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iQ Explorer II User’s Manual Dukane Part No. 403–585– 01 Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797– 4900 Dukane products are manufactured in ISO registered facilities www.dukane.com iQ Explorer II User’s Manual Copyright © 2019 Dukane 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 shall not have any liability to any person or entity with respect to any liability, loss, or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual, or by the hardware products described herein. Specifications subject to change 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: 403-585-01 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. 403-585-01 Revision History Revision Number - 00 . - 01 . . Revision Summary Date Original release. March 7, 2013 Updated Pictures Updated Features April 16, 2019 Dukane User’s Manual Part No. 403-585-01 Page iii iQ Explorer II User’s Manual This page intentionally left blank Page iv Dukane User’s Manual Part No. 403-585-01 Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 Section 2 - System Requirements . . . . . . . . . . . . . . . . 5 Section 3 - Installation . . . . . . . . . . . . . . . . . . . . . . . . 15 Section 4 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . 21 Section 5 - Networking . . . . . . . . . . . . . . . . . . . . . . . . 75 Section 6 - Contacting Dukane . . . . . . . . . . . . . . . . . 85 Section 7 - Appendices . . . . . . . . . . . . . . . . . . . . . . . 89 A - List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 B - List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 C - Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Dukane User’s Manual Part No. 403-585-01 Page v iQ Explorer II User’s Manual This page intentionally left blank Page vi Dukane User’s Manual Part No. 403-585-01 Section 1 – Introduction SECTION 1 Introduction General User Information . . . . . . . . . . . . . . . . . . .3 Read The Manual First. . . . . . . . . . . . . . . . . . . . . . 3 Notes, Cautions and Warnings. . . . . . . . . . . . . . . . . . 3 Drawings and Tables. . . . . . . . . . . . . . . . . . . . . . . 3 iQ Explorer II Overview . . . . . . . . . . . . . . . . . . . .4 Key Features . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dukane User’s Manual Part No. 403-585-01 Page 1 iQ Explorer II User’s Manual This page intentionally left blank Page 2 Dukane User’s Manual Part No. 403-585-01 Section 1 – Introduction 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 allow you to learn how to effectively operate this program. Examples given are chosen for their simplicity to illustrate basic operation concepts. Notes, Cautions and Warnings NOTE Note statements provide additional information or highlight procedures. Throughout this manual we use NOTES to provide information that is important for the successful application and understanding of the product. A NOTE block is shown to the right. In addition, we use special notices to make you aware of safety considerations. These are the CAUTION and WARNING blocks as shown here. They represent increasing levels of important information. These statements help you to identify and avoid hazards and recognize the consequences. One of three different symbols also accompany the CAUTION and WARNING blocks to indicate whether the notice pertains to a condition or practice, an electrical safety issue or a operator protection issue. CAUTION Caution statements identify conditions or practices that could result in damage to the equipment or other property. WARNING Warning statements point out conditions or practices that could result in personal injury or loss of life. Drawings and Tables The figures and tables are identified by the section number followed by a sequence number. The sequence number begins with one in each section. The figures and tables are numbered separately. The figures use Arabic sequence numbers (e.g. –1, –2, –3) while the tables use roman sequence numerals (e.g. –I, –II, –III). As an example, 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. 403-585-01 Condition or Practice Electrical Hazard Hearing Protection Page 3 iQ Explorer II User’s Manual iQ Explorer II Overview This program enhances any compatible iQ Series ES ultrasonic generator/press through a user interface that allows 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 • Production analysis screen - Displays eighthour 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 tooling. • Work cell - A Dukane Lean Work Cell can be integrated with basic PLC managed operations. • Windows operating system - Familiar file folder menu structure, requiring no special training. • iQLogiX™ - Feature that contains options that support the iQLogiX™ interface. • Touch screen input - Makes programming easier. All welder setup parameters are programmed from one menu page. (Currently, availability is limited for use with the iQ HMI or PCs with touch screen, such as tablets.) • Data Analysis for SPC - Feature that aggregates and charts large quantities of cycle data results. • Barcodes - Feature that allows scanned barcodes from parts to be attributed to cycle data. • 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 II. • 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 II 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. Page 4 Dukane User’s Manual Part No. 403-585-01 Section 2 – System Requirements SECTION 2 System Requirements Computer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Processor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Video Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hard Disk Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Software Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Windows ® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 .NET Framework . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 iQ System Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Dukane User’s Manual Part No. 403-585-01 Page 5 iQ Explorer II User’s Manual This page intentionally left blank Page 6 Dukane User’s Manual Part No. 403-585-01 Section 2 – System Requirements Computer Requirements iQ Explorer II 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. 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. 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 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. Figure 2-1 Select Control Panel from the Start Menu (Windows XP) Continued Dukane User’s Manual Part No. 403-585-01 Page 7 iQ Explorer II User’s Manual Continued from Previous Page In the Control Panel window, double-click the Display icon. See Figure 2-2 below. 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/ 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. Figure 2-3 Setting Display Colors and Resolution (Windows XP) Continued Page 8 Dukane User’s Manual Part No. 403-585-01 Section 2 – System Requirements Continued from Previous Page Hard Disk Space The iQ Explorer II software requires approximately 24MB of hard disk space for installation. Communication Ports USB Port At least 1 USB port is required for the iQ Explorer II installation on a laptop or desktop. The iQ HMI does not require a security key (dongle). Ethernet Port An Ethernet port is required for the iQ Explorer II 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. Continued Dukane User’s Manual Part No. 403-585-01 Page 9 iQ Explorer II User’s Manual Continued from Previous Page Software Requirements iQ Explorer II software is only compatible with the Microsoft Windows operating system. Windows ® The computer operating system (OS) must be Microsoft 32 or 64 bit versions of: Windows XP, Windows Vista, Windows 7, Windows 8.1, or Windows 10. 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. Figure 2-4 Figure 2-5 Page 10 Selecting View System Information (Windows XP) Selecting My Computer (Windows XP) Continued Dukane User’s Manual Part No. 403-585-01 Section 2 – System Requirements Continued from Previous Page After selecting View System Information a new popup window will appear (See Figure 2-6) showing: A - Version of Windows™ currently installed, B - Type of processor used, and C - Amount of memory installed. A B C Figure 2-6 Checking Operating System Version (Windows XP) Continued Dukane User’s Manual Part No. 403-585-01 Page 11 iQ Explorer II User’s Manual Continued from Previous Page Windows 7 The four-step process outlined here is a quick guide to viewing system information when using the Windows 7 operating system. 1. Select Computer as shown in Figure 2-7 below. Select Computer Figure 2-7 Start Menu, Select Computer (Windows 7) 2. The Computer window appears. An example is shown in Figure 2-8 below. Figure 2-8 Computer Window (Windows 7) Continued Page 12 Dukane User’s Manual Part No. 403-585-01 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. Computer 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. Figure 2-10 Properties - Hardware and Software Details (Windows 7) Continued Dukane User’s Manual Part No. 403-585-01 Page 13 iQ Explorer II User’s Manual Continued from Previous Page .NET Framework For Windows 10, Microsoft .NET Framework 2.0 is loaded, but not enabled. To enable .NET Framwork 2.0: • Press the Windows key on the keyboard or toolbar. • Type “Windows Features”, and press enter. A Windows Features dialog box will appear with check boxes to turn Windows Features on or off. • Select the .NET Framework 3.5 (includes .NET 2.0 and 3.0) check box. • Select OK, and reboot computer if prompted. iQ System Requirements iQ Explorer II 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 II, please contact Dukane. Page 14 Dukane User’s Manual Part No. 403-585-01 Section 3 – Installation SECTION 3 Installation Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Launching the Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Dukane User’s Manual Part No. 403-585-01 Page 15 iQ Explorer II User’s Manual This page intentionally left blank Page 16 Dukane User’s Manual Part No. 403-585-01 Section 3 – Installation Unpacking Carefully open your shipping container, and make sure it contains the items shown on the shipping documents. Inspect all items, and report any missing items or damage immediately. iQ Explorer II Kit Contents: Item CD (Dukane Part No. 438-987) Dukane Part No. 437-00255 Security Key 433-38 Ethernet Patch Cable User’s Manual 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 installation process 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]) 3. The iQ Explorer II 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. 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 II 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 (Recommended) 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 II installation. . Figure 3-1 4. Insert the USB Security Key (Part No. 433-38) into any available USB port on the computer. (This Security Key is also referred to as a dongle.) Installation Start-up Screen Dukane User’s Manual Part No. 403-585-01 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. Launching the Software The program can be launched in several ways: by using the Autoboot feature of your computer, or by clicking on the program’s desktop icon. Autoboot Add the programs’s shortcut to the startup directory so that iQ Explorer II will autoboot (automatically begin) after the PC has been started. Figure 3-2 illustrates how the screen will look on start-up. The NOTE to the right lists steps to make a shortcut. Click Icon You may prefer to launch iQ Explorer II by double clicking its desktop icon. Figure 3-2 Page 18 iQ Explorer II Start-up Screen NOTE To change the autoboot feature, you may add this program to your computer’s start-up sequence using these steps: 1. Click on the Start button. 2. Click on All Programs. 3. Right click on the Startup file folder. 4. Go to Open. 5. Click on the File menu, and New, and then Shortcut. 6. Next, locate the execute file for iQ Explorer II. Click on My Computer, then on Local Disk (C:), then go to Program Files, then to Dukane, then to iQ Explorer II, and finally click on iQ Explorer II.exe Click on Add, and the shortcut has been created. In some cases a Wizard may also act as a guide for the process just described. Continued Dukane User’s Manual Part No. 403-585-01 Section 3 – Installation Continued from Previous Page iQ Explorer II Connects with Generator 1. At first connection, iQ Explorer II and the iQ ES generator connect immediately using their default network configurations. 2. When connection has been made, the welder(s) available to the software are shown when the user presses the Show Welders button on the toolbar on the left of the application. See Figure 3-3 to the right. Click to show list of available welders. Scan Network 3. An example list of available welders is shown in Figure 3-4 to the right. Notice that the button has changed to Hide Welders. Dukane User’s Manual Part No. 403-585-01 Figure 3-3 Show Welders - 1 Figure 3-4 Show Welders - 2 Page 19 iQ Explorer II User’s Manual This page intentionally left blank Page 20 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation SECTION 4 Operation Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Main Screen Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Icon Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Making an Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Save and Retrieve Setup Files . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Save and Retrieve Part Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Save and Restore Graph Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Using the Help System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Dukane User’s Manual Part No. 403-585-01 Page 21 iQ Explorer II User’s Manual This page intentionally left blank Page 22 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation 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 II. 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. Figure 4-1 Main Menu - File 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 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. Continued Dukane User’s Manual Part No. 403-585-01 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 II. 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, 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 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. 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. 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. Continued Page 24 Dukane User’s Manual Part No. 403-585-01 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 Figure 4-2 Main Menu - Tools Figure 4-3 Main Menu - Tools > Options Window 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 feature 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. Data Analysis This group has features for data analysis related to SPC. Setup 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. This option contains features related to the storage of setup files. Continued Dukane User’s Manual Part No. 403-585-01 Page 25 iQ Explorer II User’s Manual Continued from Previous Page Barcode This feature provides two ways to incorporate barcode scanning into this system; either attributing a barcode scan per part, or one to three barcode scans to load a setup. Force This feature provides an enhancement to display air pressure settings in units of force. Appearance With this feature, the PC display image can be enhanced when iQ Explorer II is running. Among other things a background image and a watermark for reports can be set. SynQro™ This group relates to a custom press. Please contact a Dukane representative for more details. Diagnostics This option enables the ability to save messages to and from the welders. NOTE: this should only be enabled when instructed by the Dukane Service Department for the purpose of troubleshooting. Language This menu displays the list of available languages supported by iQ Explorer II. All iQ Explorer II 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. Page 26 Continued Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page Snapshot! Select this menu item to start the process that compresses a copy of the iQ Explorer II 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. Window Select this menu to rearrange window interfaces. See Figure 4-4 to the right for the Window menu. Figure 4-4 Main Menu - Window Figure 4-5 Main Menu - Help Help See Figure 4-5 to the right for the Help menu. 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 II. About iQ Explorer II iQ Explorer II version information is available here. Dukane User’s Manual Part No. 403-585-01 Page 27 iQ Explorer II 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. Function appears as the cursor crosses the icon. Figure 4-6 Main Screen Icons Continued Page 28 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page Icon Detail Print current item Keyboard keys Delete setup file Open or Load setup file from disk Change options Save current item Figure 4-7 • Numeric keys Help Shutdown Exit Undo Icon and Function Open or Load 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. • 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. If the 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. 403-585-01 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 screen. 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. • Undo - undo or reverse previous command/action. • 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. • 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. • Help - Open an extensive help file • Exit - Shuts down the iQ Explorer II application. Page 30 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page • Shutdown - When running on a Dukane HMI, there is an additional shut down icon (See Figure 4-8). After the shutdown icon is selected a popup will appear to prompt the shutdown process (Figure 4-9). For a safe shutdown to prevent corrupting the HMI, use the shutdown button before powering down your system. Dukane User’s Manual Part No. 403-585-01 Figure 4-8 Shutdown Icon Figure 4-9 Shutdown Prompt Page 31 iQ Explorer II User’s Manual 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 confirm your selection. 2. Type in the changes, and press the ENTER key. NOTE Entry box prompts: There may be a flashing vertical bar, or the entire entry box might be filled with a flashing color. 3. 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. 2. 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. 3. Tap the ENTER key on either the numeric keypad or the keyboard to apply the entry. Continued Page 32 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Options This feature helps you manage the welding process with the settings offered through the options listed below: • Communications • Security • PLC Interface • Shifts • Force • Graph Data NOTE The Help file of iQ Explorer II is a good source of information for reviewing the purpose of particular features. • Cycle Data • Data Analysis • Setup • Appearance • SynQro™ and, • 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 Dukane User’s Manual Part No. 403-585-01 Page 33 iQ Explorer II User’s Manual Continued from Previous Page Option Communications Security 1 PLC Interface Table 4-I What the Operator Can Do with the Option Turn Feature On or Off • Automatically display welder access window when discovered. • Automatically synchronize HMI/PC time to connected welder • Enable security. • Enable auto log off timeout. • Prevent Operator level user from clearing Latch on Bad Part • Permit Operator level user to Reset Part Count • Enable Network Security • Enable auto log off timeout. • 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. • Disable outputs to operators. • At startup navigate directly to machine interface. • Prevent unspecified user to log on as operator. iQLogiX™ • At startup navigate directly to machine interface. • Disable outputs to operators. • Show iQlogiX™ steps in machine interface. Shifts • Enable saving Cycle Data in shifts. Force • Enter Force instead of Pressure. Enter Data Make a Selection • IP Address List - Enter permitted IP addresses. • Add users with access passwords. • Directory to store FDA 21 CFR Part 11 audit file. • Domain name of Windows Active directory • Organizational Unit in the specified domain • Configure PLCs. • iQLogiX™ Editor. • Name the shift and enter times. • Enable shift(s). • Select air cylinder bore size. Options Choices for the Operator 1 NOTE Password protection prevents editing. It limits those without proper access permission from making unauthorized changes to the weld process or to iQ Explorer II options. Page 34 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page Option What the Operator Can Do with the Option Turn Feature On or Off Graph Data • Automatically save graph data to file. • Show graph in cycle data screen • Show graph data types: Distance, Velocity, Power, Energy, etc. • On alarm, automatically save data (and alarm list). • On alarm, automatically take Snapshot (and alarm list) Cycle Data • Save cycle data from multiple welders to one file. • Directories to save cycle 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. Data Analysis • Enable barcode scan • Interval - Save cycle data (minutes) to file. • Directories to save cycle data to file. • One cycle data per CSV file • Populate Notes field in cycle data with select setup information • Automatically save setup changes to file. • Select serial port • Enter barcode specs. • Locations for: Default Setup Image, Background Image, and Report Watermark. • Disable/enable watermark on report. • Frequency threshold for U/S test. • Power threshold for U/S test. •Amplitude threshold for U/S test. SynQro™ Table 4-I • Directories to save graph data to file. • Save setup file directory Appearance Diagnostics Make a Selection • Enable data analysis support. • Filter all measurements of zero. • Filter all measurements related • Data Analysis Directory. to cycles marked as bad part. • Number of days of results to • Show line depicting running store to file. average. • Enable display of Six Sigma calculations. Setup Barcode Enter Data • Enable message log to/from welders. • Location for saved messages to/from welders. Options Choices for the Operator Dukane User’s Manual Part No. 403-585-01 Page 35 iQ Explorer II User’s Manual Continued from Previous Page Communications This option relates to how iQ Explorer II connects to iQ generators on the network. See Figure 4-10 for a view of this tab. Auto-Display Welder Contents A 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. Synchronize Clocks B Enable this feature to automatically apply the time and date on the HMI/PC to all connected welders. Permitted IP Addresses C Add IP addresses of iQ generators to this list to limit the iQ Explorer II 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 II is dedicated to a subset of the generators on that network. A B C Figure 4-10 Options - Communications Tab Page 36 Continued Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation 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 II 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 II 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 II. 1. 2. 3. 4. 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 is permitted to edit any parameters. 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. If the 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 II will be permitted to modify any parameter. 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. Continued Dukane User’s Manual Part No. 403-585-01 Page 37 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 II) 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 decision 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 II 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 II 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 38 Continued Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page Using the Security Tab The Security option tab is shown in the figure below. Yield Access - A 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 - B Enable user level access to force a login to access iQ Explorer II. See Figure 4-11 below. A A B B Figure 4-11 Options - Security Tab 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 4-12. The user needs to enter an administrator display name, user name and password. This is illustrated in Figure 4-13: C This will open up more security related features. 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 levels. More explanation about these levels is given on the next page. Figure 4-12 Options - Enable Administrator Password C Figure 4-13 Options - Set Password Dukane User’s Manual Part No. 403-585-01 Continued Page 39 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. 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 iQ Explorer II connects to an ES generator that currently has only Operator access, iQ Explorer II will be granted immediate access. There will be no need to wait for an Operator at the ES generator to yield access. An Operator cannot decline access to edit parameters. Custom 1, Custom 2 These levels are the same as the Setups level, but may be customized by the user to 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; Reset Part Count; Frequency Scan; and Servo Position Limits. Operator This access level prevents write access to all parameters, and prevents access to any action in the file menu or tool bar. Continued Page 40 Dukane User’s Manual Part No. 403-585-01 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 4-14 to the right. Figure 4-14 Options - Security - Setup Users 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 4-15 to the right to add a user. Creating User Profiles Figure 4-16 below shows that entries are made with the virtual keyboard: User Display Name, User Name, User Level Figure 4-16 Options - Security - Create User Profiles Dukane User’s Manual Part No. 403-585-01 Figure 4-15 Options - Security - Add New User Continued Page 41 iQ Explorer II User’s Manual Continued from Previous Page Creating Custom Level User Profiles Figure 4-17 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 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 4-18 to the right. Figure 4-17 Options - Security - Custom Security Levels Enable Automatic Log Off Timeout Another security option for the Administrator is the Automatic Log Off Timeout as see in Figure 4-18 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. Prevent Operator level user from clearing Latch on Bad Part This setting only affects generators that have Latch on Bad Part enabled and allow user to clear Latch on Bad Part. When the system is latched, any user can clear the latched iQ generator from iQ Explorer II. If this option is enabled, Operator level users will not be able to clear the latched iQ generator. Other security level users will be able to clear the latch after they log in. Figure 4-18 Options - Security Tab - Enable Auto Timeout and Enable Auditing NOTE An iQ Explorer II connection is required to execute a weld on an iQ ES generator with Part 11 active. Continued Page 42 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page Permit Operator level user to Reset Part Count When this option is enabled, a user logged in as an Operator will have permission to reset the part count. Network Security When this option is enabled, iQ Explorer II will attempt to gain access to Windows Active Directory and access user accounts in the domain specified by the administrator. The administrator may also enter a “Location” to help refine the number of groups to apply security access levels. Press the Assign Groups button to display the list of network groups within the Domain and Location. The administrator may assign a different iQ Explorer II security level to each group. Without any changes, iQ Explorer II assigns Operator level to all groups by default. These security level settings are persistent in this running instance of iQ Explorer II. This means that the administrator would need to apply these settings to each instance of iQ Explorer II running on the network. Enable Auditing to Support FDA 21 CFR Part 11 Compliance In addition to standard password protection, iQ Explorer II offers a feature that complies with FDA 21 CFR Part 11. To support Part 11, iQ Explorer II attaches a user ID to every cycle, alarm, setup modification and other events. iQ Explorer II 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. Dukane User’s Manual Part No. 403-585-01 Page 43 iQ Explorer II User’s Manual Continued from Previous Page Audit Trail Introduction When auditing is enabled in iQ Explorer II, 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 FDA 21 CFR 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 II. Exporting 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. 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 II starting up. 2. Closing of the audit file, marking iQ Explorer II shutting down. 3. Successful user logons with user information. 4. Failed logons with failed user identification. 5. User log off. 6. 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 Page 44 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation 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 4-19 to the right. User levels must be enabled with the Security tab so this PLC interface can be used. NOTE Please contact a Dukane custom applications specialist before enabling the PLC Interface feature. Figure 4-19 Options - PLC Interface Tab Figure 4-20 Options - Shifts Tab 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 4-20 to the right. Continued Dukane User’s Manual Part No. 403-585-01 Page 45 iQ Explorer II User’s Manual Continued from Previous Page Graph Data File Management - 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 4-21 to the right. On Alarm, Automatically Save Graph Data - Enabling the option to automatically save graph data on alarm will only trigger a request to acquire graph data when a weld cycle contains an alarm from the Alarm List. The Alarm List is preloaded with the most common alarms. However, the user may add more alarm types to the list if they so choose. On Alarm Automatically Take Snapshot - Enabling this option to automatically take a Snapshot on alarm will trigger the Snapshot process following a weld cycle that contains an alarm from the Alarm List. The Alarm List is preloaded with the most common alarms. However, the user may add more alarm types to the list if they so choose. This feature is only available on i220 Servo generators. Figure 4-21 Options - Graph, Files Tab Figure 4-22 Options - Graph, Display Tab 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 - When Show Graph in Cycle Data Screen is checked, a smaller copy of the graph is displayed on the Cycle Data tab. See Figure 4-22 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. Continued Page 46 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page Cycle Data Save Cycle Data Directories - Cycle data can be stored in three directories at the same time. A With this feature, the user can store data on a network or on a USB flash drive while saving data on the PC itself. If the user requires a third party application to obtain cycle data in real-time, the user should enable saving ‘one cycle data record per CSV file’. If the user enables this feature, each set of cycle data will be saved to its own CSV file, complete with a header to identify the contents of the cycle data. See Figure 4-23 to the right. B A Figure 4-23 Options - Cycle Data Figure 4-24 Options - Cycle Data File Management If no directory is selected, no cycle data is saved to file. Data from Multiple Welders - B When iQ Explorer II is connected to several welders on a network, this option can be enabled so that cycle data will be saved to a single file. Cycle Data File Management - When Display Only Most Recently Welded....is checked, only the most recent cycle data will be shown in the Cycle Data tab. See Figure 4-24 to the right. C When Limit the File Size... is checked, the number of Kbytes entered limits the maximum size of the cycle data file. When Limit the Number of Cycle Data... is checked, the cycle data file will never exceed the number of cycles entered. When this setting is enabled, you WILL lose historical cycle data. Figure 4-25 Options - Notes Per Cycle 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. Notes Per Cycle - set notes per cycle C to prepopulate system with user defined setup information. See Figure 4-25 to the right. Continued Dukane User’s Manual Part No. 403-585-01 Page 47 iQ Explorer II User’s Manual Continued from Previous Page 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. Automatically save cycle data to file - When this option is enabled, any change to any parameter on any connected iQ generator will be saved to a file. The file will be named with the same name as the setup name and will be stored in the Setup File Directory. B Barcode There are two ways to incorporate barcode support in iQ Explorer II. Either a unique barcode reading is associated with a part, or one or more barcode readings are associated with a specific setup. When Enable Lot Barcode Scan is activated it will introduce the ability to scan a separate barcode that links to a lot. Once scanned this barcode is linked to every cycle following it being scanned. The lot barcode is added to each cycle data record. To force the scan of a new lot barcode, press the Reset Barcode Process button in the large toolbar. This option works with both types of barcode scanning features A Figure 4-26 Options - Barcode Tab Figure 4-27 Options - Barcode Tab - Link Names When Enable Barcode Scan to Activate Setup is activated, between one and three barcode scans can be programmed to select a setup. A See Figure 4-26 to the right. The user must associate a barcode or set of barcodes with a setup name loaded on the welder or stored in the setup directory of the PC. Press the Associate Barcodes button. B A new pop-up screen as shown in Figure 4-27 appears. On this screen (Figure 4-27 to the right) the user links a barcode, or barcodes to a setup name. In addition, buttons are used to browse the setup file, to reset the screen, and to add, modify or delete setup file data. Once a barcode is scanned, the associated setup will be activated or loaded. 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. Enabling this feature prevents the use of the welder unless iQ Explorer II is connected as well. Page 48 Continued Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page When Enable Barcode Scan to Store Per Cycle is enabled, the last scanned barcode is stored and displayed with the cycle data of the weld. It is required that a barcode can be scanned before the operator or automation will be allowed to execute a weld. If the user scans multiple barcodes before a weld cycle is executed, the first barcode scan is used in the cycle data and the other barcode scans are discarded. Continued Dukane User’s Manual Part No. 403-585-01 Page 49 iQ Explorer II User’s Manual Continued from Previous Page Force When this option is enabled, the user can have air pressure settings displayed in units of force (instead of pressure). See Figure 4-28 to the right. Calculated pressure settings are still displayed. The user needs to select which air cylinder the press uses. When the generator is paired with a servo press, this feature is not available. Figure 4-28 Options - Force Tab Figure 4-29 Options - Appearance Tab Appearance With this feature, the PC display image can be enhanced when iQ Explorer II is running. See Figure 4-29 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. There is a selectable option to Enable watermark on printable report. 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 4-30 shown to the right illustrates this option. Diagnostics Figure 4-30 Options - Appearance - Default Image Changed Figure 4-31 Options - Diagnostics Tab With this feature enabled, communication between iQ Explorer II and the iQ generator can be diagnosed by Dukane during a troubleshooting process. Figure 4-31 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. This option is purely diagnostic and meant to aid Dukane IAS, LLC track unusal communication problems between iQ Explorer II and the iQ ES generator. Page 50 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Basic Setup When iQ Explorer II 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 press the Show Welders button to the left of the application as shown in Figure 4-32. Once a welder has been detected, all setup information in the welder is synchronized with the PC. Show Welders Button Figure 4-32 Setup - Show Welders 2. Click on a welder button to open the interface to it. Figure 4-33 below shows that Welder 1 was selected. Select Welder 1 Figure 4-33 Setup - Select a Welder Continued Dukane User’s Manual Part No. 403-585-01 Page 51 iQ Explorer II User’s Manual Continued from Previous Page Basic Setup 3. F 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 4-34 below for location of the items in the list that follows. A - Welder name. B - Serial number unique to Welder 1. C - List of 25 setups that are currently loaded in the welder. D - New name for the setup. Click Rename to apply. E - Use the button to search the PC for a setup file to be displayed. - Current time kept in the welder. - Button used to apply the PC time to the welder. G H - IP address of the connected welder. - Model and version information of embedded software. I C F A B G D C E I H On-line - When Green: Generator can enable an ultrasound signal. Off-line - When Yellow: A cycle can be run but no ultrasound is signaled. Figure 4-34 Setup - Hardware Page 52 I E-Stop - When Red. Emergency Stop is active. The generator will not be able to start a cycle. Continued Dukane User’s Manual Part No. 403-585-01 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 4-35. A - Initiate Mode, Top of Stroke for iQ servo. B - Settings before and at trigger. C - Settings to monitor the weld. D - Enable Melt Detect (patented iQ servo setting). E - iQ servo Motion Control and profiling. F - Hold settings, Travel Limit for iQ servo. G - Afterburst. H- Enable Advanced settings. I - Advanced servo settings. J - Amplitude J A H B C D E I F G View Live Data - Touch the button to view real time weld data. Figure 4-35 Setup - Process Settings Dukane User’s Manual Part No. 403-585-01 Continued Page 53 iQ Explorer II User’s Manual Continued from Previous Page Basic Setup 5. To weld a part successfully, some users require 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. Cycle data for all process characteristics are always saved. The user determines whether these are shown in the cycle data display. Latch on Bad Part - Only available when Initiate Mode is Manual. Removes item from the weld cycle data display. Adds item to the weld cycle data display. Figure 4-36 Adds the limit(s) to the weld cycle data display, and to the appropriate column (Lower Bad, Lower Suspect, Upper Suspect, and Upper Bad) on this Process Limits page. Setup - Process Limits Drop Down Menu Detail Continued Page 54 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation 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 II 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. Basic Setup 6. If the user has more information to associate with a setup, click the Notes tab. A sample display is shown in Figure 4-37 below. Several text entry boxes appear. Whatever text is entered is stored within the setup. Figure 4-37 Notes Continued Dukane User’s Manual Part No. 403-585-01 Page 55 iQ Explorer II User’s Manual Continued from Previous Page Basic Setup 7. 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 4-38 shows a sample of the Cycle Data page. The columns displayed reflect the Process Limits example shown in Figure 4-36. Figure 4-38 Setup - Cycle Data Continued Page 56 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page Basic Setup 8. Click on the Graph tab. Then, click on the Graph Setup button. Next, make choices to set up the graphing function to illustrate a pictorial view of the welding process. Make/Change Selections: (Figure 4-39 below shows two views of the graph setup window.) - Axis Labels - Choose labels for left, right, and horizontal axes of the graph. The figure shows a drop down list from which to select. A - Zoom - Choose when the graph display of the cycle should start and stop. The figure shows a drop down list from which to select. B - 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. C A sample graph appears on the next page. A B C Figure 4-39 Setup - Graph Setup Continued Dukane User’s Manual Part No. 403-585-01 Page 57 iQ Explorer II User’s Manual Continued from Previous Page Basic Setup 9. Click on the Graph Display tab. See Figure 4-40 below to view a sample graph. Figure 4-40 NOTE The values 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. Setup - Graph Display Continued Page 58 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page Graph Features ♦ = 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. Transition Points Figure 4-41 Graph Display Detail Continued Dukane User’s Manual Part No. 403-585-01 Page 59 iQ Explorer II User’s Manual Continued from Previous Page Graph Features Interaction - Check the Interaction box to activate interactive features that use the left button of the computer mouse. A These features, Zoom, Scale, and Translate are shown at B in Figure 4-42 below. C B A Figure 4-42 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. C Continued Page 60 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page Basic Setup 10. Click on the Production tab. This page provides a graphic analysis of parts produced — the good, the suspect, and the bad. See Figure 4-43 below for a sample of this type of graphic feedback. Figure 4-43 Setup - Production Display Continued Dukane User’s Manual Part No. 403-585-01 Page 61 iQ Explorer II User’s Manual Continued from Previous Page Basic Setup 11. C Click on the Utilities tab. Some setup management and diagnostic tools are offered here. See Figure 4-44 below for these things. Test - WARNING Clear area around stack before executing the sonics test. Sonics will stay active as long as the user presses the button. 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 The user may press and hold the Test button for as long is enabled. as necessary. When the user’s finger is lifted (from a B Setup Utilities - Use Setup Control to choose touch screen) or the finger is released from the button (of a mouse), the test ends and a graph is displayed. a setup. One setup can be erased with Erase (a) See Figure 4-43. Setup or all setups can be erased with Erase All Setups. D View real time data. This section can be used to select a different stored E View the alarm history. setup from the welder. Renaming the setup and F Verify Stack on Power Up - If prompted, this will selecting a different image for the setup can be execute a test immediately following a generator power done here as well. up. A C A F D E B Figure 4-44 Page 62 Setup - Utilities Continued Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page Utilities Sonics Test Figure 4-45 below illustrates the kind of data displayed after the TEST button is activated on the Utilities page. The graph may be saved to file to be used as a historical reference. Test results may also be saved to the General Notes field, for reference. When pressed, saving the test results to notes will save the average of the power and frequency measurements for the last 50 milliseconds to the General Notes field, along with the current time and date. NOTE The values 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. Click EXIT when finished reviewing this data. Figure 4-45 Setup - Utilities Test Display Sample Continued Dukane User’s Manual Part No. 403-585-01 Page 63 iQ Explorer II User’s Manual Continued from Previous Page Basic Setup 12. Click on the System tab. A WARNING appears immediately indicating that changing hardware settings may affect operation of the generator. WARNING Modifying hardware settings may affect operation of the welder. Click OK to proceed with hardware modification. Figure 4-46 Setup - System Warning Continued Page 64 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page System [modifications] Output Mode - Determines what is sent (All, Good, Bad, etc.) Hardware fine tuning is offered on the System page. See Figure 4-47 for an overview. Make/Change Selections: 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 a line feed (LF). Enable Limit Indicators - When enabled, a “<” or a “>” precede a field of cycle data that is either lower or higher than a process limit, respectively. Print Header - Press this button and it triggers the transmission of the delimited header for cycle data to the serial port. - System I/O - Designed for flexibility when integrating the ultrasonic system with automation. A Refer to Dukane’s website for Application Notes that deal with automation interface: http://www.dukane.com/us/DL_ApplData.asp. B - Buzzer Status - When this setting is disabled, the buzzer does not make a sound. When enabled, the buzzer sounds when cycle data is outside the suspect or bad part limits. D - View Generator I/O - Press this button to provide access to real time generator output settings and the current generator input readings. Buzzer at Trigger - The buzzer sounds when the trigger condition is met. E Buzzer at Top of Stroke - The buzzer sounds when - Servo Press - Specific to servo press systems: - This button gives access to an array of low-level readings from the servo controller. View Servo I/O - This button provides access to current servo and iQ generator input status. Servo performance results can also be acquired. View Servo Diagnostics the press is moved to its top of stroke position. C - System - Serial Communications - This is for configuring the serial port as an output for cycle data. Output Format - Determines how cycle data fields are separated. A B E C D Figure 4-47 Setup - System Overview Dukane User’s Manual Part No. 403-585-01 Continued Page 65 iQ Explorer II User’s Manual Continued from Previous Page Basic Setup 13. Click on the Operation Summary tab. Figure 4-48 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 A , generator output data can be seen as it happens. The Graph Setup button B can be clicked allowing the operator to customize the graphing display. A Figure 4-48 Page 66 B Operation Summary Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Save and Retrieve Setup Files Retrieve a Setup 1. Click File on the Main Menu. (Refer to Figure 4-49.) 2. From the drop-down menu you can save a setup file (to a file on the PC’s hard drive) in several ways: Save Current Setup File, or Save Current Setup File As. . . 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. Save a Setup Save and Retrieve Cycle Data 1. Click the Options icon. 2. Click on the Cycle Data tab. 3. Data Storage - Cycle data can be stored in three directories simultaneously. The user can store data on a network or on a USB memory stick while still saving it on the PC. If no directory is selected, then no cycle data is saved to file. See the figure below. Figure 4-49 Save and Retrieve Setup Files 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 to a single cycle data file. Figure 4-50 Save Cycle Data - 1 Continued Dukane User’s Manual Part No. 403-585-01 Page 67 iQ Explorer II User’s Manual Continued from Previous Page Figure 4-51 Save Cycle Data - 2 See the figure above for the next four Cycle Data features. 5. Display Most Recent Data - Only the most recent cycle data will be displayed when this feature is selected. Regardless of this number, all cycle data is saved. 6. 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. 7. 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. 8. Saved to File Rate - Cycle data is automatically saved to file at this rate. If the user sets it to zero, cycle data will only be saved on exit. Page 68 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Save and Restore Graph Data 1. Click the Options icon. (Refer to Figure 4-52.) 2. Click on the Graph Data tab, and then the File Management section. 3. Using the Main and Reference categories, you may enter the designated directories where graph data and reference graph data are stored. Figure 4-52 - Save Graph Data - File Management Dukane User’s Manual Part No. 403-585-01 Page 69 iQ Explorer II User’s Manual 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 II 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 4-53). Clicking Help from the menu and then clicking on Help opens the Help window. An example of the window is shown in Figures 4-54 and 4-55 on the next page. Figure 4-53 Help File Access from Top Menu Bar 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 II. A click on that phrase brings up a window containing facts about the software version used by the PC. 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. Page 70 Continued Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation 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 Figure 4-54 Help File - Using the Index Tab Contents Tab Figure 4-55 Help File - Using the Contents Tab Dukane User’s Manual Part No. 403-585-01 Page 71 iQ Explorer II User’s Manual 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: • the iQ Explorer II software requires that a value or other data be entered, or • the generator may have a error/fault/alarm. So, in response to these situations, the iQ Explorer II displays windows with prompts for the operator. Several examples are shown in Figure 4-56 below, and in Figure 4-57 on the next page. 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 general guidance in identifying the kinds of messages that may arise. Yellow background indicates a problem. In this example, with the Hardware tab displayed, the message is: Off Top of Stroke Figure 4-56 Problem Prompt in Yellow Continued Page 72 Dukane User’s Manual Part No. 403-585-01 Section 4 – Operation Continued from Previous Page Parameter Conflict Example In the following example shown in Figure 4-58 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 where a change needs to be made. Parameter Conflict explanation. Note the warning symbol and the yellow background for the message itself. Yellow background indicates a problem. In this example, with the Process Settings tab displayed, there is a Parameter Conflict. Figure 4-57 Parameter Conflict Display Dukane User’s Manual Part No. 403-585-01 Page 73 iQ Explorer II User’s Manual This page intentionally left blank Page 74 Dukane User’s Manual Part No. 403-585-01 Section 5 - Networking SECTION 5 Networking Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 DHCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Network Settings on the iQ ES Generator . . . . . . . . . . . . . . . . 77 Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Direct Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 DHCP Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 DHCP Disabled on the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 DHCP Disabled on the iQ ES Generator . . . . . . . . . . . . . . . . . . . 78 HMI Directly Connected to a Single Generator . . . . . . . . . . . . 79 Connection through a Stand-alone Network . . . . . . . . . . . . . . 81 Connection to a Local Area Network . . . . . . . . . . . . . . . . . . . . 82 Dukane User’s Manual Part No. 403-585-01 Page 75 iQ Explorer II User’s Manual This page intentionally left blank Page 76 Dukane User’s Manual Part No. 403-585-01 Section 5 - Networking Introduction iQ Explorer II 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 long 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 iQ ES Generator Configuration of network settings on the iQ 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. 403-585-01 Page 77 iQ Explorer II User’s Manual Network Settings Direct Connection The most common use for iQ Explorer II 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 selfassign 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 is 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 iQ 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 II 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 78 Dukane User’s Manual Part No. 403-585-01 Section 5 - Networking HMI Directly Connected to a Single Generator 1. 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. Figure 5-1 Network Connections Window Figure 5-2 Local Area Connection Properties Continued Dukane User’s Manual Part No. 403-585-01 Page 79 iQ Explorer II User’s Manual Continued from Previous Page 2. In the Internet Protocol (TCP/IP) Properties window, enter the following IP address: 169.254.0.10 3. Enter Subnet mask: 255.255.0.0. See the Figure below. Click to show list of available welders. Scan Network 169 . 254 . 0 .10 255 . 255 . 0 . 0 Figure 5-3 Figure 5-4 Show Welders - 1 Figure 5-5 Show Welders - 2 Internet Protocol (TCP/IP) Properties 4. Click OK, and close the Network window. You may need to restart the computer before changes take effect. 5. Run iQ Explorer II. • At first connection, iQ Explorer II and the iQ ES generator connect immediately using their default network configurations. • When connection has been made, the welder(s) available to the software are shown when the user presses the Show Welders button on the toolbar on the left of the application. See Figure 5-4 to the right. • 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 80 Dukane User’s Manual Part No. 403-585-01 Section 5 - Networking Continued from Previous Page If nothing is displayed after pressing the Show Welders button: • Check that the correct subnet was entered. • Check that the part of the IP address that is masked by the subnet is entered correctly. • Your firewall could be preventing communications. In that case, see the IT administrator for help. 6. If the 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 Address to HMI: 169.254.0.10 169.254.0.2 Figure 5-6 169.254.0.3 169.254.0.4 169.254.0.5 Simple Stand-alone Network Configuration Dukane User’s Manual Part No. 403-585-01 Page 81 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 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 II 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. NOTE If any installed HMI has a one-to-one relationship 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 II does not need any IP configuration. It automatically finds the generators on the network as long as a firewall or router permits UDP broadcast packets. To desktop PC Local Area Network (LAN) Figure 5-7 Page 82 Connection to Local Area Network Continued Dukane User’s Manual Part No. 403-585-01 Section 5 - Networking Continued from Previous Page Modify the Permitted IP Address List 1. Click the Options icon. NOTE 2. Go to the Communications tab. 3. See Figure 5-8 for a view of this tab. Auto-Display Welder Contents A 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 Dukane recommends: Add the list of generator IP addresses to the Permitted IP Address List of iQ Explorer II. That reduces the impact of handling network overhead for the HMI. B Add IP addresses of iQ generators to this list to limit the iQ Explorer II 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 II is dedicated to a subset of the generators on that network. A B Figure 5-8 Options - Modify Permitted IP Address List Dukane User’s Manual Part No. 403-585-01 Page 83 iQ Explorer II User’s Manual This page intentionally left blank Page 84 Dukane User’s Manual Part No. 403-585-01 Section 6 – Contacting Dukane SECTION 6 Contacting Dukane Dukane User’s Manual Part No. 403-585-01 Page 85 iQ Explorer II User’s Manual This page intentionally left blank Page 86 Dukane User’s Manual Part No. 403-585-01 Section 6 – Contacting Dukane Contacting Dukane Identify Equipment When contacting Dukane about a service-related problem, be prepared to give the following information: • Model and serial numbers of the press and generator. • Fault/error/alarm indicators from the generator display or iQ Explorer II software. • Software versions. (On generators with a display, go to Main Menu and press Help. On generators without a display, in iQ Explorer II, go to Help on the top menu bar, and select About iQ Explorer II.) • Problem description and steps taken to resolve it. • 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 2900 Dukane Drive St. Charles, IL 60174 US Phone: (630) 797–4900 E-mail: [email protected] Fax: Main (630) 797–4949 Service & Parts (630) 584–0796 Website The website has information about our products, processes, solutions, and technical data. Downloads are available for many kinds of literature. Here is the address for the main website: www.dukane.com You can locate your local representative at: www.dukane.com/us/sales/ Dukane User’s Manual Part No. 403-585-01 Page 87 iQ Explorer II User’s Manual This page intentionally left blank Page 88 Dukane User’s Manual Part No. 403-585-01 Section 7 – Appendices SECTION 7 Appendices Appendix A - List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 Appendix B - List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Appendix C - Regulatory Agency Compliance . . . . . . . . . . . . 95 Dukane User’s Manual Part No. 403-585-01 Page 89 iQ Explorer II User’s Manual This page intentionally left blank Page 90 Dukane User’s Manual Part No. 403-585-01 Section 7 – Appendices Appendix A List of Figures No. Description Page 2-1 Select Control Panel from the Start Menu (Windows XP)................................................7 2-2 Select Display from the Control Panel Window (Windows XP)........................................8 2-3 Setting Display Colors and Resolution (Windows XP).....................................................8 2-4 Selecting My Computer (Windows XP)..........................................................................10 2-5 Selecting View System Information (Windows XP)........................................................10 2-6 Checking Operating System Version (Windows XP)...................................................... 11 2-7 Start Menu, Select Computer (Windows 7)....................................................................12 2-8 Computer Window (Windows 7).....................................................................................12 2-9 Computer, Right Click Displays Submenu (Windows 7).................................................13 2-10 Properties - Hardware and Software Details (Windows 7).............................................13 3-1 Installation Start-up Screen............................................................................................17 3-2 iQ Explorer II Start-up Screen........................................................................................18 3-3 Show Welders - 1...........................................................................................................19 3-4 Show Welders - 2...........................................................................................................19 4-1 Main Menu - File.............................................................................................................23 4-2 Main Menu - Tools..........................................................................................................25 4-3 Main Menu - Tools>Options Window..............................................................................25 4-4 Main Menu - Window......................................................................................................27 4-5 Main Menu - Help...........................................................................................................27 4-6 Main Screen Icons..........................................................................................................28 4-7 Icon and Function...........................................................................................................29 4-8 Shutdown Icon................................................................................................................31 4-9 Shutdown Prompt...........................................................................................................31 4-10 Options - Communications Tab......................................................................................36 4-11 Options - Security Tab....................................................................................................39 4-12 Options - Enable Administrator Password......................................................................39 4-13 Options - Set Password..................................................................................................39 4-14 Options - Security - Setup Users....................................................................................41 4-15 Options - Security - Add New User.................................................................................41 4-16 Options - Security - Create User Profiles.......................................................................41 4-17 Options - Security - Custom Security Levels..................................................................42 Continued Dukane User’s Manual Part No. 403-585-01 Page 91 iQ Explorer II User’s Manual Continued from Previous Page Appendix A List of Figures No. Description Page 4-18 Options - Security Tab - Enable Auto Timeout and Enable Auditing...............................42 4-19 Options - PLC Interface Tab...........................................................................................45 4-20 Options - Shifts Tab........................................................................................................45 4-21 Options - Graph, Files Tab.............................................................................................46 4-22 Options - Graph, Display Tab.........................................................................................46 4-23 Options - Cycle Data......................................................................................................47 4-24 Options - Cycle Data File Management.........................................................................47 4-25 Options - Notes Per Cycle..............................................................................................47 4-26 Options - Barcode Tab....................................................................................................48 4-27 Options - Barcode Tab - Link Names.............................................................................48 4-28 Options - Force Tab........................................................................................................50 4-29 Options - Appearance Tab..............................................................................................50 4-30 Options - Appearance - Default Image Changed...........................................................50 4-31 Options - Diagnostics Tab..............................................................................................50 4-32 Setup - Show Welders....................................................................................................51 4-33 Setup - Select a Welder.................................................................................................51 4-34 Setup - Hardware...........................................................................................................52 4-35 Setup - Process Settings................................................................................................53 4-36 Setup - Process Limits Drop Down Menu Detail............................................................54 4-37 Notes..............................................................................................................................55 4-38 Setup - Cycle Data.........................................................................................................56 4-39 Setup - Graph Setup......................................................................................................57 4-40 Setup - Graph Display....................................................................................................58 4-41 Graph Display Detail......................................................................................................59 4-42 Setup - Interaction Points...............................................................................................60 4-43 Setup - Production Display.............................................................................................61 4-44 Setup - Utilities...............................................................................................................62 4-45 Setup - Utilities Test Display Sample..............................................................................63 4-46 Setup - System Warning.................................................................................................64 4-47 Setup - System Overview...............................................................................................65 4-48 Operation Summary.......................................................................................................66 4-49 Save and Retrieve Setup Files.......................................................................................67 Continued Page 92 Dukane User’s Manual Part No. 403-585-01 Section 7 – Appendices Continued from Previous Page No. Description Appendix A Page 4-50 Save Cycle Data - 1.......................................................................................................67 4-51 Save Cycle Data - 2.......................................................................................................68 4-52 Save Graph Data - File Management.............................................................................69 4-53 Help File Access from Top Menu Bar.............................................................................70 4-54 Help File - Using the Index Tab......................................................................................71 4-55 Help File - Using the Contents Tab.................................................................................71 4-56 Problem Prompt in Yellow..............................................................................................72 4-57 Parameter Conflict Display.............................................................................................73 5-1 Network Connections Window.......................................................................................79 5-2 Local Area Connection Properties..................................................................................79 5-3 Internet Protocol (TCP/IP) Properties.............................................................................80 5-4 Show Welders - 1...........................................................................................................80 5-5 Show Welders - 2...........................................................................................................80 5-6 Simple Stand-alone Network Configuration...................................................................81 5-7 Connection to Local Area Network.................................................................................82 5-8 Options - Modify Permitted IP Address List....................................................................83 Dukane User’s Manual Part No. 403-585-01 Page 93 iQ Explorer II User’s Manual List of Tables Appendix B No. Description 4-I Options Choices for the Operator................................................................................... 34 Page 94 Page Dukane User’s Manual Part No. 403-585-01 Section 7 – Appendices Regulatory Agency Compliance FCC The equipment complies with the following Federal Communications Commission regulations. • The limits for FCC measurement procedure MP-5, “Methods of Measurement of Radio Noise Emissions from ISM Equipment”, pursuant to FCC Title 47 Part 18 for Ultrasonic Equipment. CE Marking This mark on your equipment certifies that it meets the requirements of the EU (European Union) concerning interference causing equipment regulations. CE stands for Conformité Europeéne (European Conformity). The equipment complies with the following CE requirements. Appendix C UL The iQ generator complies with these standards: Underwriters Laboratories: UL 61010-1, and National Standards of Canada: CAN/CSA C22.2 No. 61010-1-12 as verified by TÜV Rheinland. • The EMC Directive 2014/30/EC for Heavy Industrial EN 61000-6-4 EN 55011 EN 61000-6-2 EN61000–4–2 EN61000–4–3 EN61000–4–4 EN61000–4–5 EN61000–4–6 EN61000–4–8 EN61000–4–11 • The Low Voltage Directive 2014/35/EU. • The Machinery Directive 2006/42/EC. EN 60204: Safety of Machinery - Electrical Equipment of Machines Part 1: General Requirements. • EN ISO 12100: Safety of Machinery - General principles of design, risk assessment, and risk reduction. IP Rating The vibration welder has an IP (International Protection) rating from the IEC (International Electrotechnical Commission). The rating is IP2X, in compliance with finger-safe industry standards. Dukane User’s Manual Part No. 403-585-01 CAUTION DO NOT make any modifications to the PLC, its program, or to the vibration welder as delivered by Dukane. Unauthorized changes made to the system may result in violating one or more regulations under which this equipment is manufactured. In addition, any warranties applying to the system expressed or implied may be void. Page 95 iQ Explorer II User’s Manual This page intentionally left blank Page 96 Dukane User’s Manual Part No. 403-585-01 Index Index Dukane User’s Manual Part No. 403-585-01 Page 97 iQ Explorer II User’s Manual This page intentionally left blank Page 98 Dukane User’s Manual Part No. 403-585-01 Index Index A Advanced Settings 53 Afterburst 53 Alarm History 53 Amplitude 53 Appearance 50 Appendices List of Figures 91 List of Tables 94 Regulatory Agency Compliance 95 B Barcode 48 Basic Setup 51 Cycle Data 56 Graph 57 Graph Display 58 Hardware 52 Name the Welder 52 Notes 55 Operation Summary 66 Graph Setup 66 View Live Data 66 Process Limits 54 Process Limits Helper 55 Process Settings 53 Advanced Servo Settings 53 Advanced Settings 53 Afterburst 53 Amplitude 53 Enable Melt Detect 53 Hold 53 Initiate Mode 53 Power Regulation 53 Production 61 Select a Welder 51 Show Welders 51 System Buzzer Status 65 Modify Hardware Settings 64 Serial Communications 65 Servo Press 65 System I/O 65 Utilities 62 Alarm History 62 Part Count 62 Setup Utilities 62 Sonics Test 62 View Real Time Data 62 Buzzer Status 65 Dukane User’s Manual Part No. 403-585-01 C Computer Requirements 7 Cycle Data 56 D Data Data from Multiple Welders 67 Data Storage 67 DHCP 77 Diagnostics 50 Dukane Address 87 Contacting 87 E-mail 87 Fax 87 Intelligent Assembly Solutions 87 Address 87 E-mail 87 Fax 87 Phone: 87 Phone 87 Website 87 www.dukane.com/ 87 www.dukane.com/contact-us/ 87 E E-mail 87 F FDA 21 CFR Part 11 Compliance 43 G General User Information 3 Drawings and Tables 3 Notes, Cautions and Warnings 3 Graph 57 Interaction 60 Save and Restore Graph Data 69 Save as Reference 59 Show Reference 59 Transition Point 59 Graph Display 58 Graph Setup 66 Continued Page 99 iQ Explorer II User’s Manual Continued from Previous Page H N Hardware Modification 64 Hardware Tab 52 Help System 70 F1 Key 70 Top Menu Bar Using the F1 Key 70 Hold 53 Networking 75 Connection through a Stand-alone Network 81 Connection to a Local Area Network 82 DHCP 77 HMI Directly Connected to a Single Generator 79 Network Settings 78 DHCP Disabled on the HMI 78 DHCP Disabled on the iQ ES Generator 78 DHCP Enabled 78 Direct Connection 78 Network Settings on the iQ ES Generator 77 Notes 55 I Icons 28 Index 97 Initiate Mode 53 Installation Installing 17 Launching the Software 18 Unpacking 17 IP Address 52 Modify the Permitted IP Address List 83 iQ Explorer II Key Features 4 Overview 4 iQ System Requirements 14 K Keyboard and Mouse 32 Key Features 4 L LAN 82 Latch on Bad Part 54 Launching the Software 18 Change Autoboot 18 Click Icon 18 List of Figures 91 List of Tables 94 M Main Screen Icons 28 Melt Detect 53 Menu Icons 23 Microsoft .NET Framework 17 Modify Hardware Settings 64 Multiple Welders 67 O Operation Basic Setup 51 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 32 Keyboard and Mouse 32 Touch Screen 32 Continued Page 100 Dukane User’s Manual Part No. 403-585-01 Index Continued from Previous Page O Options 33 Appearance 33 Communications 33 Graph Data 33 Shifts 33 Supervisor 33 Setup 51 Cycle Data 56 Graph 57 Graph Display 58 Process Settings 53 Production 62 System 65 Utilities 63 Operation Summary 63 Options 33 Appearance 50 Barcode 48 Communications 36 Cycle Data 47 Diagnostics 50 Force 50 Graph Data 46 PLC Interface 45 Security Creating Custom Level User Profiles 42 Enable Auditing to Support FDA 21 CFR Part 11 Compliance 43 Setup Users 41 User Access Levels 40 Shifts 48 Serial Communications 65 Servo Press 65 Servo Settings Advanced 53 Shutdown 31 Shutdown Process 31 Software Prompts 72 Software Requirements .NET Framework 14 Windows 10 Sonics Test Test Display 63 System 64 System I/O 65 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 94 Testing Ultrasonics 62 Time 52 Touch Screen 4, 31, 40, 62 P U Parameter Conflict Example 73 Power Regulation 53 Process Limit Helper 54 Process Settings 53 Production 61 Using the Help System Using the Index Tab and the Contents Tab 71 Utilities 63 Utilities Sonics Test 63 R V Regulatory Agency Compliance 87 View Live Data 66 View real time data 62 S W Save and Restore Graph Data 69 Save and Retrieve Cycle Data 67 Save and Retrieve Part Data 67 Save and Retrieve Setup Files 67 Security Key 9, 17 Windows Windows 7 12 Windows XP 10 Dukane User’s Manual Part No. 403-585-01 Page 101 iQ Explorer II User’s Manual This page intentionally left blank Page 102 Dukane User’s Manual Part No. 403-585-01 Dukane ISO ISO CERTIFICATION Dukane chose to become ISO certified 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, manufacturing, delivery and service. This certificate reinforces Dukane's status as a quality vendor of technology and products. To achieve ISO certification, you must prove to one of the quality system registrar groups that you meet three requirements: 1. Leadership 2. Involvement 3. Quality in Line Organizations and Quality System Infrastructure. The ISO standards establish 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 Dukane no longer focuses on inspection, but on individual processes. Dukane's quality management system is based on the following three objectives: 1. Customer oriented quality. The aim is to improve customer satisfaction. 2. Quality is determined by people. The aim is to improve the internal organization and cooperation between staff members. 3. Quality is a continuous improvement. The aim is to continuously improve the internal organization and the competitive position. Dukane products are manufactured in ISO registered facilities View the Dukane ISO certificate of compliance at: https://documents.dukane.com/Certifications/ISO-Cert.pdf Dukane User’s Manual Part No. 403-585-01 Page 103 Please refer to our website at: www.dukane.com/contact-us/ to locate your local representative. iQ Explorer II User's Manual Part No. 403 – 585– 01 www.dukane.com Printed in the United States of America Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900
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