Dukane iQ Series ES Pneumatic Press - Ultrasonic Power Supply Manual

Series
ULTRASONIC GENERATOR/POWER SUPPLY
Pneumatic Systems
ES
AUTOMATED
HAND PROBE
PRESS
User's Manual
Dukane Part No. 403 – 584 – 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 Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES 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.
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: 403-584-01
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
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Dukane Manual Part No. 403-584-01
Revision History
Revision
Number
Revision
Summary
Date
- 00Original release. December 6, 2013
- 01
Clarified wording of Bad Limit
Dukane Manual Part No. 403-584-01
June 21, 2019
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Dukane Manual Part No. 403-584-01
Contents
Section 1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . 1
General User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Press System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Key Generator Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Section 2 - Health and Safety . . . . . . . . . . . . . . . . . . . 5
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Plastics Health Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Lifting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Section 3 - Installation . . . . . . . . . . . . . . . . . . . . . . . 11
Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Panel Layout Overview . . . . . . . . . . . . . . . . . . . . . . . . . .
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recheck Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connect AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
15
15
16
25
26
28
29
33
33
33
Section 4 - Control Panel . . . . . . . . . . . . . . . . . . . . . 35
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Operating Mode Keys . . . . . . . . . . . . . . . . . . . . . . . . .
Navigation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Power Output Level . . . . . . . . . . . . . . . . . . . . . . . . . .
Screen Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
38
39
40
41
Continued
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Continued from Previous Page
Contents
Section 5 - Operation . . . . . . . . . . . . . . . . . . . . . . . . 43
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45
45
46
47
Section 6 - System Operational Testing . . . . . . . . . 93
Section 7 - Set-up Guidelines and Troubleshooting . 99
Section 8 - Maintenance . . . . . . . . . . . . . . . . . . . . . 113
Section 9 - Options . . . . . . . . . . . . . . . . . . . . . . . . . 117
Section 10 - Contacting Dukane . . . . . . . . . . . . . . 123
Section 11 - Specifications . . . . . . . . . . . . . . . . . . . 127
Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Weights, Dimensions, Operating Environment . . . . . . . . . . 132
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Ultrasonic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Interpreting the Model Number . . . . . . . . . . . . . . . . . . . . . . 135
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . 136
Section 12 - Appendices . . . . . . . . . . . . . . . . . . . . 137
Appendix A - List of Figures . . . . . . . . . . . . . . . . . . . . . . . . 139
Appendix B - List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . 143
Appendix C - Sequencing Notes . . . . . . . . . . . . . . . . . . . . 144
Appendix D - Menu Structure Diagrams . . . . . . . . . . . . . . . . 147
Index
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vi
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Dukane Manual Part No. 403-584-01
Section 1 - Introduction
SECTION 1
Introduction
General User Information . . . . . . . . . . . . . . 3
Press System Overview. . . . . . . . . . . . . . . 4
Key Generator Features. . . . . . . . . . . . . . . 4
Dukane Manual Part No. 403-584-01
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Dukane Manual Part No. 403-584-01
Section 1 - Introduction
General User Information
Read this Manual First
Before operating your ultrasonic system, read this User’s
Manual to become familiar with the equipment. This will
ensure correct and safe operation. The manual is organized
to allow you to learn how to safely operate this equipment.
The examples given are chosen for their simplicity to illustrate basic operation concepts.
This manual provides information to set up, operate, and
interface this generator/power supply as an integral part of
Dukane’s iQ Series ES press system.
Particular models are listed in Section 11 - Specifications.
NOTE
Note statements provide additional
information or highlight procedures.
Notes, Cautions and Warnings
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 Manual Part No. 403-584-01
Condition
or Practice
Electrical
Safety Issue
Operator
Protection
(hearing)
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Press System Overview
An iQ Series Ultrasonic Press System ES consists of
these components: the iQ generator, press (with thruster,
switches, controls, cables, transducer, booster, horn, and
fixture) and iQ Explorer II software. The software allows
the operator to control the system either remotely or at the
press location.
The iQ Series ES generator has rugged internal ultrasonic
circuitry and ensures a continuous resonant frequency lock
at the start of each weld.
The generator’s compact size allows multiple units to be
placed into an industrial equipment cabinet. This generator will operate at the same international line voltage input
specifications as the other generators of this product family (unless the 120V option is installed). It also includes an
RFI line filter that passes FCC, CE, UL, and CSA testing
for global applications.
•
Line Voltage Regulation automatically maintains
constant amplitude regardless of line voltage deviation. The available output power is maintained with
any voltage input within the specified range. This
provides consistent system performance regardless of
line voltage fluctuations. It also eliminates the need
for bulky, external constant–voltage transformers.
•
Load Regulation provides constant ultrasound amplitude automatically regardless of power draw. The
ultrasonic output amplitude level is held to within
±1% to provide weld process consistency and reduced
weld cycle times.
•
Wide Line Voltage Operation means that standard
systems will operate worldwide within their standard
AC voltage ranges.
•
Flow Through Cooling Tunnel with a matched high–
performance heatsink and thermostatically controlled
fan reduces thermal gradients and increases component life.
Key Generator Features
•
The Generator Interface has a 5" LCD color display
and soft keys to ease the intuitive menu navigation.
•
•
Digital Control of all power supply functions, including digital frequency synthesis, and parameters allows
for unique configurations and allows for future upgrades.
AC Power Inrush protection reduces electrical stress
on the internal components by protecting them from
AC power startup transient current surges.
•
Multiple Electronic Overload protection circuits
prevent instantaneous component failure in the
event of extreme output overload conditions. The
overload power limit is based on the actual true RMS
power output level.
•
Process Limits include: distance, time only, time and
energy, and peak power. These programmable limits
provide the means to adapt to a wide variety of welding applications.
•
Rear Panel Expansion Slot is available to allow for
custom configurations for OEM and cost effective solutions.
•
RS-232 Serial Configuration Port is used for field
software upgrades, troubleshooting and advanced
hardware setup with optional PC-based configurator.
•
CE Certification means that the system meets the
required European standards to be sold and used in
Europe (high line voltage models only).
•
ISO 9001 Certification means that this system has
been manufactured to high quality standards and assures you of manufacturing excellence.
•
TUV Certification - TÜV Rheinland certifies Dukane products comply with applicable UL (Underwriters Laboratories) and CSA (Canadian Standards
Association) requirements.
•
Process Parameters such as frequency, amplitude
and power are all updated at a 0.5 ms rate.
•
Pulse Width Modulation incorporates patented
circuitry giving the power supply the ability to
efficiently change and maintain the output amplitude.
This makes it possible to start large horns with reduced
power. It also provides more power-efficient switchmode generator operation and increased reliability.
•
•
Linear Ramp Up/Down circuitry allows the acoustic
stack to be brought to operating amplitude smoothly,
minimizing start-up surges and undue stress to stack
and generator. This circuitry also allows decreases to
amplitude as the weld cycle ends. The stack is brought
down from its maximum operating amplitude smoothly, reducing shock stress.
Digi-Trac Tuning tracks the resonant frequency of the
acoustic stack (horn, booster, and transducer) and adjusts the generator output frequency to match it. This
is done for every weld cycle and eliminates the need
to manually tune the generator.
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Dukane Manual Part No. 403-584-01
Section 2 - Health and Safety
SECTION 2
Health and Safety
General Considerations . . . . . . . . . . . . . . . . 7
Plastics Health Notice. . . . . . . . . . . . . . . . . 8
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Domestic Power Grounding . . . . . . . . . . . . . . . . . . . . . . . 9
International Power Grounding . . . . . . . . . . . . . . . . . . . . 9
Lifting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 10
Dukane Manual Part No. 403-584-01
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Dukane Manual Part No. 403-584-01
Section 2 - Health and Safety
General Considerations
Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your
equipment.
Proper Installation - Operate system components only
after they are properly installed.
No Unauthorized Modifications - Do not modify your
system in any way unless authorized to do so by Dukane.
Unauthorized modifications could cause equipment damage and/or injury to the operator. In addition, unauthorized
modifications will void equipment warranty.
Keep the Cover On - Do not remove any equipment
cover unless directed to do so by Dukane. The generator produces hazardous electrical voltages which could
cause injury.
Grounded Electrical Power - Operate this equipment
only with a grounded electrical connection.
See Electrical Safety for grounding instructions, Page 9.
Comply with Regulations - You may be required to add
accessories to bring the system into compliance with
applicable regulations (OSHA in the USA) for machine
guarding and noise exposure.
Use Eye Protection - Wear ANSI approved safety impact
goggles.
Acoustic Stack Hazard - When an acoustic stack (transducer, booster, horn and tip) is energized by the ultrasound
signal, it presents a potential hazard. Stay clear of an
energized stack.
System E-STOP (abort) Switch - Install a system ESTOP (abort) switch at each operator station when ultrasonic plastic assembly equipment is used with automatic
material handling equipment in an automated system.
Foot Switch - Do not use a foot switch. Using a foot
switch in place of the optical touch finger switches (operate switches) violates OSHA regulations.
NOTE
These recommendations apply to the
welding system. System in this manual
refers to a complete group of components
associated with the welding of parts, also
known as an ultrasonic assembly system.
A typical iQ Series System consists of the
iQ generator, a press with thruster, switches, controls, cables, transducer, booster,
horn, fixture, and iQ Explorer II software.
WARNING
Any fixture manufactured by
a third party must comply
with all OSHA and ANSI requirements. All fixtures must
be guarded as necessary.
Dukane does not assume any
responsibility or liability for
fixtures manufactured by the
customer or any third party
manufacturer.
WARNING
Never operate the generator
with the cover off. This is
an unsafe practice and may
cause injury.
CAUTION
At some time you may be asked
to remove equipment covers
by the Dukane Service Dept.
personnel. Before doing so,
disconnect the unit electrically from the incoming line AC power. If the unit is a press/
thruster, lock the Air Lockout Valve, located
on the rear panel, in its closed position.
Continued
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Continued from Previous Page
General Considerations
Pre-trigger Switch Adjustment - The pre-trigger switch
option starts the horn vibrating before contacting the part
to be welded. To ensure safe operation, adjust the pretrigger so the ultrasound signal will not activate if the
horn is more than ¼ in (7 mm) from the part to be welded.
System Electrical Cabling - Electrical power must be
off when connecting or disconnecting electrical cables.
Do Not Wear Loose Clothing or Jewelry - They can
become caught in moving parts.
Stay Alert - Watch what you are doing at all times. Use
common sense. Do not operate the press when you are
tired or distracted from the job at hand.
Do Not Operate the Equipment - Your judgement or
reflexes could be impaired while taking prescription medications. If so, do not operate the equipment. Be familiar
with warning labels and recommended activity restrictions
that accompany your prescription medications. If you have
any doubt, do not operate the equipment.
Plastics Health Notice
Certain plastic materials, when being processed, may
emit fumes and/or gases that may be hazardous to the
operator’s health. Proper ventilation of the work station
should be provided where such materials are processed.
Inquiries should be made to the U.S. Department of Labor
concerning OSHA regulations for a particular plastic prior
to processing with Dukane ultrasonic equipment.
Electrical Safety
The iQ Series generator provides the operating power
and power returns. Make sure the generator is grounded
properly.
In addition to the safety considerations, proper grounding
is essential for the effective suppression of RFI (Radio
Frequency Interference). Every generator contains a RFI
filter which blocks noise on the AC power line from entering the generator control circuitry. This filter also prevents
ultrasonic RFI from being fed back into the AC power line.
If you experience problems with RFI from the press, run
an additional grounding wire from the press base grounding stud to the nearest grounded metal pipe or equivalent
earth ground by means of a ground clamp. Use at least 14
AWG wire for the connection to the press base.
CAUTION
Parts being joined ultrasonically will at times vibrate at
audible frequencies. Wear ear
protectors to reduce annoying
or uncomfortable sounds. In
addition, ultrasound baffles, sound enclosures, or materials that absorb sound may be
located to surround the system. Ultrasound
pressure level could exceed 110dB. See
Ultrasonic Pressure, Table 11-IV, Page 134.
WARNING
Keep head, hands, limbs
and body at least six
inches (152 mm) away
from an operating press/
thruster. A vibrating, descending horn
can cause burns and/or crushing
injuries.
CAUTION
When making cable connections to system equipment
or disconnecting cables
from system equipment,
make sure electrical power to the system
is turned off, and AC power cords are
removed from their receptacles. After the
cables have been securely connected
and the connections and cable routing
checked a final time, the power may be
restored.
Continued
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Dukane Manual Part No. 403-584-01
Section 2 - Health and Safety
Continued from Previous Page
Electrical Safety
Domestic Power Grounding
For safety, the power cords used on this product have a
three-wire, grounding-type power cord. Figure 2-1 illustrates the appropriate electrical outlet to use with the
power cord that is included with systems shipped to North
America.
CAUTION
If you have a two-prong electrical receptacle, we strongly
recommend that you replace
it with a properly grounded
three-prong type. Have a qualified electrician replace it following the National
Electric Code and any local codes and
ordinances that apply.
See Figures 2–1 and 2–2.
Approved 2 pole, 3 wire grounding
receptacle HUBBELL No. 5652 or
equivalent to NEMA 6–15R or 6–20R
Figure 2–1
Example of 220/240 Volt, Grounded, 3-Prong Receptacle
International Power Grounding
The power cable normally provided for international use is
compatible with the power outlet used in many Continental European countries (Refer to Figure 2–2.) However,
if your application requires another type of power cord,
check with your equipment supplier, and follow local regulations concerning proper wiring and grounding.
CAUTION
If there is any question about
the grounding of your receptacle, have it checked by a
qualified electrician. Do not
cut off the power cord grounding prong,
or alter the plug in any way. If an extension cord is needed, use a three-wire
cord that is in good condition. The cord
should have an adequate power rating
to do the job safely. It must be plugged
into a grounded receptacle. Do not use a
two-wire extension cord with this product.
Grounding Contacts
100/120 Volt AC Systems (North America or
Japan)
Typical Outlet
Provided Cable
Figure 2–2
International 220/240V Grounding
The power cord (including strain relief) supplied
with the 100/120VAC systems is permanently
attached to the rear of the generator. Units with this
power cord are for use in North America or Japan.
240V Systems
High power generators with power ratings above
2400W also use permanently attached power cords.
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Lifting the Equipment
How to Lift Safely
•
Before lifting, take a moment to think about what
you’re about to do.
•
Examine the object for sharp corners, slippery spots
or other potential hazards. Know your limit and don’t
try to exceed it.
•
Ask for help if needed, or if possible, divide the load
to make it lighter.
•
Know where you are going to set the item down, and
make sure it and your path are free of obstructions.
Then follow these steps:
1.
Page
Stand close to the load with your feet spread
apart about shoulder width, with one foot
slightly in front of the other for balance.
2.
Squat down bending at the knees (not your
waist). Tuck your chin while keeping your
back as vertical as possible.
3.
Get a firm grasp of the object before beginning the lift. Begin slowly lifting with your
LEGS by straightening them. Never twist
your body during this step.
4.
Once the lift is complete, keep the object as
close to the body as possible. As the load’s
center of gravity moves away from the body,
there is a dramatic increase in stress to the
lumbar region of the back.
5.
If you must turn while carrying the load,
turn using your feet-not your torso. To place
the object below the level of your waist, follow the same procedures in reverse order.
Remember, keep your back as vertical as
possible and bend at the knees.
10
NOTE
For equipment weights see Page 132,
Table 11-I in Section 11, Specifications.
CAUTION
Take care when lifting the equipment. We recommend using a
mechanical lift device to assist.
Dukane Manual Part No. 403-584-01
Section 3 - Installation
SECTION 3
Installation
Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
When to Use Lockout/Tagout Devices . . . . . . . . . . . . . . . 13
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Rear Panel Layout Overview . . . . . . . . . . . . . . . . . . . 16
AC Power Inlet Panel . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connector Descriptions . . . . . . . . . . . . . . . . . . . . . . . 26
Power Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Recheck Connections . . . . . . . . . . . . . . . . . . . . . . . 33
Connect AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Dukane Manual Part No. 403-584-01
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Dukane Manual Part No. 403-584-01
Section 3 - Installation
Before Installation
As you plan for the installation of your generator,
please consider these important subjects as listed
below:
• When to use lockout / tagout devices
• Lifting the generator safely - See Section 2 Health and Safety, Page 10.
When to Use Lockout /
Tagout Devices
Figure 3-1
Lockout Device In Open Position, Unlocked
The typical kind of LOTO device for this generator
is a clam shell type device (with lockout capability).
The LOTO device is placed over the plug end of the
generator electrical cord. This effectively prevents
access to the energy isolation point. See the example
of one such device in the figure above.
The figure to the right shows the lockout device in the
closed, locked position.
Figure 3-2
Bottom Lockout Device In Closed Position, Locked
WARNING
Electrical safety hazards exist inside the
generator chassis.
Before making any internal adjustments to the generator, apply
a lockout/tagout (LOTO) device to
the generator chassis.
Continued
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Continued from Previous Page
Lockout/Tagout
Procedure to use BEFORE making any internal
adjustments to the generator:
1. Push the generator's AC power switch/breaker
to the OFF position.
2. Unplug the generator's electrical cord from its
source.
3. Authorized personnel apply a lockout/
tagout (LOTO) device to the plug end of the
generator's electrical cord. Using a typical
clam shell type LOTO device:
1) Open the clam shell.
2) Place the electrical cord plug end inside the
shell.
3) Close the shell.
4) Secure the shell with its lock, and lock it.
4. Wait a minimum of five minutes for the
generator to discharge its electrical energy.
5. After taking these steps, make the necessary
adjustments to the generator.
Assuming the generator is being put back into
service. . .
Procedure to use AFTER making any internal
adjustments to the generator:
1. Authorized personnel remove the lockout/
tagout device from the plug end of the
generator's electrical cord. Using a typical
clam shell type LOTO device:
1) Unlock the protective shell.
2) Open the shell, exposing the electrical cord
end.
3) Remove the LOTO device, and set it aside.
2. Plug the generator's electrical cord into its AC
power source.
3. Push the generator's AC power switch/breaker
to the ON position.
Page
14
Dukane Manual Part No. 403-584-01
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 damage immediately.
Placement
Generator placement and cable routing should permit
easy access and not interfere with normal system operation.
Allow at least 5 inches [13 cm] of space on both ends of
the generator chassis for air circulation. Allow space between 3-6 inches, [8-15 cm] - at the rear of the chassis
for cable clearance. (The amount of space depends on the
chassis type and what rear panel connections there are.)
See Section 11 - Specifications, for generator drawings.
CAUTION
Allow 5 inches for air ventilation at the cooling air inlet and
at the exhaust air outlet. The
fan draws in fresh air to cool
the internal components, reduce thermal
gradients and increase component life.
17.16
[435.86]
5.19
[131.83]
Exhaust Air
Outlet
Cooling Air Inlet
IN
[mm]
Figure 3-3 Generator Front View (Typical High Profile)
NOTE
Active Seismic Region Placement - If the
generator will be put in an active seismic
region, please refer to Application Note
511 at, http://www.dukane.com/us/
DL_ApplData.asp
Dukane Manual Part No. 403-584-01
Page
15
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Rear Panel Layout Overview
This section provides an overview of the generator rear
panel layout, which includes panel areas dedicated to various standard system functions and options that are available. Figure 3-4 illustrates a typical panel layout.
B
K
D
DUKANE CORP.
I
ST. CHARLES IL. 60174
MADE IN U.S.A.
C
0
SYSTEM INPUTS
J6 BASE/ABORT
-WARNING-
PE
A
US
UL: 1012:2010
CSA: C22.2 61010-1-12
IEC: 61010-2012
LINE VOLTAGE:
200-240 Vac
50/60Hz, 10A
J5 THRUSTER
SYSTEM OUTPUTS
POWER LINE OUTLET
MUST BE GROUNDED
DISCONNECT LINE POWER
BEFORE REMOVING COVER
U.S. PATENTS 7,475,801
7,819,158 AND 7,225,965
J3
J9 ETHERNET
J10
RS-232
CONFIGURATION
ULTRASOUND
J1
J4
C
Figure 3-4
E
J2
J11 ENCODER
H
F
G
REAR VIEW PNEUMATIC PRESS/THRUSTER
Generator Rear Panel - Pneumatic Press/Thruster
AC Power Inlet Panel
Options Module Panel
A IEC Power Inlet Connector – Attaches to an IEC style
H Communications Board (See NOTE below.)
power cord.
B Power Switch – Circuit Breaker – Used to switch
system power ON and OFF.
C Chassis Grounding Stud – Chassis connection for a
protective earth ground.
Shown in the example above are these ports:
J9 - Ethernet
J10 - Serial RS-232
K Press Interface Module (See NOTE below.)
Shown in the example above are these ports:
The System I/O Panel
J6 - Base/Abort
D System Input Connector (J2) – Connections for sys-
J5 - Thruster
tem control input signals.
E System Output Connector (J3) – Connections for sys-
J11 - Encoder
tem status output signals.
F Ultrasound Output Connector (J1) – Coaxial high
voltage connection to ultrasonic stack.
G Configuration Port Connector (J4) – Digital control
port to modify system parameters.
Page
16
NOTE
The press interface board is available in
several different configurations.
See Section 9, Options for more information about Data Transfer using the
Communications Board and more about
the Press Interface Module.
Dukane Manual Part No. 403-584-01
Section 3 - Installation
AC Power Inlet Panel
The standard AC power inlet panel is described in this section.
IEC AC Power Inlet Connector
The IEC AC power inlet connector mounted on the system
AC power inlet panel requires a properly configured IEC
compliant power cord, which enables worldwide system
operation by simply changing the power cord.
Low profile systems are equipped with a 10 amp rated IEC
inlet connector. The high profile systems include a 16/20
amp rated IEC inlet connector. 120 VAC and 3600/4800W
systems include a non-detachable power cord.
An appropriately rated power cord must be securely attached to the welding system’s IEC inlet connector. If the
correct power cord configuration is not included with the
system for the local AC power outlet at your location, an
appropriate IEC power cord should be available from a
local electrical parts supplier. Note that the system undervoltage lockout will inhibit system operation if a North
American power cord configured for 120V is connected to
the system. A minimum of 180V is required for the system
to operate.
Power Switch/Circuit Breaker
The power switch/circuit breaker has a rocker type actuator switch that will activate or deactivate the AC power
to the system. The power ON position is marked with the
internationally recognized I symbol, the power OFF position is marked with the O symbol. This power switch also
integrates an appropriately sized over-current protection
circuit breaker function in the generator.
If an over-current condition trips the circuit breaker, it will
automatically switch to the OFF position. If the overload
current that caused the circuit breaker to trip is due to a
transient condition, the circuit breaker can be reset by
switching the actuator back to the ON position. If when
resetting the circuit breaker after it has tripped, it immediately trips again, there is likely an internal system malfunction, and the generator will require service.
Do not repeatedly try to reset the circuit breaker. If it trips,
this will only cause more damage to the generator.
Chassis Grounding Stud
The chassis grounding stud is used to attach a protective earth ground to the generator. This will aid in the
suppression of electrical interference or radio frequency
interference (RFI) that is common in an industrial environment. The chassis ground stud is C in Figure 3-5.
Proper system grounding is discussed on Page 9.
DUKANE CORP.
I
ST. CHARLES IL. 60174
MADE IN U.S.A.
C
0
US
UL: 1012:2010
CSA: C22.2 61010-1-12
IEC: 61010-2012
LINE VOLTAGE:
200-240 Vac
50/60Hz, 10A
-WARNING-
PE
POWER LINE OUTLET
MUST BE GROUNDED
DISCONNECT LINE POWER
BEFORE REMOVING COVER
U.S. PATENTS 7,475,801
7,819,158 AND 7,225,965
C
Figure 3-5
IEC AC Power Inlet Connector
System I/O Panel
The standard system I/O panel is described in this section. See Figure 3-6 on the next page.
System Inputs Connector
The SYSTEM INPUTS connector mounted on the system I/O panel includes connections for all of the basic
system control input signals, that will typically come
from an automated control system. The cable attached to
this connector includes all of the available system control signals, which will be controlled by an output card
or output port on the automation controller.
The user can determine which signals to use for each
particular welding application, but there must be at least
one connection to this connector in order to activate the
ultrasound output. All of the input signals on this connector are electrically isolated (signals are NOT referenced
to chassis ground) and activated when a 24VDC voltage
source is connected to the signal input pin, referenced
to the isolated common pin. The electrically isolated input signals can be driven from an automation controller
output that is either sinking (NPN) or sourcing (PNP),
depending upon how the isolated common connection
is terminated. All inputs sink or source 10mA of current
from a 24VDC power supply.
Continued
Dukane Manual Part No. 403-584-01
Page
17
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Continued from Previous Page
Note that a simple switch closure (relay contact) connected to a control input can not activate the input without
adding an external power supply to power the input. Adding jumper connections to pins available on the System
Inputs connector, can configure switch closure inputs to
operate referenced to generator chassis ground (non-isolated), without adding a separate power supply, if desired.
Refer to Application Note AN507 (Automation Interface
Guidelines) at http://www.dukane.com/us/DL_ApplData.asp for wiring diagrams of example applications.
System Inputs Connector Pinout
The SYSTEM INPUTS connector is a HD-15F (high
density D-subminiature 15 circuit female) connector.
Connector pin numbers for this connector are shown in
Figure 3-7. The male connector on the cable is a mirror
image of the panel-mounted connector and is shown in
Figure 3-8. Table 3-I lists the signal names and descriptions, with more detailed descriptions that follow. The
wire color coding for the system input cable is listed in
Table 3-II, to assist with custom automation system wiring and assembly.
Figure 3-6
System I/O Panel (Standard Panel Shown)
NOTE
Refer to Section 9, Options for information
on optional features.
Continued
Page
18
Dukane Manual Part No. 403-584-01
Section 3 - Installation
Continued from Previous Page
Pin
Signal Name
Cable Color Code
Signal Option Requirements
1
+22VDC Power Supply
BLK
2
+22VDC Power Ground
WHT
3
Remote Setup Selection Bit 0 Input
RED
4
Remote Setup Selection Bit 1 Input
GRN
5
Remote Setup Selection Bit 2 Input
ORN
6
Remote Setup Selection Bit 3 Input
BLU
7
Remote Setup Selection Bit 4 Input
WHT/BLK
8
Ultrasound Activation/Cycle Start Input
RED/BLK
9
Not Used
GRN/BLK
Not Used
10
Front Panel Control Lock Input
ORN/BLK
Not Used
11
Press Inhibit for Hand Probes
BLU/BLK
Hand Probe
12
System Latch Reset Input
BLK/WHT
13
Isolated Common
RED/WHT
14
Not Used
GRN/WHT
15
Automation Cycle Stop Input
BLU/WHT
Table 3-I
Not Used
Generator Input Signals (J2)
System Inputs Signal Descriptions
5
4
3
2
1
Pin 1 (+22VDC Power Supply)
This pin can supply +22VDC at up to 250mA to power the
user’s automation controls.
Pin 2 (+22VDC Power Ground)
Pin 2 is the +22VDC return and is tied to the system chassis ground.
10
6
15 14 13 12 11
Figure 3-7
HD-15F, Generator Input Connector
Pin 3 (Remote Setup Selection Bit 0 Input)
Pin 3 is the Remote Setup Selection Bit 0, which is the
least significant bit used to select different welding setups
with an automation control system.
1 2 3 4 5
6
Pin 4 (Remote Setup Selection Bit 1 Input)
Pin 4 is the Remote Setup Selection Bit 1, which is the
second least significant bit used to select different welding
setups with an automation control system.
10
11 12 13 14 15
Figure 3-8
HD-15M, Generator Input Cable
Connector
Continued
Dukane Manual Part No. 403-584-01
Page
19
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Continued from Previous Page
Pin 5 (Remote Setup Selection Bit 2 Input)
Pin 5 is the Remote Setup Selection Bit 2, which is the
third least significant bit used to select different welding
setups with an automation control system.
Pin 6 (Remote Setup Selection Bit 3 Input)
Pin 6 is the Remote Setup Selection Bit 3, which is the
second most significant bit used to select different welding setups with an automation control system.
Pin 12 (System Latch Reset Input)
Pin 12 is used to reset the Any Fault or System Overload
status outputs (See Status Output descriptions.). If a fault
occurs during a weld cycle, these outputs will normally
remain active until the next weld cycle is initiated. Activating this input will reset the status output faults and may
simplify automation programming.
Pin 7 (Remote Setup Selection Bit 4 Input)
Pin 7 is the Remote Setup Selection Bit 4, which is the
most significant bit used to select different welding setups
with an automation control system.
Pin 8 (Ultrasound Activation/ Cycle Start
Input)
Pin 8 is used to activate the generator ultrasound output.
Activation of this control input will switch the ultrasound
output ON, and deactivating this signal will switch ultrasound OFF. This input signal will also function as a cycle
start input, where the ultrasound activation and timing
are completely under the control of the process controller.
Depending on the welding process controller setup, this
input signal could be activated momentarily (minimum of
50 ms) to start a welding cycle.
Pin 9 (Not Used)
Pin 10 (Not Used)
Pin 11 (Press Inhibit for Hand Probes)
Pin 11 is used to disconnect power applied to a press or
thruster, if a hand probe is connected to the system input
connector, for safety considerations. The hand probe activation switch could unexpectedly start a welding cycle that
activates a press or thruster to the down position. The hand
probe cable connector is wired to apply chassis ground to
this pin, when it is attached to the system, which activates
a press inhibit relay that disconnects power from the pneumatic press valves. This pin must be left open whenever
a press control board is installed. Connecting this pin to
chassis ground will inhibit press operation.
Page
20
NOTE
Refer to Latch on Bad Part, on Page 50 for
more information.
Pin 13 (Isolated Common)
Pin 13 is electrically isolated from chassis ground. Using
isolated sourcing (PNP) output drivers, this common line
would be connected to isolated ground potential. Using
isolated sinking (NPN) output drivers, this common line
would be connected to the isolated positive supply voltage output.
Pin 14 (Not Used)
Pin 14 is an open connection.
Pin 15 (Automation Cycle Stop Input)
Pin 15 is an input control signal that when enabled, can
be used by the automation control system as a redundant
signal to shut the ultrasound output off. This signal could
also be reconfigured through menu selections to function
as an automation end-of-weld control signal input.
Dukane Manual Part No. 403-584-01
Section 3 - Installation
Pin
Signal Name
Cable Color Code
1
+22VDC Power Supply
BLK
2
Spare Output
WHT
3
+22VDC Power Ground
RED
4
Programmable Status Output 1
GRN
5
Programmable Status Output 2
ORN
6
Ultrasound Active Status Output
7
Any Fault Status Output
8
Press Trigger Status Output
RED/BLK
9
System Overload Status Output
GRN/BLK
10
System Online Status Output
ORN/BLK
11
Press Top of Stroke Status Output
BLU/BLK
12
Current Loop OK Status Output
BLK/WHT
13
Analog Monitor Signal Common
RED/WHT
14
Not Used
GRN/WHT
15
Power Signal Monitor Output
BLU/WHT
16
Amplitude Monitor Output
BLK/RED
17
Programmable Status Output 3
WHT/RED
18
MPC Ready Status Output
ORN/RED
19
System Power OK Status Output
BLU/RED
20
Bad Part Status Output
RED/GRN
21
Good Part Status Output
22
System Ready Status Output
BLK/WHT/RED
23
Suspect Part Status Output
WHT/BLK/RED
24
Isolated Common
RED/BLK/WHT
25
Not Used
GRN/BLK/WHT
Table 3-II
Signal Option Requirements
BLU
WHT/BLK
Not Used
Not Used
ORN/GRN
System Output Connector Signals (J3)
System Outputs Connector
The SYSTEM OUTPUTS connector mounted on the generator I/O panel includes connections for all of the basic
system status and monitor output signals, which will typically connect to an automated control system. The cable
attached to this connector includes all of the available
system output signals, which will be read or monitored by
a digital input card or analog inputs on the user-supplied
automation controller.
The user can determine which signals are appropriate for
each welding application.
The system monitor output signals are analog signals used
to monitor ultrasonic amplitude setting and ultrasonic output
power levels, referenced to the Monitor Common (Pin 13).
13
25
Figure 3–9
Figure 3–10
11
23
9
21
7
19
5
3
17
1
15
DB-25F, Generator Output Connector (J3)
DB-25M, Generator Output Cable
Connector
Continued
Dukane Manual Part No. 403-584-01
Page
21
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Continued from Previous Page
This is at system chassis ground potential (non-isolated).
All of the digital output status signals on this connector,
are isolated (signals are not referenced to generator chassis
ground). When a status output signal is activated, it will
sink current (500mA Max. sourced by a 24VDC supply)
to isolated common. In automation terms, the outputs are
NPN (sinking) and would drive a PNP (sourcing) input
that is referenced to the Isolated Common pin.
The digital status output signals can only sink current to
isolated common. They cannot be changed to a sourcing
(PNP) type output. If sourcing status outputs are required,
there is an optional isolated NPN to PNP conversion
module that is DIN rail mountable. The module converts
the standard isolated sinking (NPN) status output signals
to isolated sourcing (PNP) status output signals. Consult
your local sales representative for information about the
conversion module.
System Outputs Connector Pinout
The SYSTEM OUTPUTS connector is a DB-25F (standard
D-subminiature 25 circuit female) connector. Connector
pin numbers for this connector are shown in Figure 3-9.
The male connector on the cable is a mirror image of the
panel mounted connector and is shown in Figure 3-10.
Table 3-III lists the signal names. Detailed descriptions
are listed in System Outputs Signal Descriptions that follow. To assist with custom automation system wiring and
assembly, the wire color coding for the system outputs
cable is listed in Table 3-III.
System Outputs Signal
Descriptions
Pin 1 (+22VDC Power Supply)
This pin can supply +22VDC at up to 250mA to power
the user’s automation controls.
Pin 2 (Not Used)
Pin 2 is an open connection.
Pin 3 (+22V Power Ground)
Pin 3 is the +22VDC return and is tied to the system
chassis ground.
Pin 4 (Programmable Status Output 1)
Pin 4 is a digital active low status output that can be
reassigned to other system status signals. The output
can be assigned to E-STOP or Over Temperature.
[The Pin 4 default output: E-STOP.]
Pin 5 (Programmable Status Output 2)
Pin 5 is a digital active low status output that can be
reassigned to other system status signals. The output
can be assigned to Hold, In Cycle, or In Cycle with
No Afterburst.
[The Pin 5 default output: Hold.]
Pin 6 (Ultrasound Active Status Output)
Pin 6 is a digital active low status output that activates
when the system is delivering ultrasonic power to the
load attached to the ultrasound output connector. This
output will be an open circuit when the ultrasound
output is off.
Pin 7 (Any Fault Status Output)
Pin 7 is a digital active low status output that activates
whenever any fault condition is detected that inhibits
ultrasound output and normal system operation. This
output will be an open circuit when no system fault
conditions are detected.
Generator faults that will activate the Any Fault output:
• Overload (Average, Peak, or Frequency)
• Overtemperature Fault
• System Power Fault
Continued
Page
22
Dukane Manual Part No. 403-584-01
Section 3 - Installation
Continued from Previous Page
Pin 8 (Press Trigger Status Output)
Pin 14 (Not Used)
Pin 8 is a digital active low status output that activates
when the specified trigger type has occurred. It will remain active until the thruster head raises to the top of the
stroke. This output will be an open circuit when a trigger
condition hasn’t been detected.
Pin 14 is connected to the system chassis ground.
Pin 9 (System Overload Status Output)
Pin 9 is a digital active low status output that activates
whenever any overload condition is tripped. Activation
of the overload status output signal could be caused by an
average overload, a positive peak overload or a negative
peak overload condition. After the overload status output
activates, it will remain active until the next ultrasound
activation cycle begins and this output will automatically
reset. This output will be an open circuit when no overload
conditions have been detected.
Pin 10 (System On-Line Status Output)
Pin 10 is a digital active low status output that activates
when the system is in the ON LINE operating mode, which
enables the activation of the ultrasonic output. This output
will be an open circuit if the system is switched to the OFF
LINE operating mode, which will prevent the start of a
welding cycle or activation of the ultrasound output. Note
that an automation controlled process can not weld any
parts, if the system is, accidentally or otherwise, switched
to the OFF LINE operating mode.
Pin 15 (Power Signal Monitor Output)
Pin 15 is an analog output signal used to monitor the power
output from the welding system. The scaling on this output
signal is as shown below:
15kHz, 20kHz, 30kHz and 40kHz systems
1 Watt = 0.001 VDC (1mV per Watt)
50kHz and higher systems
1 Watt = 0.010 VDC (10mV per Watt)
Examples:
20kHz system measures 0.525 VDC on
Power Monitor Output = 525 Watts
50kHz system measures 0.525 VDC on
Power Monitor Output = 52.5 Watts
Pin 16 (Amplitude Monitor Output)
Pin 16 is an analog output signal used to monitor the
system amplitude setting. The scaling on this output signal is 100% amplitude = 10.0 VDC, or 0.1 VDC per 1%
amplitude. This monitor signal output would typically
be used when a remote control option board is installed
in the system. The automation control system will adjust
the system’s amplitude setting remotely, using a 4-20mA
current loop attached to the input of the remote control
board. Using this monitor output, the control system can
verify that the amplitude is set to the expected programmed
amplitude level.
Pin 11 (Press Top of Stroke Status Output)
Pin 11 is a digital active low status output that activates
when the press/thruster head is in the top of stroke position. This output will be an open circuit when the press/
thruster head is not at the top of stroke position.
Pin 12 (Not Used)
Pin 13 (Analog Monitor Signal Common)
Pin 13 is the signal common (ground) connection for all
of the analog monitor signals (on Pins 15 and 16). This
signal common pin is connected to system chassis ground
and is not isolated from the generator chassis. This is an
analog signal ground connection. Do not connect anything
to this ground connection, except the wiring to the inputs
of the analog instrumentation devices used to measure the
monitor output signals.
Continued
Dukane Manual Part No. 403-584-01
Page
23
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Continued from Previous Page
Pin 17 (Programmable Status Output 3)
Pin 17 is a digital active low status output that activates
when the system is regulating the amplitude level
correctly. This output becomes an open circuit when the
system falls out of regulation. When that happens, it can
­not adjust the system output to the output level that was
programmed as the regulation set point.
This signal will be activated at the end of the ramp-up
time until the beginning of the ramp-down time. This
status signal will be active for the time the ultrasound is
at the programmed amplitude setting.
The output can only be assigned to Amplitude
Regulation Status.
Pin 18 (Not Used)
Pin 19 (System Power OK Status Output)
Pin 19 is a digital active low status output that activates
when no fault conditions are detected by any of the power
fault detection circuits included in the system. This output
will be an open circuit when any power related fault is
detected in the system.
Pin 20 (Bad Part Status Output)
Pin 20 is a digital active low status output that activates,
either momentarily or until the start of the next welding
cycle, when the welding parameters recorded during the
previous welding cycle are outside of the programmed
bad part limits. This output will be an open circuit when
a bad part has not been detected.
Pin 22 (System Ready Status Output)
This status output signal will activate only when the system
is ready to activate ultrasound or begin a weld cycle. Pin
22 is a digital active low status output that activates when
a weld processing cycle is completed and the welding
process control system is ready to start the next welding
cycle. This output will be an open circuit when the welding
process controller determines that the next welding cycle
cannot be started. This includes system faults or off line
active, but not a process fault like Overload.
Pin 23 (Suspect Part Status Output)
Pin 23 is a digital active low status output that activates, either momentarily or until the start of the next welding cycle,
when the welding parameters recorded during the previous
welding cycle are outside of the programmed suspect part
limits. This output will be an open circuit after a welding
cycle when a suspect part has not been detected.
Pin 24 (Isolated Common)
Pin 24 is electrically isolated from chassis ground. This
common line should be connected to negative output at a
user-provided isolated 24VDC power supply. The isolated
NPN status output signals can drive PNP inputs.
Pin 25 (Not Used)
Pin 25 is an open connection.
Pin 21 (Good Part Status Output)
Pin 21 is a digital active low status output that activates,
either momentarily or until the start of the next welding
cycle, when the welding parameters recorded during the
previous welding cycle do not exceed the programmed
suspect or bad part limits. This output will be an open
circuit after a welding cycle when either a suspect or bad
part has been detected.
Page
24
Dukane Manual Part No. 403-584-01
Section 3 - Installation
RFI Grounding
The iQ Series generator provides the operating power
and power returns. Make sure the generator is grounded
properly.
In addition to the safety considerations, proper grounding
is essential for the effective suppression of RFI (Radio
Frequency Interference). Every generator contains a RFI
filter which blocks noise on the AC power line from entering the generator control circuitry. This filter also prevents
ultrasonic RFI from being fed back into the AC power line.
If you experience problems with RFI from the press, run
an additional grounding wire from the press base grounding stud to the nearest grounded metal pipe or equivalent
earth ground by means of a ground clamp. Use at least 14
AWG wire for the connection to the press base.
Dukane Manual Part No. 403-584-01
CAUTION
To minimize electrical noise
and eliminate ground currents, ground the chassis
as shown. Use a STAR configuration (illustrated below). Do not DAISY CHAIN
the grounds.
Chassis Grounding
Stud
Recommended protective
earth ground connection
wire color: green or green
with yellow stripe.
Earth
Ground
Fixed Probe Mount
or 2nd Chassis
Grounding Stud
#14 Gauge
Stranded or
Solid Wire
3rd Chassis
Grounding
Stud
Page
25
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Connector Descriptions
iQ Generator Connectors
J1 - Ultrasound Output Connector
The ultrasound output connector used with all standard generators is a high voltage (5000V) coaxial style
SHV-BNC connector. This connector provides superior shielding of electrical noise, compared to other
types of connectors. The ultrasound output connector
mates with fully shielded coaxial ultrasound cables
that are secured with a simple and reliable quarter-turn
bayonet style attachment mechanism.
Figure 3-11
Ultrasound Output Connector
J2 - System Inputs Connector
The SYSTEM INPUTS connector includes connections for all of the basic system control input signals
that will typically come from an automated control
system. The cable attached to this connector includes
all of the available system control signals, which will
be controlled by an output card or output port on the
automation controller.
The user can determine which signals to use for each
particular welding application, but there must be at
least one connection to this connector in order to
activate the ultrasound output.
J3 - System Outputs Connector
The SYSTEM OUTPUTS connector includes connections for all of the basic system status and monitor
output signals, which will typically connect to an
automated control system. The cable attached to this
connector includes all of the available system output
signals, which will be read or monitored by a digital
input card or analog inputs on the user-supplied automation controller.
The user can determine which signals are appropriate
for each welding application.
CAUTION
The ultrasonic output from
this connector (that drives the
attached ultrasonic load) is a
very high AC voltage (1200VAC). At high
power levels this can exceed 2 amperes of
current and must be securely terminated
via the ultrasound cable for safe operation.
Use original equipment ultrasound cables
for safe and reliable system operation. Improperly assembled ultrasound cables can
result in high voltage arcing and will destroy
the ultrasound connectors.
Do not use your generator if there is any
evidence of arcing (black carbon deposits)
on either the ultrasound output connector
or the ultrasound cable connectors.
NOTE
For details on integrating the welder
with automation, refer to Application
Note AN507 (Automation Interface
Guidelines) at www.dukane.com/us >
DL_ApplData.asp
Continued
Page
26
Dukane Manual Part No. 403-584-01
Section 3 - Installation
Continued from Previous Page
J4 - Configuration Port Connector
The configuration port connector is a DB-9M (standard D-subminiature 9 circuit male) typically used
for RS-232 serial communications. This serial port
(DTE) connects to a serial port (DCE) on a computer
via a standard 9- pin serial cable. If the computer does
not have a serial port, you may use a USB-to-serial
conversion cable.
This port is used for field updates to the generator
firmware, without removing the enclosure cover.
This port can also be used with a software application running on a Windows PC to modify the factory
default system settings and hardware configurations.
Contact your local sales representative for software
availability information and access to documentation
that will allow you to make use of the configuration
port features.
Figure 3-12
Configuration Port Connector
J6 - Base/Abort
The Base/Abort connector accepts the operate and
emergency stop signals from the optical operate
switches and abort switch on the base. If you are
using custom automation, you may have separate
operate and abort switches, but these still connect to
this connector on the generator.
J9 - Ethernet
This port is used for Ethernet communication
between the generator and HMI running iQ
Explorer II software.
J10 - RS-232
This port is primarily used for welder diagnostic
functions accessible via serial communication to
a PC. Guidance will be provided by Dukane if the
need to use the capability arises.
J11 - Encoder
This connector accepts signals from the distance
encoder on the press.
J5 – Thruster
This connector is used to interface various control
signals between the press and generator.
Dukane Manual Part No. 403-584-01
Page
27
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Power Cords
The AC line cords supplied with the standard generators
are matched to the ultrasonic output power rating and the
continent of specified use. See Table 3-III.
CAUTION
The power cord is equipped
with a three-prong, grounded-type plug for your
safety. Whenever a two-slot receptacle
is encountered, we strongly recommend that it is replaced with a properly
grounded three-lead receptacle.
Have a qualified electrician do the
replacement in accordance with the
National Electrical Code and local
codes and ordinances. DO NOT cut
off the power cord grounding prong or
alter the plug in any way.
Continent of Use
North America
Continental Europe
Table 3-III
Page
28
Power Cord
Part Number
Power
200 - 1110
240V, 15A
200 - 1541
240V, 10A
200 - 1111
240V, 16A
200 - 1542
240V, 10A
Power Cords
Dukane Manual Part No. 403-584-01
Section 3 - Installation
Cable Connections
Reference: Cable numbers correspond with those used
in Figure 3-13 and Table 3-IV.
1.
Grounding - Thruster and Press Base - Cables
8 and 9 respectively.
Generator Chassis - Cable 10. (A supplied
14-Gauge wire, to be attached to the grounding
stud. [See Figure 3-5 for stud location.] )
2.
Ultrasound (J1) - Cable 3. This output connects
the Ultrasound Output of the iQ Series generator
to the transducer, through a coaxial cable. The
electrical welding signal is transmitted through
this cable.
3.
Operational Control (J201) - Cable 1. This
cable runs from J201 on the thruster to the
generator's Thruster connector (J5). The generator provides controls for triggering the weld,
operating the thruster’s pneumatic system, and
providing 24 VDC operating voltage through this
cable. The press driver card in the generator also
provides monitoring for these functions.
4.
Encoder (J11) (Optional) - Cable 2. The purpose of the encoder cable is to connect the distance encoder option to the generator's Encoder
Port (J11).
5.
Ethernet Cable (J9) - Cable 5. Connects to the
HMI/PC, LAN port.
6.
RS-232 Cable (J10) - Connects to a PC, RS-232
port.
7.
Base/Abort Cable (J8) - Cable 4. Connects to
the press base plate connector (J35) or an automation PLC.
8.
Connect the AC Power Cords: Cable 6. To the
HMI. Cable 7. To the IEC power inlet connector
on the ultrasonic generator. Plug the other end(s)
into an approved AC outlet.
Dukane Manual Part No. 403-584-01
CAUTION
The power cord is equipped
with a three-prong, grounded-type plug for your
safety. Whenever a two-slot receptacle
is encountered, we strongly recommend that it is replaced with a properly
grounded three-lead receptacle.
Have a qualified electrician do the
replacement in accordance with the
National Electrical Code and local
codes and ordinances. DO NOT cut
off the power cord grounding prong or
alter the plug in any way.
NOTE
Some connectors have a pair of
threaded jack screws to secure the
connector. Make sure the screws are
snug, but do not overtighten them.
CAUTION
DO NOT operate the
generator unless the ultrasound coaxial cable is
connected and the transducer is installed in the thruster.
Otherwise, an overload condition
could occur, with possible damage
to the generator.
Page
29
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Three Configurations
The iQ generator, ES models are configured in three
basic ways:
1) With a pneumatic press/thruster
2) With a remote controller and a servo press/
thruster
3) With a servo press/thruster
The diagram and table that follow show the pneumatic
configuration and list the cables used.
Page
30
NOTE
For information about the iQ ES generator
for servo systems, please refer to Dukane
User's Manual, 403-587-00.
Dukane Manual Part No. 403-584-01
6
Figure 3-13
Dukane Manual Part No. 403-584-01
7
5
PE
LINE VOLTAGE:
200-240 Vac
50/60Hz, 15A
U.S. PATENT 5,880,580
OTHER PATENTS PENDING
ST. CHARLES IL 60174
MADE IN U.S.A.
DUKANE CORP
-WARNING-
POWER LINE OUTLET
MUST BE GROUNDED.
DISCONNECT LINE POWER
BEFORE REMOVING COVER.
J8
BASE/ABORT
J9
ETHERNET
J5
1
J10
RS-232
THRUSTER
J11
2
ENCODER
10
J4
CONFIGURATION
J3
ULTRASOUND
J1
SYSTEM OUTPUTS
J2
SYSTEM INPUTS
3
4
12
8
iQ Generator and Pneumatic Press/Thruster - Connections Diagram
Earth
Ground
Automation Equipment
11
9
Section 3 - Installation
Pneumatic Press/Thruster
Continued
Page
31
Page
32
Table 3-IV
8
9
10
11
12
7
6
2
3
4
5
1
Cable
No.
AC INPUT
-
-
-
-
PE
-
-
-
GRND
-
-
AC INPUT
PE
J2
J3
2.4
2.4
5
5
5
XX
XX
200-1557
200-1557
200-1380-XXM
200-1381-XXM
ETHERNET
-
J35
-
OPERATIONAL
CONTROL
ENCODER
ULTRASOUND
-
HMI
J11
J1
J8
J9
-
J5
XX
Thruster
Connections
XX
XX
XX
XX
Base
Generator
Length
(Meters)
200-1613-XXM
200-479-XXM
200-1545-XXM
200-1553-XXM
One of the following:
200-1541 (240 VAC, 10A, US)
200-1542 (240 VAC, 10A, Europe)
200-1624 (240 VAC, 10A, India)
200-1576 (120 VAC)
One of the following:
200-1110 (240 VAC, 15A, US)
200-1111 (240 VAC, 16A, Europe)
200-1612 (240 VAC, 15A, India)
200-1541 (240 VAC, 10A, US)
200-1542 (240 VAC, 10A, Europe)
200-1624 (240 VAC, 10A, India)
(for 120 VAC models, power cord is integral to generator)
200-1557
200-1556-XXM
Part Number
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Continued from Previous Page
Pneumatic Press/Thruster
iQ Generator and Pneumatic Press/Thruster Cables
Continued
Dukane Manual Part No. 403-584-01
Section 3 - Installation
Networking
Where several welders are connected, please refer to the
iQ Explorer II User's Manual, 403-585-00. Refer to the
Section on networking.
Among other things, there is information about connection
through:
• Simple Stand-alone Configuration,
• Unique IP Address, and
• Connection to Local Area Network.
Recheck Connections
Recheck all cabling connections for the:
• iQ ES Generator
• Press/Thruster
• Connections to Local Area Network
Connect AC Power
When all cabling connections have been made, and they
have been systematically rechecked, connect AC line power
to your system.
WARNING
Any modifications to the
Activation Switch (also
known as the Operate
Switch) circuit must
comply with all OSHA and ANSI
requirements. Compliance with all
local building and electrical codes
is also required.
Dukane does not assume any
responsibility or liability for circuitry modifications made by the
customer or by any third party
manufacturer.
WARNING
Any modifications to the
Emergency Stop Switch (also
known as the E-STOP or Abort
Switch) circuit must comply
with all OSHA and ANSI requirements.
Compliance with all local building and
electrical codes is also required.
Dukane does not assume any responsibility or liability for circuitry
modifications made by the customer or
by any third party manufacturer.
Dukane Manual Part No. 403-584-01
Page
33
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
This page intentionally left blank
Page
34
Dukane Manual Part No. 403-584-01
Section 4 - Control Panel
SECTION 4
Control Panel
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
System Operating Mode Keys . . . . . . . . . . . . . . . . . . 38
Navigation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
System Power Output Level . . . . . . . . . . . . . . . . . . . 40
Screen Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
This page intentionally left blank
Page
36
Dukane Manual Part No. 403-584-01
Section 4 - Control Panel
Overview
This section introduces the iQ Series ultrasonic generator
ES control panel and color display with this information:
NOTE
• Functions of the panel components shown in Figure
Do not touch the display. Touch only
the System Operating Mode Keys, the
Navigation Keys and the Soft Keys to
the left and right of the display.
4-1 below are discussed.
• Some screen basics are introduced:
— Making selections,
— Interpreting onscreen arrows,
— Using the virtual keyboard feature, and
— Taking a look at setup identification.
Color Display
Soft Keys (8)
Cleaning - If the display is dirty, clean it
by first putting a mild cleaning solution
on a clean, soft cloth. Then, gently wipe
the cloth over the screen.
Navigation Keys (4)
Lighted Power Indicator
System
Operating
Mode
Keys (3)
CANCEL Key
Figure 4-1
iQ Generator Display and Control Keys
Dukane Manual Part No. 403-584-01
ENTER Key
Page
37
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
System Operating Mode Keys
ONLINE - After AC power has been activated and the
generator is operating normally, ONLINE is the normal
operating mode. The generator can produce ultrasound
signals in this mode.
The display has a WHITE background and the word,
Online appears in a GREEN box in the lower right corner
of the display.
TEST - After AC power has been activated and the gen-
erator is operating normally, in the ONLINE mode, the
TEST key can be pushed.
This activates a momentary ultrasound pulse allowing
the operator to test system function. The display will
show the real time settings for Amplitude, Power, and
Operating Frequency.
This information is useful in troubleshooting.
OFFLINE - After AC power has been activated and the
generator is operating normally, the OFFLINE key may
be pressed to put the generator into the offline mode. In
this mode the generator can not generate an ultrasound
signal.
The display has a YELLOW background, and the word,
Offline appears in a yellow box in the lower right corner
of the display. See Figure 4-3 to the right.
Operating Mode Indicator:
Online (green); Offline (yellow); or, E-STOP (red).
Figure 4-2
Display Detail, Operating Mode Indicator
CAUTION
If a transducer is not connected
to the ultrasound output connector, the system should be
set to the OFFLINE mode. Do not activate the ultrasound output without a
transducer connected. Make sure that
the stack is properly assembled before
it is connected to the system. The horn
should never come in direct contact with
a metal fixture or anvil with ultrasound
activated.
The display has a RED background, and the word,
E-STOP appears in a red box in the lower right corner
of the display.
Operating Mode Indicator
Offline (yellow)
Figure 4-3
Page
38
Generator in Offline Condition
Dukane Manual Part No. 403-584-01
Section 4 - Control Panel
Navigation Keys
Navigation Key (4)
R
EL
NC
TE
R
CA
EL
gation keys to move the display’s
cursor left or right
NC
respectively.
Press the up and down navigation keys to move up one
level in the menu, or to move back one level. Also, use the
keys to change the value of a selected digit.
EN
CA
Moving the Cursor - Press the left and right navi-
TE
EN
Enable/Disable - The navigation keys have another
function. Any of the four keys can be pressed to either
enable or disable a particular menu item.
See Figure 4-4.
ENTER Key
Press ENTER to confirm and store a selection in memory.
Example: After entering a time value, press ENTER.
CANCEL Key
Press the CANCEL key to return to the previous screen
or cursor position. Think of it as a “back” key. Selection
is not stored in memory.
Soft Keys Bordering the Display (8)
Press one of the
navigation keys to
Enable the function.
Press again, to
Disable the function once more.
Figure 4-4
Navigation Keys (4), with Enter and Cancel
Active Key
Use the eight keys that border the display to make selections from the choices shown on the display.
Not all keys will be active on any given screen.
Example 1: For the display shown on the right, three of
the eight soft keys are active:
Administrator Password, Erase, and Done.
Figure 4-5
Active Soft Keys, Example 1
Active Key
Example 2: At times the soft keys act like navigation keys
to help move from screen to screen. In the example shown
to the right, the two keys nearest the arrow (on either side
of the display) will respond to an operator's touch. The
arrows indicate more information is available - either left
or right. In the example shown in the figure to the right,
pressing the active soft key(s) will display more real time
data. If the lower active keys are pressed, they will display
the Operate screen (left) or the Main Menu (right).
Dukane Manual Part No. 403-584-01
Figure 4-6
Active Soft Keys, Example 2
Page
39
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
System Power Output Level
(Bar Graph)
A bar graph displays the percentage of ultrasonic power
being drawn by the load.
The display uses LED’s that show:
GREEN - normal operation.
YELLOW - warning of potential overload.
RED - warning that an overload condition exists.
Peak Detect Feature
To indicate the maximum peak power achieved during a
weld cycle, the LED in the bar graph corresponding to
the peak level remains on (for about one second) after the
weld cycle has been completed.
Flash on Overload at 90%
The OVERLOAD indicator begins to flash (RED) when
the generator produces 90% of the overload power rating.
This feature alerts the operator to an impending overload
fault condition.
Bar Graph Power Scaling
Power scaling is related to amplitude. At 100% amplitude
the whole graph is lit, and the generator is operating at
100% power. At 50% amplitude the entire graph is lit, and
the generator is operating at 50% power.
If the amplitude setting is lowered, the graph rescales
automatically according to the revised amplitude.
Example: With a 1200W generator, at 50% amplitude, if
the whole graph is lit, that represents 600W.
Bar Graph
Figure 4-7
System Power Output Level, Bar Graph and
Overload Indicator
CAUTION
If the System Output Power
Level red overload indicator
is lit, that means there is an
overload fault. If this happens, verify that the ultrasonic stack
is not damaged.
Lighted Power Indicator
While the indicator glows GREEN, it shows that the generator has been powered by the AC current.
Page
40
Dukane Manual Part No. 403-584-01
Section 4 - Control Panel
Screen Basics
Making Selections
Figure 4-8 shows there are several ways that an item has
been selected:
•
A word or phrase is bounded by a black border.
•
A black box surrounds the selected item.
•
A line of text is highlighted.
•
The cursor shows what digit is selected.
Word bounded by black border
Black box surrounds selected item
Figure 4-8
Line of highlighted text
Cursor showing selected digit
Making Selections
Interpreting Onscreen Arrows
Arrows pointing up, down, left and right give visual cues
that more text is available in the direction the arrow points.
Two examples are shown below. For the screen on the left,
the up or down navigation keys are used. For the screen on
the right, active soft keys are used. (See Figure 4-6.)
Display arrows point in direction of more text
Figure 4-9
Arrows Indicate More Text
Dukane Manual Part No. 403-584-01
Page
41
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Virtual Keyboard
A virtual keyboard pops up when there is a need to make
an entry for the Security and Hardware screens.
In the example shown below the operator is prompted to
choose a Setup Name.
Figure 4-10
Virtual Keyboard
Setup Identification
Setup identification can be seen in the lower right corner
of the screen.
The example shown in Figure 4-11 illustrates that setup
control is by automation (Auto) and that Setup #1 program has been selected for the generator.
Setup can also be controlled by iQ System (iQ) or by sequencing (A pair of numbers that resemble a ratio such as
2:3 appears. In this example 2 is the number for the segment, and 3 is the number of the cycle in that segment.)
Figure 4-11
Main Menu Detail - Setup Identification
See Page 67 for more on Setup.
Page
42
Dukane Manual Part No. 403-584-01
Section 5 - Operation
SECTION 5
Operation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Generator Start-up Sequence . . . . . . . . . . . . . . . . . . . 45
Stopping the Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . 46
Using the Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Process Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Process Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Process Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Operate Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Dukane Manual Part No. 403-584-01
Page
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
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Page
44
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Overview
The iQ Series generator, model ES, is typically part of a
system. Major system components would be:
• iQ generator,
• iQ Explorer II (software),
• User Interface (HMI),
or computer (user supplied), and
• iQ Press System.
With this type of system, the user controls nearly all aspects
of the welding process and has several choices of how best
to accomplish this:
Control can be done through the color front panel of the
iQ ES generator.
System control can also be done with the User Interface
(HMI) or a computer (user supplied), using iQ Explorer II.
NOTE
Press, acoustic stack, and tooling will
require their own individual adjustments as
those components are integrated into your
particular system.
Helpful information on a wide variety of
assembly equipment, processes and
techniques can be found at the Dukane
website:
http://www.dukane.com/us/PPL_upa.htm
See Downloads for these User's Manuals:
• iQ Explorer II (Part No. 403-585-00), and
• iQ Press System ES (Part No. 403-569-00).
Generator Start-up Sequence
1. Press the rear panel AC breaker switch to ON.
2. The front panel lighted power indicator flashes during
the start up sequence, then turns a steady GREEN (See
(ON)
(OFF)
Figure 5-1) when the generator is activated.
3. After the generator is activated, the LCD displays an
image that identifies the Dukane iQ Series type. The
Lighted Power
Indicator
sequence ends when the Main Menu screen is displayed
as shown in Figure 5-2.
Figure 5–1
Figure 5–2
Dukane Manual Part No. 403-584-01
Front Panel's Lighted Power Indicator
Main Menu Screen
Page
45
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Stopping the Weld Cycle
Normal Conditions
The cycle stops when the programmed welding cycle ends
or when the rear panel's Cycle Stop input is activated.
Emergency Conditions
Push the power switch on the generator's rear panel to the
OFF position. The front panel lighted power indicator goes
out showing that power has been turned off.
Manual System
Do either of these things:
1. Press OFFLINE to stop the ultrasound signal. This
may be done under any condition, OR
2. Push the power switch on the generator's rear panel to
the OFF position.
Page
46
NOTE
Automated System External Controls:
Customer-supplied external controls provide the means to stop the cycle for an
automated system.
An auxiliary cable connects these external
controls to the iQ generator at connector
J2.
Activating the System Input called "Automation Cycle Stop" will stop the weld process
or the complete cycle depending on if it's
configured for "End of Weld" or "End of
Cycle." See Page 20 for a description of
Automation Cycle Stop Input.
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Using the Menus
Navigation through the menus typically begins at the Main
Menu. This menu can take two forms as shown below. If
either the Administrator or Process Eng (Process Engineer) has logged in, the screen looks like that shown in
Figure 5-3. If Setup has logged in, the screen looks like
that shown in Figure 5-4.
The screens look identical with one exception:
The Administrator/Process Engineer screen has Utilities/
Hardware while the Setup screen has Select Setup. Go to
the pages referenced for more detail about each sub-menu.
Pages 48-59
Page 82
Pages 60-65
Page 84-85
Pages 66-81
Page 86
Pages 87-91
Page 83
iQ 1
Figure 5–3
Navigating from the Main Menu (Administrator/Process Engineer Logged In)
Figure 5–4
Navigating from the Main Menu (Setup Logged In)
Page 68
NOTE
Security detail can be found on Pages 87-91.
Dukane Manual Part No. 403-584-01
Page
47
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Main Menu
Process Setup
Initiate Mode
Trigger Type
Auto
Manual
Enable
Latch on Bad Part
Disable
Maintained
Max Trigger Time
Momentary
Max Trigger Time
Force
Force at Trigger
When Motion Stops
Max Trigger Time
Max Trigger Time
Power
Trigger Power
Position
Trigger Position
** See NOTE.
Max Trigger Time
Time
Distance
Primary
Weld Method 1
Position
Energy
Peak Power
Single
Ground Detect
** Secondary
Weld Method 1
Primary
Weld Method 1
Weld Distance
Weld Position
Energy
Weld Energy
Position
Weld Position
Max. Weld Time
Ground Detect
Weld Method 1
Dual
Weld Distance
Position
Weld Position
Energy
Weld Energy
Time
Distance
Primary
Weld Method 2
Weld Energy
Max. Weld Time
Weld Power
Max. Weld Time
Max. Weld Time
Scrub
Disabled
Distance
Peak Power
Position
Energy
Peak Power
Ground Detect
Weld Time
Weld Distance
Max. Weld Time
Weld Position
Max. Weld Time
Weld Energy
Max. Weld Time
Weld Power
Max. Weld Time
Max. Weld Time
Scrub
Weld Method 1
Distance
Weld Distance
Position
Weld Position
Energy
Peak Power
Figure 5–5
Page
48
Process Setup Menu Diagram (1 of 2)
Scrub Time
Disable
NOTE
Available weld choices depend
on Security access level (See
Table 5-I.) system configuration, and primary weld method.
Enable
Scrub Time
Disable
** NOTE
The Secondary Weld Method
choices are based on the
selection of the Primary Weld
Method.
These selections are based on
the Primary Weld Method being
Distance.
Weld Power
Disabled
** Secondary
Enable
Weld Time
Weld Distance
Max. Weld Time
Peak Power
See Page 80 for Advanced
Trigger features not shown
here but illustrated in Figure
5-42.
Weld Power
Distance
Energy
** Secondary
Max. Weld Time
Scrub
Position
Time
** NOTE
Weld Time
Weld Distance
Max. Weld Time
Weld Position
Max. Weld Time
Weld Energy
Max. Weld Time
Weld Power
Max. Weld Time
Disabled
Distance
Peak Power
Weld Mode
Start Amplitude
Max Trigger Time
Enable
Scrub Time
Disable
Weld Energy
Weld Power
Process Setup, Continued
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Process Setup, Continued from Previous Page
Process Setup
Disabled
Hold Method
Hold Time
Time
Hold Distance
Distance
Until Motion Stops
Enabled
Afterburst
Max. Hold Time
Max. Hold Time
Afterburst Delay Time
Afterburst Duration
Afterburst Amplitude
Disabled
Weld Amplitude
Pressure Profiling
Pressure
Enabled
Pressure 1 - Set Profile
Pressure 2 - Set Profile
Disabled
Downstroke Pressure
Hold Pressure
Upstroke Pressure
Weld Pressure 1
Weld Pressure 2
Free Run Frequency
Scan Stack
Scan Stack
Frequency Tracking
Frequency Lock and Hold
Enable
Disable
Enable
Disable
Wide
Advanced Process Settings
System Frequency Limits
Normal
Narrow
Manual
Ramp Up Time
Ramp Down Time
Restore Advanced Process Defaults
Figure 5-5
Yes
No
Process Setup Menu Diagram (2 of 2)
Process Setup, Continued
Dukane Manual Part No. 403-584-01
Page
49
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Process Setup
To gain a better understanding of Process Setup, please
read this material.
The first of the Process Setup submenus is:
Initiate Mode
Initiate Mode controls the way a cycle is started, using
either of two modes, Manual or Auto.
Manual
The cycle is started by depressing both operate switches
on the press base (Operate Switch 1 and Operate Switch
2) within 0.35 seconds of each other.
Depress the operate switches continuously until the
trigger switch on the press has activated or until the
ultrasonic signal is applied.
Latch on Bad Part
When this feature is active (It is available only with the
Manual Initiate mode.), the cycle stops when a bad part
is detected, and SYSTEM LOCKED, Bad Part Limit
Exceeded, LATCHED appears on the iQ display. The
operator must deal with the LATCHED message before
a new cycle will start.
The next cycle will not activate until the latch is cleared.
There are two ways the latch can be cleared:
• Remove the LATCHED Message from the Display
1. Go to the Main Menu.
2. Go to Utilities, and then to Part Count Settings.
3. Enable Clear Bad Part. (See Figure 5-6 to the
right.)
When these three steps are completed, the operator can
press the ENTER key to clear the latch, or
• Activate the System Latch Reset Input
The System Latch Reset Input signal (Pin 12 of J2, the
System Inputs connector) can be activated.
See Page 20 for information about Pin 12 of the System
Inputs (J2) connector. The pin can be used for latch reset.
Auto
The AUTO mode requires a voltage signal applied to
J2 pin 8. The applied voltage level, either ground or
+22VDC, must be the opposite of the voltage level
applied to J2 pin 13. See Pages 19 and 20 for additional
information.
Apply the auto input signal for a minimum of 50 milliseconds to ensure that the cycle has been started.
Page
50
Enabled
Figure 5-6
Enable Clear Bad Part
NOTE
What is a “bad part”? Bad part limits define what is considered to be a bad part.
If the UPPER limit of a selected characteristic is reached during its phase of the weld
cycle, the weld process is stopped, and the
part is identified as a bad part.
If the LOWER limit of a selected parameter
is not reached by the end of its phase of
the weld cycle, the assembly process is
stopped, and the part is identified as a
bad part.
See Page 64.
Process Setup, Continued
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Process Setup, Continued from Previous Page
Trigger Type
Trigger Type is the next Process Setup submenu.
See Figure 5-7.
“Trigger” defines the type of event that turns on the ultrasound signal. This event can be:
• a contact closure from the trigger switch in the press,
• an absolute encoder position as in the case of pre-triggering,
• a velocity reached by the press.
NOTE
Pre-trigger and Trigger Delay information
can be found on Page 80.
NOTE
Available trigger types depend on system configuration, and primary weld
method.
Types can be:
• Maintained
Maintained
Max Trigger Time
• Momentary
Momentary
Max Trigger Time
Force
Force at Trigger
• Force
Trigger Type
• When Motion Stops
• Power
When Motion Stops
Max Trigger Time
Max Trigger Time
Power
Trigger Power
Position
Trigger Position
Max Trigger Time
Start Amplitude
Max Trigger Time
• Position
Figure 5-7
Trigger Type Submenu Diagram
Maintained - A Maintained trigger means that the trig-
ger switch signal is active for the entire weld portion of the
cycle. The signal comes from the trigger switch found on
presses without an Electronic Pressure Regulator (EPR).
Momentary - With a Momentary trigger, the trigger
switch signal is ignored after it has activated. If the trigger switch opens during the weld portion of the cycle, the
weld continues normally. The signal comes from the trigger
switch found on presses without an Electronic Pressure
Regulator (EPR).
Force - If the ultrasonic press system has an electronic
pressure regulator and load cell, the trigger type can be
Force. The load cell takes the place of the mechanical trigger switch in the press.
When Motion Stops - When the downstroke veloc-
ity of the thruster reduces to zero, the ultrasound signal is
triggered. Choose this trigger type when the operator wants
the ultrasound signal to start as the horn has completely
compressed the part to be welded. If the maximum trigger
time is reached the weld is aborted and the press is returned
to top of stroke.
Dukane Manual Part No. 403-584-01
NOTE
Available trigger types depend on system
configuration, and primary weld method.
CAUTION
Use extreme caution when
using the Momentary trigger
type. Opening the trigger
switch will NOT terminate
the weld cycle. Guard the horn/fixture
“pinch point” to prevent hands, or fingers
from being crushed by the vibrating horn.
Process Setup, Trigger Type , Continued
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Process Setup, Trigger Type, Continued from Previous Page
Power - Dukane has patented Trigger by Power. Go
to Dukane's blog: http://usblog.dukane.com/2010/01/
trigger-by-power-feature-aids-weld_27.html for more
information about this feature.
During the downstroke, the ultrasound signal is immediately turned on with the Start Amplitude setting. When the
power level reaches the trigger value, the weld amplitude is
applied. Choose this trigger type when the operator wants
the ultrasound signal to start as the horn touches the part
to be welded. If the maximum trigger time is reached, the
weld is aborted and the press is returned to top of stroke.
Position - The trigger source is via the distance encoder.
When the position is reached the ultrasound signal is triggered.
Program Notes
After selecting the appropriate trigger type, the operator
enters data where the trigger type calls for it.
For instance, all trigger types call for a Max Trigger
Time to be entered.
Power calls for Trigger Power and Start Amplitude as
well.
For Position, Trigger Position is required.
See Figure 5-7, Trigger Type Submenu Diagram.
Process Setup, Continued
Page
52
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Process Setup Continued from Previous Page
Weld Mode
Process Setup menu description continues with the
Weld Method submenu.
Weld Method defines when the ultrasound signal is
terminated after it has been triggered.
There are two methods of welding:
• Single (Single Pressure), and
• Dual (Dual Pressure)
Choosing one method automatically deactivates the
other method.
Time
Distance
Primary
Weld Method 1
Position
Energy
Peak Power
Ground Detect
Single
** Secondary
Weld Method 1
Weld Distance
Position
Weld Position
Energy
Weld Energy
Time
Weld Mode
Single Pressure (Primary Weld Method 1) is a preset
pressure applied to the part during the weld process.
The pressure continues until the control parameter
(Time, Distance, Position, Energy, or Peak Power)
specified under the Weld Method submenu is reached.
Primary
Weld Method 1
Weld Method 1
Dual
When Dual Pressure is chosen, two separate pressures
are applied to the part (Primary Weld Method 1
and Primary Weld Method 2) while the ultrasound
signal is on. When the control parameter is reached
for P1, the pressure changes to Pressure 2. The weld
continues until the control parameter for P2 is reached
(or a process characteristic moves outside its process
limits). Control parameter limits set for the parameters
are specific to each pressure.
Dual
Position
Weld Position
Max. Weld Time
Weld Distance
Position
Weld Position
Energy
Weld Energy
Time
Distance
Primary
Weld Method 2
Weld Energy
Max. Weld Time
Weld Power
Max. Weld Time
Disabled
Distance
Peak Power
Position
Energy
Peak Power
Ground Detect
Weld Power
Weld Time
Weld Distance
Max. Weld Time
Weld Position
Max. Weld Time
Weld Energy
Max. Weld Time
Weld Power
Max. Weld Time
Max. Weld Time
Scrub
Disabled
** Secondary
Weld Method 1
Distance
Weld Distance
Position
Weld Position
Energy
Peak Power
Figure 5–8
Scrub Time
Disable
Weld Power
Weld Distance
Max. Weld Time
Peak Power
Enable
Weld Time
Distance
Energy
** Secondary
Max. Weld Time
Scrub
Disabled
Distance
Peak Power
Single
Weld Time
Weld Distance
Max. Weld Time
Weld Position
Max. Weld Time
Weld Energy
Max. Weld Time
Weld Power
Max. Weld Time
Enable
Scrub Time
Disable
Weld Energy
Weld Power
Weld Mode Submenu Diagram
Program Notes
After selecting the appropriate weld mode, the operator enters data where the weld mode calls for it.
Figure 5-8 illustrates the weld mode submenu
structure.
Process Setup, Weld Mode, Continued
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Process Setup, Weld Mode, Continued from Previous Page
Control Parameters – Single and Dual Pressure Welding
Time
Welding by time means that the generator applies the ultrasound signal for a user-specified period. The range is from
0 to 99.999 seconds with a .001 second increment.
Distance (For Systems with Distance Encoder Only)
Welding by distance means that the generator applies the
ultrasound signal until the press travels a user-defined distance from the trigger point. The range is from 0 to 7.0000
inches (0 to 177.800 mm) with a 0.0001 inch (0.001 mm)
increment.
Position (For Systems with Distance Encoder Only)
NOTE
MAX WELD TIME is a secondary characteristic of Distance, Position, Energy and Peak
Power. The time forces the weld portion of
the cycle to stop even if the specified control
parameter is not met.
Welding by position means the generator turns off the ultrasound signal after the horn travels a user-defined distance
from the distance encoder reference mark. (This is independent of when the horn touches the part to be welded.)
Position terminates the ultrasound signal at the specified
programmed distance.
Energy
With Energy as the selected weld control parameter, the
system welds until the generator delivers a specified level
of energy to the transducer while the horn is in contact with
the part.
Energy, measured in joules, has a range of 0 to 100000.0,
and has a 0.1 joule resolution.
Peak Power
With Peak Power as the selected weld control parameter,
the system welds until the generator delivers a specified
level of power to the transducer.
Peak Power, measured in Watts, has a 0.1 Watt resolution.
Peak Power range is dependent on the generator's maximum
power rating.
Ground Detect
NOTE
Downstroke Distance = Distance the horn
travels until the ultrasound trigger point is
reached.
Weld Distance = Distance the horn moves
during the application of ultrasound to create the weld.
Hold Distance = Distance the horn moves
during the hold or “cooling” portion of the
weld cycle.
Position = Downstroke Distance + Weld
Distance.
When Ground Detect is enabled the ultrasonic signal is
shut off when the horn touches the isolated metal fixture
during the welding process.
Scrub (when enabled) extends the weld time generated
when the weld portion of the cycle is ended by the ground
detect input. Typically this is used in cutting applications.
Often the horn cuts through the material at a single point.
This activates the ground detect input and ends the weld
portion of the cycle.
There may be an incomplete cut however. Scrub time allows the cut to be completed by keeping the ultrasound
signal on for a maximum of 127 milliseconds.
Page
54
Process Setup, Continued
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Process Setup, Continued from Previous Page
Hold Method
The Hold Method determines in what way pressure on the
part is held after the ultrasound signal has ended. Holding
allows the material to solidify (under pressure) before the
press head retracts. Hold Method choices are:
• Disabled,
• Time,
• Distance, and
• Until Motion Stops
See Figure 5-9.
Disabled
Hold Method
Time
Distance
Until Motion Stops
Figure 5–9
Hold Method Submenu Diagram
Disabled
Choose Disabled when no hold method is needed.
Time
The iQ generator will keep pressure on the part for the
time period specified.
Distance (For Systems with Distance Encoders
Only)
Holding by collapse distance involves keeping pressure
on the part until a specified distance from the start of hold
is reached.
As with the weld methods, to prevent the press from staying
on the part indefinitely if the hold distance is not reached,
a MAX HOLD TIME must be entered with this option.
Until Motion Stops (For Systems with Distance
Encoders Only)
Pressure will be kept on the part until the speed
of the press drops to zero. Like the weld methods,
a user specified maximum time prevents infinite
holding due to an unreachable distance.
Process Setup, Continued
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Process Setup, Continued from Previous Page
Afterburst
In some applications the horn can stick to the part being
welded as the head of the press retracts. Afterburst dislodges the part by sending a short burst of ultrasound on
the upstroke.
Afterburst is defined by three values: the delay time, the
duration of the afterburst, and by the amplitude. See Figure
5-10.
Delay is the time from the start of the upstroke until the
start of the afterburst.
Afterburst Delay Time
Afterburst Duration
Afterburst
Enabled
Disabled
Afterburst Amplitude
Figure 5–10 Afterburst Submenu Diagram
Duration is how long the afterburst ultrasound signal is on.
Amplitude defines the amplitude of the afterburst ultrasound signal.
The afterburst feature can be turned off by choosing DISABLE, or it can be turned on by choosing ENABLE.
When enabled, the delay and duration times and the amplitude are then entered.
Weld Amplitude
The last parameter to enter is Weld Amplitude.
Amplitude refers to the peak-to-peak excursion of the horn
at its workface.
Amplitude settings are given as a percent of the horn’s
nominal amplitude in the range of 20% - 100%.
Process Setup, Continued
Page
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Dukane Manual Part No. 403-584-01
Section 5 - Operation
Process Setup, Continued from Previous Page
Pressure
Figure 5-11 to the right diagrams the basic pressure submenu for systems with electronic pressure regulation.
Pressure selections begin with a choice about Pressure
Profiling. If Enabled, Pressure Profiling is explained on
Page 58.
Pressure Profiling Disabled - With Pressure Profiling
disabled, there are five pressures to be entered.
See Figure 5-12 to the right.
NOTE
Manual Pressure Regulation - For systems
without electronic pressure regulation, pressure adjustments are made with manual
regulators on the front of the thruster.
The weld pressure values (1 and 2) can be
added to the setup using the Notes feature
found in the Utilities screen.
Downstroke Pressure - This is the pressure for the
first part of the weld cycle (as the head begins to
travel down towards the part to be welded). This
is also the pressure responsible for triggering the
ultrasound signal. When using force, more pressure
may be needed to accomplish this.
Enter the Downstroke Pressure value.
Weld Pressure 1 - This is the pressure used in single
pressure welding, and it is also the first of two pressures used with dual pressure welding. In presses
with an electronic pressure regulator, this setting
controls the air pressure.
Enter the Weld Pressure 1 value.
Enabled
Pressure Profiling
Disabled
Pressure
Downstroke Pressure
Pressure 1 - Set Segments
Pressure 2 - Set Segments
Weld Pressure 1
Weld Pressure 2
Hold Pressure
Upstroke Pressure
Figure 5–11 Pressure Submenu Diagram
Weld Pressure 2 - This is the second pressure used
during a dual pressure weld cycle. In presses with
an electronic pressure regulator, this setting controls
the air pressure. Enter the Weld Pressure 2 value.
Hold Pressure - Enter the pressure for the Hold
portion of the weld cycle.
In presses without an electronic pressure regulator,
the manual regulator setting controls the air pressure
amount of the Hold portion of the weld.
Upstroke Pressure - This is the pressure for the final
part of the weld cycle, as the head retracts. Enter the
Upstroke Pressure.
Figure 5–12 Pressure Profiling Disabled
Process Setup, Pressure, Continued
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Process Setup, Pressure, Continued from Previous Page
Pressure Profiling - Up to ten different pressures can
be programmed to occur during a single pressure weld
cycle. If welding with dual pressure, the iQ generator can
be programmed for up to twenty pressure steps.
With Pressure Profiling enabled, there are three single
pressures to be entered, and two pressure profiles to
create.
NOTE
Pressure profiling is only available when the
press is equipped with the electronic pressure regulator feature.
Figure 5-13 shows the display after Pressure Profiling
has been enabled.
Downstroke Pressure - This is the pressure for
the first part of the weld cycle (as the head begins
to travel down). Enter the Downstroke Pressure
value.
Pressure Profile Pressure 1 - These are the
pressures used in single pressure welding, and it
is also the first of two pressure profiles used with
dual pressure welding.
Figure 5–13 Pressure Profiling Enabled
Enter the Pressure Profile Pressure 1 values.
Figure 5-14 shows a Pressure Profile Pressure 1
display and the profile points 1-10.
Enter the 10 values for the profile points, and press
the DONE soft key.
Pressure Profile Pressure 2 - This is the second
pressure profile used during a dual pressure weld
cycle.
Enter the 10 values for the profile points, and press
the DONE soft key.
Hold Pressure - Enter the pressure for the Hold
portion of the weld cycle.
Upstroke Pressure - This is the pressure for the
final part of the weld cycle, as the head retracts.
Enter the Upstroke Pressure.
Page
58
Figure 5–14 Pressure - Set Profile 1
Program Notes
Pressure profiling relates to how the weld method is
programmed during setup.
EXAMPLE:
If the total weld distance = 0.010 inch.
With a 10-step profile, each step equals
one-tenth of the total distance. In this
example, each step = 0.001 inch.
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Process Setup, Continued from Previous Page
Advanced Process Settings
Advanced Process Settings are enabled through the
Utilities/Hardware menu.
Please see Hardware Setup, Pages 76-81 for information
on enabling these settings and for brief descriptions of
each:
- Free Run Frequency and Scan Stack,
- Frequency Tracking,
- Frequency Lock and Hold,
- System Frequency Limits,
- Ramp Up, and
- Ramp Down.
Process Setup, Continued
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Process Limits
Overview
As the weld cycle progresses, time, distance, power, and
energy data are kept for each portion of the cycle. These
measurements, also called process characteristics, create a process record for each part. Records’ analysis can
establish parts limits which then can be used to determine
if the current process is “in control”. The iQ generator can
report the process characteristics as Bad or Suspect. The
characteristics can also be displayed or printed without
evaluation.
Limits are set using either statistical methods or physical
system constraints. Statistical methods can be applied
to pre-production parts that were evaluated for physical
characteristics of quality (e.g., strength, appearance).
Results of this evaluation are correlated to the process
characteristics. Limits for the characteristics related to part
quality are calculated. Other limits are determined by the
system itself. For instance, Total Cycle Time limits may be
established to end the cycle before an index table moves.
Downstroke Distance may be set to detect a misload or
incomplete assembly.
Available Process Characteristics
The list of available process characteristics is shown in
Figure 5-15 on the following page. This is followed by
brief descriptions of each characteristic.
NOTE
Of the available process characteristics,
the ones that apply to a particular part depend on the current iQ setup for that part.
Process Limits, Continued
Page
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Dukane Manual Part No. 403-584-01
Section 5 - Operation
Process Limits, Continued from Previous Page
Main Menu
Process Limits
Downstroke Time
Downstroke Distance
Contact Air Pressure
Method 1 Weld Time
Method 1 Distance
Method 1 Weld Energy
Method 1 Weld Peak Power
Method 1 Weld End Position
Method 2 Weld Time
Suspect Limits
Method 2 Distance
Method 2 Weld Energy
Method 2 Weld Peak Power
Bad Limits
OFF
ON
Low Limits
High Limits
Low Limits
High Limits
OFF
ON
Display Only
Method 2 Weld End Position
Total Weld Time
Show All / Show None
Total Weld Energy
Hold Time
Hold Distance
Total Cycle Time
Total Stroke Distance
Total Weld Distance
Alarm Status
Time
Date
Setup
NOTE
The list of available process characteristics depends on Security access level
(See Table 5-I.) system configuration,
and on the chosen weld mode:
Single Weld mode, a list of 15 characteristics would be shown;
Dual Weld mode, a list of 23 characteristics appears. (That list includes the
Single Weld 15, plus eight more characteristics shown in shaded boxes in the
diagram to the left.)
Figure 5–15 Process Limits Menu Diagram
Process Limits, Continued
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Process Limits, Continued from Previous Page
Process Characteristics Defined
Downstroke Time – This is the time from the start of the
welding cycle to the trigger point.
Downstroke Distance (Distance Encoder Systems Only) –
This is the distance from the distance encoder reference
mark to the trigger point.
Contact Air Pressure (Electronic Pressure Regulator
Systems Only) – This is a measurement of the line pressure at the trigger point.
Method 1 Weld Time – This is the length of time the
ultrasound is applied to the part while Pressure 1 is applied to the part.
Method 1 Distance – (Distance Encoder Systems Only)
This is the distance the press travels while the ultrasound
signal is applied to the part during the first weld method.
Method 1 Weld Energy – This is the amount of energy
drawn from the generator while the ultrasound signal is
applied to the part under Pressure 1.
Method 1 Weld Peak Power – This is the highest instantaneous power delivered to the transducer during the
Pressure 1 portion of the weld cycle.
Trigger Delay Time – The ultrasound signal
can be delayed by a specified amount of time
after the trigger switch has closed. This characteristic is set in milliseconds.
Trigger Delay Distance – The ultrasound
signal can be delayed until the press travels a
specific distance beyond the trigger point. This
characteristic is set in inches.
Total Weld Distance (Distance Encoder Systems Only) – This is available when dual pressure welding is selected. It is the total of P1 and
P2 weld distances.
Total Weld Energy – This is available when
dual pressure welding is selected. It is the total
of P1 and P2 weld energies.
Method 1 Position - This is the position relative to the
reference mark of the mounted distance encoder at the
instant of the end of weld method 1.
Method 2 Weld Time – This is the length of time the
ultrasound is applied to the part while Pressure 2 is on
the part.
Method 2 Distance - This is the distance the press travels
while the ultrasound signal is applied to the part during
the second weld method.
Weld Distance (Distance Encoder Systems Only) – This
is the distance the press travels while the ultrasound signal
is applied to the part under pressure.
Process Limits, Continued
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Dukane Manual Part No. 403-584-01
Section 5 - Operation
Process Limits, Continued from Previous Page
Method 2 Weld Energy – This is the amount of energy
drawn from the generator while the ultrasound signal is
applied to the part under Pressure 2.
Method 2 Weld Peak Power – This is the highest instantaneous power delivered to the transducer during the
Pressure 2 portion of the weld cycle.
Method 2 Distance – (Distance Encoder Systems Only)
This is the distance the press travels while the ultrasound
signal is applied to the part during the second weld method.
Total Weld Time – This is available when dual pressure
welding is selected. It is the total of method 1 and method
2 weld times.
Total Weld Energy - This is the sum of energy drawn from
the generator during weld method 1 and weld method 2.
Hold Time – This is the time the horn maintains
pressure on the part after the ultrasound signal has
stopped.
Hold Distance - This is the distance the press travels
while maintaining pressure during the hold process, after
the ultrasound signal has stopped.
Total Cycle Time – This is the period from the start of
the weld cycle to the end of the weld cycle. The start
of the cycle is defined as the point the auto input signal
begins or when manual operate switches are closed. The
end of the cycle is defined as the point the head retracts
from the part.
Total Stroke Distance – This is the position relative to
the reference mark of the mounted distance encoder at
the end of the hold process.
Total Weld Distance - This is the sum of the collapse distances of weld method 1 and weld method 2.
Figure 5–16
Process Limits - Alarm Status
Alarm Status – See Figure 5-16. This feature is included
with the Part Limits menu to compliment part cycle data. It
does this to show that a system alarm (www.dukane.com/
us/DL_EasyAlarm.asp) was active during the weld cycle
for a particular part.
There are four options with Alarm Status – one that disables
the feature, and three other options that allow for the part
record to show that an alarm was active.
Options:
1) Disabled – Alarm Status is off. If an alarm
occurs, no signal will be generated for the
welded part record.
2) and 3) Force Bad, or Force Suspect – The
ultrasonic generator will provide a signal
when a system alarm activates. The operator
chooses whether to categorize the part under this
circumstance as Suspect or as Bad. Whatever
designation is given to the part, it will be carried
on to become an item in the part record.
Figure 5-16 above shows with the red square
symbol, that Force Bad has been chosen as the
option for Alarm Status.
4) Display – Whenever a system alarm happens,
the ultrasonic generator indicates this on
the display's Operate screen. A square green
indicator appears alongside the term Alarm
Status. This is a visual cue to the operator. The
part record will not have this information.
Time – This is the current time of day according to the iQ
generator timer.
Date – This is the current date according to the iQ generator timer.
Setup – This is the number of the current setup.
Process Limits, Continued
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Process Limits, Continued from Previous Page
Data from Process Characteristics
Data from each weld cycle can be monitored through the
available process characteristics.
Programming choices for each characteristic are:
— No Display
— Display Only,
— Bad Limits, and
— Suspect Limits.
No Display
Figure 5-17 shows that Method 1 Weld Energy is the
selected process characteristic, and no choices have been
made for that characteristic. Weld characteristic is not
displayed.
Figure 5–17 Process Limits - No Choice
Display Only
Figure 5-18 shows Display Only was chosen for the Setup
process characteristic.
That process characteristic is displayed during normal operation using the Operate screen.
Bad Limits
This is also known as Bad Part Limits.
Figure 5-19 shows that Downstroke Time is the selected
characteristic. Bad Limits are ON, and Low Limits and
High Limits need to be set.
Figure 5–18 Process Limits - Display Only
The Bad part limits are used to establish boundaries that define unacceptable results for parts that are being processed. If
a bad limit is exceeded, the weld cycle is ended immediately,
and the operator is notified in these ways:
• Two beeps are given (if buzzer is set to ON).
(See Buzzer, Page 79.)
• The iQ ES bad part output is activated.
• BAD is displayed in the part cycle data.
Figure 5–19 Process Limits - Bad Limits
Process Limits, Continued
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Dukane Manual Part No. 403-584-01
Section 5 - Operation
Process Limits, Continued from Previous Page
Suspect Limits
This is also known as Suspect Part Limits.
Suspect part limits detect out-of-limit conditions without ending the weld cycle. These limits are used when
process characteristics are grouped within a "gray area"
between good and bad. Parts can be sorted as good, bad,
and suspect. Suspect parts can be inspected manually.
Suspect limits can also be used as a form of pre-control
in applications where statistical process control methods
are being used.
When a suspect part limit has not been met or that it was
exceeded, the operator is notified in these ways:
• One beep is given (if buzzer is set to ON).
(See Buzzer, Page 79.)
• The iQ ES suspect part output is activated.
• SUSPECT is displayed in the part cycle data.
In Figure 5-20 the selected characteristic is Method 2
Weld Distance.
Both Suspect Limits and Bad Limits are ON for which
both Low Limits and High Limits need to be entered.
Part Cycle Data
Figure 5–20
Process Limits - Suspect Limits
The weld characteristics chosen to be displayed can be
seen in real time using the Operate Screen.
See OPERATE SCREEN on Page 82.
Show All
Notice that Figure 5-20 indicates there is an active soft
key for the selection: Show All.
Press this key to display all process characteristics.
Show None
After pressing the Show All soft key, the key designation
changes to Show None.
NOTE
Change your mind?
If you change your mind and decide not to
display all of the characteristics, press the
Show None soft key, to turn off the display
feature for all of the characteristics.
Press the key so that none of the process characteristics
are displayed.
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Main Menu
Utilities/Hardware
Process Utilities
Hardware Setup
Serial Port
Welder Name
Setup Control
Copy Setup
Setup Name
Horn
Output Format
Booster
LF After CR
Erase Setup
Fixture
Part Count Settings
Manual P1
Notes
Output Mode
Baud Rate
Manual P2 / Hold
Serial Limit Indicators
Dynamic Trigger
Language
Down Speed / Flow Control
Base Units
Mechanical Stop
Date Format
HSC Setting
Time
HSC Start Position
Pre-trigger / EOW Flags
Date
Serial Headers
System Status I/O
Auto Start Input
Auto Stop Input Enabled
J3 pin 4
J3 pin 5
Output Duration
Restore System I/O Defaults
Adv Process Settings
Buzzer
Text Keyboard
Test at Power Up
Adv Trigger Settings
Network Settings
Restore Factory Defaults
Figure 5–21 Utilities/Hardware Menu Diagram
NOTE
The list of available Process Utilities and
Hardware items depends on Security access level (See Table 5-I.) and on system
configuration.
Process Utilities, Continued
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Section 5 - Operation
Process Utilities, Continued from Previous Page
Process Utilities
Overview
Process Utilities provides setup management and part tracking tools. Notes are included to allow unique names to be
given to many setup components.
Setups and their components can be identified. This information can be used to recall setup conditions.
Figure 5-22 shows that, with the exception of Notes, there
are 10 utilities to consider. Review the brief descriptions of
these utilities below:
Figure 5–22
Setup Control
Figure 5–23
Setup Control - Select a Method
Figure 5–24
Setup Control - Sequencing Chosen
Figure 5–25
Defining the Sequence
Welder Name
Use the virtual keyboard to give the welder its own identification.
Setup Control
Setup Control defines where control for setup originates:
with the iQ System, with Automation, or with Sequencing.
Select a Method of Control - When the soft key
Change Method is pressed, an image like the one shown
in Figure 5-23 appears.
Choose from three methods that define where control for a
particular setup originates:
iQ System - Control originates through the iQ generator
and its program.
Sequencing - Control originates through the sequence
definition as programmed through the iQ generator.
See more on Sequencing in Appendix C.
Automation - Control originates with equipment external
to but in communication with the iQ generator.
If Sequencing is selected, then the screen shown in Figure
5-25 appears. Typically, Define Sequence would be chosen.
Defining the sequence involves entering the information
suggested by Figure 5-25: Sequence Length, etc.
For more on Sequencing, go to Appendix C.
Dukane Manual Part No. 403-584-01
Process Utilities, Setup Control Continued
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Process Utilities, Setup Control, Continued from Previous Page
Choose a Setup
Choosing a setup depends on two factors:
Setup Control, and Security Access
Setup Control - Using Setup Control through the Process
Utilities menu, the three types of control deal with setup
selection in these ways:
- iQ System - Press the Select Setup soft key.
(See Figure 5-22.)
iQ 1
Figure 5–26
Setup Control - Automation Selected
- Sequencing - Press the Edit Setup soft key.
(See Figure 5-24.)
- Automation - Press the Edit Setup soft key.
(See Figure 5-26.)
After pressing the Select Setup or Edit Setup key, a
Choose Setup screen like the one shown in Figure 5-27
is displayed.
Then, highlight a setup from the setup number list.
Next, press the Choose Setup soft key to confirm the
choice.
iQ 1
Figure 5–27
Security Access - If Security access has been established,
then menu access can be limited depending on what Security access level is active.
If the Setup Security is active, then the main screen would
look like it does in Figure 5-28 to the right.
Setup Control - Choose Setup
NOTE
Read the Security material starting on
Page 84 for more information.
To choose a setup in this case, press the Select Setup
soft key.
As with System Control, a list of setups is displayed.
Highlight a setup from the list and press Choose Setup.
iQ 1
Figure 5–28
Select Setup - When Setup Security
Access is Active
Process Utilities, Continued
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Section 5 - Operation
Process Utilities, Continued from Previous Page
Copy Setup
This feature allows data from one setup to be copied to
another setup. In Figure 5-29 to the right, Copy Setup
is selected from the Process Utilities list.
Press the Copy Setup soft key, and the display shown
in Figure 5-30 appears.
Choose setups: Copy From, and Copy To.
Then press the soft key, Press Here to Copy.
The display will appear as it does in Figure 5-31.
iQ 1
Figure 5–29
Copy Setup - 1
Figure 5–30
Copy Setup - 2
iQ 1
Figure 5–31
Copy Setup - 3
Process Utilities, Continued
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Erase Setup
Setup data can be erased for the current setup, or for all
setups. See Figure 5-32.
Part Count Settings
This utility permits part count modification through its
three submenus: (See Figure 5-33.)
Reset Part Count - Selecting this sets the part count
to zero (0).
Preset Part Count - Enter a number that starts the
part counter.
Figure 5–32
Erase Setup
Figure 5–33
Part Count Settings
Count Bad Parts - Enable this to increment the part
count if a bad part occurs.
Language
Choice of language displayed by the front panel is made
through this utility.
Base Units
Select either Imperial or Metric units with this display
utility.
Date Format
The date utility allows for three ways of displaying the
date: MM/DD/YYYY, DD/MM/YYYY, or YYYY/MM/DD
Time
This utility is used to set the time, in the 24 hour format.
Date
Entering the current date will be done in the date format
already chosen.
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Dukane Manual Part No. 403-584-01
Section 5 - Operation
Process Utilities, Continued from Previous Page
Notes
It is important to document information about your
process. With the dozen components or fields that
make up Notes for one setup, a customized record
can be invaluable. See Figure 5-34 below.
Program Notes
This utility makes it easy to name, or identify each of
the fields using the virtual keyboard.
With a manual press, pressure values for P1 and P2 are
not part of the Setup file itself.
The Erase Name option also makes it easy to quickly remove a name.
Notes become part of the setup, so a major benefit is
EXAMPLE:
Why use Notes?
However, to record those values using the Notes feature will allow for those pressures to be recalled.
Use the Manual P1 and Manual P2/Hold fields to
record the information.
that future setup time will be much shorter when trying to create the same or similar setup.
Setup Name
Horn
Booster
Fixture
Manual P1
Notes
Manual P2 / Hold
Dynamic Trigger
Down Speed / Flow Control
Mechanical Stop
HSC Setting
HSC = Hydraulic Speed Control
HSC Start Position
Pre-trigger / EOW Flags
Figure 5–34
EOW = End of Weld
Notes
Process Utilities, Continued
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Process Utilities, Continued from Previous Page
Hardware Setup
Hardware Setup and its submenus can be used before
start-up, or during normal operation.
Typically Process Utilities have been set before Hardware Setup is completed.
Time, Date, Base Units, Setup Control, and the other
utilities have usually already been established before
Hardware Setup is programmed.
Serial Port
The first group of hardware settings deals with the serial
port on the generator. These selections configure the iQ
generator's port to transfer cycle data to a separate computer. See Figure 5-35.
Output Format
Use the Output Format function to choose one of three
keyboard characters as the delimiter:
Comma - Tab - Semicolon
Most database and spreadsheet programs are able to read
or save data in a delimited format. See Page 120 for more
detailed information about the serial data format.
LF after CR
Each line of output ends with a carriage return (CR). Some
devices automatically insert a line feed (LF) to advance
the paper, while others do not. Enabling the LF After CR
function makes it possible to insert a line feed at the end
of an output string.
Hardware Setup
Serial Port
Output Format
LF After CR
Output Mode
Baud Rate
Serial Limit Indicators
Serial Headers
Figure 5–35 Serial Port Selections
Output Mode
Use Output Mode to determine the type of data that will
appear in the part record. Selections are defined below:
All - All parts are sent to the output device immediately
after the weld cycle.
None - No parts are sent to the output device.
Good - Only good parts are sent to the output device.
Bad - Only bad parts are sent to the output device.
Suspect - Only suspect parts are sent to the output
device.
Bad and Suspect - All bad and suspect parts are sent
to the output device.
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Hardware Setup, Continued
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Hardware Setup, Continued from Previous Page
Baud Rate
Baud rate is the serial port output speed in bits per second.
Choose a baud rate appropriate for your output device.
Serial Limit Indicators
Limit indicators are characters that appear in front of displayed or printed part data indicating whether the data has
reached or exceeded an upper or lower limit.
NOTE
Baud rate settings on both the sending
unit (iQ generator) and the receiving unit
(computer) must be the same for communication between the devices to work
properly.
The greater than sign (>) means that an upper limit Suspect
value has been exceeded.
Two greater than signs (>>) mean that an upper limit Bad
value has been exceeded.
The less than sign (<) means that a lower limit Suspect
value has not been reached.
Two less than signs (<<) mean that a lower limit Bad value
has been exceeded.
Select Disable if the limit indicator might confuse a program that is running an SPC or data collection application.
Select Enable to allow use of the limit indicators.
Serial Headers
At the end of every cycle, the cycle data also gets sent out
via the serial port.
The user can send (print) this data, each time the Print soft
key is pressed.
Hardware Setup, Continued
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Hardware Setup, Continued from Previous Page
System Status I/O
The next group of hardware settings (following the Serial
Port settings) deals with the generator's System Status I/O.
These six selections enable customization of some of the
iQ generator's input and output signals. Figure 5-36 shows
these functions.
Auto Start Input
Use the Auto Start Input function to choose one of two
types of input that can originate the Auto Start signal:
Solid State, or
Mechanical
Choosing Mechanical presents another choice. That is
Switch Debounce Time - choose 5ms, 10ms or 25ms.
Switch debounce time is typically used when using a relay
to activate the Auto Start input.
Auto Stop Input Enabled
This function can be disabled or enabled. The default setting is Enabled and set to End of Cycle.
Hardware Setup
Serial Port
System Status I/O
Auto Start Input
Auto Stop Input Enabled
J3 pin 4
J3 pin 5
J3 pin 17
Output Duration
Restore System I/O Defaults
Figure 5–36 System Status I/O Selections
When the Auto Stop Input is enabled, the operator selects either End of Weld, or End of Cycle.
• End of Weld - When Auto Stop is set to End of
Weld, the auto stop input signal terminates the weld
but not the complete weld cycle. If hold is enabled,
it begins at the trigger of this signal.
• End of Cycle - When Auto Stop is set to End
of Cycle, the auto stop input signal terminates the
complete weld cycle (hold is not executed, even if
enabled).
Programmable Status Output 1 (J3 pin 4)
J3 represents the generator's output connector, and Pin 4
is programmable.
It can be programmed to provide:
E-Stop Status or Overtemp Status.
The default setting is E-Stop.
Hardware Setup, Continued
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Section 5 - Operation
Hardware Setup, Continued from Previous Page
Programmable Status Output 2 (J3 pin 5)
J3 represents the generator's output connector, and Pin 5
is programmable.
It can be programmed to provide:
Hold Status, In-Cycle Status, or In-Cycle no Afterburst
The default setting is Hold Status.
Output Duration
This is the duration of the Good, Suspect, or Bad part
output signal. Use the Output Duration function to select
the length of the output signal:
Figure 5–37 Restore System I/O Defaults
Maintained or 100ms Pulse
The default setting is Maintained.
Restore System I/O Defaults
Choose this function to restore the original system input/
output defaults.
Once Restore is chosen, a secondary screen is displayed
asking the operator to verify the choice:
Are you sure you want to Restore I/O Defaults?
See Figure 5-37 for the screen view.
Hardware Setup, Continued
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Hardware Setup, Continued from Previous Page
Additional Hardware Settings
Hardware Setup
The next group of hardware settings (following the Serial
Port settings and the System Status I/O settings) deals with
a variety of functions. These six selections provide further
customization of the iQ generator. Figure 5-38 diagrams
these selections.
Serial Port
System Status I/O
Adv Process Settings
Buzzer
Advanced Process Settings
Enabling Advanced Process Settings allows for adjustment of several advanced process settings within the
Process Setup menu. Brief descriptions of these settings
are given below.
Text Keyboard
Test at Power Up
Adv Trigger Settings
Network Settings
- Free Run Frequency and Scan Stack,
- Frequency Tracking,
- Frequency Lock and Hold,
Restore Factory Defaults
Figure 5–38
Additional Hardware Settings Diagram
Figure 5–39
Advanced Process Settings Warning
- System Frequency Limits,
- Ramp Up, and
- Ramp Down.
• Free Run Frequency - Free run is the frequency at
which the generator drives the ultrasound output pulses
until the actual operating frequency is detected. Typically
this value should be 50-100 Hz below the operating frequency of the stack.
• Scan Stack - With Advanced Process Settings enabled:
Run the scan: Return to the Main Menu. Select the
Process Setup soft key to display the Process Setup
screen. Scroll to Adv. Process Settings in the list and
select the Adv. Process Settings soft key. Scroll to Free
Run Frequency in the displayed list and select the
Scan Stack soft key. Follow the displayed instructions.
For more detail on the Scan Stack feature please refer to
our website to download Application Note 512 at http://
www.dukane.com/us/DL_ApplData.asp
CAUTION
Before adjustments to advanced process settings are
allowed, an intermediate
screen with a warning appears. See Figure 5-39. This warning
reminds the operator that modifying
settings may damage the generator, or
the ultrasonic stack.
Hardware Setup, Continued
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Dukane Manual Part No. 403-584-01
Section 5 - Operation
Hardware Setup, Continued from Previous Page
• Frequency Tracking - When Enabled, at the end of each
cycle the operating frequency is applied to the Free Running Frequency setting. It's based on a 16 point average.
Therefore, after 16 cycles, the actual operating frequency
will be the Free Running Frequency setting. If the generator has not been cycled for a minimum of 5 minutes, the
generator will request that the stack be scanned in order
to verify the optimum Free Running Frequency setting.
For more information about Frequency Tracking, refer to
our Application Note 513 on the Dukane website at: http://
www.dukane.com/us/DL_ApplData.asp
• Frequency Lock/Hold - When frequency lock and hold
is disabled, the frequency of the stack is tracked by changing the frequency of the ultrasound driving pulses to match
the actual operating frequency.
When enabled the frequency of the stack is tracked until
lock is achieved. Then it is ignored and the ultrasound
output remains at a fixed frequency until the end of the
weld.
For more information about Frequency Lock/Hold, refer to
our Application Note 505 on the Dukane website at: http://
www.dukane.com/us/DL_ApplData.asp
• System Frequency Limits Wide - In wide mode the upper and lower frequency
limits are set to the maximum and minimum allowed
frequencies for the generator. These values are dependent on the system frequency of the generator.
Normal - In Normal mode the upper and lower frequency limits equal the free run frequency ± 500Hz.
Narrow - In Narrow mode the upper and lower frequency limits equal the free run frequency ± 200Hz.
Manual - In Manual mode the user sets the upper and
lower frequency limits. To be valid, the settings must
be within the maximum and minimum values for the
generator and at least 25Hz greater than the "upper"
free run frequency and 25Hz less than "lower" free
run frequency.
NOTE
Why System Frequency Limits Modes
Might be Chosen
Wide - This mode is primarily used for
testing "bare" transducers (no booster or
horn attached).
Normal - This mode is the one most often
used covering a wide variety of horns.
Narrow - This mode is used when the
acoustic stack has known unwanted frequencies that are close to the main operating frequency.
Manual - This mode allows for a frequency range to include only frequencies
that are wanted, and excluding unwanted
frequencies.
Hardware Setup, Continued
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Hardware Setup, Continued from Previous Page
• Ramp Up Time - Although the Ramp Up time is factory set, it is variable and can be adjusted to account for
starting characteristics of a particular stack.
The Ramp Up setting depends on the generator load at
the start of a cycle.
The Ramp Up time increases the amplitude linearly,
in the programmed time period at the start of the weld,
from zero to the programmed amplitude level. The stack
is brought up to the operating amplitude smoothly, without shock stress.
• Ramp Down Time - Although the Ramp Down time
is factory set, it is variable and can be adjusted to account for characteristics of a particular stack.
Ramp Down Time decreases the amplitude linearly to
zero in the programmed time period following the end of
the weld, when ultrasound is shutting off.
The stack is brought down from its weld amplitude,
reducing shock stress.
• Restore Advance Process Defaults - Enable this
feature by pressing the Restore Defaults soft key.
A screen appears with the question,
Are you sure you want to Restore
Advance Process Defaults?
Select YES to restore all of the advanced process settings to their factory defaults.
NOTE
Ramp Down Time
Ramp Down Time extends the service life
of complex acoustic stacks by minimizing
stresses encountered during the process
of shutting off the ultrasound. It is especially recommended for very large horns,
or when the ultrasound is shut off in air.
Hardware Setup, Continued
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Dukane Manual Part No. 403-584-01
Section 5 - Operation
Hardware Setup, Continued from Previous Page
Buzzer
Use the Buzzer function to turn the internal generator
buzzer on or off.
Disabled - The buzzer will not sound.
Enabled - The buzzer can signal two different
events. See Figure 5-40 to the right.
• Buzzer Top of Stroke - When enabled, buzzer
sounds when top of stroke is reached.
• Buzzer at Trigger - When enabled, buzzer sounds
when the trigger point is reached.
Figure 5–40
Buzzer Enabled
• Parts Alert: The buzzer, when enabled, beeps once
when a suspect part is detected, and it beeps twice when
a bad part is detected.
Text Keyboard
The virtual keyboard is enabled by default, and it pops up
when required. When disabled, the virtual keyboard will
not appear.
Test at Power Up
Each time the generator is powered On, the operator
will be prompted to execute a TEST of the ultrasonics
stack. The TEST can also be cancelled. The feature can
be disabled from the Hardware Settings screen. Test at
Power Up is Enabled by default.
See Figure 5-41.
The “Test at Power Up” feature can also be cancelled by
activating the “System Latch Reset” input (J2-12).
Test at Power Up is enabled.
Please clear area around the
stack and press Test button
for 1 second before welding
parts.
Press CANCEL to abort.
iQ 1
Figure 5–41
Test
Test at Power Up
Hardware Setup, Continued
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Hardware Setup, Continued from Previous Page
Advanced Trigger Settings
When Advanced Trigger Settings are enabled, basic trigger
settings are enhanced.
For example, in the Process Setup menu, when Force is
the Trigger Type, Sensing Start Position is added to refine
the Force selection. See the figure below where basic and
advanced trigger functions are illustrated.
Maintained
Max Trigger Time
Pre-trigger
Enabled
Pre-trigger Amplitude
Pre-trigger Position
Not a choice if Pre-trigger is Enabled
Trigger Delay
Disabled
Key to Trigger Function:
Delay by Time
Basic Trigger Function
Delay by Distance
Momentary
Max Trigger Time
Pre-trigger
Trigger Delay
Enabled
Advanced Trigger Function
Pre-trigger Amplitude
Pre-trigger Position
Not a choice if Pre-trigger is Enabled
Disabled
Delay by Time
Trigger Type
Delay by Distance
Force
Force at Trigger
Max Trigger Time
Pre-trigger
Enabled
Trigger Delay
Sensing Start Position
Pre-trigger Amplitude
Pre-trigger Position
Not a choice if Pre-trigger is Enabled
Disabled
When Motion Stops
Delay by Time
Max Trigger Delay Time
Delay by Distance
Trigger Delay Distance
Max Trigger Time
Pre-trigger
Trigger Delay
Enabled
Max Trigger Delay Time
Pre-trigger Amplitude
Pre-trigger Position
Not a choice if Pre-trigger is Enabled
Disabled
Delay by Time
Power
Trigger Power
Max Trigger Time
Position
Trigger Position
Max Trigger Time
Start Amplitude
Trigger Delay
Disabled
Delay Until Auto In
Figure 5–42
Trigger Function - Basic and Advanced
Hardware Setup, Continued
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Dukane Manual Part No. 403-584-01
Section 5 - Operation
Hardware Setup, Continued from Previous Page
Network Settings
The Network Settings screen as seen in Figure 5-43 has
five elements:
DHCP - These initials stand for Dynamic Host Configuration Protocol. The protocol was established for assigning dynamic IP addresses to devices on a network.
DHCP should be enabled if connecting multiple generators when using an Ethernet router or switch.
Figure 5–43 Network Settings
DHCP can be enabled or disabled depending on customer requirements.
NOTE
IP Address - This Internet Protocol address is a number unique to a piece of equipment acting as an identifier when the equipment is connected to a network.
An IP address is specified when a static IP is required.
Network Mask - Automatically assigned by the DHCP
server.
Gateway Address - Automatically assigned by the
DHCP server.
Network Link - This shows the status of the connection to a network:
Linked - This displays the speed of the network
connection.
If the user is directly connecting to a laptop
or PC, the PC's IP address should be set
to 169.254.0.x (x must be 2-255).
The (x_ in the computer's IP address can
not be the same x as in the generator's IP
address.
NOTE
Network Settings are maintained even
after a Restore Factory Defaults.
Are you sure you want to Restore Factory Defaults?
Not Linked - Down
Restore Factory Defaults
Choose Restore Factory Defaults when restoring the
generator software to the factory default settings.
Before this is allowed, however, an intermediate screen
questioning the action appears. See Figure 5-44.
Main Menu
Figure 5–44
Restore Factory Defaults?
NOTE
Performing a Restore Factory Defaults
can not be reversed.
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Operate Screen
The Operate screen displays weld cycle data in real time.
Figure 5-45 shows the main Operate screen.
Total Parts
Processed
Process
Characteristic
Setup Name
Process characteristics listed below the setup name are
the ones chosen (as process limits) to be displayed or
programmed.
Part # in the upper left corner of the Operate screen records
the running total of processed parts.
When a minimum of 10 parts have been processed, press
the soft key next to the total number of parts box. The next
screen Search Part History appears, and allows searches
by Part Number, Time, Date, Previous Bad, Previous Suspect, and Previous Alarm.
Figure 5–45
Main Operate Screen
Part Number History
Search by Part # - Press this soft key to search for a
specific part number in the cycle data.
Pressing the Part # soft key displays a search screen after
a minimum of 10 parts are in the cycle data.
Search by Time - Press this soft key to search for a part
know to have been welded at a specific time in the cycle
data.
Search by Date - Press this soft key to search for a
specific part welded on a specific date in the cycle data.
Previous Bad - Press this soft key to search for a
previously welded bad part in the cycle data. Pressing
the soft key again will continue searching for the next
previously welded bad part.
Previous Suspect - Press this soft key to search for a
previously welded suspect part in the cycle data. Pressing
the soft key again will continue searching for the next
previously welded suspect part.
Previous Alarm - Press this soft key to search for a
previously part that had an alarm in the cycle data.
Pressing the soft key again will continue searching for the
next previous part that had an alarm.
Direction - Press this soft key to change the direction of
the search from previous cycle data parts to next cycle
data parts.
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Section 5 - Operation
Current Setup
While viewing the Operate screen, (or from the Main
Menu), press the soft key next to Current Setup, and a
view similar to the one shown in Figure 5-46 will appear.
This is usually a multiple page (display) list of the main
parameters that were set for the current setup.
Process Limits
Press the soft key next to Process Limits, and the process
limits list, similar to the one shown in Figure 5-47 is displayed. Adjustments to the list of process characteristics
can be made easily.
Figure 5–46
Current Setup
Figure 5–47
A Process Limits List
Figure 5–48
Real Time Data
Press Back when finished making adjustments to the list of
process characteristics, and once again the main Operate
screen will be shown.
Real Time Data
See Figure 5-48.
Press the soft key next to Real Time Data, and the display
changes to show press characteristics for the current setup
and weld cycle.
The possible characteristics are: Pressure, Force, Distance, Power, and Frequency.
Characteristics displayed depend on system configuration.
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Graph
The generator is factory programmed to provide graphs
with amplitude and power as the vertical axes.
Figure 5-49 shows the graph screen.
Graph Setup
Figure 5-50 shows the graph setup screen used when selecting parameters for the two vertical axes of the graph.
(The horizontal axis represents time.)
Figure 5–49
Graph Screen
Select from these parameters:
Amplitude, Power, Frequency, Energy, Distance,
Speed, Pressure, Force
Speed
1. Red Axis - Press one active soft key representing
the parameter for the vertical (red) axis. This axis is
on the left side of the graph.
2. Blue Axis - Press one active soft key representing
the parameter for the vertical (blue) axis. This axis is
on the right side of the graph.
Figure 5–50
Graph Axis Setup Screen
Figure 5–51
Start Graph at Setup
Figure 5–52
End Graph at Setup
Figure 5-51 shows the graph setup screen used to choose
a starting point for the graph.
3. Choose one of the active soft keys representing
the event that starts the graphing procedure.
The events are:
Cycle Start, Trigger, or Weld Start.
Figure 5-52 shows the graph setup screen used to select
the end point for the graph.
4. Choose one of the active soft keys representing
one of two events that after they have finished, the
graphing procedure will come to an end. The events
are:
Weld End, Hold End
NOTE
As the graph is being designed with these
setup screens, press ENTER to display the
graph.
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Continued
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Graph, Continued from Previous Page
Completed Graph
The figure below shows a completed graph.
This particular image resulted after pressing the TEST key.
See Figure 5-53 below.
Red Vertical Axis,
Power
Figure 5–53
Horizontal Axis,
Time
Blue Vertical Axis,
Frequency
Example Graph Following Test
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Help
From the main screen, (Figure 5-54 to the right) press the
soft key next to Help.
This will produce a screen that gives information about your
generator, including model and serial numbers.
An example of this screen is seen in Figure 5-55.
iQ 1
Figure 5–54
Locating Help on the Main Menu
Color Front Panel
app: v1.11.00 - Aug 16 2013 / 08:43:09
boot: v1.03 - Sep 20 2012 / 11:04:37
Motherboard
app: v3.11.02 - Aug 9 2013 / 11:20:24
boot: v1.04 - Sep 20 2012 / 08:48:10
Model # 20HS2402QP6
Serial # 229180
Figure 5–55
Page
86
Back
iQ 1
Online
Help Screen Example
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Security
NOTE
The Security menu choices control access to the programming menus by using individual logins for three levels:
Administrator, Process Engineer, and Setup.
Operator - Usually the operator does
not need to use the Security feature.
Typically an operator only monitors the
weld cycle using the Operate and Graph
screens.
The table below shows what access each security level
has. In addition the Operator column shows the access a
generator operator would have when the three levels of
control are in use.
Main Menu Item
Graph Screen
Operate Screen
Process Setup
Process Limits
Process Utilities
Hardware Setup
Current Setup
Persons needing an individual login.
Administrator
O
O
O
O
O
O
O
O = Access
Process
Engineer
O
O
O
O
O
X
O
•• = Select Setup is available.
Table 5 - I
Setup
Operator
O
O
X
X
O ••
X
O
X= No Access
O
O
X
X
X
X
X
Security Access to Main Menu Item
Remote User Timeout
The purpose of this option of the Security menu is to
yield (allow) or deny access to the programming features
of the iQ generator under certain conditions.
Access (to program the generator),
is assigned to the Administrator as
a default setting if no passwords
have been set.
This feature is most useful when a remote user (using iQ
Explorer II software) and a user at the generator might
both want to control the generator. A request for control
(by either user) shows on the generator display and on the
remote computer display.
Security Screen
If no response is given (by either user) to this request
within 30 seconds, then in whatever state the generator
had been left (Deny Control or Yield Control) before the
request for control, that is the state in which the generator
will continue to operate.
Example: A remote user requests control of the generator, and no one is at the generator to respond to the
request. If the generator had been programmed to yield
control, then after 30 seconds, the remote user would
have control.
Dukane Manual Part No. 403-584-01
07/01/2013 13:31
Administrator Access [Default]
Setup Password None
Process Eng Password None
Administrator Password None
Remote User Timeout Deny Control
Done
iQ 1
Figure 5-56
Online
Security Screen - No Passwords Set
Continued
Page
87
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Using Security
Enabling Passwords for the First Time
Administrator
Password
1. Press the Security soft key. The Security Screen
appears as shown in Figure 5-57. The word None
means no passwords have been enabled or set.
In the example that follows, three passwords will be set:
First, for the Administrator, then for the Process Engineer, and finally, for the Setup password.
2. Select, Administrator Password None in the list.
(The selected phrase is highlighted in green.)
The soft keys Administrator Password, and Done are
now displayed. See Figure 5-57.
Security Screen
07/01/2013 13:31
Administrator Access [Default]
Setup Password None
Process Eng Password None
Administrator Password None
Remote User Timeout Deny Control
iQ 1
Done
Online
Figure 5-57 Security Screen - Administrator Password
Selected
3. Press the Administrator Password soft key, and the
alphanumeric virtual keyboard is displayed. This is shown
in Figure 5-58.
Enter a password of up to 15 characters.
Press Apply Changes when finished.
The next screen to appear looks like Figure 5-59.
Figure 5-58
Virtual Keyboard
Login
Password
Security Screen
06/01/2013 13:31
Security Enabled: Currently Logged Out
Because the screen message says, Security Enabled:
Currently Logged Out, the Administrator must enter the
Login Password to activate access to security features.
iQ 1
Done
Online
Figure 5-59 Security Screen - Currently Logged Out
Once the Administrator password has been entered, the
screen appears as shown in Figure 5-60.
Note the change in the Security Screen from what is
seen in Figure 5-58. The Administrator Password has
been Enabled. Also Administrator Access is followed
by [Admin] showing that the Administrator has current
security access.
Login
Password
Logout
Security Screen
06/01/2013 13:31
Administrator Access [Admin]
Setup Password None
Process Eng Password None
Administrator Password Enabled
Remote User Timeout Deny Control
Login is complete for the Administrator.
iQ 1
Done
Online
Figure 5-60 Security Screen - Administrator Access
Enabled
Continued
Page
88
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Security, Continued from Previous Page
At this point the Administrator typically has four options:
• Logout - Press the soft key next to Logout, and
the Administrator will be logged out. None of the security
levels will be active.
• Done - Press the soft key next to Done to exit
and return to the main menu.
• Erase - Select Administrator Password Enabled in the list. Press the Erase soft key, and the password
will be erased or,
• Continue enabling passwords.
For additional passwords, complete Steps 4 and 5.
Also, please read the NOTE to the right.
NOTE
If the Login Password soft key is pressed,
and a wrong password is entered, a
screen prompt indicates an incorrect
password has been entered. The next
screen shows that the person has been
logged out. Restart the login process to
activate the security features.
4. After enabling the Administrator password, the next
level to activate is usually Process Engineer.
Select, Process Eng Password None in the list.
Next, Select Process Eng Password with the upper
left soft key, and the alphanumeric virtual keyboard is
displayed. Enter a password of up to 15 characters.
Press Done when finished.
5. After setting the Administrator password and the Process Engineer Password, select the line: Setup Password
None. Set a password for Setup repeating the methods
already explained.
Figure 5-61 shows the Security Screen when all three
passwords have been enabled.
Press the Logout key.
Figure 5-62 shows that the Administrator has logged out.
Login
Password
Logout
Security Screen
06/01/2013 13:31
Administrator Access [Admin]
Setup Password Enabled
Process Eng Password Enabled
Administrator Password Enabled
Remote User Timeout Deny Control
iQ 1
Done
Online
Figure 5-61 Security Screen - Passwords Enabled
Login
Password
Security Screen
06/01/2013 13:31
Security Enabled: Currently Logged Out
Login Password and Done are choices.
Press the soft key next to Login Password to login.
Press Done to exit and return to the main menu.
iQ 1
Done
Online
Figure 5-62 Security Screen - Logged Out
Continued
Dukane Manual Part No. 403-584-01
Page
89
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Security, Continued from Previous Page
After Passwords are Enabled
Once passwords have been enabled as described above,
generator menu access is controlled.
For each person assigned a password, please use the
four steps detailed below for the login/logout procedure.
1. Press the soft key for Security. The Security Screen
appears as shown in Figure 5-63.
NOTE
When using the Security feature,
only one person can be logged in at
a time. Each login session must end
with a logout.
Login
Password
Security Screen
06/01/2013 13:31
Security Enabled: Currently Logged Out
The previous user has logged out.
iQ 1
Figure 5-63
Done
Online
Security Screen - Logged Out
2. Any of the three passwords (Setup, Process Eng,
or Admin) that were already enabled can be entered.
In this case, the Setup password will be entered, and the
screen then will resemble what is shown in Figure 5-64.
The Security Screen indicates that Setup Eng controls
access to the generator.
Login
Password
Logout
Security Screen
Setup Access [Setup Eng]
Setup Password Enabled
3. Press Done to continue working with the available
menus.
Available menus for Setup Eng are: Select Setup,
Operate Screen, Graph, Help, and Security.
4. When finished working with the generator, press
Security to get to the Security Screen again. Then press
the soft key next to Logout to quit.
06/01/2013 13:31
iQ 1
Figure 5-64
Done
Online
Security Screen - Setup is Logged In
NOTE
Refer to Table 5-I for a guide to the
levels of access that are possible
when using the Security function.
5. Finally, press Done so that the main menu screen is
displayed when the session is complete.
Continued
Page
90
Dukane Manual Part No. 403-584-01
Section 5 - Operation
Security, Continued from Previous Page
Other Security Prompts
With login passwords in use, the levels of access to the
generator are established.
Setup Access
Required
Please Log In
Security prompts - like the samples seen in Figures
5-65 and 5-66 to the right - are displayed when access
to menu features has been limited.
iQ 1
Forgotten Password?
Figure 5-65
Security Prompt for Process Engineer
Access
Contact Dukane if the password has been forgotten.
See Section 10 - Contacting Dukane.
Process Eng Access
Required
Please Log In
iQ 1
Figure 5-66
Dukane Manual Part No. 403-584-01
Security Prompt for Setup Access
Page
91
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
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Page
92
Dukane Manual Part No. 403-584-01
Section 6 - System Operational Testing
SECTION 6
System Operational Testing
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Operational Test of the Acoustic Stack . . . . . . . . . . . . . . . . . 96
Cycling the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
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Page
94
Dukane Manual Part No. 403-584-01
Section 6 - System Operational Testing
Overview
An iQ Series generator must be operating and connected
to the press/thruster in order to test the system.
For efficient operation of a Dukane ultrasonic assembly
system, the ultrasound signal from the generator must
match the frequency (vibrational characteristics) of the
stack that is being driven. Each stack has unique vibrational characteristics dependent on the combination of
stack components. In addition, the characteristics of a
particular stack may vary slightly during operation because
of temperature and loading factors.
To match the generator output signal with the characteristics of a particular stack, the generator output frequency
is adjusted by Dukane’s patented phase-locked-loop DigiTrac pulse-width modulation circuitry.
The Digi-Trac feature automatically adjusts the ultrasound
signal to match the vibrational characteristics of the stack
being driven. When the ultrasound turns on during each
operating sequence, the Digi-Trac circuit monitors the
motion of the stack on a frequency cycle-by-cycle basis
and adjusts the ultrasound signal for the optimum setting.
Because the Digi-Trac continuously monitors each operating sequence, it compensates for vibrational changes
that occur during repeated operations due to heating of
the stack components. It also compensates for changes
that occur over longer time periods due to aging of the
piezoelectric crystals in the transducer, or possible wear
of the ultrasonic horn.
The Digi-Trac feature excels in environments hostile to
reliable operation, such as high duty cycles or high stress,
and continuous-duty applications. In such situations, the
Digi-Trac circuit compensates for the unique vibrational
characteristics of each stack due to differences caused by
aging, loading, temperature changes, and differences in
horn configurations.
Dukane Manual Part No. 403-584-01
Page
95
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Operational Test of the Acoustic Stack
The following test procedure is suggested before starting
the generator, to verify that the vibrational characteristics
of the stack fall within the range of the Digi-Trac. All
Dukane stack components are manufactured to tolerance
specifications within this range. A non-Dukane horn,
an improperly assembled stack, or a stack component
that is worn or damaged, can result in vibrational characteristics outside these specifications, and will require
some adjustment. This test reveals the existence of any
problems and directs you to corrective action.
1. Check the following:
a. Make sure that the correct booster and horn for
the application are installed in the thruster.
b. Check the iQ Series system components for
proper grounding.
c. Check the ultrasound cable connections on the
generator and thruster for proper seating and
security.
d. Verify that the horn is not under load (not in
contact with a fixture or part).
2. Push the generator REAR panel AC breaker switch
to ON. Then the FRONT panel power indicator will
flash on start-up, and finally turn a steady GREEN.
This indicates that the system is operational.
If the power indicator stops flash­ing, but remains
RED, do not go any further, there is a problem with
an internal power supply.
3. Press the TEST key (in ONLINE mode only). See
Figure 6-1.
a. System Power Output:
•
•
TEST Key
If the power output display remains less
than the typical 200 Watts and the horn
frequency is within the standard frequency range, the stack should be operational.
If the power output exceeds 200 Watts,
there may be a problem with the stack.
System Power Output Level
Figure 6-1
iQ Generator TEST Key
Continued
Page
96
Dukane Manual Part No. 403-584-01
Section 6 - System Operational Testing
Continued from Previous Page
•
•
•
b.
Press the TEST key. As long as this key is
pressed, test data, as shown in Figure 6-2 appears.
Press the GRAPH soft key to display the graph
screen.
A display like the one shown in Figure 6-3 to
the right will appear as a graph resulting from
the test sequence.
If an overload alarm is displayed, a mismatch
has occurred between the generator’s ultrasonic
output signal and the stack.
Figure 6-2 TEST, Screen Display
Refer to the next section, Set-up Guidelines and
Troubleshooting, and see the Alarm Message table.
4. If all the indicators pass their tests, the stack is within
the Digi-Trac range.
Typically ultrasonic acoustic stacks operate between
50-200 Watts depending on the gain of the booster/
horn. The vibration amplitude of the horn and booster
and the mass of the horn determine the amount of
power needed to vibrate the stack.
•
If the system passes the tests of these four steps,
proceed to Cycling the System, on the next page.
•
If one or more of these tests have failed, go to the
next step.
Figure 6-3 TEST, Graph Display
NOTE
Note the Frequency and Power values in
the graph above.
If using iQ Explorer II software to control
the process, you have the option of saving the test data for future reference.
5. Turn the generator OFF. Check the stack for proper assembly, damaged components, or dirty mating surfaces.
Recheck the ultrasound cable for proper connections.
Repeat Steps 1 through 4. If the test still fails, go to
the next step.
Continued
Dukane Manual Part No. 403-584-01
Page
97
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Continued from Previous Page
Acoustic Stack Test
6. Turn the generator OFF, remove the stack from the
thruster, and remove the horn from the stack. Reinstall
the transducer-booster assembly in the thruster and
turn the generator ON. Repeat Steps 2 through 4.
If the assembly passes with the horn removed, the horn
is outside the specifications required for operation with
the Digi-Trac preset range. Reassemble the horn to the
stack.
If any failure indications are present with the horn
removed, check the booster and the transducer for the
following
• Any visible damage
• Loose or cracked stud
• Pitted or dirty mating surfaces
Make any necessary repairs or adjustments.
Go to Step 7.
7. Repeat Steps 1 through 6.
• If the failure indications disappear, reassemble the
horn to the stack and repeat Steps 2 through 4.
• If any failure indications are still present, do not
run this stack. Return the transducer and booster
to Dukane for analysis.
Cycling the System
1. Check that you have correctly performed the
following:
a.) Installed the stack in the thruster and have closed
the stack access cover securely.
NOTE
For more information about stacks, see this
article:
www.dukane.com/us/SE_stackarticle.htm
b.) Secured the fixture in place.
c.) Performed the Operational Test of the Acoustic
Stack as detailed on Page 96 of this section.
2. Verify that all controls on the Press/Thruster and the
generator are set as required for this operation.
3. Place a part in the fixture.
4. Manually cycle the system.
Activate both operate switches at the same time to start
the system, and hold fingers in place until the ultrasound starts. Releasing the fingers before ultrasound
starts will abort the cycle.
Page
98
Dukane Manual Part No. 403-584-01
Section 7 - Set-up Guidelines and Troubleshooting
SECTION 7
Set-up Guidelines and Troubleshooting
Set-up Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Default Settings - Process Setup . . . . . . . . . . . . . . . . . . . 101
Changing Default Settings . . . . . . . . . . . . . . . . . . . . . . . . 101
Charts: Trigger Force, Weld Time, Weld Force . . . . . . . . . 102
Air Cylinder Size and Force . . . . . . . . . . . . . . . . . . . . . . . 105
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
The iQ Generator Won't Cycle . . . . . . . . . . . . . . . . . . . . . 106
No Ultrasound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
The Power-up Sequence Stops . . . . . . . . . . . . . . . . . . . 107
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Dukane Manual Part No. 403-584-01
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iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
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Page
100
Dukane Manual Part No. 403-584-01
Section 7 - Set-up Guidelines and Troubleshooting
Set-up Guidelines
The iQ Series ES generator is shipped from the factory with a few default settings. See the table below
for those values.
Default Settings - Process Setup
(iQ Series Generator ES Pneumatic)
Item
Setting
Initiate Settings
Initiate Mode
Manual
Latch on Bad Part
Disabled
Trigger Settings
Trigger Type
Force
Trigger Force
0 lb
Max Trigger Time
0.000 s
Advanced Trigger Settings
Disabled
Weld Settings
Weld Mode
Single Method
Downstroke
0.0 psi
Primary Method 1
Distance
Max Weld Time 1
0.0000 in
0.000 s
Secondary Method 1
Disabled
Weld Pressure 1
0.0 psi
Upstroke
0.0 psi
Weld Amplitude
100%
Hold Settings
Hold Method
Time
Hold Pressure
0.000 s
0.0 psi
Afterburst Settings
Afterburst
Disabled
Advanced Settings
Enable Advanced Settings
Disabled
Table 7-I Default Settings - Process Setup
Changing Default Settings
From the Main Menu, go to Process Setup. Each of
the items shown in the table above is listed as a Process Setup submenu item and can be customized for
your process. Refer to Section 5, Operation, Pages
48-59 for more information about working with the
Process Setup menu.
Dukane Manual Part No. 403-584-01
Page
101
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Charts:Trigger Force, Weld Time, Weld Force
The charts that follow can help find starting values for
Trigger Force, Weld Time, and Weld Force.
Using the Charts:
1. Measure the approximate length of the linear weld
joint.
2. Find the corresponding number on the horizontal
axis of each graph.
3. Follow that number up into the shaded portion of the
chart for the appropriate value.
EXAMPLE: A part with a linear joint of 8 inches would
have the following ranges:
Trigger Setting = 2.6 -3.2 (40 -55 pounds)
Weld Time = 0.40 - 0.65 seconds
Weld Force = 150 - 240 pounds
Initial Trigger Force
110
105
100
95
Force (pounds)
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
Figure 7-1
Page
102
2
4
6
8
10
12
14
16
18
20
22
24
Linear Weld Joint (inches)
Suggested Initial Trigger Force
26
28
30
32
34
36
Continued
Dukane Manual Part No. 403-584-01
Section 7 - Set-up Guidelines and Troubleshooting
Continued from Previous Page
Initial Weld Time
Suggested Initial Weld Time
1.4
1.3
1.2
1.1
.95
.90
.85
.80
Time (seconds)
.75
.70
.65
.60
.55
.50
.45
.40
.35
.30
.25
.20
.10
0
0
Figure 7-2
2
4
6
8
10
12
Suggested Initial Weld Time
14
16
18
20
22
24
26
28
30
32
34
36
Linear Weld Joint (inches)
Continued
Dukane Manual Part No. 403-584-01
Page
103
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Continued from Previous Page
Initial Weld Force
NOTE
Force (pounds)
Downstroke pressure must be programmed so that enough force will be
available to achieve the programmed
Trigger Force. If there is not enough
downstroke pressure, it may cause the
system to fault at Max Trigger Time.
500
500
150
450
400
400
360
360
340
340
320
320
300
300
280
280
260
260
240
240
220
220
200
200
180
180
160
160
140
140
120
120
100
100
80
80
60
60
40
40
20
20
0
0
0 2 2 4 4 6 6 8 8 10 10 12 12 14 14 16 16 18 18 20 20 22 22 24 24 26 26 28 28 30 30 32 32 34 34 36 36
Figure 7-3
Page
104
Linear Weld Joint (inches)
Suggested Initial Weld Force
Dukane Manual Part No. 403-584-01
Section 7 - Set-up Guidelines and Troubleshooting
Air Cylinder Size and Force
Verify the size of your air cylinder diameter.
Use Table 7-II below to determine actual force at a given
pressure.
Pressure
(psi)
Cylinder Diameter (in)
1.5
2.0
2.5
3.0
0
0
0
0
0
5
9
16
25
35
10
18
39
49
71
15
27
47
74
106
20
35
63
98
141
25
44
79
123
177
30
53
94
147
212
35
62
110
172
247
40
71
126
196
283
45
80
141
221
318
50
89
157
246
354
55
97
173
270
389
60
106
188
295
424
65
115
204
319
460
70
124
220
344
495
75
133
236
368
530
80
142
251
393
566
85
150
267
417
601
90
159
283
442
636
95
168
298
466
672
100
177
314
491
707
105
186
330
516
742
110
195
345
540
778
Table 7- II
Pounds of Force Comparison
between Dukane Air Cylinders
Dukane Manual Part No. 403-584-01
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105
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Troubleshooting
The iQ Generator Won’t Cycle
Just before a weld cycle starts, the iQ generator waits for
an initiating signal. If an initiating signal is applied and
the system does not begin to cycle, check the following:
•
Make sure the iQ generator’s Initiate Mode in the
Process Control menu is set to the appropriate setting:
Manual if using operate switches; Auto if the system
is configured for use with an automated system.
•
Remove all inhibiting inputs and check that no Cycle
Start error messages are displayed.
•
Ensure that cabling is connected properly and that
user interface circuitry is operating.
NOTE
The Initiate Mode selection must
be set for each setup used. This is
extremely important in the case of
Sequencing and setup selection.
No Ultrasound
•
To verify that the generator is producing an ultrasonic
signal, use the acoustic stack test procedure described
in Section 6, System Operational Testing.
•
Verify on the front panel that the generator is in the
ONLINE mode.
•
Verify pressure settings.
•
Review the program. There should be a Weld Time
P1 (and Weld Time P2 if dual pressure is used). Set
the weld characteristic to Display using the generator's front panel Process Limits screen.
•
From the Main Menu screen, select the Operate
Screen key. Start the weld cycle, and view the reported weld time shown on the display. This tells that
the controller has directed the generator to produce
the ultrasonic signal for the programmed time.
•
Verify that a time for the weld cycle is displayed.
•
Verify that a value shows in Weld Peak Power,
Method 1.
Page
106
NOTE
If no value displays, there is a problem. For help, go to Section 10
- Contacting Dukane, Page 123.
Dukane Manual Part No. 403-584-01
Section 7 - Set-up Guidelines and Troubleshooting
The Power-up Sequence Stops
Under normal conditions, power up starts when the generator REAR panel AC breaker switch is pushed to the ON
position. Then the FRONT panel power indicator will flash
for a few seconds, and finally turn a steady GREEN. This
indicates that the system is operational.
If the power indicator stops flashing and remains RED,
do not go any further, there is a problem with an internal
power supply.
Operation of the front panel lighted power
indicator:
NOTE
If troubleshooting does not provide satisfactory results, please contact Dukane
(see Section 10 - Contacting Dukane)
for servicing. The iQ ES generator is
serviceable only by Dukane personnel.
Unauthorized attempts to service this
product will void any warranty.
• Steady Green - Generator is ready to cycle.
• Steady Red - There is a problem with an internal
power supply.
Dukane Manual Part No. 403-584-01
Page
107
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Alarm Messages
The following table lists alarms that may appear for
the pneumatic systems containing a generator with a
color front panel display (Q-Series) or iQ Explorer II
software.
Information on particular alarms may also be obtained
on the Dukane '"Easy Alarm" web page: http://www.
dukane.com/us/DL_EasyAlarm.asp
Continued
Page
108
Dukane Manual Part No. 403-584-01
Alarm Message
Configuration Fault
Bad Parameter Alarm
Watchdog Reset Alarm
Hardware Fault
Frequency Overload Fault 1
(PLL Lock Fail)
Frequency Overload Fault 2
(PLL Lock Lost)
POS Peak Overload Fault
NEG Peak Overload Fault
Average Overload Fault
Bad Current Loop Fault
Alarm Code
U100
U101
Table 7-III
U102
U103
U104
U105
U106
U107
U108
U109
Contact Dukane.
Contact Dukane.
This is a disabling condition for the generator; contact
Dukane.
Solution
Alarm Message Screens - Page 1 of 3
Dukane Manual Part No. 403-584-01
4-20 mA current loop is not connected
to the remote amplitude card, or 4-20
mA current loop is defective (poor
electrical).
Generator ultrasound overload.
Generator ultrasound overload.
Generator ultrasound overload.
The stack may be coupling the part to
the fixture.
The generator did not obtain a frequency lock by the end of ramp up period.
Check for proper connection to remote amplitude card.
Check for damage to wiring.
This is a disabling condition for the generator; contact
Dukane.
Reduce the force being applied to the part (on a pneumatic
press) or reduce the weld speed (on a servo press).
Check if one of the stack components is defective.
Check if one of the stack components is loose.
Check if the iQ generator's system frequency settings are
set correctly.
Check if one of the stack components is defective.
Check if one of the stack components is loose.
Check if the iQ generator's system frequency settings are
set correctly.
Attempt to decouple vibrations from fixture by using a compliant medium, such as a sheet of silicone or cork, between
the part and fixture, or fixture and base.
Press Test button on the power supply. Verify that the ultrasonic stack will operate in a test condition.
Verify that the stack is operating at proper Frequency and
Power draw.
Reduce trigger pressure, force, and/or down speed.
If stack will not operate in test perform stack care and maintenance.
Follow this link to stack care and maintenance procedure.
If Stack will not operate in test condition, remove horn and
re-inspect.
Enable “Advanced Process Settings” to adjust free run frequency to the “in air” operating frequency that results from
a test.
Enabling a pre-trigger source that allows for full ramp-up
time to elapse still “in air” before contacting the part should
eliminate all “Frequency Overload Fault 1” occurrences for a
properly maintained stack.
If the above steps do not resolve problem, contact Dukane.
Hardware configuration or options were This is a disabling condition for the generator; contact
changed since last generator power up. Dukane.
Internal generator fault.
Internal generator fault.
Default Setup corrupted, Model Number incorrect, Serial Number incorrect,
Feedback Scaling incorrect, etc.
Explanation
Section 7 - Set-up Guidelines and Troubleshooting
Continued from Previous Page
Continued
Page
109
Alarm Message
Power not OK Fault
Overtemperature Fault
Frequency Overload Fault 3
(PLL Limit Exceeded)
Alarm Code
U110
U111
U112
Explanation
Page
110
The operating frequency was artificially
bounded by the system frequency
limits for 25 consecutive milliseconds.
This is usually due to excessive operating frequency drift (operating frequency
is “far” from free run frequency) due to
heating of the stack.
Generator has exceeded its temperature limit.
Problem with incoming AC line voltage.
Solution
Adjusting the Free Run Frequency may also be advisable.
A sudden shift in frequency (as observed on the graph) immediately before a Frequency Overload Fault 3, as opposed
to a general frequency drift, indicates stack/horn coupling
to the part during the weld or an another abrupt change in
stack resonance. This does not imply an operating frequency drift issue, but a weld application setup issue.
Often as a horn/stack heats up, it may begin to have trouble
starting (Frequency Overload Fault 1) because the operating frequency is drifting away from the generator’s Free Run
Frequency setting.
Execute the following steps to alleviate the problem:
Observe the last operating frequency from a test graph.
Enable “Advanced Process Settings”.
Change “System Frequency Limits” to “Manual” and adjust
the offending upper/lower frequency limit to an acceptably
safe value for your horn/stack/application.
Check for blockage of air vents on the sides of the generator, restricting air flow to the inside of the generator.
Check if the internal fan is defective.
Verify that the incoming AC Line voltage supplied to the
generator is within the range specified for the generator.
Consult the manual for your generator
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Continued from Previous Page
Table 7-III Alarm Message Screens - Page 2 of 3
Continued
Dukane Manual Part No. 403-584-01
Max Trigger Time set to Zero
Forced Shutdown Alarm
Part Detected Too Early
Max Trigger Time Exceeded
Max Trigger Delay Time Exceeded
End of Weld Signal Detected
End of Cycle Signal Detected
U407
U411
U413
U414
U501
U502
Weld Power set to Zero
U402
U406
Weld Time set to Zero
U401
Weld Position set to Zero
Weld Limits enabled for continuous operation
U400
U405
Generator or Press Not Ready
U308
Weld Energy set to Zero
Auto In Switch closed at End of
Cycle
U302
Weld Distance set to Zero
Operate Switch 2 Pressed before Cycle Start
U301
U404
Operate Switch 1 Pressed before Cycle Start
U300
U403
Alarm Message
Alarm Code
Remove active Auto-In signal.
Verify wiring to Auto-In signal.
Release Switch 2 before pressing both activation switches
to start a cycle.
Verify wiring of both operating switches.
Release Switch 1 before pressing both activation switches
to start a cycle.
Verify wiring of both switches.
Solution
This alarm is for information only.
Adjust maximum trigger time to be greater than zero.
Increase maximum trigger time.
Start the weld process sooner.
When Auto-stop is enabled and set for
End of Cycle, this alarm indicates that
the signal has been detected.
When Auto-stop is enabled and set for
End of Weld, this alarm indicates that
the signal has been detected.
This alarm is for information only.
This alarm is for information only.
Trigger delay distance was not reached Increase maximum trigger delay time.
within the specified time limit.
Start the weld process sooner.
Trigger did not occur within the specified time limit.
Contact between the horn and part was Adjust Sensing Start Position to be above contact with part.
detected before reaching the Sensing
Account for variation of heights of unassembled parts.
Start Position.
NOTE: Repeated occurrences of this alarm may result in
costly damage to servo actuator.
External command was received by
generator to end weld cycle.
Adjust weld position to be greater than zero.
Adjust weld distance to be greater than zero.
Adjust weld energy to be greater than zero.
Adjust weld peak power to be greater than zero.
Adjust weld time to be greater than zero.
Change Weld Mode from Automation.
Disable Weld Method.
iQ generator initialization process is not Wait for initialization process to complete.
complete.
Cycle power on iQ generator.
If alarm persists, contact Dukane.
Explanation
Section 7 - Set-up Guidelines and Troubleshooting
Continued from Previous Page
Table 7-III Alarm Message Screens - Page 3 of 3
Continued
Dukane Manual Part No. 403-584-01
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111
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Dukane Manual Part No. 403-584-01
Section 8 - Maintenance
SECTION 8
Maintenance
Dukane Manual Part No. 403-584-01
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114
Dukane Manual Part No. 403-584-01
Section 8 - Maintenance
Front and Rear Panels
Cleaning
•
Do not use any solvents or abrasive cleaners to clean
any of the panels.
•
Do not spray or apply cleaner directly on the generator.
•
Apply a small amount of cleaner on a soft, clean cloth
first. Then, clean the panel with the moistened cloth.
AC Power Cord
The AC power cord should be kept in good condition and
free from any cuts. The AC plug should be straight with
no bent prongs.
Power Button
The button responds well to firm, gentle finger pressure.
Do not use sharply pointed tools or other objects that could
damage the button.
Chassis
Sheet Metal Cover
The cover is preformed to fit over the chassis and has protective grills over the cooling air vents. Keep the cover on
at all times because there are high voltages present which
could cause injury. The internal case also contains capacitors which continue to hold a high electrical charge, even
after the power is shut off.
Air Ventilation Slots
Keep the ventilation slots free from obstructions. If excessive dust or dirt collects on the slots, wipe or vacuum them
clean. Do not use compressed air to clean them as this may
force the dirt inside the chassis.
Allow 5 inches (127 mm) of clearance outside each ventilation slot.
WARNING
Never operate the generator with the cover off.
This is an unsafe practice, and the high voltage
present may cause injury.
The air intake is on the right, and the exhaust is on the left.
This is shown in Figure 3–3, Page 15.
I/O Connector
The Input/Output connector has a pair of 4-40 threaded jack
screws to secure the connector. Make sure the screws are
snug, but do not overtighten them.
Dukane Manual Part No. 403-584-01
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Dukane Manual Part No. 403-584-01
Section 9 - Options
SECTION 9
Options
Power Inlet Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Ethernet Port J9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
RS-232 Port J10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Press Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
P4 Dual Pressure Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
P5 Dual Pressure with Distance . . . . . . . . . . . . . . . . . . . . . . . . 122
P6 EPR/Load Cell with Distance . . . . . . . . . . . . . . . . . . . . . . . 122
Dukane Manual Part No. 403-584-01
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118
Dukane Manual Part No. 403-584-01
Section 9 - Options
Power Inlet Options
120V Systems for North America and
Japan
120V systems for North America and Japan have a fixed
(non-detachable) power cord.
This option is available on generators with power
ratings up to 1200 Watts.
240V Systems
Generators with power ratings above 2400 Watts also
have fixed power cords.
NOTE
Refer to Section 2 - Health and Safety,
Pages 8 and 9 for information about Electrical Safety including grounding.
See Table 11-II in Section 11, Specifications.
Dukane Manual Part No. 403-584-01
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119
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Data Transfer
Board and port locations are shown in Figure 3-4.
Ethernet Port, J9
Pa rt Numb er = 417
the HMI Ethernet port.
RS-232 Port, J10
Cycle data can be sent from this serial RS-232 port. Typically the data is sent to a PC where it can be stored or
manipulated to suit the user.
.
0
0
. 1 0 1 ,
. 0 1 0 0 ,
0
W eld 1 Energy = 210.0 joules
0 0 1 3
2 1 0 . 0
,
Weld 1 Power = 392 Wa tt
3 9 2 ,
0 0 1 4
Tota l Cycle Time = 0.211 second
0 0 2 7
Output Format - The Comma Separated Value (CSV)
format is used. With this format, each characteristic value
is output along with an additional part data index unique
to a particular characteristic.
,
Weld 1 Distance = 0.0100 inch
0 0 1 2
Press - When using a press with the generator, cycle
data is sent following each cycle.
7
Downstroke Time = 0.101 second
0 0 0 4
Probe - When using a probe with the generator, cycle
data can be sent at predetermined intervals.
4 1
0 0 0 1
J9 is the generator's Ethernet port. A cable connects J9 to
0 . 2 1 1 ,
Carriage Return and optional Linefeed
CR LF
Figure 9 - 1
CSV Output Format
This allows a program to identify each characteristic and
store it in an appropriate file regardless of the order in
which the characteristic is received.
Figure 9-1 shows an example of this output format, and
Table 9-I on the next page gives the Part Data Index numbers and descriptions.
Page
120
Dukane Manual Part No. 403-584-01
Section 3 - Installation
Part Data Indexes
Number
Description
1
Part Number
2
Sequence Index
3
Sequence Count
4
Downstroke Time
5
Downstroke Distance
6
Average Down Velocity
7
Trigger Pressure
8
Trigger Delay Time
9
Trigger Delay Dist
10
Force At Trigger
11
Weld 1 Time
12
Weld 1 Distance
13
Weld 1 Energy
14
Weld 1 Power
15
Weld 1 Position
16
Weld Peak Force
17
Weld 2 Time
18
Weld 2 Distance
19
Weld 2 Energy
20
Weld 2 Power
21
Weld 2 Position
22
Total Weld Time
23
Total Weld Distance
24
Total Weld Energy
25
Hold Time
26
Hold Distance
27
Total Cycle Time
28
Total Stroke
50
Time Format: HH:MM:SS
51
Date -> Formats: DD/MM/YYYY, MM/DD/YYYY, YYYY/MM/DD
52
Setup Number
53
Error Code -> "U Number" without the 'U'
Table 9-I
NOTE
Individual data
records are separated
by a comma, tab,
or semicolon. The
character used is set in
the Hardware Settings
screen. See Page 72
for setting the Output
Format character.
The indexes are printed
as 4 characters '0' padded, and the entire field
size is 20 characters
including the delimiter.
The data is right justified
with spaces.
Complete cycle data record is terminated by carriage return and optional
line feed characters.
The format is meant to
mimic Dukane's DPC
generator protocol as
closely as possible.
Part Data Indexes
Dukane Manual Part No. 403-584-01
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121
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Press Interface Module
This board is also known as the Options Slot #1 as
shown in Figure 11-4, Interpreting the Model Number.
Module location is shown in Figure 3-4.
Each option is described in general terms:
P4 - Dual Pressure Only
P/N 110-4426
Dual pressure is a feature that is exclusive to Dukane press
systems. It increases clamp force to improve the plastic
melt and flow during the weld portion of a cycle and assures tight assembly during the hold portion by welding
parts at one pressure and holding them together at a second
pressure. Dual pressure can also be used to begin a weld
at one pressure, finish the weld at a second pressure, then
hold the assembly together at the second pressure.
P5 - Dual Pressure with Distance P/N 110-4427
Dual pressure is a feature that is exclusive to Dukane press
systems. See the P4 description above.
Weld by distance mode controls the melt collapse distance
to ensure that the same volume of material melts on each
part. The result: finished joint strength is consistent.
All distance parameters - downstroke, trigger delay, weld,
hold, absolute weld, total weld, and total stroke distance are monitored to show upper and lower limits for bad and
suspect parts. This will verify part quality and uniformity.
Dukane's linear optical encoder has a one-micron resolution to insure exceptional precision and repeatability.
P6 - EPR/Load Cell with Distance P/N 110-4428
This option offers programmable pressure profiling and
force by interfacing with the EPR (electronic pressure
regulator), pressure transducer, and load cell. Increased
control, repeatability and consistency are benefits.
The electronic pressure regulator and pressure transducer
are components of the same system. The electronic pressure
regulator accepts commands from the generator and sets the
air pressure to the user-selected value. The pressure transducer
senses the pressure and transmits it to the generator via a 4-20
mA current loop.
The force transducer (load cell) senses force exerted on
the part and controls when the ultrasound signal is applied.
See P5 for more information on distance.
Page
122
Dukane Manual Part No. 403-584-01
Section 10 - Contacting Dukane
SECTION 10
Contacting Dukane
Dukane Manual Part No. 403-584-01
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123
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Dukane Manual Part No. 403-584-01
Section 10 - Contacting Dukane
Contacting Dukane
Identify Equipment
When contacting Dukane about a service–related problem,
be prepared to give the following information:
• Model number and serial number.
• Alarm indicators from the generator or displayed by
iQ Explorer II.
• Software version.
• Problem description and steps taken to resolve it.
Many problems can be solved over the telephone, so it is
best to call from a telephone located near the equipment.
Intelligent Assembly Solutions
Mailing Address:
Dukane
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/contact-us/
Dukane Manual Part No. 403-584-01
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Dukane Manual Part No. 403-584-01
Section 11 - Specifications
SECTION 11
Specifications
Generator Outline Drawings . . . . . . . . . . . . . . . . . . 129
Weights, Dimensions, Operating Environment . . . . 132
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . 133
Ultrasonic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 134
Interpreting the Model Number . . . . . . . . . . . . . . . . 135
Regulatory Agency Compliance . . . . . . . . . . . . . . . 136
Dukane Manual Part No. 403-584-01
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Dukane Manual Part No. 403-584-01
Section 11 - Specifications
12.99
[329.95]
0.12
[3.05]
17.16
[435.86]
18.76
[476.50]
ALLOW 3" IN BACK FOR CABLES
18.16
[461.26]
LIGHTED POWER INDICATOR
11.37
[288.80]
ALLOW 5"
BOTH
SIDES
FOR
COOLING
0.81
[20.57]
12.57
[319.28]
0.25 X 0.50 SLOT
(2 PLCS)
3.44
[87.34]
OPTIONAL RACK
MOUNT BRACKETS
147-4720
3.25
[82.55]
ULTRASOUND &
SYSTEM I/O
PRESS CONTROL, COMMUNICATION
& OPTIONS CARDS
AC POWER ENTRY
WEIGHT 20 lbs / 9 kg
129
Page
Dukane Manual Part No. 403-584-01
ALLOW 5"
BOTH
SIDES
FOR
COOLING
3.82
[97.03]
OPTIONAL DISPLAY
& OPERATOR CONTROLS
IN
[mm]
Figure 11-1 Layout - Low Profile iQ Generator iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
14.61
[371.09]
ALLOW 5"
EA SIDE FOR
COOLING
5.19
[131.83]
OPERATOR
DISPLAY
17.16
[435.86]
LIGHTED POWER INDICATOR
ALLOW 6" IN BACK FOR CABLING
OPERATOR
CONTROLS
IN
[mm]
17.64
[448.06]
ALLOW 5"
EA SIDE FOR
COOLING
5.50
[139.70]
WEIGHT: 34 lbs / 15.42 kg
POWER SWITCH
ULTRASOUND &
SYSTEM I/O'S
OPTIONS CARDCAGE
PANELS
AC POWER
ENTRY
COOLING FAN
Dukane Manual Part No. 403-584-01
130
Page
Layout - High Power iQ Generator
Figure 11-2
Section 11 - Specifications
12.91
[327.91]
2.25
[57.15]
1.42
[36.07]
17.16
[435.86]
18.76
[476.50]
ALLOW 3" IN BACK FOR CABLES
18.16
[461.26]
LIGHTED POWER INDICATOR
12.52
[318.01]
OPTIONAL RACK
MOUNTS
147-4721
11.51
[292.35]
ALLOW 5"
BOTH
SIDES
FOR
COOLING
0.64
[16.26]
0.203 DIA.
5.16
0.25" X 0.50" SLOT
4.00
[101.6]
5.50
[139.70]
0.59
[14.99]
4.31
[109.48]
ULTRASOUND &
SYSTEM I/O
5.11
[129.79]
PRESS CONTROL, COMMUNICATION
& OPTIONS CARDS
AC POWER ENTRY
WEIGHT 25 lbs / 11.34 kg
131
Page
Dukane Manual Part No. 403-584-01
ALLOW 5"
BOTH
SIDES
FOR
COOLING
0.12
[3.05]
OPTIONAL OPERATOR
DISPLAY AND CONTROLS
IN
[mm]
Figure 11-3 Layout - High Profile iQ Generator
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Weights
High Profile
Low Profile
High Power
lb
kg
lb
kg
lb
kg
Generator
Only
25
11.3
20
9.1
34
15.4
Generator
+ Packing
Materials
30
13.6
25
11.3
39
17.7
Table 11–I iQ Generator Weights
Dimensions Dimensions - in (mm)
Model
Height **
Width
Depth
Low Profile
3.45 (87.6)
17.16 (435.9)
12.55 (318.8)
High Profile
5.19 (131.8)
17.16 (435.9)
12.55 (318.8)
High Power
5.19 (131.8)
17.16 (435.9)
14.51 (368.6)
Table 11–II iQ Generator Dimensions
NOTE
** Add approximately 0.4" (10 mm) to height when the generator is equipped with factory installed
feet.
Add between 3" and 6" (76 - 152 mm) behind the generator and 5" (127 mm) for air flow and
cable connections.
Operating Environment
Operate the equipment within these guidelines:
Temperature:
40°F to 100°F (+5°C to +38°C)
Air Particulates:
Keep the equipment dry.
Minimize exposure to moisture, dust, dirt, smoke
and mold.
Humidity:
5% to 95% Non–condensing @ +5°C to +30°C
Storage guidelines for deactivated equipment:
Temperature:
-4°F to 158°F (-20°C to +70°C)
Air Particulates:
Keep the equipment dry.
Minimize exposure to moisture, dust, dirt, smoke
and mold.
Humidity:
5% to 95% Non–condensing @ 0°C to +30°C
Page
132
Dukane Manual Part No. 403-584-01
Section 11 - Specifications
20kHz
20kHz
20kHz
20kHz
20kHz
15kHz
15kHz
Operating
Frequency
20HS180-2Q-XX-XX
20HS120-2Q-XX-XX
20HS120-1Q-XX-XX
20HS090-2Q-XX-XX
20HS090-1Q-XX-XX
20HS060-2Q-XX-XX
20HS060-1Q-XX-XX
15HS480-2Q-XX-XX
15HS360-2Q-XX-XX
Generator
Model Number
2400
1800
1200
1200
900
900
600
600
4800
3600
Overload
Power
Ratings
200-240V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 12 Amps
200-240V 50/60 Hz @ 8 Amps
**100-120V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 8 Amps
**100-120V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 5 Amps
100-120V 50/60 Hz @ 8 Amps
200-240V 50/60 Hz @ 30 Amps
200-240V 50/60 Hz @ 25 Amps
North America/
Japan
AC Outlet Rating
30 Amps
15 Amps
30 Amps
700 - 1300 VAC
(Nominal)
1.5 - 3 A
Output
Current
(Max)
(Nominal)
5A
Output
Voltage
(Max)
1400 VAC
(Nominal)
WARNING
Do not operate machine at
voltages lower than 100V.
Current will exceed rating
causing a shock hazard.
(Nominal)
5A
AC Power Requirements
20kHz
20HS240-2Q-XX-XX
200-240V 50/60 Hz @ 25 Amps
Generator
20kHz
3600
200-240V 50/60 Hz @ 30 Amps
(Nominal)
The AC line voltage and current needed depend on whichever generator has been chosen for your system. See the table below.
20kHz
20HS360-2Q-XX-XX
4800
Input AC Power Requirements
Nominal AC Volt
@ Maximum RMS Current
20kHz
20HS480-2Q-XX-XX
Generator AC Power Requirements
(Watts)
20kHz
Table 11- III
NOTES:
An X used above in the Model Numbers is a “wildcard” character meaning any valid character
code combination.
Maximum line current requirement is specified at the minimum nominal AC line voltage and the
rated power level.
**If the input line voltage is less than 100V, the output current will exceed 15 Amps.
(Nominal)
133
1400 VAC
Page
Dukane Manual Part No. 403-584-01
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Ultrasonic Pressure
Ultrasonic Pressure
iQ Generator Models - kHz
15
20
Useful Beam
30
40
50
360 degrees
Ultrasonic Pressure @ Operator's Position - dB
125
140
130
130
130
Ultrasonic Pressure 1 m from the Equipment- dB
110
130
110
105
110
Table 11–IV
iQ Generator Ultrasonic Pressure
NOTE
All measurements taken with Data Physics
Dynamic 4-Channel Signal Analyzer with
calibrated 377C01 Microphone and 426B02
Preamplifier.
Page
134
Dukane Manual Part No. 403-584-01
Section 11 - Specifications
Interpreting the Model Number
2 0
Q
System Process Controls
2
Power Level
P 6
ES Series Options
Options Slot #1
Press System
Q = ES Graphics Color LCD w/ Press Card
K = ES Graphics Color LDC Probe
(w/o Press Card)
Both Generator Models Support the iQ Explorer II
Software.
AC Line Input
480 = 4800 Watts
360 = 3600 Watts
240 = 2400 Watts
180 = 1800 Watts
120 = 1200 Watts
060 = 600 Watts
090 = 900 Watts
024 = 240 Watts
018 = 180 Watts
012 = 120 Watts
2 4 0
iQ Generator Model Number Codes
H S
Nominal U/S Frequency
15 = 15kHz
20 = 20kHz
30 = 30kHz
40 = 40kHz
50 = 50kHz
70 = 70 kHz
Chassis Style
HS = Horizontal Bench Chassis
P4 = Press Interface Board
P5 = Press Interface Board w/Distance
P6 = Press Interface Board w/ Distance &
Press Options
135
Page
Dukane Manual Part No. 403-584-01
2 = 200-240V for 5.25” Tall chassis
1800W and 2400 W only
2 = 200-240V for 3.5” Short chassis
1200W and below
1 = 100-120V for 5.25” Tall chassis
1200W and below (fixed power cord)
Example System Number shown above:
20HS240 - 2Q - P6
System Assembly Detailed Description:
20kHz 2400 Watt Bench System in a 5.25” Tall chassis that operates on a 200-240V AC Line for a
Pneumatic thruster and a Color LCD.
System power cord (if needed) is listed as a separate line item on the sales order matching user’s
AC line power outlet configuration.
Figure 11-4 Interpreting the Model Number
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Regulatory Agency Compliance
FCC
The generator 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.
• The EMC Directive 2004/108/EC
for Heavy Industrial —
EN 61000-6-4: 2001
EN 55011: 2003
EN 61000-6-2: 2005
EN61000–4–2
EN61000–4–3
EN61000–4–4
EN61000–4–5
EN61000–4–6
EN61000–4–8
EN61000–4–11
• The Low Voltage Directive 2006/95/EC.
UL
The iQ generator complies with these standards:
Underwriters Laboratories:
UL 1012: 2010
UL 61010-1:2012, and
National Standards of Canada:
CAN/CSA C22.2 No. 61010-1-12:2012
as verified by TÜV Rheinland.
• The Machinery Directive 2006/42/EC.
EN 60204: 2006
Safety of Machinery - Electrical Equipment of
Machines Part 1: General Requirements.
IP Rating
The iQ generator has an IP (International Protection)
rating from the IEC (International Electrotechnical
Commission).
The rating is IP2X, in compliance with finger-safe
industry standards.
Page
136
CAUTION
DO NOT make any modifications to the generator
or associated cables as
the changes may result
in violating one or more
regulations under which
this equipment is manufactured.
Dukane Manual Part No. 403-584-01
Section 12 - Appendices
SECTION 12
Appendices
Appendix A - List of Figures . . . . . . . . . . . . . . . . . . . 139
Appendix B - List of Tables . . . . . . . . . . . . . . . . . . . 143
Appendix C - Sequencing Notes . . . . . . . . . . . . . . . 144
Appendix D - Menu Structure Diagrams . . . . . . . . . 147
Dukane Manual Part No. 403-584-01
Page
137
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Page
138
Dukane Manual Part No. 403-584-01
Section 12 - Appendices
Appendix A
No.
Description
List of Figures
Page
2-1
Example of 220/240 Volt Grounded 3-Prong Receptacle.................................................9
2-2
International 220/240 Volt Grounding ..............................................................................9
3-1
Lockout Device in Open Position, Unlocked..................................................................13
3-2
Bottom Lockout Device in Closed Position, Locked.......................................................13
3-3
Generator Front View (Typical High Profile)...................................................................15
3-4
Generator Rear Panel - Pneumatic Press/Thruster.......................................................16
3-5
IEC AC Power Inlet Connector.......................................................................................17
3-6
System I/O Panel (Standard Panel Shown)...................................................................18
3-7
HD-15F, Generator Input Connector..............................................................................19
3-8
HD-15M, Generator Input Cable Connector...................................................................19
3-9
DB-25F, Generator Output Connector (J3).....................................................................21
3-10
DB-25M, Generator Output Cable Connector................................................................21
3-11
Ultrasound Output Connector.........................................................................................26
3-12
Configuration Port Connector.........................................................................................27
3-13
iQ Generator and Pneumatic Press/Thruster-Connections Diagram.............................31
4-1
iQ Generator Display and Control Keys.........................................................................37
4-2
Display Detail, Operating Mode Indicator.......................................................................38
4-3
Generator in Offline Condition........................................................................................38
4-4
Navigation Keys (4) with Enter and Cancel....................................................................39
4-5
Active Soft Keys, Example 1..........................................................................................39
4-6
Active Soft Keys, Example 2..........................................................................................39
4-7
System Power Output Level, Bar Graph and Overload Indicator...................................40
4-8
Making Selections..........................................................................................................41
4-9
Arrows Indicate More Text..............................................................................................41
4-10
Virtual Keyboard.............................................................................................................42
4-11
Main Menu Detail - Setup Identification..........................................................................42
5-1
Front Panel's Lighted Power Indicator............................................................................45
5-2
Main Menu Screen.........................................................................................................45
5-3
Navigating from the Main Menu (Administrator /Process Engineer Logged In).............47
5-4
Navigating from the Main Menu (Setup Logged In)........................................................47
5-5
Process Setup Menu Diagram................................................................................. 48-49
Continued
Dukane Manual Part No. 403-584-01
Page
139
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Appendix A
No.
Description
Continued from Previous Page
List of Figures
Page
5-6
Enable Clear Bad Part....................................................................................................50
5-7
Trigger Type Submenu Diagram....................................................................................51
5-8
Weld Mode Submenu Diagram......................................................................................53
5-9
Hold Method Submenu Diagram....................................................................................55
5-10
Afterburst Submenu Diagram.........................................................................................56
5-11
Pressure Submenu Diagram..........................................................................................57
5-12
Pressure Profiling Disabled............................................................................................57
5-13
5-14
Pressure Profiling Enabled.............................................................................................58
Pressure - Set Profile 1..................................................................................................58
5-15
Process Limits Menu Diagram.......................................................................................61
5-16
Process Limits - Alarm Status........................................................................................63
5-17
Process Limits - No Choice............................................................................................64
5-18
Process Limits - Display Only.........................................................................................64
5-19
Process Limits - Bad Limits............................................................................................64
5-20
Process Limits - Suspect Limits.....................................................................................65
5-21
Utilities/Hardware Menu Diagram...................................................................................66
5-22
Setup Control.................................................................................................................67
5-23
Setup Control - Select a Method....................................................................................67
5-24
Setup Control - Sequencing Chosen..............................................................................67
5-25
Defining the Sequence...................................................................................................67
5-26
Setup Control - Automation Selected.............................................................................68
5-27
Setup Control - Choose Setup.......................................................................................68
5-28
Select Setup - Setup Security Access is Active..............................................................68
5-29
Copy Setup 1..................................................................................................................69
5-30
Copy Setup 2..................................................................................................................69
5-31
Copy Setup 3..................................................................................................................69
5-32
Erase Setup....................................................................................................................70
5-33
Part Count Settings........................................................................................................70
5-34
Notes..............................................................................................................................71
5-35
Serial Port Selections.....................................................................................................72
5-36
System Status I/O Selections.........................................................................................74
5-37
Restore System I/O Defaults..........................................................................................75
5-38
Additional Hardware Settings Diagram..........................................................................76
Continued
Page
140
Dukane Manual Part No. 403-584-01
Section 12 - Appendices
Appendix A
No.
Description
Continued from Previous Page
List of Figures
Page
5-39
Advanced Process Settings Warning.............................................................................76
5-40
Buzzer Enabled..............................................................................................................79
5-41
Test at Power Up............................................................................................................79
5-42
Trigger Function - Basic and Advanced..........................................................................80
5-43
Network Settings............................................................................................................81
5-44
Restore Factory Defaults?..............................................................................................81
5-45
Main Operate Screen.....................................................................................................82
5-46
Current Setup.................................................................................................................83
5-47
A Process Limits List......................................................................................................83
5-48
Real Time Data...............................................................................................................83
5-49
Graph Screen.................................................................................................................84
5-50
Graph Axis Setup Screen...............................................................................................84
5-51
Start Graph at Setup......................................................................................................84
5-52
End Graph at Setup........................................................................................................84
5-53
Example Graph Following Test.......................................................................................85
5-54
Locating Help on the Main Menu....................................................................................86
5-55
Help Screen Example.....................................................................................................86
5-56
Security Screen - No Passwords Set.............................................................................87
5-57
Password Screen - Administrator Password Selected...................................................88
5-58
Virtual Keyboard.............................................................................................................88
5-59
Security Screen - Currently Logged Out........................................................................88
5-60
Security Screen - Administrator Access Enabled...........................................................88
5-61
Security Screen - Passwords Enabled...........................................................................89
5-62
Security Screen - Logged Out........................................................................................89
5-63
Security Screen - Logged Out........................................................................................90
5-64
Security Screen - Setup is Logged In.............................................................................90
5-65
Security Prompt for Process Engineer Access...............................................................91
5-66
Security Prompt for Setup Access..................................................................................91
Continued
Dukane Manual Part No. 403-584-01
Page
141
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Appendix A
Continued from Previous Page
List of Figures
No.
Description
6-1
iQ Generator TEST Key.................................................................................................96
6-2
TEST, Screen Display....................................................................................................97
6-3
TEST, Graph Display......................................................................................................97
7-1
Suggested Initial Trigger Force....................................................................................102
7-2
Suggested Initial Weld Time.........................................................................................103
7-3
Suggested Initial Weld Force.......................................................................................104
9-1
CSV Output Format......................................................................................................120
11-1
Layout - Low Profile iQ Generator................................................................................129
11-2
Layout - High Power Generator....................................................................................130
11-3
Layout - High Profile iQ Generator...............................................................................131
11-4
Interpreting the Model Number.....................................................................................135
C-1
What is a Sequence?...................................................................................................144
C-2
Insertion Sequence Example.......................................................................................145
C-3
Sequence Definition.....................................................................................................146
D-1
Process Setup Menu Diagram............................................................................. 147-148
D-2
Process Limits Menu Diagram.....................................................................................149
D-3
Utilities/Hardware Menu Diagram.................................................................................150
Page
142
Page
Dukane Manual Part No. 403-584-01
Section 12 - Appendices
Appendix B
List of Tables
No.
Description
3-I
Generator Input Signals (J2)............................................................................................ 19
3-II
System Output Communication Signals (J3)................................................................... 21
3-III
Power Cords.................................................................................................................... 28
3-IV
iQ Generator and Pneumatic Press/Thruster Cables...................................................... 32
5-I
Security Access to Main Menu Item................................................................................. 87
7-I
Default Settings - Process Setup...................................................................................101
7-II
Pounds of Force Comparison Between Dukane Air Cylinders....................................... 105
7-III
Alarm Messages, Pneumatic-related.............................................................................109
9-I
Part Data Indexes..........................................................................................................121
11-I
iQ Generator Weights....................................................................................................132
11-II
iQ Generator Dimensions..............................................................................................132
11-III
Generator AC Power Requirements..............................................................................133
11-IV
iQ Generator Ultrasonic Pressure..................................................................................134
Dukane Manual Part No. 403-584-01
Page
Page
143
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Appendix C
Sequencing Notes
Sequencing is typically used for operations where parts must
be staked or inserted and need more than one processing step
or more than one set of process parameters.
To use the sequencing feature, the operations performed on
a part must be grouped according to a setup number. Once
the setup parameters have been established for each group,
determine the order in which the groups are to be processed.
NOTE
See Page 67 - Process
Utilities, Setup Control.
This order of operations determines the order of the segments
in the sequence definition.
(See Sequence Definition, Page 146.)
The figure below gives a graphic representation of a sequence.
0
1
2
:
3
4
5
ment
er Seg
ycles p
C
6
to 255
7
From 1
8
9
255
1
2
Sequence
3
nts:
Segme
to 8
From 1
The figure shows that a sequence
is a process having from 1 to 8 segments and each of those segments
has from 1 to 255 cycles.
4
5
8
Figure C-1 What is a Sequence?
Continued
Page
144
Dukane Manual Part No. 403-584-01
Section 12 - Appendices
Appendix C
Sequencing Notes
In this example, a sequence to be used in an insert application has two segments. The first part of the sequence
is known as Setup 01 which will process four #1 inserts.
The second part of the sequence is Setup 02 which will
process four #2 inserts.
Segment 1 deals with insert #1, and Segment 2 deals with
insert #2. Each segment has four cycles. When the cycles
are finished, the sequence is reset to begin processing
another part.
The figure below gives a graphic representation of what this
sequence might look like on an X-Y table.
Setup 01, Cycle 3
Setup 01, Cycle 4
Setup 02
Cycle 2
Setup 02
Cycle 1
Setup 02
Cycle 4
Setup 02
Cycle 3
Start Point
Stop Point
Setup 01, Cycle 1
Setup 01, Cycle 2
Figure C-2 Insertion Sequence Example
Continued
Dukane Manual Part No. 403-584-01
Page
145
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Appendix C
Sequencing Notes
Sequence Definition
Figure C-3 illustrates that when defining a sequence, there are
five parts of the definition to consider:
• Sequence Length - Choose 1-8 Segments
• Define Part as Cycle or Sequence
• Current Cycle - Choose 1-8
• Current Segment - Choose 1-8
• Process Cycles for a Given Segment - Choose 1-255
Sequence Length
(1-8 Segments)
Cycle or Sequence
Current Cycle
(1-8)
Current Segment
(1-8)
Process Cycles for a Given Segment
(1-255)
Figure C-3 Sequence Definition
Page
146
Dukane Manual Part No. 403-584-01
Section 12 - Appendices
Appendix D
Menu Structure Diagrams
Main Menu
Process Setup
Initiate Mode
Trigger Type
Auto
Manual
Enable
Latch on Bad Part
Disable
Maintained
Max Trigger Time
Momentary
Max Trigger Time
Force
Force at Trigger
When Motion Stops
Max Trigger Time
Max Trigger Time
Power
Trigger Power
Position
Trigger Position
** See NOTE.
Max Trigger Time
Max Trigger Time
Time
Distance
Primary
Weld Method 1
Position
Energy
Peak Power
Single
Ground Detect
** Secondary
Weld Method 1
Primary
Weld Method 1
Weld Distance
Weld Position
Energy
Weld Energy
Position
Weld Position
Max. Weld Time
Ground Detect
Weld Method 1
Dual
Weld Distance
Position
Weld Position
Energy
Weld Energy
Time
Distance
Primary
Weld Method 2
Weld Energy
Max. Weld Time
Weld Power
Max. Weld Time
Max. Weld Time
Scrub
Disabled
Distance
Peak Power
Position
Energy
Peak Power
Ground Detect
Weld Time
Weld Distance
Max. Weld Time
Weld Position
Max. Weld Time
Weld Energy
Max. Weld Time
Weld Power
Max. Weld Time
Max. Weld Time
Scrub
Weld Method 1
Distance
Weld Distance
Position
Weld Position
Energy
Peak Power
Figure D-1
Process Setup Menu Diagram (1 of 2)
Dukane Manual Part No. 403-584-01
Scrub Time
Disable
NOTE
Available weld choices depend
on Security access level (See
Table 5-I.) system configuration, and primary weld method.
Enable
Scrub Time
Disable
** NOTE
The Secondary Weld Method
choices are based on the
selection of the Primary Weld
Method.
These selections are based on
the Primary Weld Method being
Distance.
Weld Power
Disabled
** Secondary
Enable
Weld Power
Weld Distance
Max. Weld Time
Peak Power
See Page 80 for Advanced
Trigger features not shown
here but illustrated in Figure
5-42.
Weld Time
Distance
Energy
** Secondary
Max. Weld Time
Scrub
Position
Time
** NOTE
Weld Time
Weld Distance
Max. Weld Time
Weld Position
Max. Weld Time
Weld Energy
Max. Weld Time
Weld Power
Max. Weld Time
Disabled
Distance
Peak Power
Weld Mode
Start Amplitude
Enable
Scrub Time
Disable
Weld Energy
Weld Power
Process Setup, Continued
Page
147
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Appendix D
Menu Structure Diagrams
Process Setup, Continued from Previous Page
Process Setup
Disabled
Hold Method
Hold Time
Time
Hold Distance
Distance
Until Motion Stops
Enabled
Afterburst
Max. Hold Time
Max. Hold Time
Afterburst Delay Time
Afterburst Duration
Afterburst Amplitude
Disabled
Weld Amplitude
Pressure Profiling
Pressure
Enabled
Pressure 1 - Set Profile
Pressure 2 - Set Profile
Disabled
Downstroke Pressure
Hold Pressure
Upstroke Pressure
Weld Pressure 1
Weld Pressure 2
Free Run Frequency
Scan Stack
Scan Stack
Frequency Tracking
Frequency Lock and Hold
Enable
Disable
Enable
Disable
Wide
Advanced Process Settings
System Frequency Limits
Normal
Narrow
Manual
Ramp Up Time
Ramp Down Time
Restore Advanced Process Defaults
Figure D-1
Page
148
Yes
No
Process Setup Menu Diagram (2 of 2)
Dukane Manual Part No. 403-584-01
Section 12 - Appendices
Appendix D
Menu Structure Diagrams
Main Menu
Process Limits
Downstroke Time
Downstroke Distance
Contact Air Pressure
Method 1 Weld Time
Method 1 Distance
Method 1 Weld Energy
Method 1 Weld Peak Power
Method 1 Weld End Position
Method 2 Weld Time
Suspect Limits
Method 2 Distance
Method 2 Weld Energy
Method 2 Weld Peak Power
Bad Limits
OFF
ON
Low Limits
High Limits
Low Limits
High Limits
OFF
ON
Display Only
Method 2 Weld End Position
Total Weld Time
Show All / Show None
Total Weld Energy
Hold Time
Hold Distance
Total Cycle Time
Total Stroke Distance
Total Weld Distance
Alarm Status
Time
Date
Setup
Figure D-2
NOTE
The list of available process characteristics depends on Security access level
(See Table 5-I.) system configuration,
and on the chosen weld mode:
Single Weld mode, a list of 15 characteristics would be shown;
Dual Weld mode, a list of 23 characteristics appears. (That list includes the
Single Weld 15 characteristics, plus eight
more characteristics shown in shaded
boxes in the diagram to the left.)
Process Limits Menu Diagram
Dukane Manual Part No. 403-584-01
Page
149
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
Appendix D
Menu Structure Diagrams
Main Menu
Utilities/Hardware
Process Utilities
Hardware Setup
Serial Port
Welder Name
Setup Control
Copy Setup
Setup Name
Horn
Output Format
Booster
LF After CR
Erase Setup
Fixture
Part Count Settings
Manual P1
Output Mode
Baud Rate
Manual P2 / Hold
Notes
Serial Limit Indicators
Dynamic Trigger
Language
Down Speed / Flow Control
Base Units
Mechanical Stop
Date Format
HSC Setting
Time
HSC Start Position
Pre-trigger / EOW Flags
Date
Serial Headers
System Status I/O
Auto Start Input
Auto Stop Input Enabled
J3 pin 4
J3 pin 5
Output Duration
Restore System I/O Defaults
Adv Process Settings
Buzzer
Text Keyboard
Test at Power Up
Adv Trigger Settings
Network Settings
Figure D-3
Utilities/Hardware Menu Diagram
Restore Factory Defaults
NOTE
The list of available Process Utilities and
Hardware items depends on Security access level (See Table 5-I.) and on system
configuration.
Page
150
Dukane Manual Part No. 403-584-01
Index
Index
Dukane Manual Part No. 403-584-01
Page
151
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
This page intentionally left blank
Page
152
Dukane Manual Part No. 403-584-01
Index
Index
A
Acoustic Stack 96
Test 96
AC Power Cord 115
AC Power Requirements 133
Advanced Process Settings 59,76
Buzzer 79
Free Run Frequency 76
Frequency Lock/Hold 77
Frequency Tracking 77
Ramp Down Time 78
Ramp Up Time 78
Scan Stack 76
System Frequency Limits 77
Test at Power Up 79
Text Keyboard 79
Advanced Trigger Settings 80
Afterburst 56
Agency Compliance 136
CE Marking 136
FCC 136
IP (International Protection) Rating 136
Alarm Messages 108
Alarm Status 63
Appendices 137
A - List of Figures 139
B - List of Tables 143
C - Sequencing Notes 144
D - Menu Structure Diagrams 147
List of Figures 139
List of Tables 143
Menu Structure Diagrams 147
Sequencing Notes 144
Auto Start Input 74
Auto Stop Input Enabled 74
B
Before Installation 13
Buzzer 79
C
Chassis Grounding Stud 17
Connect AC Power 33
Connecting Cables 29
Recheck Connections 33
Connector
Descriptions 26
iQ Generator Connectors 26
Connector Descriptions 26
Control Panel 37
Navigation Keys 39
Overview 37
Screen Basics 41
Interpreting Onscreen Arrows 41
Making Selections 41
Setup Identification 42
Virtual Keyboard 42
System Operating Mode Keys 38
System Power Output Level 40
Current Setup 83
Cycling the System 98
D
Digi-Trac 95
Drawings and Tables 3
Dukane 95
Address 125
Contacting 123
Contacts 125
Digi-Trac 95,?96
E-mail 125
Fax 125
Intelligent Assembly Solutions
Phone 125
Website 125
125
E
Electrical Safety 9
100/120 Volt Systems 9
Domestic Power Grounding 9
International Power Grounding 9
E-mail 125
End of Cycle 74
End of Weld 74
F
FCC 136
Free Run Frequency 76
Frequency Lock/Hold 77
Frequency Tracking 77
G
General User Information 3
Drawings and Tables 3
Notes, Cautions and Warnings 3
Continued
Dukane Manual Part No. 403-584-01
Page
153
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
G
Continued
Read This Manual First 3
Generator Features 4
AC Power Inrush 4
CE Certification 4
Digital Control 4
Digi-Trac Tuning 4
Flow Through Cooling Tunnel 4
High Line Voltage Power Supply 4
Interface 4
ISO 9001 Certification 4
Linear Ramp Up/Down 4
Line Voltage Regulation 4
Load Regulation 4
Multiple Electronic Overload 4
Process Limits 4
Process Parameters 4
Pulse Width Modulation 4
Rear Panel Expansion 4
Rear Panel Expansion Slot 4
RS-232 Serial Configuration Port 4
TUV Certification 4
Wide Line Voltage Operation 4
Generator Outline Drawings 129
Graph 84
H
Hardware Setup 72
Advanced Process Settings 76
Advanced Trigger Settings 80
Baud Rate 73
LF after CR 72
Network Settings 81
Restore Factory Defaults 81
Serial Headers 73
Serial Limit Indicators 73
Serial Port 72
System Status I/O 74
Health and Safety 5
Electrical Safety 8
Domestic Power Grounding 9
International Power Grounding 9
General Considerations 7
How to Lift Safely 10
Plastics Health Notice 8
Recommendations 7
Help 86
How to Lift Safely 10
Page
154
I
IEC AC Power Inlet Connector 17
Initiate Mode 50
Installation 11
Before Installation 13
When to Use Lockout /
Tagout Device 13
Cable Connections 29
Configurations 30
Pneumatic Press/Thruster 31
Connect AC Power 33
Connecting Cables 29
Connector Descriptions 26
Networking 33
Power Cords 28
Rear Panel 16
AC Power Inlet Panel 17
Chassis Grounding Stud 17
IEC AC Power Inlet Connector 17
Power Switch/Circuit Breaker 17
System I/O Panel 17
System Inputs Connector 17
Rear Panel Layout Overview 16
AC Power Inlet Panel 17
System I/O Panel 17
Recheck Connections 33
RFI Grounding 25
Three Configurations 30
Unpacking 15
Placement 15
Unpacking and Placement 15
When to Use Lockout /
Tagout Devices 13
Interpreting the Model Number 135
IP (International Protection) Rating 136
K
Keyboard
Virtual 42
L
Latch on Bad Part 50
Layout - High Power iQ Generator 130
Layout - High Profile iQ Generator 131
Layout - Low Profile iQ Generator 129
Lifting the Equipment 10
List of Figures 139
List of Tables 143
Lockout /Tagout Devices 13
Dukane Manual Part No. 403-584-01
Index
M
Maintenance 113,?115
AC Power Cord 115
Air Ventilation Slots 115
Chassis 115
Cleaning 115
Cover 115
Front and Rear Panels 115
I/O Connector 115
Menu Structure Diagrams 147
N
Networking 33
Network Settings 81
Notes, Cautions and Warnings 3
O
Operate Screen 82
Part Number History 82
Operation 45
Current Setup 83
Generator Start-up Sequence 45
Graph 84
Hardware Setup 72
Help 86
Overview 45
Process Limits 60
Process Setup 50
Advanced Process Settings 59
Afterburst 56
Control Parameters - Single and Dual Pressure Welding 54
Hold Method 55
Initiate Mode 50
Pressure 57
Trigger Type 51
Weld Mode 53
Process Setup Menu Diagram 48
Process Utilities 67
Real Time Data 83
Security 87
Start-up 45
Stopping the Weld Cycle 46
Using the Menus 47
Options 117
Data Transfer 120
Power Inlet Options 119
Press Interface Board 122
P4 - Dual Pressure Only 122
P5 - Dual Pressure with Distance 122
Dukane Manual Part No. 403-584-01
P6 - EPR/Load Cell with Distance 122
Press Interface Module 122
Output Duration 75
P
Plastics Health Notice 8
Power Cords 28
Power Switch/Circuit Breaker 17
Press System Overview 4
Key Generator Features 4
Pressure 57
Downstroke Pressure 57
Hold Pressure 57
Pressure Profiling 58
Upstroke Pressure 57
Weld Pressure 1 57
Weld Pressure 2 57
Process Characteristics 62
Contact Air Pressure 62
Downstroke Distance 62
Downstroke Time 62
Hold Distance 63
Hold Time 63
Method 1 Distance 62
Method 1 Position 62
Method 1 Weld Energy 62
Method 1 Weld Peak Power 62
Method 1 Weld Time 62
Method 2 Distance 62,?63
Method 2 Weld Energy 63
Method 2 Weld Peak Powe 63
Method 2 Weld Time 62
Total Cycle Time 63
Total Stroke Distance 63
Total Weld Distance 63
Total Weld Energy 63
Total Weld Tim 63
Weld Distance 62
Process Limits 60
Alarm Status 63
Bad Limits 64
Date 63
Display Only 64
No Display 64
Part Cycle Data 65
Process Characteristics Defined 62
Process Limits List 83
Setup 63
Show All 65
Show None 65
Suspect Limits 65
Time 63
Continued
Page
155
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
P
Continued
Process Limits Menu Diagram 61
Process Setup 50
Advanced Process Settings 59
Initiate Mode 50
Process Utilities 67
Base Units 70
Choose a Setup 68
Copy Setup 69
Date 70
Date Format 70
Erase Setup 70
Language 70
Notes 71
Part Count Settings 70
Setup Control 67
Time 70
Welder Name 67
Programmable Status Output 1 74
Programmable Status Output 2 (J3 pin 5) 75
Q
Quick Start - Pneumatic Welder
Process Settings
Initial Weld Time 103
Pressure
Initial Weld Force 104
Trigger
Initial Trigger Force 102
R
Ramp Down Time 78
Ramp Up Time 78
Real Time Data 83
Regulatory Agency Compliance 136
CE Marking 136
FCC 136
IP Rating 136
UL 136
Restore Factory Defaults 81
Restore System I/O Defaults 75
RFI Grounding 25
S
Scan Stack 76
Screen Basics 41
Scrub 54
Security 87
Page
156
After Passwords are Enabled 90
Enabling Passwords for the First Time 88
Forgotten Password? 91
Other Security Prompts 91
Remote User Timeout 87
Sequencing Notes 144
Set-up Guidelines 101
Air Cylinder Size and Force 105
Changing Default Settings 101
Initial Trigger Force 102
Initial Weld Force 104
Initial Weld Time 103
Setup Identification 42
Specifications 127
AC Power Requirements 133
Dimensions 132
Interpreting the Model Number 135
Layout Drawings 129
Layout - High Power iQ Generator 130
Layout - High Profile iQ Generator 131
Layout - Low Profile iQ Generator 129
Operating Environment 132
Ultrasonic Pressure 134
Weights 132
Stopping the Weld Cycle 46
System 98
Cycling 98
System Frequency Limits 77
System Inputs Connector 17
System Inputs Connector Pinout 18
System Inputs Signal Descriptions 19
System I/O Panel 17
System Inputs Connector 17
System Inputs Connector Pinout 18
System Inputs Signal Descriptions 19
System Outputs Connector 21
System Outputs Connector Pinout 22
System Outputs Signal Descriptions 22
System Operational Testing 93
Cycling the System 98
Test of the Acoustic Stack 96
System Outputs Connector 21
System Outputs Connector Pinout 22
System Outputs Signal Descriptions 22
System Power Output 96
System Status I/O 74
Auto Start Input 74
Auto Stop Input Enabled 74
Output Duration 75
Programmable Status Output 1 (J3 pin 4) 74
Programmable Status Output 2 (J3 pin 5) 75
Restore System I/O Defaults 75
Dukane Manual Part No. 403-584-01
Index
T
Test at Power Up 79
Testing
Acoustic Stack 96
System Power Output 96
TEST Key 96
Text Keyboard 79
Troubleshooting 99,?106
Alarm Messages 108
iQ Generator Won’t Cycle 106,?107
No Ultrasound 106
The iQ Generator Won’t Cycle 106
The Power-up Sequence Stops 107
U
User Information 3
Drawings and Tables 3
Notes, Cautions and Warnings 3
Read this Manual First 3
Using the Menus 47
Utilities/Hardware Menu Diagram 66
W
Weld
Amplitude 56
Distance 54,?62
Energy 62
Initial Weld Force 104
Initial Weld Time 103
Max Weld Time 54
Method 53
Dual 53
Single 53
Mode 53
Peak Power 62
Pressure 57
Time 62
Total Cycle Time 63
Total Weld Distance 63
Total Weld Time 63
Trigger Force 102
Welder Name 67
Dukane Manual Part No. 403-584-01
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157
iQ Series Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual
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Page
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Dukane Manual Part No. 403-584-01
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
Please refer to our website at:
www.dukane.com/contact-us/
to locate your local representative.
Series Ultrasonic Generator/Power Supply, Pneumatic Systems,
ES User's Manual
Part No. 403 - 584 - 01
www.dukane.com
Printed in the United States of America
Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900