA TF o Help About iQ Explorer II Operation Summary Process Settings Process Limits Not Figure 4 5 Main Menu Help Page 27 iQ Explorer Il User s Manual Main Screen Icons The icon bar just below the main menu allows easy access to frequently used features In the pages that follow you will get an overview of their usefulness O iQ Explorer Il File Tools Window Help Delete setup File from disk w gt a o a T g Function appears as the cursor crosses the icon Figure 4 6 Main Screen Icons Continued Page 28 Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page Icon Detail Print current item Delete setup file Scan for welders Hig Explorer Il File Tools un T M Open or Load setup file from disk Change opti
28. Intelligent Assembly Solutions 10 Explorer II Intelligent Assembly Solutions 3 pi User s Manual Intelligent Assembly Solutions KANE Intelligent Assembly Solutions DUKANE Intelligent Assembly Solutions DUKANE Intelligent Assembly Solutions DUKANE Explorer Dukane Part No 403 585 00 Dukane Intelligent Assembly Solutions 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949 l S 0 9 0 0 1 H 2 0 0 8 a in ISO 327 www dukane com us iQ Explorer II 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 li ability 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
29. No 433 38 into any available USB port on the computer This Security Key is also referred to as a dongle A Found New Hardware Wizard window will appear The Wizard detects a new USB device and searches for the appropriate software When the Wizard completes its search a message will appear The wizard has finished installing the software for USB Dongle Software Protection Device If you are prompted to search Windows Update for the driver select NO not this time and click Next NOTE Without the USB security key iQ Explorer IT will run for only a few minutes The time and date bar at the bottom of the window flashes red if the key is not installed 5 Select Install the Software Automatically Recom mended and click Next 6 Click Finish to end the Found New Hardware Wizard NOTE The software checks to see if Microsoft NET Framework is installed If it is not put the iQ Explorer II CD back into the CD ROM drive tray and close it Go to START then RUN and key in d NetFx20SP1_x86 exe Where d is your CD ROM drive to install the NET Framework After NET Framework is installed restart the computer and complete the iQ Explorer IT installation Continued Page 17 iQ Explorer II User s Manual Continued from Previous Page Generator Connection Power up the generator and connect it to the PC with an ethernet cable if not already powered and connected NOTE To change the autoboot feat
30. Options 7 Communications Security PLC Ipterface Shifts Force Graph Data Cycle 4 gt KA Bu Automatically display welder age ss window when discovered Y 7 E 4 Y a 3 A A Permitted IP Address Li A Modify List 4 Figure 4 8 Options Communications Tab Page 34 176 17 5 100 OK Cancel Continued Dukane User s Manual Part No 403 585 00 Continued from Previous Page Security Overview Introduction For Dukane iQ ES generator models and iQ Explorer II security refers to more than standard password protection Security includes protection from multiple users modifying the same set of parameters simultaneously This section explains how iQ Explorer I influences access to parameter settings as well as explaining its various password protection features No Password Protection The factory settings of the ES generator include disabled password protection The user can modify any parameter available on any of the generator s screens When iQ Explorer IT first makes a network connection to the generator it is in a read only access level At this stage all of the parameters stored on the generator are uploaded to iQ Explorer IT 1 To open the user interface on iQ Explorer II click the button associated with the welder Since the user interface at the generator has initial access rights iQ Explorer II needs confirmation before it 1s permitted to edit any parameters
31. Save Current Setup File s Setup Copy Setup to Welder Save and Retrieve Cycle Data Erase Setup from Welder O1 Seh 1 Click the Options icon ave sta A a ae Progr 2 Click on the Cycle Data tab 3 Data Storage Cycle data can be stored in three di Krine eee rectories simultaneously The user can store data on a Print Setup network or on a USB memory stick while still saving xl Exit iton the PC If no directory is selected then no cycle data is saved to file See the figure below 4 Data from Multiple Welders When iQ Explorer II is connected to multiple welders on a network the user can enable this option to have all cycle data saved Figure 4 47 Save and Retrieve Setup Files to a single cycle data file K Options Shifts Graph Data Cycle Data Setup Barcode Force Appearance Diagnostics Files Other F Save cycle data from multiple welders to one file Save Cycle Data Directories XML Directory 1 C Documents and Settings All Users Application Data Dukane C F XML Directory 2 F CSV Directory Figure 4 48 Save Cycle Data 1 Continued Page 64 Dukane User s Manual Part No 403 585 00 Continued from Previous Page Options Shifts Graph Data Cycle Data Setup Barcode Force Appearance Diagnostics Files Other w Display only most recently welded cycle data Limit the file size of XML cycle data files file Period t
32. Troubleshoot Figure 2 3 Setting Display Colors and Resolution Windows XP Continued Page 8 Dukane User s Manual Part No 403 585 00 Continued from Previous Page CD ROM Drive A CD ROM drive is required to install the iQ Explorer II software Hard Disk Space The iQ Explorer II software requires approximately 22MB of hard disk space for installation Communication Ports USB Port At least 1 USB port is required for the iQ Explorer IT installation The port will be used by the security key Ethernet Port An Ethernet port is required for the iQ Explorer IT installation Security Key A USB security key is required The driver for the key is installed when the iQ Explorer II program installs on your computer Please refer to Section 3 Installation Page 17 for more information Dukane User s Manual Part No 403 585 00 Section 2 System Requirements Continued Page 9 iQ Explorer Il User s Manual Software Requirements iQ Explorer Microsoft Windows operating system Windows The computer operating system OS must be Microsoft 32 or 64 bit versions of Windows XP Windows Vista or Windows 7 To determine which version of Windows you have select My Computer in the Windows Start menu as shown in Figure 2 4 Windows XP Select View System Information as shown in Figure 2 5 below 4 My Computer Continued from Previous Page II software is only comp
33. al This page intentionally left blank Page 98 Dukane User s Manual Part No 403 585 00 Dukane ISO O ISO CERTIFICATION Dukane chose to become ISO 9001 2008 certi fied in order to demonstrate to our customers our continuing commitment to being a quality vendor By passing its audit Dukane can assure you that we have in place a well defined and systematic approach to quality design manu facturing delivery and service This certificate reinforces Dukane s status as a quality vendor of technology and products To achieve ISO 9001 2008 certification you must prove to one of the quality system regis trar groups that you meet three requirements 1 Leadership 2 Involvement 3 Quality in Line Organizations and Quality System Infrastructure Dukane User s Manual Part No 403 585 00 The ISO 9001 2008 standard establishes a minimum requirement for these requirements and starts transitioning the company from a traditional inspection oriented quality system to one based on partnership for continuous improvement This concept is key in that Du kane no longer focuses on inspection but on individual processes Dukane s quality management system is based on the following three objectives 1 Customer oriented quality The aim is to improve customer satisfaction 2 Quality is determined by people The aim is to improve the internal organization and cooperation between staff members 3 Quality is a continuous impro
34. ame LAN or High Speed Internet Local Area Connection LAN or High Speed Inter Connected Firewalled Intel R PRO 100 YE Net Wizard G New Connection Wizard Ka Figure 5 1 Network Connections Window L Local Area Connection Properties Je General Authentication Advanced Connect using ES Intel R PRO 100 VE Network Conne This connection uses the following items M El Client for Microsoft Networks M dE File and Printer Sharing for Microsoft Networks MA 2 005 Packet Scheduler Y 5 Intemet Protocol TCP IP Description Transmission Control Protocol Intemet Protocol The default wide area network protocol that provides communication across diverse interconnected networks C Show icon in notification area when connected Notify me when this connection has limited or no connectivity Figure 5 2 Local Area Connection Properties Continued Dukane User s Manual Part No 403 585 00 Page 75 iQ Explorer II User s Manual Continued from Previous Page 2 Inthe Internet Protocol TCP IP Properties window enter the following IP address 169 254 0 10 3 Enter Subnet mask 255 255 0 0 Click to See the Figure below show list of available Scan Network welders Internet Protocol TCP IP Properties A General Q iQ Explorer Il You can get IP settings assigned automatically if your network supports this capability Otherwise you need to ask your net
35. and Importing Users Users may need to access multiple ES model iQ welders in a network In addition each of these welders may be controlled by their own copy of iQ Explorer II software If this is the case entering user information repeatedly could become tiresome and vulnerable to data entry mistakes In the Setup Users section of the Security tab in Options iQ Explorer II provides Export Security and Import Security features Export Security saves user information to an encrypted file with an extension of iqu Import Security loads user information from such a file into a different PC With this capability the user can easily distribute user information Also the user has a way to back up user information Dukane User s Manual Part No 403 585 00 Audit Storage What is Tracked Each stored event contains an attribute of the logged in user ID The following events are stored in the audit files 1 Opening of the audit file marking iQ Explorer IT starting up 2 Closing of the audit file marking iQ Explorer IT shutting down Successful user logons with user information Failed logons with failed user identification User log off DH Mm A Modification to any parameter identifying the parameter and its new setting 7 Execution of a weld 8 Setup change identifying the new setup name 9 Setup erase 10 Alarms 11 Restore factory defaults 12 Adding a user 13 Removing a user Continued
36. and profiling O Hold settings Travel Limit for iQ servo O Afterburst O Amplitude and Power Regulation O Enable Advanced settings Q Advanced servo settings 8 iQ Explorer II Welder 1 Seryo1 O Ele Tools Window Help a a a 8 e e i Gee Operation Summary Process Settings Process Limits Notes Cycle Data Graph Production Utilities System Hardware Initiate Mode Amplitude and Power Regulatio Enable Advanced Settings O p g O opo AG Weld Amplitude 60 96 Manual 1 0000 in Teach i Power Regulation Advanced Trigger gg O Sensing Start Type Force Max Trigger Time Sensing Speed Position Force 15 0 5 000 s 0 0900 in s 1 5372 in Teach T Enable Advanced Trigger Settings Advanced Weld Primary Method Energy Max Time Secondary Method Energy 150 0 J 2 000 s Disabled K Enable Melt Detect After Force Drops By 2 Advanced Servo Weld Motion Control QO p pi Weld Profile Speed Speed z Constant 0 0100 in s Q Post Weld Dynamic Hold Method Hold Distance Speed Max Time Travel Limit Distance 0 0010 in 0 0100 ins 5 000 s 5 0000 in Teach Static Hold Method Hold Time Time 0 100 s r Afterburst Forme EStop kag Monday December 03 2012 317 17PM View Live Data Touch the button to view real time weld data Figure 4 32 Setup Process Settings Continued Dukane User s Manual Part No 4
37. arefully open your shipping container and make sure it contains the items shown on the shipping documents Inspect all items and report any missing items or damage immediately iQ Explorer II Kit Contents Dukane Part No 438 987 item DukanePartNo 437 00255 Security Key 433 38 Ethernet Patch Cable 200 1552 03M 403 585 Installing Microsoft Windows Operating System Only 1 Place the CD in the PC s CD ROM drive tray and close the tray 2 The CD should start the automatically If this does not happen go to START then RUN and key in this command d setup exe Where d is your CD ROM drive installation process 3 The iQ Explorer IT installation window will appear Follow the on screen instructions to complete the installation and remove the CD from the CD ROM drive tray when finished 15 iQ Explorer Welcome to the iQ Explorer Setup Wizard The installer will guide you through the steps required to install iQ Explorer on your computer WARNING This computer program is protected by copyright law and international treaties Unauthorized duplication or distribution of this program or any portion of it may result in severe civil or criminal penalties and will be prosecuted to the maximum extent possible under the law Cancel Installation Start up Screen Figure 3 1 Dukane User s Manual Part No 403 585 00 Section 3 Installation 4 Insert the USB Security Key Part
38. at least 800 x 600 resolution and 256 colors 8 bit is required SVGA Higher resolution and or more colors will improve display characteristics To determine your settings click on the Start menu as shown in Figure 2 1 Then select Control Panel as shown Your system may be capable of higher resolution and or more colors You may increase these settings to your preference When you are finished click the OK button and then close the Control Panel window Dukane User s Manual Part No 403 585 00 Section 2 System Requirements TIP The minimum requirements are not the same as the suggested configuration 1 60 GHz processor with 2G of RAM Just as we have a Minimum Daily Requirement of vitamins and calories no one tries to live on 600 calories per day Internet My Documents Internet Explorer Y LI E mail 3 My Recent Documents gt Microsoft Outlook ed My Pictures 2 My Music A Microsoft Excel wg My Computer f Adobe Acrobat 4 0 a My Network Places Microsoft Word tb Control Panel pa Printers and Faxes Calculator DA Shortcut to PM65 Help and Support P Search 7 Run Solitaire Deti Dell Solution Center Log Off g Shut Down All Programs gt Select Control Panel from the Start Menu Windows XP Figure 2 1 Continued Page 7 iQ Explorer II User s Manual Continued from Previous Page In the Control Panel window double
39. atible with the File Edit View Favorites Cue a Tools Help 3 ya Search 3 Folders EJ Address W My Computer v E so System Tasks a View e Change a setting Other Places QD My Documents G Control Panel tem information T Add or remove progra a My Network Places Hard Disk Drives cg Local Disk C Shows information about your computer such as the processor speed and tl Devices with Removable Storage EX Exploring My Computer Internet Internet Explorer Adobe Acrobat 4 0 Xy Microsoft Excel Microsoft Word la E Calculator Shortcut to PM6S id Solitaire E mail Microsoft Outlook All Programs gt No My Documents B My Recent Documents My Pictures 2 My Music ngg My Computer 4 My Network Places G Control Panel B Printers and Faxes Help and Support P Search W Run Bese Dell Solution Center Figure 2 4 Log off 0 shut Down Selecting My Computer Windows XP olx t Re File Edit View Go Favorites Tools Help Detail k3 4 Be etails A e G a 9 pa Ka x My Computer i Back Forward Up Cut Copy Paste Undo Delete Properties System Folder Niin Address B My Computer y Folders x Name Type Total Size Se KA Desktop 3 Inch Floppy Disk PB Conois Local Disk 1 49GB ae E Explore L Network Connec
40. ce Appearance With this feature the PC display image can be enhanced when iQ Explorer IT is running Among other things a background image and a watermark for reports can be set Diagnostics This option enables the ability to save messages to and from the welders Language This menu displays the list of available languages supported by iQ Explorer II All iQ Explorer IT displays will be converted to the language selected Units Imperial Select this and it converts all contents in all windows to show Imperial units This does not have an effect on how units are displayed in any generator Metric Select this and it converts all contents in all windows to show Metric units This does not have an effect on how units are displayed in any generator Snapshot Select this menu item to start the process that compresses a copy of the iQ Explorer IT environment into a zip file and places it on the Windows desktop The zip file contains version information the current setup recent cycle and graph data alarm history and basic configuration information The Dukane Service Department may ask for a Snapshot while troubleshooting your system Page 26 Continued Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page Window Select this menu to rearrange window interfaces See Figure 4 4 to the right for the Window menu Help See Figure 4 5 to the right for the Help menu
41. click the Display icon See Figure 2 2 below e Control Panel Fie Edit View Favorites Tools Help Back lt 2 3 po Search gt Folders E Address Es Control Panel Grao 6 E D W y Accessibility Add Hardware Add or Administrative Automatic Date and Time Dis lay GF Switch to Category View Options Remov Tools Updates e A 1 4 ee YD PN Find Fast Folder Options Fonts Game Intel R Intel R TA et Ka Windows Update Controllers Extre PROSet II Options Help and Support EX a e a an aa Figure 2 2 Select Display from the Control Panel Window Windows XP A new popup window appears showing your current display properties Click the Settings tab to view your current settings Use the slider in the lower left corner of the window to adjust the display to at least 800 x 600 The drop down menu in the lower right indicates the current color palette Select at least 256 colors 8 bit See Figure 2 3 to the right Your system may be capable of higher resolution and Display Pro perties Themes Desktop Screen Saver Appearance Settings or more colors You may increase these settings to your preference When you are finished click the OK button T isplay and then close the Control Panel window Philips 1075 10751 on Intel R 82845G GL GE PE GY Graphics Controller Screen resolution Color quality Less More Highest 32 bi iy 1024 by 768 pixels NG BG NG
42. coconononanonononono ANA NANANA NANANA NANANA NANANA nn nro E i eE 58 4 42 SOUP Wiltes EN NAA E AA AANI NANA 59 4 43 Setup Utilities Test Display Sample 1 1 1777 7 777002 0000 a a aa a a 60 4 44 Setup Systemi Wa TI anakan anaie 61 4 45 Setup System Overview nono nono r E E E E Ea EPERE ERa 62 4 46 Operation SUMMAT osas otaa A E O AA 63 4 47 Save and Retrieve Setup Files 1 1170 000000000 0 anaaanananaaanananaaanaaanaaanaansaansaaasaaasaasana 64 4 48 Save Cycle Datas diri 64 4 49 save Cycle Data gt piccolo a ET EE E aS 65 Continued Page 88 Dukane User s Manual Part No 403 585 00 Section 7 Appendices Continued from Previous Page Appendix A No Description Page 4 50 SE cece ee NAA E NAA NANANA RANA RANA AANAAANAAA NANANA ANNA annaannaaanaanONN 66 4 51 Help File Access from Top Menu Bar 1077777 narra 67 4 52 Help Ele Using the Se Aa AA AA 68 4 53 Help File Using the Contents Baa ANAN NAE AG GAAN ta 68 4 54 Problem Prompt in Yellow 11111171777777 NN 69 4 55 Parameter Conflict Display NGA ceesagyedvavaeta tataatdeenedeaccxeengnndvenvatcedee teudasecees 70 5 1 Network Connections Window oooooooooocooocconcnoncnnncnncnnnnnnnnnnnnnnnnnonnnnnnnnnnnnnnnnnnnnnnoninnnnnoss 75 5 2 Local Area Connection Properties oooooooooocoooccnccnncconnconnnnnnnonnnonnnonnnnnnnnnnnnnnonnnonnnoninoos 75 5 3 Internet Protocol TCP IP Prope tle naasa 7
43. d User Display Name User Name User Level Options Communications Security PLC Interface Shifts Force Graph Data Cycle 4 r Default Yes response to automatically yield access to welder iv Enable user level access Setup Users Custom Levels Y Show keyboard on password entry for touchscreens F Enable automatic log off timeo hs minutes C Documents and Settings All Users Application Data Dukane Corp EE Cancel Figure 4 12 Options Security Setup Users Manage User Names User Display Name _ User Name User Level Rob R24 Administrator Add New Delete Reset Password Create Password Export Security Import Security Exit Figure 4 13 Options Security Add New User Figure 4 14 Options Security Create User Profiles Dukane User s Manual Part No 403 585 00 Continued Page 39 iQ Explorer II User s Manual Continued from Previous Page Creating Custom Level User Profiles Figure 4 15 to the right appears after Custom Levels has been clicked on the Security tab Two custom security profiles can be set up Use the Permit column for items the user can edit Use the Read Only column for things the user can only monitor read Show Keyboard on Password Entry for Touch Screens When enabled the pop up keyboard will automatically display when the password entry window is shown Double clicking on the
44. der the press uses Cote in When the generator is paired with a servo press this feature is not available Figure 4 25 Options Force Tab Continued Dukane User s Manual Part No 403 585 00 Page 45 iQ Explorer II User s Manual Continued from Previous Page Appearance With this feature the PC display image can be enhanced when iQ Explorer II is running See Figure 4 26 to the right There are three files that contain graphic images used by the program Default Setup Image This is an image associated with the setup files and is displayed on various screens Background Image This is an image centered and displayed that forms the background for iQ Explorer II Report Watermark This image is used as a watermark on reports generated for setups The user may choose images other than the original default images The image of a part as it appears on the tab for Hardware in Figure 4 27 shown to the right illustrates this option Diagnostics With this feature enabled communication between iQ Explorer II and the iQ generator can be diagnosed by Dukane during a troubleshooting process Figure 4 28 to the right shows that Save Messages can be enabled This activates the designated directory to receive any messages that pass to or from the software to the generator Page 46 KIN Shifts Force Graph Data Cycle Data Setup Appearance Diagnostics Default Setup Image C Progra
45. e Save setup file directory Select serial port Enter barcode specs Locations for Default Background Image and Report Watermark Setup Image Select air cylinder bore size g R Enable message log to from e Location for saved Diagnostics welders messages to from welders Table 4 1 Options Choices for the Operator NOTE Data is saved to the PC s hard drive NOTE Password protection prevents editing It limits those without proper access permission from making unauthorized changes to the weld pro cess or to iQ Explorer II options Dukane User s Manual Part No 403 585 00 Page 33 iQ Explorer II User s Manual Continued from Previous Page Communications This option relates to how iQ Explorer IT connects to iQ generators on the network See Figure 4 8 for a view of this tab Auto Display Welder Contents Q Enable this feature to always display the user interface immediately following the detection of the welder This is best used when iQ Explorer II is directly connected to a single generator Permitted IP Addresses Add IP addresses of iQ generators to this list to limit the iQ Explorer I interface to only those on the permitted list This is best used when many iQ generators are present on a single network and iQ Explorer IT is dedicated to a subset of the generators on that network Edit Permitted IP Address List iQ Advanced IP Address 176 17 5 102 Add Remove E
46. e following information e Model and serial numbers of the press and generator e Fault error alarm indicators from the generator display or iQ Explorer IT software e Software versions On generators with a display go to Main Menu and press Help On generators without a display in iQ Explorer IT go to Help on the top menu bar and select About iQ Explorer II e Problem description and steps taken to resolve it e Line voltage s for press and generator 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 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 User s Manual Part No 403 585 00 Section 6 Contacting Dukane Page 83 iQ Explorer Il User s Manual This page intentionally left blank Page 84 Dukane User s Manual Part No 403 585 00 Section 7 Appendices Appendices Appendix A List of Figures 3 a aaa 22h e40 288 ca deus 87 Appendix B List of TableS
47. eld Mode Axes Booster Buzzer at Top of Stroke Buzzer at Trigger Buzzer Status Constant Force Constant Speed Count Bad Parts Cycle Setup Swi Distance Increment Downstroke Pressure Dual Method Weld Dynamic Hold Method Dynamic Hold Until Force Reached Dynamic Hold Until Motion Stops Figure 4 52 Help File Using the Index Tab d o 8 L Hide Back Print Options Contents Index 3 Introduction Contents Tab Cj Hardware E Process Control Process Limits Notes E Graph 9 Utilities CJ System amp Options E Communications E Security E PLC Interface E Shifts E Force Aa Graph Data Cycle Data E Setup ll Appearance E Diagnostics E Operation Summary E Specifications E E EE Figure 4 53 Help File Using the Contents Tab Page 68 Dukane User s Manual Part No 403 585 00 Software Prompts One of the functions the software provides is to notify the operator of a condition that needs immediate attention These notifications may occur for one of these reasons e the iQ Explorer II software requires that a value or other data be entered or e the generator may have a error fault alarm So in response to these situations the iQ Explorer IT displays windows with prompts for the operator Several examples are shown in Figure 4 54 below and in Figure 4 55 on the next page RA iQ Explorer II Welder8 Setup 3 Welder Name Welder
48. ermo Cup 0 File Tools Window Help z ro Wr z y m iG OS WwW The user may press and hold the Test button for as long as necessary When the user s finger is lifted from a touch screen or the finger is released from the button of a mouse the test ends and a graph is displayed See Figure 4 43 View real time data G View the alarm history MEJE aie ration Summary Process Settings Process Limits Notes Cycle Data Graph Production Utilities System Hardware Part Count Reset Modify 9 Count Bad Parts nable Latch Reset Setup Utilities Setup Control iQ Selection sl Erase Setup Test Erase All Setups WARNING Clear area around stack before executing the sonics test Sonics will stay active as long as the user presses the button Setup File Name o1 Thermo Cup Rename Setup File Rename Setup File Image Vibe Part 0443 jpg am Figure 4 42 Setup Utilities Dukane User s Manual Part No 403 585 00 Friday July D6 2012 10 25 10 AM Continued Page 59 iQ Explorer Il User s Manual Continued from Previous Page Utilities Sonics Test Figure 4 43 below illustrates the kind of data displayed after the TEST button is activated on the Utilities page NOTE The values in the upper left portion of Click EXIT when finished reviewing this data the graph display seen in the figure below show the X and Y values f
49. ervo I O Serial Commynications 9 Output Format Comma Delimited Output Mode All Baud Rate 9600 Bd Add LF after CR Print Header Enable Limit Indicators 1 Restore Factory Defaults GSE E stop RE Friday July 06 2012 10 28 23 AM Figure 4 45 Setup System Overview Continued Page 62 Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page Basic Setup 14 Click on the Operation Summary tab Figure 4 46 shows a sample of data as it might appear in real time The essentials of the setup are shown along with graph and cycle data In addition by clicking on the View Live Data button O generator output data can be seen as it happens The Graph Setup button can be clicked allowing the operator to customize the graphing display iQ Explorer II Mini Servo Setup 1 ja File Tools Window Help r r y a Operation Summary Process Settings Process Limits Notes Cycle Data Graph Production Utilities system Hardware Graph Setup O ssapjaa MOYS Trigger Force 20 0 lb Sensing Speed 0 1000 inis Sensing Start 2 4919 in Position Weld Energy 20 0 J N a Force Ib N a ut a2uejsig Weld Amplitude 100 e Weld Constant Speed 0 0100 inis Hold Distance 0 0010 jn Hold Constant Speed 0 0200 inis E 0 8 1 2 Time s Static Hold Time 0 100 s Part Count Part Posi
50. faults QD WARNING Modifying hardware settings may effect operation of unit Cancel Buzzer Status F Buzzer Status F Buzzer at Trigger F Buzzer at Top of Stroke Servo Press View Servo Diagnostics View Servo I O Continued Page 61 iQ Explorer II User s Manual Continued from Previous Page System modifications Output Mode Determines what is sent All Good Bad etc Baud Rate Speed setting of the serial port in use Add LF after CR Determines what follows a data record a carriage return CR only or a CR followed by O System I O Designed for flexibility when a line feed LF integrating the ultrasonic system with automation Hardware fine tuning is offered on the System page See Figure 4 45 for an overview Make Change Selections Enable Limit Indicators When enabled a lt or a Refer to Dukane 5 website for Application Notes that gt precede a field of cycle data that is either lower or deal with automation interface higher than a process limit respectively http www dukane com us DL ApplData asp Print Header Press this button and it triggers the transmission of the delimited header for cycle data to O Buzzer Status When this setting is disabled the serial port the buzzer does not make a sound When enabled the buzzer sounds when cycle data is outside the suspect Servo Press Specific to servo press systems or bad part limits View Servo Diagno
51. g Work cell A Dukane Lean Work Cell can be integrated with basic PLC managed operations Dukane User s Manual Part No 403 585 00 Section 2 System Requirements System Requirements Computer Requirements a 7 jo A ch tee FeO Ah GAD AKA KAKA ITNA 7 E sx bakang cee etere alesse weber wel et BAKA DAA oo 7 video DISplay eee pada reaa KAG ee a aa p Ha r CD ROM DVE ernesto sisi rare pe oes 9 Hard Disk Space cisreriaiia NA LAG Ka PARAK dd 9 Communication Ports 1 i606 ii aca ca o ie 9 Software Requirements 00 000 cee eee eee 10 Windows 2 2 paaa P ede mats ad dia 10 INET FrameWwotk sico sarria ida BA BRA BANGA data Ge hi 14 iQ System Requirements 0000 cece ee o 14 Dukane User s Manual Part No 403 585 00 Page 5 iQ Explorer Il User s Manual This page intentionally left blank Page 6 Dukane User s Manual Part No 403 585 00 Computer Requirements iQ Explorer IT software requires the minimum computer hardware configuration mentioned below Processor An IBM compatible computer desktop or laptop is required The processor must have a clock speed of at least 1 60 GHz to operate A faster processor with a more advanced architecture will provide improved performance Memory At least 2GB of RAM are required Less memory will result in an unacceptable performance penalty 4GB of memory or more will enhance the system response Video Display A color display with
52. g as the DHCP server permits it If no DHCP server is available on a network following a timeout the DHCP client will self assign a random IP address in the range from 169 254 0 0 to 169 254 255 255 Network Settings on the O ES Generator Configuration of network settings on the i ES model generator can be found by pressing the Utilities Hardware button then the Hardware Setup button then scroll down to Network Settings and press that button All network configuration settings from the ES are available here To configure a hard IP address on the iQ ES model generator disable DHCP select IP Address from the list and enter a new IP address as you would any other parameter for the generator Dukane User s Manual Part No 403 585 00 Page 73 iQ Explorer II User s Manual Network Settings Direct Connection The most common use for iQ Explorer IT is directly connected to an iQ ES generator using an HMI purchased from Dukane Although this is a simple network there are a few ways to configure it DHCP Enabled As described above if the user enabled DHCP on both the HMI and the iQ ES generator those devices will self assign random IP addresses in the range 169 254 0 0 to 169 254 255 255 The main drawback to this configuration is that the timeout on the HMI or any PC is usually somewhere between 30 and 60 seconds This could be unacceptable The timeout to self acquire an IP address on the iQ ES generator i
53. ge vi Dukane User s Manual Part No 403 585 00 Section 1 Introduction Introduction General User Information 3 Read The Manual First o aaa 3 Notes Cautions and Warnings ooo aaa o 3 Drawings and Tables o a a a a 3 iQ Explorer II Overview 0000 4 Key Features veias cs 4 Dukane User s Manual Part No 403 585 00 Page 1 iQ Explorer Il User s Manual This page intentionally left blank Page 2 Dukane User s Manual Part No 403 585 00 General User Information Read This Manual First Before operating your software read this User s Manual to become familiar with it The manual is organized to al low you to learn how to effectively operate this program Examples given are chosen for their simplicity to illus trate basic operation concepts Notes Cautions and Warnings Throughout this manual we use NOTES to provide in formation that is important for the successful applica tion and understanding of the product A NOTE block is shown to the right In addition we use special notices to make you aware of safety considerations These are the CAUTION and WARNING blocks as shown here They represent in creasing levels of important information These state ments help you to identify and avoid hazards and rec ognize the consequences One of three different symbols also accompany the CAUTION and WARNING blocks to indicate whether the notice pertains to a c
54. hic feedback iQ Explorer II 20 kHz Thermo Cup j File Tools Window Help r GEA GG r G x 5 3 MOS w Operation Summary Process Settings Process Limits Notes Cycle Data Graph Production Utilities System Hardware Production Analysis Started at 07 59 15 Good Parts 8 100 0 Suspect Parts 0 0 0 Bad Parts 0 0 0 Total 8 Average Parts per Hour m Stacked Number of Parts T 07 00 08 00 08 00 09 00 09 00 10 00 Time HUA Good C7 Suspect MW Bad Friday July 06 2012 10 24 27 AM Figure 4 41 Setup Production Display Continued Page 58 Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page O Test Basic Setup 12 Click on the Utilities tab Some setup management and diagnostic tools are offered here See Figure 4 42 below for these things O Part Count This utility permits part count to be reset or modified The utility can also be used to prevent bad parts from being counted and to reset the latch that can occur when Latch on Bad Part 1s enabled O Setup Utilities Use Setup Control to choose a setup One setup can be erased with Erase a Setup or all setups can be erased with Erase All Setups This section can be used to select a different stored setup from the welder Renaming the setup and selecting a different image for the setup can be done here as well 2iQ Explorer II 20 kHz Th
55. iate cycle data column Lower Bad Lower Suspect display Upper Suspect and Upper Bad on this Process Limits page Adds item to the weld cycle data display Monday December 03 2012 22231 PM Figure 4 33 Setup Process Limits Drop Down Menu Detail Continued Page 50 Dukane User s Manual Part No 403 585 00 Continued from Previous Page Process Limits Helper This feature assists users with setting process limits from an aggregate of cycle data derived from good parts Limit Helper is an advanced iQ Explorer I feature designed to assist in setting upper and lower process limits Typically this is some number of a controlled lot of parts welded The Process Limits Helper can calculate standard deviation and average value for each process parameter defined for this controlled lot This statistical information along with part inspection is a very useful tool in setting the range for upper and lower suspect and or bad part limits See http www dukane com us PPL iQ Servo Press htm for more information on Limit Helper Figure 4 34 shows the display after the Process Limit Helper button has been activated but not enough part data exists for the feature to be used 2 iQ Explorer 11 Welder8 Setup 1 r G KA Ge Section 4 Operation Operation Summary Process Settings Process Limits Notes Cycle Data Graph Production Utilities System Hardware siapjam MOUS
56. in the upper left portion of the graph display seen in the figure below show the X and Y values for the cursor position Cursor movement causes corresponding changes to these values OR Explorer II Mini Servo Setup 1 je File Tools Window Help Operation Summary Process Settings Process Limits Notes Cycle Data Graph Production Utilities System Hardware Force Distance __Refiesh_ Refresh 0 0 F Interaction F Show Reference Br ico Graph Setup jo jo Saapa MOys Mini Servo Setup 1 Part Count 21 Friday November 09 2012 2 2 3 8 3 Force Ib Time s Friday November 09 2012 2 42 54 PM Figure 4 38 Setup Graph Display Continued Dukane User s Manual Part No 403 585 00 Page 55 iQ Explorer II User s Manual Continued from Previous Page Graph Features 0 Transition Point This is a moment in the weld cycle where one phase of the cycle ends and another phase begins Place the cursor on a transition point to read data about that specific event Save as Reference Press this button to save the current graph as the reference graph associated with the current setup Show Reference Check the box to have the reference graph appear along with the real time graph Save as Reference Graph Setup F Interaction l Show Reference Mini Servo Setup 1 Part Count 21 Transition Points Friday November 09 2012 E Figure 4 3
57. inistrator display name user name and password This is illustrated in Figure 4 11 This will open up more security related features Yes An Administrator level user can modify any features in the Options popup including adding users The following levels of user are available administrator process engineer setups operator and two user defined custom Password levels More explanation about these levels is given on O the next page a Password Repeat Password OK Cancel Figure 4 11 Options Set Password Continued Dukane User s Manual Part No 403 585 00 Page 37 iQ Explorer II User s Manual Continued from Previous Page User Access Levels There are six access levels on iQ Explorer II and ALL of them require passwords The list of access levels is as follows Administrator This level permits access to all parameters and features available in iQ Explorer II Process Engineer This level permits access to all setup parameters and setup files This level prevents changing language units and the Options settings as well as limiting write access to parameters in the System tab Setups This level permits access to changing or loading setups but excludes write access of any parameter setting individually This level also prevents changing language units and the Options settings Custom 1 Custom 2 These levels are the same as the Setups level but may be customized by the user t
58. it will prompt you to overwrite it Save Current Setup File As A pop up window displays the list of stored setup files on the PC This pop up window can be used to navigate to a directory other than the one defined in the Options The user can change the name of the setup when saving to file If the name of the file is changed the corresponding name of the setup stored in the file itself is changed to match the filename Copy Setup to Welder A small pop up window displays the list of slots in order to have the user select the target slot on the welder to copy the currently active setup Erase Setup From Welder Select this action to erase the currently active setup file from the welder Delete Setup File from Disk A pop up window displays the list of stored setup files This pop up window can be used to navigate to a directory other than the one defined in the Options The user can select a file and delete it from the PC Save Cycle Data As A pop up window displays the list of cycle data files on the PC This pop up window can be used to navigate to a directory other than the one defined in the Options The user can change the name of the cycle data file when saving it Page 24 Save Graph Data As A pop up window displays the list of graph data files on the PC This pop up window can be used to navigate to a directory other than the one defined in the Options The user can change the name of the graph data file when saving it
59. ith O Ea ia 4o an 3 nable barcode 3 lame a setup name loaded on the welder or stored in the setup directory of the PC Press the Associate Barcodes button A new pop up screen as shown in Figure 4 24 appears Figure 4 23 Options Barcode Tab On this screen Figure 4 24 to the right the user links a barcode or barcodes to a setup name In addition buttons Setup Name ABS 12 ETA are used to browse the setup file to reset the screen and Scan to add modify or delete setup file data Scan Scan Once a barcode is scanned the associated setup will be aga activated or loaded oag The welder is not permitted to weld until an identified barcode or set of barcodes are scanned properly and the associated setup has been properly loaded Cancel Delete Enabling this feature prevents the use of the welder Figure 4 24 Options Barcode Tab Link Names unless iQ Explorer II is connected as well Force When this option is enabled the user can have air pressure Security PLC Interface Shifts Graph Data Cycle Data Setup Barcode Force Appearance 1 4 gt settings displayed in units of force instead of pressure F Enter force instead of pressure 1 1 y Select Air Cylinder See Figure 4 25 to the right 1 5 inch bore air cylinder Calculated pressure settings are still displayed at Z i 3 0 inch bore air cylinder The user needs to select which air cylin
60. m Files Dukane Corporation iQ Explorer IINQEII Default jp Background Image C Program Files Dukane Corporation iQ Explorer IINQEII Default jp Report Watermark C Program Files Dukane Corporation iQ Explorer IINDUKANE jpg Cancel Figure 4 26 Options Appearance Tab eee Operation Summary Process Settings Process Limits Notes Cycle Data Graph Production Utilties System Hardware Welder Name 20 kHz Welder Time 7 6 2012 10 43 AM Set Welder Date Time Serial Number Setup File Name 01 Handle Rename Setup File Rename Setup File Image C Documents and Settingsimjohnston My Documents My Pictures Dukane Jpegs 7 27 07 Wibe Pa Installed Hardware IP Address IG Motherboard Version v3 08 02 00 Figure 4 27 Options Appearance Default Image Changed EZ Options Shifts Graph Data Cycle Data Setup Barcode Force Appearance Diagnostics Directory to log messages from to welders Save messages le Documents and Settings All Users Application Data Dukane Corporation iQ Explore Figure 4 28 Options Diagnostics Tab Dukane User s Manual Part No 403 585 00 Basic Setup When iQ Explorer IT starts up it seeks communication with ES Model iQ welders It can establish a session with as many connections as the user has welders In the following example two welders have been detected on the network 1 To view the available connections
61. n nono no E a EER E 43 4 21 Options Cycle Data Tab PIES ntarantcresdoatansicacicaiapiaa rita Ea ceadaialanciana 44 4 22 Options Cycle Data Tab Other visas 44 4 23 Options Barcode Tabunan AA aaa Nan a 45 4 24 Options Barcode Tab Link Names 1111 7077700 amanasasawaaanananaanaaanaaanaaaanaasanaaaaasaaaaaaanana 45 4 25 Opiions Force Tabasa NAGANA AA AVE idolo 45 4 26 Options Appearance la Derecesi a NANANA 46 4 27 Options Appearance Default Image Changed coooooccoccccocooocoonoconcnoncnnncnncnoncnoncnoncnononos 46 4 28 Options Diagnostics Tabs 46 4 29 Setup Show Welders 111111111111ramararn nA 47 4 30 Setup Selecta Weldam maman GANAN aa AGA 47 4 31 Setup HardWare eerren nra AGA AA Abad 48 4 32 DOU Process SOWING S AA a 49 4 33 Setup Process Limits Drop Down Menu Detail ooooooooooocooocococooocooncnnncnncnnncnnncnoncnononos 50 4 34 Setup Process Limits Helper When Not Enough Data oooooooccocooononicocaccocononeninnanas 51 4 35 NOLS oc 52 4 36 A O A o A Un O AARNE EN NEE 53 4 37 Setup Graph Setup 1 11 70700000000000 000 a0 NE nono nono AE NARE NANANA nro nono nono AANAAA NANANA nnnnnnnnnnnnnnnnnnnnnnnos 54 4 38 Setup Graph Display saaan NAAAGNAS 55 4 39 Graph Display Detail aman AABANGAN cia 56 4 40 Setup Interaction Points 1 1 777000 sasawa aaa GANAN ANA ANA NANA nono nono nn nono nn nnnnnnnnnnnnnnnnnnnnnnnnnnnos 57 4 41 Setup Production Display oooooccccccccccono
62. ntinued from Previous Page Using the Security Tab The Security option tab is shown in the figure below Yield Access Q iQ Explorer II and the iQ generator are restricted from changing settings at the same time The user has to request access from the user interface that is currently in control This option determines whether access is yielded by default The timeout for the default response is thirty seconds Enable User Level Access Enable user level access to force a login to access iQ Explorer II See Figure 4 9 below 150 Options A Communications Security PLC Interface Shifts Graph Data Cycle Data Setup Barcode Fon 4 gt W Default Yes response to automatically yield access to welder W Enable user level access Setup Users Custom Levels Show keyboard on password entry for touchscreens lF Enable automatic log off timeout 15 minutes Directory to store audit trail Enable auditing to support FDA 21 CFR Part 11 compliance e Documents and Settings All Users Application Data Dukane Corporation iQ Explore os Cancel Figure 4 9 Options Security Tab Options When this feature is enabled the user becomes an Administrator A pop up window appears to enable an administrator level password as shown in the example to the right in Figure 4 10 shd 2 Do you want to set an administrator level password to enable security levels and auditing The user needs to enter an adm
63. o include a subset of parameters for this user to modify The user may define a unique name to each of these access levels The groups of parameter settings that can be included in the list of allowable parameters are Amplitude Trigger Pressure Weld Hold and Reset Part Count Operator This access level prevents write access to all parameters and prevents access to any action in the file menu or tool bar TIP If no user is logged in to the generator and passwords have been defined then the access level is Operator Operator is a read only interface When O Explorer IT connects to an ES generator that currently has only Operator access iQ Explorer II will be granted im mediate access There will be no need to wait for an Operator at the ES generator to yield access An Operator cannot decline ac cess to edit parameters Continued Page 38 Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page Setup Users The Administrator adds names and creates user profiles by first clicking on the Setup Users button as shown in Figure 4 12 to the right Adding Names The Administrator s details appear in the Manage User Names pop up window Click on the Add New button as shown in Figure 4 13 to the right to add a user Creating User Profiles Figure 4 14 below shows that entries are made with the virtual keyboard User Display Name User Name User Level Passwor
64. o save cycle data setto zero to save at exit only Limitthe number of cycle data to single 25 5000 10 parts Kbytes parts minutes Figure 4 49 Save Cycle Data 2 See the figure above for the next four Cycle Data features Display Most Recent Data Only the most recent cycle data will be displayed when this feature is se lected Regardless of this number all cycle data is saved Limit File Size The number of Kbytes entered will limit the maximum size of the cycle data file When it is time to save the cycle data file and it is in excess of this amount a new file will be created to store any future cycle data Regardless of the file size all cycle data is saved Limit Cycle Data When this option is selected the cycle data file will never exceed the number of cycles entered Only the most recent results will be saved to a single undated file When this setting is enabled you WILL lose historical cycle data Saved to File Rate Cycle data is automatically saved to file at this rate Ifthe user sets it to zero cycle data will only be saved on exit Dukane User s Manual Part No 403 585 00 Cancel Section 4 Operation Page 65 iQ Explorer II User s Manual Save and Restore Graph Data 1 Click the Options icon Refer to Figure 4 50 2 Click on the Graph Data tab and then the Files tab 3 Using the Main and Reference categories you may enter the designated directo
65. on to yield or not yield is defined by an option setting in the Security screen of the ES generator and the Options Security tab of iQ Explorer II By default the answer to the question is to deny the access to the remote user Stand alone Password Protection on the iQ ES Generator User Access There are four access levels three require passwords When the user specifies a password for any of these levels the user is required to enter that password to modify a subset of parameters Please see the generator User s Manual for further information on the levels of password protection that are available iQ Explorer IT and Generator Password Protection Once a password at any level has been defined on the iQ ES generator the password defined at the highest level is used as a lockout for any iQ Explorer II connection that may be on the network When an iQ Explorer II connection is attempted the user at iQ Explorer I is required to enter the highest level password to gain access to the generator even as a read only connection Once the user enters the proper password iQ Explorer II retains the password for that specific welder and uses it every time it needs to establish a connection to the welder For instance this will allow iQ Explorer II to connect to that generator indefinitely or until new passwords are assigned at the generator Page 36 Continued Dukane User s Manual Part No 403 585 00 Section 4 Operation Co
66. ondition or practice an electrical safety issue or a operator protection issue Drawings and Tables The figures and tables are identified by the section num ber followed by a sequence number The sequence num ber begins with one in each section The figures and tables are numbered separately The figures use Arabic sequence numbers e g 1 2 3 while the tables use roman sequence numerals e g I II IID As an ex ample Figure 3 2 would be the second illustration in section three while Table 3 II would be the second table in section three Dukane User s Manual Part No 403 585 00 Section 1 Introduction NOTE Note statements provide additional information or highlight procedures WARNING ms Warning statements point out conditions or P practices that could re sult in personal injury or loss of life Condition Electrical Hearing or Practice Hazard Protection Page 3 iQ Explorer II User s Manual iO Explorer II Overview This program enhances any compatible iQ Series ES ul trasonic generator press through a user interface that al lows monitoring and setup to be done virtually anywhere Whether installed on your desktop or laptop PC this tool gives more flexibility and control for the processes you manage Key Features iQ Explorer II User Interface Page Windows operating system Familiar file folder menu structure requiring no special training Touchscreen inp
67. ons Keyboard keys Figure 4 7 Icon and Function OpenorLoad setup file from disk Opens an existing setup file or loads a setup file from disk If the topmost window shows the interface of a connected welder then pressing this button will load a setup from file into the currently selected slot of the welder If the topmost window shows any other interface or no interface then pressing this button will open a setup file into its own interface as an offline setup Delete setup file Deletes an existing setup file If the topmost window shows the interface of a connected welder then pressing this button will delete the setup from the currently selected slot of the welder If the topmost window shows any other interface or no interface then pressing this button will delete a setup file from disk e Save current item Save data frequently Pressing this button will save the contents of what is currently on screen to file If the user is viewing cycle data pressing this button will save cycle data to file Ifthe user is viewing graph data pressing this button will save the graph to file If the user is viewing process settings pressing this button will save the setup to file Continued Dukane User s Manual Part No 403 585 00 Page 29 iQ Explorer II User s Manual Continued from Previous Page Print current item Print screen data Pressing this button will print the contents of what the user sees on sc
68. or the cursor position Cursor movement causes corresponding changes to these values Time Frequency Power A a F Interaction Save Test Data Amplitude 54 Y Value 3 N 5 E S 3 5 v 2 E i Time s Exit Figure 4 43 Setup Utilities Test Display Sample Continued Page 60 Dukane User s Manual Part No 403 585 00 Continued from Previous Page Basic Setup 13 Click on the System tab A WARNING appears immediately indicating that changing hardware settings may affect operation of the generator Click OK to proceed with hardware modification File Tools Window Help Section 4 Operation r a A E r r x 5 al o co i Operation Summary Process Settings Process Limits Notes Cycle Data Graph Production Utilities System Hardware System I O Status Output Duration Maintained M Auto Start Input Solid State Y Enable Auto Stop Input Define Auto Stop At End of Cycle El Define Programmable Output 1 J3 Pin 4 Servo Error Status Define Programmable Output 2 J3 Pin 5 Home Servo Status Define Programmable Output PADD Serial Communications Output Format Comma Delimited Output Mode All Baud Rate 9600 Bd Add LF after CR Print Header Enable Limit Indicators Restore Factory Defaults Figure 4 44 Setup System Warning Dukane User s Manual Part No 403 585 00 Restore I O De
69. press the Show Welders button to the left of the application as shown in Figure 4 29 Once a welder has been detected all setup information in the welder is synchronized with the PC File Tools Window Help Show Welders Button spem moys Figure 4 29 Setup Show Welders 2 Click on a welder button to open the interface to it Figure 4 30 below shows that Welder 1 was selected KB io Explorer Il Select Welder 1 a r Po r r a E 9 a sJ8pjam PIH Figure 4 30 Setup Select a Welder Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued Page 47 iQ Explorer Il User s Manual Continued from Previous Page Basic Setup O Current time kept in the welder 3 The Hardware tab is the initial tab displayed following selection of a welder This tab contains information specific to the identification of the welder itself See Figure 4 31 below for location of the items O IP address of the connected welder in the list that follows O Button used to apply the PC time to the welder Model and version information of Q Welder name embedded software O Serial number unique to Welder 1 List of 25 setups that are currently loaded in the welder O New name for the setup Click Rename to apply G Use the button to search the PC for a setup file to be displayed BA i0 Explorer 11 Welder 1 Seryo1 O file Tools Window Help r r r G G E Pi
70. r connect immediately using their default network configurations 2 When connection has been made the welder s Click to show list of available to the software are shown when the user available Scan Network presses the Show Welders button on the toolbar on welders the left of the application See Figure 3 3 to the right i 1G iQ Explorer Il 3 An example list of available welders is shown in Ele Took Window Hep Figure 3 4 to the right Notice that the button has changed to Hide Welders KI saapa MOYS a E Og io Ed i a Figure 3 3 Show Welders 1 H iQ Explorer Il File Tools Window Help r r 4 x Welder O Welder k I T T a T un Figure 3 4 Show Welders 2 Dukane User s Manual Part No 403 585 00 Page 19 iQ Explorer Il User s Manual This page intentionally left blank Page 20 Dukane User s Manual Part No 403 585 00 Section 4 Operation Operation Main MGA 46 02 oie owe ew eee ek ewes der ee dre ceo 23 PUL uss iacat PE edd owe bees anh OLE BASA BG Ba 23 WON Se ce uno gts ec es eee Gk ed ee eS NG AAO 25 NALIPAT 27 Os ap kas ie etn tae eee eek ae Re Lee E E ease Be 27 Main Screen ICONS 25 samaan cra cia KA 28 Making an Entry cru ia ee Kaka KAG acm oon oe hd eda SS 31 OPUS me tus se ec nada EE EEA E EE k R oe 32 Basic Setup xodo das odas 47 Save and Retrieve Setup Files 64 Save and Retrieve Part Data 0 00000
71. reen If the user is viewing cycle data pressing this button will print cycle data in a table format If the user is viewing graph data pressing this button will print only the graph If the user is viewing any interface that contains setup parameters pressing this button will process the setup into a report and print it If the user is viewing any other interface pressing this button will print a complete screen shot Change options Make settings to enhance how the PC manages the welding process Scan for welders See which welders are active in the network e Keyboard keys When no regular keyboard is available A simulated keyboard appears Use the mouse to position the cursor on the key you want Click to select Letters appear in the preview panel Click ENTER to place the text in the chosen entry box of the active window e Numeric keys For use when no regular keypad is available A simulated keypad appears Use the mouse to position the cursor on the key you want Click to select Numbers appear in the preview panel Click ENTER to place the numbers in the chosen entry box of the active window e Help Open an extensive help file e Exit Shuts down the iQ Explorer II application Page 30 Dukane User s Manual Part No 403 585 00 Making an Entry Keyboard and Mouse 1 Use the mouse to place the cursor in a white entry box and click This activates a flashing vertical bar and the box itself to
72. ries where graph data and reference graph data are stored 4 Using the Display tab you may limit the types of data that will be stored in the graph Another selection to make allows you to display a smaller sized graph in the cycle data screen 170 Options Communications Force Shifts Security Graph Data Industrial Appearance Part Data Tools Files Display I Automatically save graph data m Save Graph Data Directories C Proaram File Juka ation iQ Explorer GraphD ata Reference C Program Files Dukane Corporation iQ Explorer RefGraph Figure 4 50 Save Graph Data Page 66 Dukane User s Manual Part No 403 585 00 Using the Help System This help system is a reference tool to assist in understanding key terms of the ultrasonic welding process It can also provide information about software features and functions The iQ Explorer IT Help function can be accessed using the top menu bar or by pressing the F1 key as explained below Top Menu Bar Help is one of the top menu bar items as shown on the right in Figure 4 51 Clicking Help from the menu and then clicking on Help opens the Help window An example of the window is shown in Figures 4 52 and 4 53 on the next page About iQ Explorer II Another selection that can be made from the top menu bar after clicking on Help is to select About iQ Explorer Il A click on that phrase brings up a window containing facts about the software version used by the PC
73. s Serial Number 240485 Setup File Name MEET Section 5 Networking NOTE Refer to Making an Entry Page 31 for information about putting information in an entry box NOTE The material in this section of the User s Manual is intended to offer gen eral guidance in identifying the kinds of messages that may arise Welder Time 10 12 2012 4 29 PM SetWelder Date Time Rename Setup File Rename Setup File Image C Program Files Dukane Corporationtia Explorer INIQEI_Defaultjpg x Installed Hardware IP Address 172 16 26 81 iQ Motherboard Version v3 10 02 iQ Front Panel Version v1 09 00 Press Controller Version 245 2 v22 13 00 Model Number 40HS060 10 P7 Servo with Load Cell 625 22 System Frequency 40 KHz Power Level 600 W Friday October 12 2012 4 38 04 PM Yellow background indicates a problem In this example with the Hardware tab displayed the message is Off Top of Stroke Figure 4 54 Problem Prompt in Yellow Dukane User s Manual Part No 403 585 00 Continued Page 69 iQ Explorer Il User s Manual Continued from Previous Page Parameter Conflict Example In the following example shown in Figure 4 55 below yellow is used in several areas of the display not only to call attention to a problem but also to show what parameter needs to be addressed Yellow background indicates the entry box
74. s insignificant DHCP Disabled on the HMI To reduce the long delay due to the DHCP server timeout Dukane assigns the HMI in the factory a hard IP address of 169 254 0 10 and 169 254 0 11 to its two local connections DHCP Disabled on the O ES Generator To reduce unnecessary extra processing on the HMI iQ Explorer II may be configured to exclusively connect to one IP address First the user should disable DHCP on the iQ ES generator The default IP address assigned to the iQ ES generator when DHCP is disabled is 169 254 0 2 This is acceptable On iQ Explorer IT click on the Options button and look at the Communications tab At the bottom of the tab there is a section labeled Permitted IP Address List Press the Modify List and add 169 254 0 2 to the list Press OK to exit both windows See Figure 5 8 Now an explicit connection between the HMI and the iQ ES generator is established This is the optimum connection between an HMI and an iQ ES generator Page 74 Dukane User s Manual Part No 403 585 00 Section 5 Networking HMI Directly Connected to a Single Generator Open Network Connections in the Windows Control Panel The window should be similar to the one shown below Right click on Local Area Connection and select Properties a Network Connections File Edit View Favorites Tools Adve Address Network Connections Q Back O BP LP search Ey Folders XO m Name Type Status Device N
75. sing the Windows 7 operating system 1 Select Computer as shown in Figure 2 7 below j2 iQ Config Prod cil Getting Started lacopetti Paul Documents Connect to a Projector Pictures a Calculator Select Computer w Sticky Notes E an Computer y Q Snipping Tool Sanet Control Panel F Paint Devices and Printers gd XPS Viewer EY Windows Fax and Scan a Remote Desktop Connection gt All Programs Default Programs Help and Support Shutdown gt Figure 2 7 Start Menu Select Computer Windows 7 2 The Computer window appears An example is shown in Figure 2 8 below Organize v System properties Uninstall or change a program K Favorites 4 4 Hard Disk Drives 1 HZ Desktop de Downloads Go on 257 GB free of 297 GB i Recent Places 4 Devices with Removable Storage 1 Libraries E Documents a DVD RW Drive D a Music 8 E Pictures 4 Network Location 11 Ef Videos apps f roosevelt F NTFS jE Computer amp Local Disk C Figure 2 8 Computer Window Windows 7 Page 12 era useng sh roosevelt H r PICACOPETTI2 W7 Domain DUKANE DOM COM Processor Intel R Core TM i5 24 Continued Dukane User s Manual Part No 403 585 00 Section 2 System Requirements Continued from Previous Page 3 With the Computer window open right click to display the Computer submenu as shown below in Figure 2 9
76. stics This button gives access to Buzzer at Trigger The buzzer sounds when the an array of low level readings from the servo controller trigger condition is met View Servo I O This button provides access to Buzzer at Top of Stroke The buzzer sounds when current servo and iQ generator input status Servo the press is moved to its top of stroke position performance results can also be acquired O System Serial Communications This is for Engineers at Dukane Corporation can use these configuring the serial port as an output for cycle data readings to help diagnose problems and to provide ist ldi lications Output Format Determines how cycle data fields a erent Gee aes are separated iQ Explorer II 20 kHz Thermo Cup 0 File Tools Window Help p r a Ea CG r G o x fa SA 3 ye EA Operation Summary Process Settings Process Limits Notes Cycle Data Graph Production Utilities System Hardware System I O Buzzer Status O Status Output Duration Maintained r Buzzer Status Auto Start Input Solid State S28P aM MOUS pg y r Buzzer at Trigger r Buzzer at Top of Stroke Enable Auto Stop Input Define Auto Stop At End of Cycle Define Programmable Output 1 J3 Pin 4 Servo Error Status Servo Press Define Programmable Output 2 J3 Pin 5 Home Servo Status View Servo Diagnostics Restore I O Defaults Ignore Alarm on Auto Stop Signal View S
77. strate a pictorial view of the welding process Make Change Selections Figure 4 37 below shows two views of the graph setup window O Axis Labels Choose labels for left right and horizontal axes of the graph The figure shows a drop down list from which to select O Zoom Choose when the graph display of the cycle should start and stop The figure shows a drop down list from which to select O Reference Select a graph to overlay with a graph from the current cycle A reference graph can be saved for any setup at any time Reference graphs are stored in a directory separate from ordinary graphs A sample graph appears on the next page Graph Setup Axis Labels O Show Left Axis Force Amplitude Show Right Axis Distance Horizontal Axis ENer Frequency vo Power Start Graph At Speed Stop Graph At End of Hold Reference Graph Filename Coreled Cancel Figure 4 37 Setup Graph Setup Page 54 Axis Labels Show Left Axis Show Right Axis Horizontal Axis Start Graph At Start of Cycle Start of Cycle Stop Graph At Sensing Start Position Trigger Delay Start of Weld Reference Graph Filename Setup Coreled O Select Continued Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page Basic Setup 10 Click on the Graph Display tab NOTE See Figure 4 38 below to view a sample graph The values
78. subject to change without notice This user s manual documents product features hardware and controls software available at the time this user s manual was published Printed in the United States of America Dukane Part Number 403 585 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 User s Manual Part No 403 585 00 Revision History Revision Revision Number Summary Date 00 Original release March 7 2013 Dukane User s Manual Part No 403 585 00 Page iii iQ Explorer Il User s Manual This page intentionally left blank Page iv Dukane User s Manual Part No 403 585 00 Contents Section 1 Introducti0N oooooooo 1 Section 2 System Requirements 5 Section 3 Installation 15 Section 4 Operation 21 Section 5 Networking 71 Section 6 Contacting Dukane 81 Section 7 Appendices 85 A Listot FIQUISS a ou 52s AKDANG n KG ABA NI KASI aria 87 B List of Tables lt 622000804 60 804 LAGA NGA kA KA Dada e 90 C Regulatory Agency Compliance aa 91 o A AA 93 Dukane User s Manual Part No 403 585 00 Page v iQ Explorer II User s Manual This page intentionally left blank Pa
79. t the part of the IP address that is masked by the subnet is entered correctly e Your firewall could be preventing communications In that case see the IT administrator for help 6 Ifthe generator s name is displayed click that name and you are ready to start configuring your generator Connection through a Stand alone Network Using the simplified illustration shown in Figure 5 6 1 Connect the computer and the iQ ES generator to the Ethernet switch Every computer and generator are each considered nodes on the network 2 Connect the nodes to the Ethernet switch to establish cross connectivity through the stand alone network Ethernet Switch Factory Assigned IP 3 F E Address to Gea HMI p A rh 169 254 0 10 a uw a uw aa co 169 254 0 2 169 254 0 3 169 254 0 4 169 254 0 5 Figure 5 6 Simple Stand alone Network Configuration Dukane User s Manual Part No 403 585 00 Page 77 iQ Explorer II User s Manual Connection to a Local Area Network Most companies have a DHCP server running on their Local Area Network LAN Simply connect all ES model iQ welders to the LAN enable DHCP and the DHCP server will assign a unique IP address to each ES When DHCP is enabled on an HMI select Obtain an IP address automatically from the TCP IP properties it too can have a unique IP address assigned However the HMI does not have much available storage and it has below average processing
80. the Options The user can select a file and load the contents into a separate window of iQ Explorer II Load Setup from Disk A pop up window displays the list of stored setup files This pop up window can be used to navigate to a directory other than the one defined in the Options The user can select a file and load the contents into the CURRENTLY SELECTED SLOT of the welder Dukane User s Manual Part No 403 585 00 Section 4 Operation 1 iQ Explorer II Welder8 Setup 1 Figure 4 1 File Tools Window Help Select Active Setup Open Cycle Data File Open Graph Data File Open Setup From Disk Load Setup From Disk New Setup File Offline Save Current Setup File Save Current Setup File As Copy Setup to Welder Erase Setup From Welder 3 01 Sett caProgr Print Screen Print Setup Exit iQ Motherboard Version v3 10 0 iQ Front Panel Version v1 10 0 Press Controller Version 245 Main Menu File Continued Page 23 iQ Explorer II User s Manual Continued from Previous Page New Setup File Offline A pop up window displays the list of welder types that can be the target of the new setup Make the selection and press OK A blank setup for the welder will be displayed in a separate window of iQ Explorer I Save Current Setup File Select this action to save the currently active setup to a file on the PC with the existing setup name If the file already exists
81. tion Sy c Open Network Connection E Find System Folder E Create Shortcut Control Panel System Folder EEE G Dial Up Networking System Folder E Scheduled Tasks System Folder web Folders System Folder 4 28 Web Folders HEN My Documents Recycle Bin My Briefcase H My Computer 1 Figure 2 5 Selecting View System Information Page 10 Windows XP Continued Dukane User s Manual Part No 403 585 00 Section 2 System Requirements Continued from Previous Page After selecting View System Information a new popup window will appear See Figure 2 6 showing System Properties System Restore Automatic Updates Remote O A TM General Computer Name Hardware Advanced Version of Windows currently installed System O Type of processor used and Microsoft windon A Professional O Amount of memory installed Version 2002 Service Pack 2 Registered to 55555 0EM 0000000 00000 Manufactured and supported by Dell Computer Corpgf fion Dell OPTIPLEX GX Intel R DOLL Celeron R CPU 2 00GHz 1 99 GHz 512 MB of INC Support Information Figure 2 6 Checking Operating System Version Windows XP Continued Dukane User s Manual Part No 403 585 00 Page 11 iQ Explorer Il User s Manual Continued from Previous Page Windows 7 The four step process outlined here is a quick guide to viewing system information when u
82. tion Weld Weld Weld Weld Peak Weld Peak Hold Hold Setup Analysis at Trigger Time Distance Energy Power Force Time Distance Name Low BadiLow Suspect 73 774 19 8 20 0 High Suspect High Bad 891193 1 20 8 21 0 78 8 20 4 0 0011 Setup 1 09 Nov 2012 13 56 33 78 5 20 3 0 0011 Setup 1 09 Nov 2012 13 56 31 79 1 20 4 0 0011 Setup 1 09 Nov 2012 13 56 27 0 0 0 0 0 0000 Setup 1 09 Nov 2012 13 56 13 80 5 20 3 0 0011 Setup 1 09 Nov 2012 13 56 07 78 1 20 1 0 0011 Setup 1 09 Nov 2012 13 55 43 77 8 20 5 0 0011 Setup 1 09 Nov 2012 13 55 39 84 9 20 3 0 0011 Setup 1 09 Nov 2012 13 55 30 Alarm Date Time Friday November 09 2012 2 43 30 PM Figure 4 46 Operation Summary Dukane User s Manual Part No 403 585 00 Page 63 iQ Explorer II User s Manual Save and Retrieve Setup Files 1 Click File on the Main Menu Refer to Figure 4 47 77 Retrieve a Setup 1 iQ Explorer Il Welder8 Setup 1 2 From the drop down menu you can save a setup file File Tools Window Help to a file on the PC s hard drive in several ways Save Current Setup File or Select Active Setup Open Cycle Data File Save Current Setup File As Open Graph Data File 3 To retrieve a setup click on Select Active Setup to get a list of setups that are active Then select a setup from that list Load Setup From Disk New Setup File Offline Open Setup from Disk Save Current Setup File
83. ture mounted with strap clamps Booster 2 1 Horn ssblade Fixture 2clamp Monday December 03 2012 1 36 53PM Figure 4 35 Notes Page 52 Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page Basic Setup 8 Click on the Cycle Data tab to reveal accumulated cycle data from all recent weld cycles To select what columns to display go to the Process Limits tab Figure 4 36 shows a sample of the Cycle Data page The columns displayed reflect the Process Limits example shown in Figure 4 33 Utilities System Hardware Downstroke Position Force at Weld Weld Weld Weld End Weld Peak Time at Trigger Trigger Time Distance Energy Position Force Low Bad Low Suspect 0 0100 0 0150 50 0 High Suspect High Bad 0 0200 0 0300 150 0 0 0150 100 2 ji H 03 Dec 2012 0 0150 101 0 E H 03 Dec 2012 0 0150 100 6 d H 03 Dec 2012 0 0150 100 1 A 03 Dec 2012 0 0150 100 6 K il 03 Dec 2012 0 0150 100 4 E K 03 Dec 2012 0 0150 100 1 H H 03 Dec 2012 0 0150 100 7 H 03 Dec 2012 Part Count Monday December 03 2012 22237PM Figure 4 36 Setup Cycle Data Continued Dukane User s Manual Part No 403 585 00 Page 53 iQ Explorer Il User s Manual Continued from Previous Page Basic Setup 9 Click on the Graph tab Then click on the Graph Setup button Next make choices to set up the graphing function to illu
84. ure you may z add this program to your computer s start up Launching the sequence using these steps Softwa re Click on the Start button Click on All Programs The program can be launched in several ways by using Right click on the Startup file folder the Autoboot feature of your computer or by clicking on Go to Open the program s desktop icon Click on the File menu and New and Autoboot then Shortcut Add the programs s shortcut to the startup directory so Next locate the execute file for iQ Ex that iQ Explorer II will autoboot automatically begin plorer II Click on My Computer then after the PC has been started Figure 3 2 illustrates how on Local Disk C then go to Program the screen will look on start up Files then to Dukane then to iQ Explorer The NOTE to the right lists steps to make a shortcut IT and finally click on iQ Explorer Il exe Click on Add and the shortcut has been Click Icon created You may prefer to launch iQ Explorer II by double click In some cases a Wizard may also act as a ing its desktop icon KO guide for the process just described O iQ Explorer Il EEE File Tools Window Help r x slapjaa MOYS Figure 3 2 iQ Explorer II Start up Screen Continued Page 18 Dukane User s Manual Part No 403 585 00 Section 3 Installation Continued from Previous Page iQ Explorer II Connects with Generator 1 At first connection iQ Explorer II and the iQ ES generato
85. ure works in conjunction with Security settings Shifts This option affects cycle data in the context of shifts rather than at end of day Graph Data This group contains features related to graph data management Cycle Data This group has features related to cycle data management Setup This option contains features related to the storage of setup files Barcode Enabling this feature will have one to three barcode scans select a setup Enabling this feature prevents the use of the welder unless O Explorer IT is connected as well Dukane User s Manual Part No 403 585 00 aig Explorer Il Welder8 Setup 1 je File Tools Window Help Options Language gt Units b Process Settings Snapshot Welder Name Ta sapan MOYG Serial Numb Figure 4 2 Main Menu Tools Communications Security PLC Interface Shifts Graph Data Cycle Data Setup Barcode For_4 gt M Automatically display welder access window when discovered Permitted IP Address List 156 22 14 90 Modify List 156 23 15 91 OK Cancel Figure 4 3 Main Menu Tools gt Options Window NOTE More Options Information Use the iQ Explorer II Help file and refer to the OPTIONS material starting on Page 32 of this User s Manual Continued Page 25 iQ Explorer II User s Manual Continued from Previous Page Force This feature provides an enhancement to display air pressure settings in units of for
86. ut Makes programming easier All welder setup parameters are programmed from one menu page Currently availability is limited for use with the i HMI or PCs with touch screen such as tablets Ethernet connectivity For connection to local area network or stand alone applications Control Control feature for locking out system controls that complies with FDA 21 CFR Part Il Remote connectivity Dukane hotline is available for system diagnostics and troubleshooting 24 hours a day VPN access to the welder s network is required Consult with your IT staff about availability One screen operations page Most recent weld cycle and graph data with ability to modify commonly used process settings F1 Help command Instantly displays explanation of function iQ Explorer II User Interface It is a peripheral device Operation is independent of the generator and removal or malfunction of the iQ Explorer IT does not affect machine functionality Eight user selectable graph parameters Velocity energy power distance amplitude frequency force and pressure for viewing and storage of each weld Production analysis screen Displays eight hour shift production statistics good bad suspect quantities and percentages Advanced stack diagnostics Includes power and frequency graphs for stack horn documentation and future reference for troubleshooting Tool identification Uses barcode system to identify toolin
87. vement The aim is to continuously improve the internal organization and the competitive position ISO 9001 2008 CERTIFIED Dukane products are manufactured in ISO registered facilities Page 99 Please refer to our website at www dukane com us sales intsales htm to locate your local representative iQ Explorer IT User s Manual Part No 403 585 00 www dukane com us Printed in the United States of America Dukane Intelligent Assembly Solutions 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949
88. wicici4600c2 ine cede teeing 90 Appendix C Regulatory Agency Compliance 91 Dukane User s Manual Part No 403 585 00 Page 85 iQ Explorer II User s Manual This page intentionally left blank Page 86 Dukane User s Manual Part No 403 585 00 Section 7 Appendices Appendix A List of Figures No Description Page 2 1 Select Control Panel from the Start Menu Windows XP ccceeeeeeeesetttneeeeeeeeeeeeee fg 2 2 Select Display from the Control Panel Window Windows XP ooooccccccnccccccccccncccccccnananos 8 2 3 Setting Display Colors and Resolution Windows XP ooooocconccoconcccccccccccnnnnnannnnnnncnnananns 8 2 4 Selecting My Computer Windows XP ama a 10 2 5 Selecting View System Information Windows XP asaran 10 2 6 Checking Operating System Version Windows XP oooooccnnccoccccoccccncccnonanacnncnoncncnanannns 11 2 7 Start Menu Select Computer Windows 7 ocoooocccnnonoccccnonancccnnnannnnnnnnnnncncnnnnncnnnnnaness 12 2 8 Computer Window WINDOWS Y its a tii 12 2 9 Computer Right Click Displays Submenu Windows T oooonnncccccccncccccononanancnonincnannnnn 13 2 10 Properties Hardware and Software Details Windows 7 oooooccccnnnnicinccccccoccccncccnnnnnno 13 3 1 Installation Startup SCOGSN siii e AR id 17 3 2 iQ Explorer Il Start Up Screen oooccccccccccncnonononononnnonnnonnnonononnnnnnnnnnonnnnnnnnnnnnnnnnnnineninnnss 18 3 3 A gardtad E A eta 19 3 4 SNOW Welders S2 pi a
89. work administrator for the appropriate IP settings File Tools Window Help r Ci Obtain an IP address automatically O Use the following IP address IP address 169 254 0 10 Subnet mask 255 255 0 01 Default gateway Sdapayy MOYS a ES x3 Ba Use the following DNS server addresses Preferred DNS server Alternate DNS server Figure 5 4 Show Welders 1 Figure 5 3 Internet Protocol TCP IP Properties i iQ Explorer Il File Tools Window Help 4 Click OK and close the Network window aa ae aj B You may need to restart the computer before changes take effect O welders Ow welder K 5 Run iQ Explorer II I a T Do a T T uw e At first connection iQ Explorer IT and the iQ ES generator connect immediately using their default network configurations e When connection has been made the welder s available to the software are shown when the Figure 5 5 Show Welders 2 user presses the Show Welders button on the toolbar on the left of the application See Figure 5 4 to the right e An example list of available welders is shown in Figure 5 5 to the right Notice that the button has changed to Hide Welders Continued Page 76 Dukane User s Manual Part No 403 585 00 Section 5 Networking Continued from Previous Page If nothing is displayed after pressing the Show Welders button e Check that the correct subnet was entered e Check tha
90. ype 64 bit Operating System Pen and Touch No Pen or Touch Input is available for this Display See also Dell support Action Center Windows Update Performance Information and Computer name domain and workgroup settings Computer name PICACOPETTI2 W7 Change settings Website Online support Figure 2 10 Properties Hardware and Software Details Windows 7 Continued Dukane User s Manual Part No 403 585 00 Page 13 iQ Explorer II User s Manual Continued from Previous Page NET Framework Microsoft NET Framework 2 0 is required for running iQ Explorer II It is built into the Windows Vista and Windows 7 operating systems iQ System Requirements iQ Explorer IT is designed to compliment the iQ Series generators the advanced models only The software allows the operator to program these generators more easily and in less time than if programmed manually If there is any question about your generator type or its compatibility with iQ Explorer IT please contact Dukane Page 14 Dukane User s Manual Part No 403 585 00 Section 3 Installation Installation Unpacking os cc se kh ne baw be eh eee eae ees 17 A he ba ee eh eee ee eee KA 17 Launching the Software n aaron a aa BAN 18 Dukane User s Manual Part No 403 585 00 Page 15 iQ Explorer II User s Manual This page intentionally left blank Page 16 Dukane User s Manual Part No 403 585 00 Unpacking C
91. ytes a Limit the number of cycle data to single Moo parts When Limit the File Size is checked the number of i Ea Period to save cycle data set to zero to save at exit only 10 minutes Kbytes entered limits the maximum size of the cycle data file Cancel When Limit the Number of Cycle Data is checked the cycle data file will never exceed the number of cycles Figure 4 22 Options Cycle Data Tab Other entered When this setting is enabled you WILL lose historical cycle data Period to Save Cycle Data Data is saved at the interval set by the user If zero data is saved only when exiting the program Setup This is the directory where saved setup files are stored The user may change the directory to another drive but if this is not done then the default location will be used for this purpose Continued Page 44 Dukane User s Manual Part No 403 585 00 Section 4 Operation Continued from Previous Page Barcode When Enable Barcode Scan to Activate Setup is Communications Security PLC Interface Shifts Graph Data Cycle Data Setup Barcode For 4 activated between one and three barcode scans can be d 1 O W Enable barcode scan to activate setup O Associate Barcodes programme to se ect a setup Select serial port COM1 y Last barcode scan COM portis open See Figure 4 23 to the right Barcode Specifications F Name The user must associate a barcode or set of barcodes w

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