Dukane iQ Series Ultrasonic Press System LE User's Manual

iQ Series
ULTRASONIC PRESS SYSTEM
LE
AUTOMATED
HAND PROBE
PRESS
User's Manual
Dukane Part No. 403–586-03
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 Press System LE 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: 403-586-03
Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents:
3,780,926 3,825,481 4,131,505 4,277,710 5,798,599 5,880,580 6,984,921, 7,225,965,
7,475,801, and 8,052,816
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Dukane Manual Part No. 403-586-03
Revision History
Revision
Number
Revision
Summary
Date
- 00Original release. August 1, 2012
- 01
Pages Affected: November 19, 2012
• Page 91 - Figure 6-3 corrected (Stroke flag position).
• Page 154 - Regulatory Agency Compliance Updated.
-02
Pages Affected:
• Page 20 - Table 3-II - Pin 6 and Pin 7, Not Used.
• Page 21 - Remove descriptions for Pin 6 and Pin 7.
• Page 33 - Replace J7 with J6 in all cases.
• Page 69 - Added, A total of eight (8) setups are available.
May 21, 2018
• Page 75 - Figure 5-54 - X's represent version numbers.
• Page 76 - 78 - Revise text and figures re: Most current version of the Advanced Process Control Menu
-03
Pages Affected:
June 24, 2019
• Page 69 - Changed in Note, A total of eight (8) setups can be made.
Dukane Manual Part No. 403-586-03
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Dukane Manual Part No. 403-586-03
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rear Panel Layout Overview . . . . . . . . . . . . . . . . . . . . . . . . . 17
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Connecting Generator Cables . . . . . . . . . . . . . . . . . . . . . . . . 28
Installing the Press System . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Installing the Thruster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Connecting Press Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Flange Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Section 4 - Controls . . . . . . . . . . . . . . . . . . . . . . . . . 37
Generator Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . .
Screen Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Press Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Press Ergonomic Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
44
46
50
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using the Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
55
56
57
83
Section 5 - Operation . . . . . . . . . . . . . . . . . . . . . . . . 53
Continued
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Contents Continued
Section 6 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Inlet Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Press Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Speed Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Distance Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87
88
90
91
93
Section 7 - Acoustic Stack/Fixture Setup . . . . . . . . 97
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Stack Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Changing Stack Components . . . . . . . . . . . . . . . . . . . . . . . . 101
Stack Assembly and Torque Values . . . . . . . . . . . . . . . . . . . 103
Fixture Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Section 8 - Stack Maintenance . . . . . . . . . . . . . . . . 109
Inspection of the Acoustic Stack Components . . . . . . . . . . . 111
Reconditioning Stack Components . . . . . . . . . . . . . . . . . . . . 112
Section 9 - Troubleshooting . . . . . . . . . . . . . . . . . . 115
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Continuous Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
117
118
125
128
131
Section 10 - System Maintenance . . . . . . . . . . . . 133
Press/Thruster Six-Month Periodic Maintenance . . . . . . . . . 135
Section 11 - Contacting Dukane . . . . . . . . . . . . . . . 137
Continued
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Dukane Manual Part No. 403-586-03
Contents Continued
Section 12 - Specifications . . . . . . . . . . . . . . . . . . . 141
Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143-148
Weights, Dimensions, Operating Environment . . . . . . . . . . 149
Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . 150
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Interpreting the Model Number Codes . . . . . . . . . . . . . . . . . 151
Replacement Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . 154
Section 13 - Appendices . . . . . . . . . . . . . . . . . . . . . 155
Appendix A - List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Appendix B - List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Section 14 - Index . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Dukane Manual Part No. 403-586-03
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Dukane Manual Part No. 403-586-03
Section 1 - Introduction
SECTION 1
Introduction
General User Information . . . . . . . . . . . . . . . 3
Read the Manual First. . . . . . . . . . . . . . . . . . 3
Notes, Cautions, Warnings . . . . . . . . . . . . . . . 3
Drawings and Tables . . . . . . . . . . . . . . . . . . . 3
Press System Overview. . . . . . . . . . . . . . . . 4
Key Generator Features. . . . . . . . . . . . . . . . 4
Dukane Manual Part No. 403-586-03
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Dukane Manual Part No. 403-586-03
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 LE press system.
Particular models are listed in Section 12 - 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 an operator protection issue.
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. 403-586-03
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.
Condition
or Practice
Electrical
Safety Issue
Operator
Protection
(hearing)
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iQ Series Ultrasonic Press System LE User’s Manual
Press System Overview
An iQ Series Ultrasonic Press System LE consists of these
components: the iQ generator, and press (with thruster,
switches, controls, and cables). Typically, transducer, booster, horn, and fixture are included as well.
The iQ Series LE 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.
It also includes an RFI line filter that passes FCC and strict
CE test specifications for global applications.
Key Generator Features
•
The Generator Interface has a 5.2" LCD display and
soft keys that enhance 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. 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 the output amplitude. This makes it
possible to start large horns with reduced power. It also
provides more power-efficient switch-mode generator
operation and increased reliability.
Linear Ramp Soft-Start circuitry allows the acoustic
stack to be brought to operating amplitude smoothly,
minimizing start-up surges and abnormal stress to the
stack and generator.
Digi-Trac Tuning tracks the resonant frequency of the
acoustic stack (horn, booster, 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.
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.
Page
4
•
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.
•
High Line Voltage Power Supply means that
standard systems will operate worldwide at the local high line voltage level, whether it is 200VAC
@60Hz in Japan, 240VAC @50Hz in Europe or
208VAC @60Hz in the United States. There are no
internal transformer taps to change for worldwide
operation.
•
Low Line Voltage Power Supply - This optional
120V power supply is designed for North American
applications.
•
Flow Through Cooling Tunnel with a matched
high–performance heatsink and thermostatically
controlled fan reduces thermal gradients and increases component life.
•
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: time, energy and distance if
supported. 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.
•
RS232 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.
Dukane Manual Part No. 403-586-03
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. 403-586-03
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Dukane Manual Part No. 403-586-03
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 8.
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 Abort Switch - Install a system abort switch at
each operator station when ultrasonic plastic assembly
equipment is used with automatic material handling equipment in an automated system.
Foot Switch - Using a foot switch in place of the optical
touch finger switches (activation 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, and fixture.
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. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
General Considerations
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.
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.
WARNING
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.
Page
8
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
Dukane Manual Part No. 403-586-03
Section 2 - Health and Safety
Continued from Previous Page
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.
Grounding Contacts
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.
100/120 Volt Systems (North America or
Japan)
Typical Outlet
Provided Cable
Figure 2–2
International 220/240V Grounding
Dukane Manual Part No. 403-586-03
The power cord (including strain relief) supplied
with the 100/120 AC systems is permanently
attached to the rear of the generator. Units with this
power cord are for use in North America or Japan.
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iQ Series Ultrasonic Press System LE 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:
CAUTION
Use a mechanical lift device to
assist in safely lifting system
components.
NOTE
Equipment weights are shown in
Section 12 - Specifications, Table 12-I.
Step 1. Stand close to the load with your feet
spread apart about shoulder width, with
one foot slightly in front of the other for
balance.
Step 2. Squat down bending at the knees (not your
waist). Tuck your chin while keeping your
back as vertical as possible.
Step 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.
Step 4. Once the lift is complete, keep the object
as close to the body as possible. As the
load’s center of gravity moves away from
the body, there is a dramatic increase in
stress to the lumbar region of the back.
Step 5. 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.
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Dukane Manual Part No. 403-586-03
Section 3 - Installation
SECTION 3
Installation
Before Installation. . . . . . . . . . . . . . . . . . 13
Lockout/Tagout Devices . . . . . . . . . . . . . . . . 13
Utilities. . . . . . . . . . . . . . . . . . . . . . 14
Placement . . . . . . . . . . . . . . . . . . . . . . . 14
Rear Panel Layout Overview . . . . . . . . . . . 17
RFI Grounding. . . . . . . . . . . . . . . . . . . . 27
Connecting Generator Cables. . . . . . . . . . . . 28
Installing the Press System . . . . . . . . . . . . 29
Installing the Press without Machine Base . . . . . . 30
Press Height Adjustment. . . . . . . . . . . . . . . . 30
Installing the Thruster . . . . . . . . . . . . . . . . 31
Connecting Press Cables . . . . . . . . . . . . . . 32
Flange Template. . . . . . . . . . . . . . . . . . . 35
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Dukane Manual Part No. 403-586-03
Section 3 - Installation
Before Installation
As you plan for the installation of your system, including generator and press, please consider these
important subjects as listed below:
• When to use lockout / tagout devices
• Lifting the equipment safely - See Section 2 Health and Safety, Page 10.
• Utilities
• Placement
When to Use Lockout /
Tagout Devices
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.
Figure 3-1 Lockout Device In Open Position, Unlocked
The typical kind of LOTO device for a 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
Continued
Dukane Manual Part No. 403-586-03
Page
13
iQ Series Ultrasonic Press System LE User’s Manual
Lockout/Tagout Continued from Previous Page
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
Utilities
Provide for electricity to meet the equipment
specifications as shown in Section 12, Specifications.
CAUTION
If transducer cooling air
is used, this compressed
air must be clean, dry and
oil free. Any particulate, oil
contamination or moisture can coat or
clog the transducer. This can result in
premature failure of the transducer.
Air pressure is determined by the
application, transducer power draw
and ambient air temperature.
Placement
Check that enough space has been set aside for the
installation. Equipment dimensions are shown in Section
12, Specifications.
In addition, take extra precautions when the
installation is made in an active seismic region. See
the recommendations for generator installation on the
following two pages.
Dukane Manual Part No. 403-586-03
Section 3 - Installation
Placing the Generator when Used in
an Active Seismic Region
If the iQ generator is to be used in an active seismic region,
secure the unit by rack-mounting it or by securing the unit
to a benchtop.
Rack- Mounting
Install the four brackets from Dukane's rack-mount kit to
the generator. See Table 3-I, and Figure 3-3 (showing a
low profile unit) below.
Mount the generator to a 19-inch equipment rack.
System Type
Dukane Part Number
High Profile
147-4721
Low Profile
147-4720
Table 3- I
Rack Mount Bracket Part Numbers
ALLOW 3" IN BACK FOR CABLES
NOTE
ALLOW 5"
BOTH
SIDES
FOR
COOLING
ALLOW 5"
BOTH
SIDES
FOR
COOLING
The figure shows how a
typical iQ generator is rack
mounted. Your generator’s
appearance may be different
from what is shown here.
0.12
[3.0]
IN
[mm]
0.25 X 0.50 SLOT
(2 PLCS)
OPTIONAL RACK
MOUNT BRACKETS
147-4720
Figure 3-3
Rack Mounting iQ Generator - Representative Low-Profile Model Shown
Continued
Dukane Manual Part No. 403-586-03
Page
15
iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
Benchtop Mounting
If you choose to mount the generator on a benchtop follow these instructions:
1. Install the four (4) optional hold down
brackets. See Figure 3-4 below.
2. Secure one side of each L bracket to the
generator's sheet metal cover.
3. Secure the other side of each L bracket to the
bench itself.
ALLOW 3" IN BACK FOR CABLING.
ALLOW 5" BOTH
SIDES
FOR COOLING.
0.280 HOLE
7.11
ALLOW 5" BOTH
SIDES
FOR COOLING.
NOTE
The figure shows how a representative iQ generator could be
benchtop mounted. Your generator’s appearance may be different
from what is shown here.
OPTIONAL HOLD DOWN BRACKETS
147-1398
IN
[mm]
Figure 3-4
Page
16
OPTIONAL HOLD
DOWN BRACKETS
Securing iQ Generator to Benchtop - Representative High-Profile Model Shown
Dukane Manual Part No. 403-586-03
Section 3 - Installation
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 3-5 illustrates a typical panel layout.
K
B
D
-WARNING-
POWER LINE OUTLET
MUST BE GROUNDED.
DISCONNECT LINE POWER
BEFORE REMOVING COVER.
I
0
SYSTEM INPUTS
LINE VOLTAGE:
200-240 Vac
50/60Hz, 15A
E
J2
J6 BASE/ABORT
J5 THRUSTER
SYSTEM OUTPUTS
J11 ENCODER
J3
A
DUKANE CORP
CONFIGURATION
ST. CHARLES IL 60174
MADE IN U.S.A.
PE
U.S. PATENT 5,880,580
OTHER PATENTS PENDING
ULTRASOUND
J1
J4
F
C
Figure 3-5
G
H
Typical iQ LE Generator Rear Panel Layout
AC Power Inlet Panel
Options Module Panel
A IEC Power Inlet Connector – Attaches to an IEC style
H Expansion Boards
power cord.
B Power Switch – Circuit Breaker – Used to switch sys-
K Press Interface Module (See NOTE below.)
Shown in the example above are these ports:
tem power ON and OFF.
C Chassis Grounding Stud – Chassis connection for a
J5 - Thruster
protective earth ground.
J6 - Base/Abort
J11 - Encoder
The System I/O Panel
D System Input Connector (J2) – Connections for system control input signals.
E System Output Connector (J3) – Connections for system 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.
Dukane Manual Part No. 403-586-03
NOTE
The press interface module is available
in several different configurations.
See Section 6, Options for more
information about the Press Interface
Module.
Page
17
iQ Series Ultrasonic Press System LE User’s Manual
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. 120VAC 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 200V 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 0 symbol. This power switch also
integrates an appropriately sized over-current protection
circuit breaker function in the generator.
If an over-current condition trips the circuit breaker, it will
automatically switch to the OFF position. If the 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 3-6.
Proper system grounding is discussed on Page 9.
I
0
LINE VOLTAGE:
200-240 Vac
50/60Hz, 10A
PE
C
Figure 3-6
IEC AC Power Inlet Connector
System I/O Panel
The standard system I/O panel is described in this section. See Figure 3-7.
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 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. Signals are activated
when the voltage difference between the signal and the
isolated common pin is 24V.
All inputs sink or source 10mA of current from a 24VDC
power supply.
Continued
Page
18
Dukane Manual Part No. 403-586-03
Section 3 - Installation
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 3-8. The male connector on the cable is a mirror
image of the panel-mounted connector and is shown in
Figure 3-9. Table 3-II 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 3-7
System I/O Panel (Standard Panel Shown)
NOTE
Refer to Section 6, Options for information
on optional features.
Continued
Dukane Manual Part No. 403-586-03
Page
19
iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
Pin
Signal Name
Cable Color Code
Signal Option Requirements
1
+22V
BLK
2
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
Not Used
7
Remote Setup Selection Bit 4 Input
WHT/BLK
Not Used
8
Ultrasound Activation/Cycle Start Input
RED/BLK
9
Automation Thruster Control Input
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-II
Generator Input Signals (J2)
System Inputs Signal Descriptions
5
4
3
2
1
Pin 1 (+22V)
This pin can supply +22VDC at up to 250mA to power the
user’s automation controls.
10
Pin 2 (Power Gnd)
Pin 2 is the 22VDC return and is tied to the system chassis
ground.
6
15 14 13 12 11
Figure 3-8
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 3-9
HD-15M, Generator Input Cable
Connector
Continued
Page
20
Dukane Manual Part No. 403-586-03
Section 3 - Installation
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 (Not Used)
Pin 7 (Not Used)
Pin 8 (Ultrasound Activation/ Cycle Start
Input)
Pin 8 is used to activate the generator ultrasound output.
Activation of this control input will switch the ultrasound
output ON, and deactivating this signal will switch ultrasound OFF. This input signal will also function as a cycle
start input, where the ultrasound activation and timing
are completely under the control of the process controller. Depending on the welding process controller setup,
this input signal could be activated momentarily to start
a welding cycle.
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.
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 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 prevents the hand probe activation
switch from unexpectedly starting a welding cycle that
activates a press or thruster to the down position. This
pin must be left open whenever a press control board is
installed. Connecting this pin to chassis ground will inhibit
press operation.
Pin 12 (System Latch Reset Input)
Pin 12 is used to reset the Any Fault or System Overload
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.
Dukane Manual Part No. 403-586-03
Page
21
iQ Series Ultrasonic Press System LE User’s Manual
Pin
Signal Name
Cable Color Code
1
+22V
BLK
2
Spare Output
WHT
3
+22V Power Ground
RED
4
Programmable Status Output 1
GRN
5
Programmable Status Output 2
ORN
6
Ultrasound Active Status Output
BLU
7
Any Fault Status Output
WHT/BLK
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
Amplitude/Power Regulation Status Output
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
ORN/GRN
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-III
Signal Option Requirements
Not Used
Not Used
System Output Connector Signals (J3)
System Outputs Connector
13
11
9
7
5
3
1
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.
Figure 3–10 DB-25F, Generator Output Connector (J3)
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).
This is at system chassis ground potential (non-isolated).
Figure 3–11
Page
22
25
23
21
19
17
15
DB-25M, Generator Output Cable
Connector
Continued
Dukane Manual Part No. 403-586-03
Section 3 - Installation
Continued from Previous Page
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.
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 3-10.
The male connector on the cable is a mirror image of the
panel mounted connector and is shown in Figure 3-11.
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 (+22V Power Supply)
This pin can supply +22VDC at up to 250mA to power
the user’s automation controls.
Pin 2 (Not Used)
Pin 2 is an open connection.
Pin 3 (+22V Power Ground)
Pin 3 is the 22VDC return and is tied to the system chassis ground.
Pin 4 (Programmable Status Output 1)
Pin 4 is a digital status output that can be reprogrammed
and assigned to other system status signals (from the
available selections) from the front panel Advanced
Settings menu.
Pin 5 (Programmable Status Output 2)
Pin 5 is a digital status output that can be
reprogrammed and assigned to another system status
signal (from the available selections) from the front
panel Advanced Settings menu.
Pin 6 (Ultrasound Active Status Output)
Pin 6 is a digital 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 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. In the case of an overload, this output stays
active until the start of the next cycle or until cleared
using the front panel keypad or system input Pin 12
(System Latch Reset input).
Generator faults that will activate the Any Fault output:
• Overload (Average, Peak, or Frequency)
• Overtemperature Fault
• System Power Fault
Pin 8 (Press Trigger Status Output)
Pin 8 is a digital status output that activates when the
specified trigger type has occurred. It will remain active until the end of cycle. This output will be an open
circuit when a trigger condition hasn’t been detected.
Continued
Dukane Manual Part No. 403-586-03
Page
23
iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
Pin 9 (System Overload Status Output)
Pin 15 (Power Signal Monitor Output)
Pin 9 is a digital 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 or until cleared via the front panel keypad
or system input Pin 12 (System Latch Reset Input). This
output will be an open circuit when no overload conditions
have been detected.
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 10 (System On-Line Status Output)
Pin 10 is a digital 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 11 (Press Top of Stroke Status Output)
Pin 11 is a digital 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 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 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.
Pin 14 (Not Used)
Pin 14 is connected to the system chassis ground.
Continued
Page
24
Dukane Manual Part No. 403-586-03
Section 3 - Installation
Continued from Previous Page
Pin 17 (Amplitude/Power Regulation Status
Output) (Contact your sales representative about
Power Regulation availability.)
This status signal is most useful when the power regulation mode is selected. This Out of Regulation status signal
would indicate that due to inadequate pressure against the
ultrasonic horn, the power regulation level setting can
not be achieved when the amplitude level is set to the
maximum level of 100%.
In the amplitude regulation mode, this signal will be
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.
Pin 17 is a digital status output that activates when the system is regulating the amplitude or power level correctly.
This output becomes an open circuit when the system falls
out of regulation. When that happens, it cannot adjust the
system output to the output level that was programmed as
the regulation set point.
Pin 18 (Not Used)
Pin 19 (System Power OK Status Output)
Pin 19 is a digital 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 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.
Dukane Manual Part No. 403-586-03
Pin 21 (Good Part Status Output)
Pin 21 is a digital status output that activates, either momentarily or until the start of the next welding cycle, when the
welding parameters recorded during the previous welding
cycle do not exceed the programmed suspect or bad part
limits. This output will be an open circuit after a welding
cycle when either a suspect or bad part has been detected.
Pin 22 (System Ready Status Output)
This status output signal will activate only when the system is ready to activate ultrasound or begin a weld cycle.
Pin 22 is a digital 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 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.
Page
25
iQ Series Ultrasonic Press System LE User’s Manual
Ultrasound Output Connector
The ultrasound output connector used with all standard
generators is a high voltage (5000V) coaxial style SHVBNC 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.
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 Ultrasound Output Connector
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.
Figure 3-13
Page
26
Configuration Port Connector
Dukane Manual Part No. 403-586-03
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. 403-586-03
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
27
iQ Series Ultrasonic Press System LE User’s Manual
Connecting Generator Cables
Step 1. Ground the generator chassis with the
supplied 14-Gauge wire, and attach it to the
grounding stud. See Figure 3-6.
Step 2. Ultrasound (J1) - 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.
Step 3. Operational Control (J201) - 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.
Step 4. Base/Abort Cable (J6) - Connects to the press
base plate connector (J35) or an automation PLC.
Step 5. Connect the AC power cord to the IEC power
inlet connector on the ultrasonic generator, and
plug the other end into an approved AC outlet.
CAUTION
The power cord is equipped
with a three-prong, grounded-type plug for your
safety. Whenever a twoslot 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.
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-IV.
Continent of Use
North America
Continental Europe
Table 3-IV
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. 403-586-03
Section 3 - Installation
Installing the Press System
The press system consists of a thruster, ergonomic base and
support package. It is assembled at the factory for shipment.
Unpacking
The system has been assembled and packaged at the factory for shipment. Depending on the system, there may be
multiple crates or boxes to deal with.
Press
The press is secured to a wooden pallet and covered with
a wooden crate. Components inside the crate are secured
with metal bands, and with additional packing materials to
give reinforcement when needed.
Before unpacking the press, take care and use mechanical
assistance to move it close to the location where it will be
installed.
1.
Carefully remove the wooden crate from the base to
expose the contents.
2.
Remove the packing material, and temporarily set
aside any other system components, leaving the press
on the shipping base.
3.
Inspect the assembly for any damage before placing
it in position.
Placement
Do not lift the press by hand. Use mechanical means to put
the press into place.
CAUTION
CAUTION
DO NOT
LIFT the
p r e s s
manually.
Lifting and/or moving
the press manually
could result in perManuallymeans
lifting the
sonal injury. Use mechanical
press system could
to move and place theresult
press.
in injury
See Section 2, Health and Safety,
Page 10 on safe lifting practices.
To place the press on the work area, use a pallet lift platform
or equivalent. Raise the assembly until the bottom edge of
the base is even with the top of the work area as shown in
Figure 3-14. Then, carefully slide the press system on to
the work area.
Dukane Manual Part No. 403-586-03
Page
29
iQ Series Ultrasonic Press System LE User’s Manual
Installing the Press System
Without Machine Base
In this configuration, secure the flange to a rigid, level stationary structure. We recommend socket-head cap screws
M12 -1.75 with a minimum length of 40 mm for securing
the flange to the supporting structure. We recommend a
minimum of 1 inch (25.4 mm) full thread engagement of
the cap screws into the supporting structure. Depending
upon the thickness and material of the supporting structure,
longer screws and/or additional hardware may be required.
A full scale template is provided for locating and drilling
holes in the supporting structure. The template is Figure
3-20 on Page 35.
Press Height Adjustment
The height of the thruster on the column is adjustable. Adjustment is made by first turning the two handles located
on the left rear side of the press.
•
To loosen the grip on the column, turn the handles
counterclockwise, as shown in Figure 3-15a. The
counterbalance spring on the column supports the
weight of the thruster while the handles are loose. If
a thruster is not installed, the unloaded column may
rise up unexpectedly, so be careful to avoid injury.
•
Adjust the column to the desired height.
•
Turn the handles clockwise, as shown in Figure 3-15b,
until tight.
•
To rotate the handles out of the way without loosening or tightening, pull the handles outward, rotate and
release, as shown in Figure 3-16.
Counterbalance
Spring
Support
Housing
Thruster
Height
Adjustment
Handles
Figure 3-14
Example of Press Placement
CAUTION
Exercise caution if a
thruster is not installed on
the support housing. The
counterbalance spring on
the unloaded housing may cause
the assembly to rise up unexpectedly when the height adjustment
handles are loosened.
(a)
– Loosen
(b)
– Tighten
Figure 3-15 Using Handles to Make Adjustments
Figure 3-16 To Relocate Handles
Page
30
Dukane Manual Part No. 403-586-03
Section 3 - Installation
Installing the Thruster
Secure the thruster to a rigid stationary structure by
placing the back of the thruster onto the support frame.
Align the bolt holes in the thruster with the bolt slots in
the support frame. Insert the two (hex head) mounting
bolts (M10-1.5 x 40mm), with flat washers, as shown in
Figure 3-17. Align the thruster with the work surface in
both the horizontal and vertical planes to assure parallelism. Tighten the bolts.
Mounting
Holes
Washers
Mounting Bolts *
When mounted to a Dukane column as in the press
configuration, the height of the thruster is adjustable on
the column. If the height of the thruster is not adjustable in your mounting arrangement, you must consider
the distance from the horn tip to the work surface when
determining the position of the thruster.
The distance between the tip of the retracted horn and
the parts in the fixture must be less than the maximum
travelling distance (stroke) of the thruster slide assembly.
If greater, the horn will be unable to contact the parts
during operation.
A shorter distance between the retracted horn tip and the
parts in the fixture means a shorter travelling distance
(stroke) during operation which results in two advantages:
•
A more stable thruster when applying pressure
to the parts
•
A shorter duty cycle for a faster production rate
However, make certain, that there is sufficient room for
the placement and removal of parts.
Dukane Manual Part No. 403-586-03
Rigid
Mounting
* (2) Hex head Mounting Bolts
Distance from horn
to work surface
should be less
than 7 inches.
M10-1.5 x 40mm
Figure 3-17 Example of Mounting the Thruster
to a Rigid Structure
NOTE
Total Stroke = 7 inches (177.8mm)
This is the thruster's maximum available
distance of travel.
Page
31
iQ Series Ultrasonic Press System LE User’s Manual
Connecting Press Cables
The press is not equipped with its own source of compressed air, electrical power, or electrical control and
monitoring. These functions are provided through the
connectors located on the rear of the thruster.
(Refer to Figure 3-18):
•
Top of Stroke (J207) - This receptacle is factory wired
to a switch in the press/thruster that opens when the
press/thruster slide assembly begins extending and
closes when the slide assembly returns to the fully
retracted (i.e. top-of-stroke) position. This contact
closure is typically used in automated systems to indicate to the controlling mechanism (supplied by the
end user) when the slide assembly is fully retracted.
A Dukane cable (Part Number 438-528) mates with
this receptacle to allow access to the switch contacts.
Top of Stroke Cable
(optional)
Ultrasound
Cable
J207
1/4 NPT
Threaded Air
Connector
J1
Filtered Air
to Thruster
Grounding Stud
J201
Operation
Control
Cable
Air Filter
NOTE
Under normal usage, do not
apply more than 24VDC @ 2
Amps to the switch contacts
at J207.
•
•
•
Ultrasound (J1) - This input connects the transducer
to the Ultrasound Output (J1) of the iQ Series generator, through a coaxial cable. The electrical welding
signal is transmitted through this cable.
Air Filter In
Air
Supply
to Filter
Air Supply
Source
Air Shut
Off Valve
Operational Control (J201) - This cable runs from
J201 on the thruster to the generator's Press Port
(J5). The generator provides controls for triggering
the weld, operating the thruster’s pneumatic system,
and providing 24VDC operating voltage through
this cable. The press driver card in the generator also
provides monitoring for these functions.
Air In - This is a 1/4 NPT threaded receptacle for a
compressed air supply that provides the thruster with
the required pressure of 80-110 psi (5.4 - 7.5 atmospheres) to operate the pneumatic system.
This connector is attached to an air filter on the press.
The input to the filter comes from the air shut-off
valve, located on the back, near the bottom of the
press.
Page
32
Encoder
Cable
Base Control
Cable
J35
Figure 3-18 Press Connector Locations
Grounding Stud
Dukane Manual Part No. 403-586-03
Section 3 - Installation
•
•
Encoder (Optional) - The purpose of the encoder
cable is to connect the distance encoder option to
the generator's Encoder Port (J11). For details on the
Encoder, see Section 6: Options.
Ergonomic Base (J35) - Connects the base controls
and display to the Base/Abort Port (J6) on the generator.
The press system requires three cables for proper operation. These cables are part of the cable package that is
shipped with the press. A customer-provided air hose
(5/16 inch dia.) is also required.
Connect the following lines and cables to the press
system:
•
Connect the ultrasound coaxial cable from J1 on the
generator to J1 on the thruster.
CAUTION
The compressed air for
the thruster must be
clean, dry and oil free.
Any particulate, oil contamination or moisture
can coat or clog the valves, sensors
and cylinder walls. This can result
in premature failure of the regulator,
pressure transducer, air cylinder or
other components of the pneumatic
system.
Top of Stroke
Cable (Optional)
DO NOT operate the generator unless this cable
is connected and the transducer is installed in the
thruster — Otherwise, an overload condition could
occur, with possible damage to the generator.
•
Connect the operational control cable from J5 on the
generator to J201 on the thruster.
•
Connect clean, dry air from an air source to the fitting
located at the lower portion of the support package.
Ultrasound
Cable
J1
J207
Filtered Air
to Thruster
Grounding Stud
J201
Figure 3-20 shows the locations of the connections.
•
Encoder cable (optional) - If the press is equipped
with an encoder, the cable will already be wired in.
•
Connect the nine-pin ergonomic base cable from J6
on the generator to J35 on the back of the base.
Thruster Only
For thrusters, the only required connections are the air
line, ultrasound cable, and the operational control cable.
Figure 3-19 shows the location of the thruster connections.
Because the thruster does not use a support package, the
air source is connected directly to the “Air In” fitting.
Thruster systems require that Dukane's cable (Part
Number 200-1546-03) is installed in the iQ generator's
J6 receptacle.
See Table 3-V.
Dukane Manual Part No. 403-586-03
1/4 NPT Threaded
Air Connector
Operation Control
Cable
Figure 3-19 Thruster Connector Locations
Cable/Signal
Generator
Press
Thruster
Ultrasound
J1
J1
J1
Operational Control
J5
J201
J201
Press Base
J6
J35
Distance Encoder
J11
Built-in
Built-in
Customer
supplied
control
J207
J207
Top of Stroke
***
***Dukane's cable (Part Number 200-1546-03) is
installed in the iQ generator's J6 receptacle.
Table 3-V
Generator to Press/Thruster Cables
Page
33
iQ Series Ultrasonic Press System LE User’s Manual
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Page
34
Dukane Manual Part No. 403-586-03
Section 3 - Installation
FRONT
7.75 inches
(196.85 mm)
3.023 inches
(76.783 mm)
3.875 inches
(98.425 mm)
2.625 inches
(66.675 mm)
2.00 inches
(50.80 mm)
1.50 inches
(38.10 mm)
2.625 inches
(66.675 mm)
2.25 inches
(57.15 mm)
2.25 inches
(57.15 mm)
Figure 3-20 Flange Template
REAR
No Scaling - Actual Size
Flange Template
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
This page intentionally left blank
Page
36
Dukane Manual Part No. 403-586-03
Section 4 - Controls
SECTION 4
Controls
Generator Front Panel Controls. . . . . . . . . . . 39
System Operating Mode Keys. . . . . . . . . . . . 40
Navigation Keys. . . . . . . . . . . . . . . . . . . . 41
Soft Keys Bordering the Display . . . . . . . . . . . 41
Hot Keys. . . . . . . . . . . . . . . . . . . . . . . . 42
System Power Output Level. . . . . . . . . . . . . . 43
Screen Basics. . . . . . . . . . . . . . . . . . . . 44
Press Controls. . . . . . . . . . . . . . . . . . . . 46
Manual Thruster Controls . . . . . . . . . . . . . . . 46
Thruster Indicators. . . . . . . . . . . . . . . . . . . 50
Press Ergonomic Base . . . . . . . . . . . . . . . 50
Dukane Manual Part No. 403-586-03
Page
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iQ Series Ultrasonic Press System LE User’s Manual
This page intentionally left blank
Page
38
Dukane Manual Part No. 403-586-03
Section 4 - Controls
Generator Front Panel Controls
This section introduces the iQ Series ultrasonic generator
LE control panel and LCD display with this information:
• Functions of the panel components shown in Figure
NOTE
4-1 below are discussed.
Do not touch the display.
Touch only the keys that are on the
front panel.
• These screen basics are introduced:
— Making selections,
— Interpreting on-screen arrows,
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.
— Taking a look at setup identification.
System Power Output Level
Online/Offline/E-Stop Status
INFO Key
Active Hot Key Indicator
Navigation Keys (4)
Power On Light
Soft Keys (3)
System
Operating
Mode
Keys (3)
AUTO 01
Process
PROCESS
STATISTICS
Statistics
SETUP Setup
#01 #01
Part Count:
PART COUNT:
WELD TIME
: Time:
Weld
ENERGY: Peak Power:
PEAK POWER :
DISTANCE Energy:
ABS Dist:
COL Dist:
Online
ONLINE
0
0
0.000s
0.000s
0W 0J
0W
0J 0in
0.000in
0.000in
Hot Keys (8)
Figure 4-1
ENTER Key
CANCEL Key
iQ Generator Display and Control Keys
Dukane Manual Part No. 403-586-03
Page
39
iQ Series Ultrasonic Press System LE 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 word, Online appears in a white outlined box in the
upper right of the display.
TEST - After AC power has been activated and the genera-
Operating Mode Indicator
Online condition shown
AUTO 01
PROCESS
STATISTICS
SETUP #01
PART COUNT:
WELD TIME :
ENERGY:
PEAK POWER :
DISTANCE
ONLINE
0
0.000s
0J
0W
0in
tor 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, Operating Frequency, and Distance (does not appear if distance is not
supported). This information is useful in troubleshooting.
While pushing the TEST key, look at the System Power
Output Level bar graph (See Figure 4-3.) There should be
at least one segment lit.
IMPORTANT - If more than three segments are lit, with
no load applied to the ultrasonic stack, make sure the stack
is properly assembled and not damaged. During normal
operation, the peak level LED segment remains lit (approximately 1 second) until the next cycle begins.
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.
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.
AUTO 01
System Power Output Level
Bar Graph
SETUP #01
The word, Offline appears in a white outlined box in thePART COUNT:
WELD TIME :
display's upper right corner.
ENERGY:
PROCESS
STATISTICS
PEAK POWER :
DISTANCE
Figure 4-3
Page
40
ONLINE
0
0.000s
0J
0W
0in
Display Detail, Power Output Level
Dukane Manual Part No. 403-586-03
Section 4 - Controls
Navigation Keys (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 stop editing a value without
saving changes to the value or to leave secondary menu
screens.
INFO Key
Press the INFO key, and the menu shown to the right in
Figure 4-5 appears.
O
+
Moving the Cursor - Press the left and right naviga) keys to move the display’s cursor
tion (
left or right respectively.
Press the up and down navigation keys ( + or - ) to scroll
through menu lists. Also, use the
keys to
move to a digit and change the value of a selected digit
with the + or - keys.
INF
ENTER L
CE
N
CA
Figure 4-4
Navigation Key (4)
Navigation Keys (4), with Enter, Info and Cancel
SYSTEM INFO
INFO MENU
ONLINE REGIONAL SETTINGS
ADVANCED SETTINGS
AMP PRE WELD Figure 4-5
POST WELD WELD LIMITS SETUPS OPERATE LIVE Info Menu Display NOTE
For more information about the INFO
menus, please see Section 5 - Operation.
Soft Keys Bordering the
Display (3)
Use the three keys bordering the left side of the display to
make selections from the choices shown on the display.
Not all keys will be active on any given screen.
Example: For the display shown in Figure 4-6 below, two
of the three soft keys are active:
Weld, and Afterburst.
ONLINE Active Keys
AMPLITUDE
AFTERBURST
AMP Figure 4-6
100%
WELD
Active Soft Keys, Example
Dukane Manual Part No. 403-586-03
PRE WELD PRESS ENTER TO ACCEPT
PRESS CANCEL TO ABORT
POST WELD WELD LIMITS SETUPS OPERATE LIVE Continued
Page
41
iQ Series Ultrasonic Press System LE User’s Manual
Hot Keys (8)
Each of the eight hot keys under the display, when
pressed, brings up one of these portions of the generator
menu:
• AMP - Adjust amplitude for Weld, Pre-Trigger
and Afterburst portions of the weld cycle.
• PRE-WELD - Select operating Mode; disable
or set Pre-Trigger values; and, select Trigger type,
trigger maximum time, and trigger delay.
• WELD - Choose weld type (time, energy, distance, position or ground detect).
• POST WELD - Set parameters for Hold and
Afterburst parts of the cycle.
• LIMITS - Set which weld characteristics to be dis-
played, and which will have their bad part or suspect
part limits enabled.
• SETUPS - Choose setup control, name setups,
copy and erase setups.
• OPERATE - This is a display-only screen
showing cycle data from the last cycle. Only those
selected to be displayed or have process limits set
will be shown.
• LIVE - This is a display-only screen showing real
time Amplitude, Power, Operating Frequency,
and Position. (If position is not supported, it is not
displayed.)
NOTE
The white bar along the bottom of the LCD
display indicates what Hot Key menu is
being displayed.
See the next section, OPERATION for more detail on
the functions of these hot key sub-menus.
Page
42
Dukane Manual Part No. 403-586-03
Section 4 - Controls
System Power Output Level
(Bar Graph)
A bar graph displays the percentage of ultrasonic power
being drawn by the load. See Figure 4-7 to the right.
AUTO 01
Peak Detect Feature
To indicate the maximum peak power achieved during a
weld cycle, the segment in the bar graph corresponding
PROCESS
to the peak level remains on (for about oneSTATISTICS
second) after
the weld cycle has been completed.
Flash on Overload at 90%
The OVERLOAD indicator begins to flash 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.
System Power Output Level
Bar Graph
SETUP #01
PART COUNT:
WELD TIME :
ENERGY:
PEAK POWER :
DISTANCE
Figure 4-7
ONLINE
0
0.000s
0J
0W
0in
Display Detail, Power Output Level
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.
Power On Light
This front panel light glows after the rear panel AC power
switch/circuit breaker is turned ON:
On start-up, the light flashes RED for a few seconds, and
then turns steady GREEN. This indicates AC power has
activated the generator.
When the AC power switch is turned to the OFF position,
the front panel light goes out indicating the generator no
longer has power.
Dukane Manual Part No. 403-586-03
NOTE
Go to Section 5 - Operation, Start-up
Sequence for an explanation of the
generator start-up sequence.
Page
43
iQ Series Ultrasonic Press System LE User’s Manual
Screen Basics
Making Selections
Figure 4-8 below shows there are several ways to show
that an item has been selected:
•
An area of white highlights a selected item.
•
The cursor shows what digit is selected.
Cursor shows selected digit under Distance below.
DISTANCE
0.0000 in
White area highlights selected item
TIME
ENERGY
> DISTANCE
POSITION
GROUND DETECT
MAX TIME
30.000s
PRESS ENTER TO ACCEPT
PRESS CANCEL TO ABORT
AMP Figure 4-8
PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Making Selections
Interpreting On-screen Arrows
Arrows pointing up and down, give visual cues that more
text is available in the direction the arrow points. An example is shown below in Figure 4-9. For this screen, the
+ and - (up or down) navigation keys are used to move in
the direction of the on-screen arrow.
Display arrow points in
direction of more text
SELECT SETUP
AMP Figure 4-9
Page
44
PRE WELD >#
#
#
#
#
#
#
1
2
3
4
5
6
7
-
SETUP#
SETUP#
SETUP#
SETUP#
SETUP#
SETUP#
SETUP#
1
2
3
4
5
6
7
ONLINE POST WELD WELD LIMITS SETUPS OPERATE LIVE Arrows Indicate Direction of More Text
Dukane Manual Part No. 403-586-03
Section 4 - Controls
Setup Identification
Setup identification can be seen at the top of the screen
as shown in the figure below.
The example shown in Figure 4-10 illustrates that setup
control is by automation (Auto 01).
Use iQ 01 if the setup selection is controlled by generator. Use Auto 01 when
controlled by automation.
AUTO 01
PROCESS
STATISTICS
AMP Figure 4-10
PRE WELD This is the name of the setup being edited if in Automation mode.
Otherwise, the setup shown is
the one in use.
SETUP #01
PART COUNT:
WELD TIME :
ENERGY:
PEAK POWER :
DISTANCE
ONLINE
0
0.000s
0J
0W
0in
POST WELD WELD LIMITS SETUPS OPERATE LIVE Main Menu Detail - Setup Identification
Dukane Manual Part No. 403-586-03
Page
45
iQ Series Ultrasonic Press System LE User’s Manual
Press Controls
This section describes the manual controls, indicators and
features of the Press/Thruster System.
If desired, the controls on the front of the thruster can be
used to manually set parameters for a given process.
Features used on the control panel are:
• Indicators associated with the controls to provide a
visual indication of the control settings.
• Metric measurements
Manual Thruster Controls
Refer to Figure 4-11 for the location of the controls.
Down Speed Adjustment
This control adjusts the downward velocity of the press/
thruster slide assembly. Turning the knob clockwise decreases the speed. Turning it counterclockwise increases
the speed of descent.
Hydraulic Slow Speed Control
(Optional)
This control is used to adjust the point in the downstroke
where the hydraulic speed damper is engaged. The SLOW
SPEED Control knob adjusts to a point along the 7 inches
(177.8 mm) of total available downstroke distance that the
hydraulic Speed Control engages.
Refer to Section 6: Options, for detailed information on
the Hydraulic Slow Speed Control.
NOTE
Total Stroke = 7 inches (177.8 mm)
This is the thruster's maximum available
distance of travel.
Continued
Page
46
Dukane Manual Part No. 403-586-03
Section 4 - Controls
Hydraulic Slow Speed Adjustment
The hydraulic slow speed adjustment is an integral part
of the optional hydraulic slow speed control. It sets the
amount of velocity damping of the hydraulic unit. (See
Figure 4-11.) For detailed information on this adjustment,
refer to Section 6: Options.
Mechanical Stop Adjustment
The function of the mechanical stop is to halt the downstroke at a predetermined point. It is used in two ways:
•
To stop the downstroke at a particular depth of travel
relative to the fixture/anvil.
•
To prevent the horn from contacting the fixture when
there is no part present. This prevents possible damage to the horn and/or fixture. Never allow the horn to
contact the fixture while ultrasonic power is applied
to the horn. Metal–to–metal contact can void the horn
and/or tooling warranty.
CAUTION
Do not allow the horn to contact the fixture while ultrasonic
power is applied to the horn.
Metal–to–metal contact can void the horn and/or
tooling warranty.
Pressure 1 Regulator
Pressure 1 regulator is used to set the amount of air pressure applied to the air cylinder during the press downstroke
and weld cycle.
Pressure 2 Regulator
In some applications the Pressure 2 regulator is set to be
maintained during the hold portion of the weld cycle.
Regulator Select Switch
The Regulator Select switch is used to select Pressure 1
regulator (Weld Pressure) or Pressure 2 regulator (Hold
Pressure) to set the required pressure on each regulator
and for monitoring the pressure gauge.
Continued
Dukane Manual Part No. 403-586-03
Page
47
iQ Series Ultrasonic Press System LE User’s Manual
Mechanical Stop Adjust
6
7
5
8
4
Down Speed Adjust
3
Pressure 1 Regulator
I
E
NC
REAS
Regulator Select
Switch
50
20
0
7
5
10
1
6
90
4
80
Pressure Gauge
60
3
70
30
40
2
Pressure 2 Regulator
REAS
E
I
NC
0
10
Stroke Position
Indicator Flag
Ultrasound Active Status Light
0
1
Mechanical
Stop Indicator
Flag
2
3
Slow Speed
Indicator Flag
NOTE
To properly set the
indicator flags, adjust
the control until the
middle of the flag lines
up with the desired
setting.
The example to the left
is set for 2 cm.
Hydraulic Slow Speed
Position Adjustment
Hydraulic
Slow Speed
Adjustment
(Velocity
Damping)
LOOSEN THE
THUMBSCREW TO
UNLOCK KNOB
20
LOWERS
SPEED CONTROL
TRIGGER
3 5 0
Trigger Control
(Numbers displayed are
for reference only.)
Figure 4-11 (Manual) Press/Thruster Controls and Indicators - Model 220 Shown
Page
48
Dukane Manual Part No. 403-586-03
Section 4 - Controls
Continued from Page 47
Trigger Control
Setting the trigger control determines the amount of preload on the part before turning on the ultrasonics.
(Numbers displayed are for reference only.)
NOTE
The actual amount of force applied
to the part depends on the following
four factors:
• The setting of the regulator(s)
• The area of the air cylinder
• The mass of the horn used
• The surface area of the horn
Continued
Dukane Manual Part No. 403-586-03
Page
49
iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
Thruster Indicators
Pressure Gauge
The pressure gauge shows the amount of air pressure applied to the upper portion of the air cylinder for the weldand-hold operation.
Ultrasound Active Status Light
This LED indicator lights up when the generator is applying ultrasonic power to the horn.
Stroke Position Indicator Flag
The stroke position indicator flag is not preset prior to
press operation. It moves with the slide assembly as the
assembly moves down and up.
Mechanical Stop Indicator Flag
This setting indicates where the downstroke will end.
Slow Speed Indicator Flag (Optional)
This indicator flag is set by the Slow Speed Control. It is
included as part of the Slow Speed Control option. When
set, it indicates the point in the downstroke where the
plunger on the hydraulic speed control is engaged.
Press Ergonomic Base
The ergonomic base, shown in Figure 4-12, consists of a
base plate, cycle activation switches (black finger switches), abort switch (red palm switch), and a status display
screen. At the back of the base is a cable connector for an
interface between the iQ Series generator and the base
front panel.
Base Plate
The machined base plate is bolted to the top of the ergonomic base. It has drilled and tapped holes that line up
with leveling screws in the fixtures to allow easy fixture
leveling for alignment with the horn. For details on the
alignment and leveling of the base plate, see Section 7:
Stack/Fixture Setup.
Page
50
Right
Operate
Switch
Left
Operate
Switch
Lower Fixture
E–Stop Switch
Figure 4-12
Ergonomic Base Controls
Dukane Manual Part No. 403-586-03
Section 4 - Controls
Activation (Operate) Switches
Located on either side of the base are two optical (RUN)
switches. These are shown in Figure 4-12. These switches
use Infrared (IR) sensors. They comply with OSHA and CE
safety standards. Both switches are identical.
Each optical–touch switch has a small red LED that is dimly
illuminated whenever the power is on, as shown in Figure
4-13 When the operator places their finger in the tray, the
LED brightens and a second LED in the opposite corner of
the tray illuminates to indicate the switch has been activated
as shown in Figure 4-14. Both switches must be activated
simultaneously to initiate a weld cycle.
Dimly Lit
Red LED
Figure 4-13 Right Operate Switch in Standby
Mode, One LED Dimly Lit
Brigtly Lit
Red LEDs
Figure 4-14 Right Switch in Operate Mode, Both
LEDs Brightly Lit
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.
Dukane Manual Part No. 403-586-03
Page
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iQ Series Ultrasonic Press System LE User’s Manual
Emergency Stop (Abort)
Switch
A red Emergency–Stop (E-STOP) switch is located in the
center of the base as shown in Figure 4-12. The emergency stop switch must be in its reset position before the
operate switches will function.
To reset the Emergency Stop, twist the large red button
about 45 degrees to the right, which will cause the button
to spring out. This is shown in Figure 4-15.
The abort switch applies 24 VDC power to the thruster/
press. Pressing the abort switch causes the generator to:
• Immediately turn off the ultrasound,
eset
Twist to R
POWER
E
IN CYCL
ABORT
Figure 4-15 Setting and Resetting the E–STOP
• Remove electrical power from the press, and
• Initiate a software abort sequence.
Base Status Display
The function of the display is to indicate one of three
status conditions of the press:
•
READY - When the abort switch is pulled out, the
•
ABORT - When the abort switch is pushed in, the
•
IN CYCLE - When both activation switches are
green READY status light indicates that power is
applied to the press and it is ready for operation.
red ABORT status indicator illuminates. Press operation is no longer possible.
pressed, the IN CYCLE display of the status indicator
is ON for the duration of the finger switch activation.
Page
52
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. 403-586-03
Section 5 - Operation
SECTION 5
Operation
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Generator Start-up Sequence . . . . . . . . . . . . . . . . . . 55
Stopping the Weld Cycle . . . . . . . . . . . . . . . . . . . . . . 56
Using the Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
AMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
PRE-WELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
WELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
POST-WELD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SETUPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
LIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Using the INFO Menus . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
This page intentionally left blank
Page
54
Dukane Manual Part No. 403-586-03
Section 5 - Operation
Overview
NOTE
The iQ Series generator, model LE, is typically part of a
system. System major components would be:
• iQ generator,
• iQ Press System, or
• iQ Probe System.
Press, acoustic stack, and tooling will
require their own individual adjustments as
those components are integrated into your
particular system.
With this type of system, the user controls nearly all aspects
of the welding process through the front panel of the iQ LE
generator.
Helpful information on a wide variety of
assembly equipment, processes and
techniques can be found at the Dukane
website:
Generator Start-up
Sequence
http://www.dukane.com/us/PPL_upa.htm
1) Press the rear panel AC breaker switch to ON. See
(ON)
Figure 5-1.
2) The front panel power on light (See Figure 5-2.) will
(OFF)
flash RED a few times, then will glow a steady GREEN.
The display's initial screen identifies the Dukane iQ
Figure 5–1
Rear Panel AC Breaker Switch
Series generator and its major components.
The start-up sequence ends when the OPERATE screen
is displayed.
Power On Light
Figure 5–2
Front Panel with Power On Light
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Stopping the Weld Cycle
Normal Conditions
The cycle stops when the programmed welding cycle ends.
Emergency Conditions
Manual System
Do either of these things:
1) Press the OFFLINE front panel key to stop the ultrasound signal. This may be done under any condition,
OR
2) If the generator's front panel power light is on, move
the rear panel AC breaker switch to the OFF position,
and the front panel power light goes out.
Automated System
Customer-supplied external controls provide the means to
stop the cycle for an automated system.
An auxiliary cable connects these external controls to the
iQ generator at connector J2.
Control input labeled, “Automation Cycle Stop Input” (Pin
15) when activated will stop the weld cycle if configured
as “End of Weld”.
Page
56
Dukane Manual Part No. 403-586-03
Section 5 - Operation
Using the Menus
The figure below provides an overview for the menu
structure and a beginning page number reference for
the item. The user can access the menus through the
generator's eight hot keys and through the INFO key.
Menu Access
Hot Keys
Page 58
AMP
INFO
Weld
System Info
Afterburst
Pre-trigger
Regional Settings
Start
Operating Mode
Page 60
PRE-WELD
Page 75
Advanced Settings
Pre-trigger
Trigger
Time
Energy
Page 64
WELD
NOTE
Distance
Position
The unique hardware configuration of
the generator determines what menus
are available.
Ground Detect
Hold
Page 66
POST-WELD
Afterburst
Scrub
Page 67
LIMITS
From the available process characteristics:
Select the ones to display, and the ones
for which limits are to be set - for bad or
suspect parts.
iQ System
Page 69
SETUPS
Setup Control
Automation
Name Setup
Edit Setup
Copy Setup
Erase Setup
Page 72
OPERATE
Page 74
LIVE
Figure 5-3
Display Only Real time Process
Characteristics.
Display Only Amplitude, Power,
Frequency, Position.
Generator Menu Overview
Dukane Manual Part No. 403-586-03
Continued
Page
57
iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
NOTE
For all menus - When a button is pressed to access the menu, the last access
parameter will be selected and ready to change if applicable.
Example: If the PRE WELD button is pressed, and the Trigger Distance value
was the setting last accessed in that menu, then Trigger Distance is highlighted
and ready to change.
NOTE
On screen Prompts - Watch for and follow on screen prompts where they appear.
Example: In Figure 5-4 below the prompts are:
PRESS ENTER TO ACCEPT, or PRESS CANCEL TO ABORT
AMP
The menu in Figure 5-4 is the default display showing
WELD with its amplitude value ready to be changed.
ONLINE AMPLITUDE
This is the only menu available if MODE is set to AUTOMATED PROBE.
This same menu is displayed if MODE is set to iQ CONTROLLED PROBE MODE, and TRIGGER BY POWER
is disabled, or if PRE-TRIGGER is disabled in either of
the press modes.
If iQ CONTROLLED PROBE MODE is selected, and
AFTERBURST is enabled in the POST WELD menu,
then the AFTERBURST soft key is also displayed as
shown in Figure 5-5 to the right. The parameter value last
accessed will be highlighted and ready to change.
100%
WELD
PRESS ENTER TO ACCEPT
PRESS CANCEL TO ABORT
AMP Figure 5-4
PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Setting Weld Amplitude
ONLINE AMPLITUDE
100%
WELD
AFTERBURST
PRESS ENTER TO ACCEPT
PRESS CANCEL TO ABORT
PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE AMP Figure 5-5
Setting Weld Amplitude with Afterburst
Enabled
Continued
Page
58
Dukane Manual Part No. 403-586-03
Section 5 - Operation
Continued from Previous Page
Online PRE-TRIGGER
If MANUAL or AUTOMATED PRESS MODE is selected, and PRE-TRIGGER is enabled in the PRE-WELD
menu, then PRE-TRIGGER amplitude is available. See
Figure 5-6 to the right.
AMPLITUDE
AMP Figure 5-6
Pressing the AMP button when TRIGGER BY POWER is
enabled, brings up the screen shown to the right. This menu
has START as the top soft key. The value last accessed is
highlighted and ready to be changed. In the example shown
in Figure 5-7, that is START > AMPLITUDE.
100%
WELD
PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Setting Weld Amplitude, Pre-Trigger
Available
ONLINE START
AMPLITUDE
100%
WELD
PRESS ENTER TO ACCEPT
PRESS CANCEL TO ABORT
AMP Figure 5-7
PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Setting Weld Amplitude with Trigger By
Power Enabled
NOTE
Amplitude Range = 20 -100%
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
PRE-WELD
The PRE WELD menu is shown in Figure 5-8. The selected mode is highlighted (AUTOMATED PROBE). To
change to a different mode, move arrow to desired mode,
and press ENTER.
MODE
AUTOMATED PROBE
iQ CONTROLLED PROBE
MANUAL PRESS
AUTOMATED PRESS
PROBE DELAY
AMP Figure 5-8
PRE WELD PRESS ENTER TO SELECT
POST WELD WELD LIMITS SETUPS OPERATE LIVE Pre Weld Menu, Mode is Automated Probe
MODE
PROBE DELAY menu is shown in Figure 5-9 at right.
Figure 5-9
ONLINE TIME
PROBE DELAY
AMP ONLINE PRE WELD 0.0000s
PRESS ENTER TO SELECT
POST WELD WELD LIMITS SETUPS OPERATE LIVE Pre Weld Menu, Probe Delay
NOTE
PROBE DELAY is only available in AUTOMATED PROBE MODE.
Continued
Page
60
Dukane Manual Part No. 403-586-03
Section 5 - Operation
Continued from Previous Page
The PRE WELD menu shown in Figure 5-10 has the selected mode highlighted (iQ CONTROLLED PROBE). To
change to a different mode, move arrow to desired mode,
and press ENTER.
MODE
AUTOMATED PROBE
iQ CONTROLLED PROBE
MANUAL PRESS
AUTOMATED PRESS
TRIGGER
AMP PRE WELD ONLINE PRESS ENTER TO SELECT
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-10 Pre Weld Menu, Mode is iQ Controlled
Probe
ONLINE MODE
TYPE
DISABLED
The TRIGGER menu is shown in Figure 5-11.
TRIGGER
AMP Figure 5-11
PRE WELD PRESS ENTER TO CHANGE
POST WELD WELD LIMITS SETUPS OPERATE LIVE Pre Weld Menu, Trigger Menu
ONLINE MODE
DISABLED
POWER
Making the selection of trigger type is shown in Figure
5-12.
TRIGGER
AMP PRE WELD PRESS ENTER TO CHANGE
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-12 Pre Weld Menu, Trigger Selection
ONLINE MODE
TRIGGER BY POWER has been chosen as the trigger
type as shown in Figure 5-13.
TYPE
AMPLITUDE
POWER
MAX TIME
TRIGGER
AMP PRE WELD POWER
100%
0W
0.000s
PRESS ENTER TO CHANGE
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-13 Pre Weld Menu, Trigger By Power
Selected
Continued
Dukane Manual Part No. 403-586-03
Page
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iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
The PRE WELD menu is shown in Figure 5-14. The selected mode is highlighted (Manual Press). To change to
a different mode, move arrow to desired mode, and press
ENTER.
MODE
PRE-TRIGGER
TRIGGER
AMP PRE WELD AUTOMATED PROBE
iQ CONTROLLED PROBE
MANUAL PRESS
AUTOMATED PRESS
ONLINE PRESS ENTER TO SELECT
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-14 Pre Weld Menu, Manual Press Mode
Trigger menu with Maintained trigger method selected is
shown in Figure 5-15.
ONLINE MODE
TYPE
MAX TIME
MAINTAINED
0.000s
PRE-TRIGGER
TRIGGER
AMP PRE WELD PRESS ENTER TO SELECT
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-15 Pre Weld Menu, Maintained Trigger
Selected
The menu display seen in Figure 5-16 at the right shows the
display when ENTER was pressed with the arrow pointing
to type, but the press does not support distance.
ONLINE MODE
PRE-TRIGGER
TRIGGER
AMP PRE WELD MAINTAINED
MOMENTARY
POWER
PRESS ENTER TO SELECT
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-16 Pre Weld Menu, Press Does Not Support
Distance
The menu in Figure 5-17 to the right shows the display
when ENTER was pressed with the arrow pointing to type
with a press that supports distance.
ONLINE MODE
PRE-TRIGGER
TRIGGER
AMP PRE WELD MAINTAINED
MOMENTARY
WHEN MOTION STOPS
POWER
POSITION
PRESS ENTER TO SELECT
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-17 Pre Weld Menu, Press Supports Distance
Continued
Page
62
Dukane Manual Part No. 403-586-03
Section 5 - Operation
Continued from Previous Page
The PRE WELD menu shown in Figure 5-18 has
PRE-TRIGGER disabled. The selection is made by
pressing ENTER.
ONLINE MODE
DISABLED
PRE-TRIGGER
TRIGGER
AMP PRE WELD PRESS ENTER TO CHANGE
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-18 Pre Weld Menu, Pre-Trigger Disabled
The PRE WELD menu shown in Figure 5-19 shows
the PRE-TRIGGER menu, but the press does not
support DISTANCE.
ONLINE MODE
DISABLED
TIME
PRE-TRIGGER
TRIGGER
AMP PRE WELD PRESS ENTER TO CHANGE
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-19 Pre Weld Menu, Pre-Trigger Menu, Press
Does Not Support Distance
The PRE WELD menu shown in Figure 5-20 has
PRE-TRIGGER enabled, and the press does support
DISTANCE.
ONLINE MODE
PRE-TRIGGER
TRIGGER
AMP PRE WELD DISABLED
POSITION
TIME
PRESS ENTER TO CHANGE
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-20 Pre Weld Menu, Pre-Trigger Enabled,
Press Supports Distance
The PRE WELD menu shown in Figure 5-21 shows
the PRE-TRIGGER menu, when TIME is selected.
ONLINE MODE
PRE-TRIGGER
TRIGGER
AMP PRE WELD DISABLED
TIME
AMPLITUDE
0.000s
20%
PRESS ENTER TO CHANGE
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-21 Pre-Trigger Menu, Time Selected
The PRE WELD menu shown in Figure 5-22 shows
the PRE-TRIGGER menu, when POSITION is
selected.
ONLINE MODE
PRE-TRIGGER
TRIGGER
AMP PRE WELD DISABLED
POSITION
AMPLITUDE
0.0000in
20%
PRESS ENTER TO CHANGE
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-22 Pre-Trigger Menu, Position Selected
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
WELD
The WELD menu seen in Figure 5-23, shows the message
that is displayed if the MODE was set to AUTOMATED
PROBE.
ONLINE WELD CONTROLLED BY AUTOMATION
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-23 Weld Menu, Mode: Automated Probe
The WELD menu shown in Figure 5-24 has the MODE set
to iQ CONTROLLED PROBE.
> TIME
TIME
0.000s
ONLINE ENERGY
USE +/- TO SELECT
PRESS ENTER TO CHANGE
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-24 Weld Menu, Mode: iQ Controlled Probe
The menu shown in Figure 5-25 at the right appears when
the MODE is MANUAL or AUTOMATED PRESS, and
DISTANCE is not supported by the generator.
> TIME
TIME
0.000s
ENERGY
GROUND DETECT
ONLINE USE +/- TO SELECT
PRESS ENTER TO CHANGE
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-25 Weld Menu, Mode: Manual/Automated
Press, Distance not Supported
The menu shown in Figure 5-26 at the right appears when
the MODE is MANUAL or AUTOMATED PRESS.
ENERGY
0J
MAX TIME
ONLINE TIME
> ENERGY
GROUND DETECT
0.000s
ENERGY has been selected, and a value for energy will
be entered.
PRESS ENTER TO ACCEPT
PRESS CANCEL TO ABORT
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-26 Weld Menu, Mode: Manual/Automated
Press, Energy Selection
Continued
Page
64
Dukane Manual Part No. 403-586-03
Section 5 - Operation
Continued from Previous Page
The menu shown in Figure 5-27 at the right appears when
the MODE is MANUAL or AUTOMATED PRESS, and
DISTANCE is supported by the generator.
TIME
0.000s
> TIME
ENERGY
DISTANCE
POSITION
GROUND DETECT
ONLINE ||||| USE +/- TO SELECT
PRESS ENTER TO CHANGE
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-27 Weld Menu, Mode: Manual/Automated
Press, Distance is Supported
The menu shown in Figure 5-28 at the right appears when
the ENERGY value is being entered. (Range in Joules:
0-99999.9)
MAX TIME, a secondary parameter, can be programmed
in its range of 0-30.00 seconds.
ENERGY
0J
MAX TIME
30.000s
TIME
> ENERGY
ONLINE ||||| DISTANCE
POSITION
GROUND DETECT
PRESS ENTER TO ACCEPT
PRESS CANCEL TO ABORT
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-28 Weld Menu, Mode: Manual/Automated
Press, Energy Entry
NOTE
Weld Time: Range is 0-30 seconds.
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
POST-WELD
NOTE
HOLD and AFTERBURST are not available as soft keys if AUTOMATED PROBE
MODE was selected in the PRE WELD
menu. Also, DISTANCE is not shown for
HOLD if DISTANCE is not supported by
the press.
The POST WELD menu seen in Figure 5-29, shows the
message that is displayed if the mode was set to AUTOMATED PROBE MODE using the PRE WELD display.
ONLINE HOLD
AFTERBURST
DISABLED
TIME
DISTANCE
DISABLED
DISABLED
USE +/- TO SELECT
PRESS ENTER TO CHANGE
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-29 Post Weld Menu, Mode: Automated Probe
When TIME has been selected as the HOLD control method, the menu appears as shown in Figure 5-30 to the right.
Note that TIME is highlighted, ready to be changed.
ONLINE HOLD
AFTERBURST
DISABLED
TIME
DISTANCE
0.000s
DISABLED
PRESS ENTER TO ACCEPT
PRESS CANCEL TO ABORT
AMP PRE WELD AMP ONLINE HOLD
AFTERBURST
DISABLED
AFTERBURST
PRESS ENTER TO CHANGE
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-31 Post Weld Menu, Afterburst Disabled
ONLINE HOLD
The menu to the right in Figure 5-32, is displayed when
AFTERBURST is enabled.
AFTERBURST
AFTERBURST
AMPLITUDE
DELAY
DURATION
ENABLED
100%
0.000s
0.000s
||||| PRESS ENTER TO ACCEPT
PRESS CANCEL TO ABORT
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-32 Post Weld Menu, Afterburst Enabled
Page
66
AFTERB
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-30 Post Weld Menu, Time Setting
The menu shown in Figure 5-31 at the right appears if the
AFTERBURST soft key has been pressed in the PRE
WELD menu.
HOLD
Dukane Manual Part No. 403-586-03
Section 5 - Operation
LIMITS
The LIMITS menu seen in Figure 5-33, shows what is
displayed when in a PROBE MODE (either iQ CONTROLLED PROBE or AUTOMATED PROBE).
In the example shown to the right, the DISPLAY ENABLED soft key was pressed to select ENABLED. Press
the key again to select DISABLED.
The LIMITS menu, shown in Figure 5-34 at the right, when
in PRESS MODE, and DISTANCE is not supported.
TRIGGER DELAY (on PRE WELD screen) and HOLD
(on POST WELD screen) are only shown when they are
ENABLED.
BAD
DISABLED
> TIME
ONLINE ENERGY
SUSPECT
DISABLED
DISPLAY
ENABLED
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-33 Limits Menu, in Probe Mode
BAD
DISABLED
SUSPECT
DISABLED
DISPLAY
ENABLED
AMP PRE WELD >
DOWNSTROKE TIME
TRIGGER DELAY TIME
TIME
ENERGY
HOLD TIME
TOTAL CYCLE TIME
ONLINE POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-34 Limits Menu, Press Mode, Distance Not
Supported
The LIMITS menu shown in Figure 5-35 at the right appears
when in PRESS MODE, and DISTANCE is supported.
BAD
DISABLED
SUSPECT
DISABLED
DISPLAY
ENABLED
AMP PRE WELD DOWNSTROKE TIME
DOWNSTROKE DIST
> TIME
ENERGY
WELD DISTANCE
WELD END POSITION
TOTAL CYCLE TIME
ONLINE POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-35 Limits Menu, Press Mode, Distance Is
Supported
Continued
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
When the BAD soft key is pressed (in the menu shown in
Figure 5-35 above), the display will appear as it does in
Figure 5-36 to the right. [Press SUSPECT to move to the
Suspect version of this screen.]
DISABLED
The LIMITS menu shown in Figure 5-37 allows setting
upper and lower limits. Use the soft keys to highlight the
parameter value to be changed. Press DONE to return to
the main LIMITS menu.
ONLINE ENABLED
AMP Selecting ENABLED will change the menu to what is
shown in Figure 5-37.
WELD TIME
BAD PART LIMIT
PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-36 Limits Menu, Bad Soft Key Pressed
UPPER LIMIT
30.000s
WELD TIME
BAD PART LIMIT
ONLINE LOWER LIMIT
0.000s
DONE
.
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-37 Limits Menu, Setting Upper and Lower
Limits
The example menu shown in Figure 5-38 appears when
BAD PART LIMITS are enabled for TIME.
BAD
ENABLED
SUSPECT
DISABLED
> TIME
ONLINE PEAK POWER
ENERGY
.
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-38 Limits Menu, Bad Parts Limits Enabled for
Time
Page
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Dukane Manual Part No. 403-586-03
Section 5 - Operation
SETUPS
Setup Control
The SETUPS menu seen in Figure 5-39, shows that iQ
SYSTEM is the default setup control setting for this menu.
SELECT SETUP is the bottom soft key in this case.
A total of eight (8) setups are available.
If AUTOMATION is selected, the bottom soft key would
be: EDIT SETUP.
IQ SYSTEM
AUTOMATION
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-39 Setups Menu, Default Display
Press SELECT SETUP, and a screen similar to the one
shown in Figure 5-40 to the right is displayed.
Then, the previous screen will be displayed.
ONLINE NAME SETUP
COPY SETUP
ERASE SETUP
SELECT SETUP
SELECT SETUP
When the > is next to the desired setup, press the SELECT
SETUP soft key, or the ENTER key.
> SETUP CONTROL
AMP PRE WELD > # 1 - SETUP# 1
#
#
#
#
#
#
2
3
4
5
6
7
-
SETUP#
SETUP#
SETUP#
SETUP#
SETUP#
SETUP#
2
3
4
5
6
7
ONLINE POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-40 Setups Menu, Select Setup
Pressing CANCEL would display the previous screen
without any setup being chosen.
Name Setup
The menu shown to the right in Figure 5-41 is displayed
when the > is moved to NAME SETUP.
The name of the current setup that is being edited (dependent on SETUP CONTROL) is highlighted and ready
for editing.
Pressing ENTER saves the name.
Pressing ERASE NAME changes the name back to the
default. (In this example, Setup #1).
SETUP NAME
SETUP #1
SETUP CONTROL
> NAME SETUP
ONLINE COPY SETUP
ERASE SETUP
ERASE NAME
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-41 Setups Menu, Name Setup
NOTE
A total of eight (8) setups can be made.
When the setup name is not highlighted, there is a box
around it. This indicates that pressing the soft key next to
the box allows the box to be edited.
Continued
Dukane Manual Part No. 403-586-03
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69
iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
Copying a Setup
Move the
5-42.
> next to COPY SETUP as shown in Figure
The current setup being used or edited is displayed under
COPY FROM.
COPY FROM
SETUP# 1
>
COPY TO
SETUP# 2
SETUP CONTROL
NAME SETUP
COPY SETUP
ERASE SETUP
ONLINE COPY SETUP
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-42 Setups Menu, Copy Setup
Copy From
When the COPY FROM soft key is pressed, a list of setups,
as shown in Figure 5-43 to the right, is displayed.
SELECT SETUP
Use the + and - keys to scroll through the list.
Press ENTER to make the setup the COPY FROM selection.
AMP PRE WELD > # 1 - SETUP# 1
#
#
#
#
#
#
2
3
4
5
6
7
-
SETUP#
SETUP#
SETUP#
SETUP#
SETUP#
SETUP#
2
3
4
5
6
7
ONLINE POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-43 Setups Menu, Copy From/To Setup
Copy To
Pressing the COPY TO soft key will bring up the same
menu once again (Figure 5-43).
Use the + and - keys to scroll through the list.
ONLINE SETUP COPIED
Press ENTER to make the setup the COPY TO selection.
When the COPY SETUP soft key is pressed, the screen
shown in Figure 5-44 is displayed - for about 5 seconds.
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-44 Setups Menu, Setup Copied Confirmation
The next screen displayed is the COPY SETUP screen as
shown in Figure 5-42 above.
Continued
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70
Dukane Manual Part No. 403-586-03
Section 5 - Operation
Erase Setup
Continued from Previous Page
Move the > next to ERASE SETUP as shown in the
Figure 5-45.
The current setup or all setups can be erased.
CURRENT SETUP
ALL SETUPS
AMP PRE WELD SETUP CONTROL
NAME SETUP
COPY SETUP
> ERASE SETUP
ONLINE POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-45 Setups Menu, Erase Setup
Erase Current Setup
Press the CURRENT SETUP soft key to bring up the
display shown in Figure 5-46.
Pressing YES will return the setup (that is currently being
run or edited) to default values.
Pressing NO or CANCEL will return the display to the
SETUPS menu without erasing anything.
ONLINE YES
ARE YOU SURE YOU WANT TO
ERASE THIS SETUP?
NO
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-46 Setups Menu, Question Erase
Erase All Setups
Pressing ALL SETUPS (as seen in Figure 5-45 above)
affects all setups in the generator returning them all to
default values.
The screen message, if ALL SETUPS was selected, would
read:
ARE YOU SURE YOU WANT TO ERASE
ALL SETUPS?
ONLINE SETUP ERASED
Confirm Erase
When YES is pressed, the screen shown in Figure 5-47
is displayed for about 5 seconds. Then, the ERASE setup
menu is shown.
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-47 Setups Menu, Confirm Erase
If ALL SETUPS was chosen in the setup menu, the message would be: ALL SETUPS ERASED.
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
OPERATE
Name of setup being edited if in
Automation Mode, Otherwise the
setup is in use.
System Power
Output Level
Online/Offline/E-Stop Status
Operating Mode
AUTO 01
PROCESS
STATISTICS
AMP PRE WELD SETUP #01
PART COUNT
WELD TIME
ENERGY
PEAK POWER
DISTANCE
ONLINE
0
0.000s
0.0J
0W
0.000IN
POST WELD WELD LIMITS SETUPS OPERATE LIVE Process Characteristics
Figure 5-48 Operate Screen - I
When the generator is powered up, there is an initial
screen that shows system information. That is followed by
the Operate screen as shown in Figure 5-48 above.
This is a display only screen. The values displayed are
from the last weld cycle. The operator can access this
screen by pressing the OPERATE hot key.
The process characteristics shown in Figure 5-48 above
are the ones where part limits have been enabled, or are
those that have been selected to display.
As an example, here is a list of all possible characteristics
that a distance press could have. (If distance is not supported, then these characteristics would not be available.)
Downstroke Time
Downstroke Distance
Trigger Delay Time
Trigger Delay Distance
Time
Peak Power
Energy
Weld Distance
Weld End Position
Hold End Position
Hold Time
Hold Distance
Total Cycle Time
Total Cycle Distance
Continued
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72
Dukane Manual Part No. 403-586-03
Section 5 - Operation
Continued from Previous Page
When the PROCESS STATISTICS soft key is pressed,
the display as shown in Figure 5-49 is seen.
The total part count along with subtotals for good, bad,
and suspect parts are displayed.
Percentages shown are of the total part count.
Example: Number of GOOD parts divided by the total
PART COUNT multiplied by 100 equals the percentage
of GOOD parts.
Dukane Manual Part No. 403-586-03
PROCESS STATISTICS
AUTO 01
PART COUNT
GOOD
BAD
SUSPECT
Online
0
0
0
0
|
0%
0%
0%
BACK
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-49 Operate Screen - II
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iQ Series Ultrasonic Press System LE User’s Manual
LIVE
When the LIVE hot key is pressed, the display as shown
in Figure 5-50 to the right is seen.
This is also called the Live Data screen.
The screen shows the current value of the parameters
shown. These values are shown regardless of whether the
generator is in cycle or not.
ONLINE
AUTO 01
SETUP #01
AMPLITUDE
POWER
OPERATING FREQUENCY
DISTANCE
AMP PRE WELD 100%
0W
19,900Hz
0.0000in
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-50 Live Data Screen
If distance is not supported, it would not be displayed.
IN CYCLE
When the LIVE hot key has been pressed, and the generator is in cycle, the screen shown in Figure 5-51 is displayed.
The screen shows the current value of the parameters
shown.
If DISTANCE is not supported, it would not be displayed.
AUTO 01
IN CYCLE
SETUP #01
AMPLITUDE
POWER
OPERATING FREQUENCY
DISTANCE
AMP PRE WELD ONLINE
100%
0W
19,900Hz
0.0000in
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-51 In Cycle Screen
TEST
When the TEST soft key has been pressed, and the
generator is online, the screen shown in Figure 5-52 is
displayed.
The screen shows the current value of the parameters
shown.
If DISTANCE is not supported, it would not be displayed.
Page
74
AUTO 01
TEST
SETUP #01
AMPLITUDE
POWER
OPERATING FREQUENCY
DISTANCE
AMP PRE WELD ONLINE
100%
0W
19,900Hz
0.0000in
POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-52 Test Screen
Dukane Manual Part No. 403-586-03
Section 5 - Operation
Using the INFO Menus
Press the INFO key, and the menu shown to the right in
Figure 5-53 appears.
ONLINE INFO MENU
SYSTEM INFO
REGIONAL SETTINGS
ADVANCED SETTINGS
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-53 Info Menu Display SYSTEM INFO - To display information about
the generator hardware, press the SYSTEM INFO
button. Figure 5-54 shows an example display of
that information. In the Figure, X's represent version
numbers.
l
DUKANE CORPORATION/IAS DIVISION
iQ LE SERIES ULTRASONIC GENERATOR
ONLINE
Model# 20HS2401ZP5
Serial# xxxxxx
236853
Front Panel Code vX.XX.XX
Motherboard Code vXX.XX.XX
www.dukane.com/us
Boot Code: MB vX.XX / FP vX.XX
PRE POST AMP WELD WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-54 System Info
REGIONAL SETTINGS - Pressing the REGIONAL
SETTINGS button allows setup for LANGUAGE
(Figure 5-55), and it allows setup for UNITS.
LANGUAGE
REGIONAL SETTINGS MENU
ONLINE ENGLISH
FRENCH
GERMAN
UNITS
BACK
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-55 Regional Settings, Language Menu
UNITS - To set up preference for units press the
INFO key, go to the REGIONAL SETTINGS
MENU, and then to the UNITS key.
See Figure 5-56.
LANGUAGE
REGIONAL SETTINGS MENU
ONLINE IMPERIAL
METRIC
UNITS
BACK
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-56 Regional Settings, Units Menu
Continued
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
ADVANCED SETTINGS - This part of the INFO menu
gives access to the four sub-menus, Adv Process Control, System Status I/O, Network and Miscellaneous
and their menu items as shown in Figure 5-57.
• Adv Process Control
• System Status IO
• Network
• Miscellaneous
WARNING
Modifying Advanced Settings may damage the
unit or ultrasonic stack.
Frequency Tracking
Free Run Frequency
Freq Lock and Hold
System Freq Limits
Ramp Up Time
Ramp Down Time
Auto Start Input
Auto Stop Input
J3 Pin 4
J3 Pin 5
Output Duration
DHCP
IP Address
Subnet Mask
EIP Conn:
Buzzer
External Control
Restore Factory Defaults
Figure 5-57 Advanced Settings Menu Overview
Pressing the ADVANCED SETTINGS button brings up
the ADV PROCESS CONTROL sub-menu first. See
Figure 5-58.
RESTORE
DEFAULTS
AMP > ADV PROCESS CONTROL
PRE WELD FREQUENCY TRACKING
FREE RUN FREQ
FREQ LOCK AND HOLD
SYSTEM FREQ LIMITS
RAMP UP TIME
RAMP DOWN TIME
ONLINE DISABLED
20000Hz
DISABLED
NORMAL
0.150s
0.000s POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-58 Advanced Process Control Menu
Continued
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Dukane Manual Part No. 403-586-03
Section 5 - Operation
Continued from Previous Page
If the RESTORE DEFAULTS key is pressed while
the Adv Process Control menu is displayed, the
screen shown at right (Figure 5-59) is seen.
ONLINE YES
NO
AMP ARE YOU SURE YOU WANT TO
RESTORE ALL ADVANCED
PROCESS CONTROL SETTINGS TO
DEFAULT VALUES?
PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-59 Restore Defaults, Adv Process Controls
If the defaults are restored, the display with the confirmation message shown in Figure 5-60 at right is
shown for 5 seconds.
ONLINE ADVANCED PROCESS CONTROL
SETTINGS HAVE BEEN RESTORED TO
DEFAULT VALUES
After that, the display will once again appear as it
does in Figure 5-58.
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-60 Restore Defaults, Confirmed,
Advanced Process Control
Continued
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Adv Process Control Sub-menu Items
The six sub-menu items and their corresponding displays
are shown (See Figure 5-61.) and described below and
on the next page:
1) 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
2) Free Run Freq
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.
Adjust manually within the prescribed limitations
for your particular generator model.
• Scan Stack - With Advanced Process Settings
enabled:
Run the scan: Scroll to Free Run Freq in the
displayed list and select the Scan Stack soft key.
Follow the displayed instructions.
TRACKING
ENABLED
FREE RUN
20000 Hz
SCAN
STACK
ENABLE
DISABLE
LIMITS
NORMAL
UPPER
20400Hz
Moving to the Next Sub-menu
When > is next to RAMP DOWN TIME, and the
down key (minus) is pressed, the next sub-menu
for System Status IO replaces the Adv Process
Control sub-menu.
Page
78
FREE RUN FREQ
FREQ LOCK AND HOLD
SYSTEM FREQ LIMITS
RAMP UP TIME
RAMP DOWN TIME
ADV PROCESS CONTROL
FREQUENCY TRACKING
> FREE RUN FREQ
FREQ LOCK AND HOLD
SYSTEM FREQ LIMITS
RAMP UP TIME
RAMP DOWN TIME
ADV PROCESS CONTROL
FREQUENCY TRACKING
FREE RUN FREQ
> FREQ LOCK AND HOLD
SYSTEM FREQ LIMITS
RAMP UP TIME
RAMP DOWN TIME
ONLINE DISABLED
20000Hz
DISABLED
NORMAL
0.150s
0.000s ONLINE ONLINE DISABLED
20000Hz
DISABLED
NORMAL
0.150s
0.000s ONLINE FREQENCY TRACKING
FREE RUN FREQ
FREQ LOCK AND HOLD
> SYSTEM FREQ LIMITS
RAMP UP TIME
RAMP DOWN TIME
TIME
0.150s
ADV PROCESS CONTROL
FREQUENCY TRACKING
FREE RUN FREQ
FREQ LOCK AND HOLD
SYSTEM FREQ LIMITS
> RAMP UP TIME
RAMP DOWN TIME
TIME
0.000s
ADV PROCESS CONTROL
Application Note 512 at http://www.dukane.com/
us/DL_ApplData.asp
When freq lock and hold is disabled the frequency
of the stack is tracked by changing the frequency of
> FREQUENCY TRACKING
TRACKING
DISABLED
For more detail on the Scan Stack feature please
refer to our website to download:
3) Freq Lock and Hold
ADV PROCESS CONTROL
>
FREQUENCY TRACKING
FREE RUN FREQ
FREQ LOCK AND HOLD
SYSTEM FREQ LIMITS
RAMP UP TIME
RAMP DOWN TIME
ONLINE ONLINE DISABLED
20000Hz
DISABLED
NORMAL
0.150S
0.000s Figure 5-61 Advanced Process Control Sub-menu Items
Continued
Dukane Manual Part No. 403-586-03
Section 5 - Operation
Continued from Previous Page
the ultrasound driving pulses to match the feedback
signal frequency.
When enabled the frequency of the feedback 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.
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.
Range is 0.000 to 0.250 seconds.
Enable or Disable this feature.
4) System Freq Limits
Limits can be: Wide, Normal, Narrow, or Manual.
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 are set to +/-500 Hz relative to
the free run frequency value.
Narrow - In Narrow mode the upper and lower
frequency limits are set to +/-200 Hz relative to
the free run frequency value.
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. The upper
frequency limit must be set at least 25Hz above
the free running frequency. The lower frequency
limit must be set at least 25Hz below the free
running frequency. It's recommended that the
lower frequency limit be set to a minimum of
25Hz below the stack operating frequency when
operating in free air.
Manual - Enter Upper and Lower Limits
Normal, Narrow, or Wide - Enter Upper and Lower Limits within prescribed limitations for your particular generator.
5) Ramp Up Time
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. This
brings the stack up to operating amplitude smoothly
preventing shock stress.
Range is 0.000 to 1.250 seconds.
6) Ramp Down Time
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
SYSTEM STATUS I/O Sub-menu
The SYSTEM STATUS I/O sub-menu is displayed in
Figure 5-62.
RESTORE
DEFAULTS
>SYSTEM STATUS I/O
AUTO START INPUT
AUTO STOP INPUT
J3 PIN 4
J3 PIN 5
OUTPUT DURATION
ONLINE SOLID STATE
END OF CYCLE
E-STOP
HOLD
MAINTAINED
Figure 5-62 System Status I/O Sub-menu
If the RESTORE DEFAULTS key is pressed while,
the SYSTEM STATUS I/O sub-menu is displayed, the
screen shown in Figure 5-63 is seen.
ONLINE YES
NO
ARE YOU SURE YOU WANT TO RESTORE
ALL SYSTEM STATUS
I/O SETTINGS TO DEFAULT VALUES?
Figure 5-63 System Status I/O Restore Defaults?
If YES is chosen, the defaults are restored, and the
display with the confirmation message shown in Figure
5-64 is shown for 5 seconds.
ONLINE SYSTEM STATUS I/O SETTINGS HAVE
BEEN RESTORED TO DEFAULT VALUES
After that, the display will once again appear as it does
in Figure 5-62.
Figure 5-64 System Status I/O Defaults Restored
Continued
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Dukane Manual Part No. 403-586-03
Section 5 - Operation
Continued from Previous Page
System Status I/O Sub-menu Items
The five sub-menu items and their corresponding displays
(Figure 5-65) are shown below:
1) Auto Start Input
Solid State, or
SOLID
STATE
SYSTEM STATUS I/O
ONLINE SOLID STATE
AUTO STOP INPUT END OF CYCLE
MECHANICAL J3 PIN 4
E-STOP
J3 PIN 5
HOLD
OUTPUT DURATION
MAINTAINED
> AUTO START INPUT
Mechanical - If this is chosen, a value (0.000 to 0.100 seconds) must be given for Debounce.
DISABLED
2) Auto Stop Input
Choose to Disable this, or select End of Weld, or End of Cycle.
3) J3 Pin 4
Choose the output signal for J3 Pin 4:
E-Stop, or Overtemp
4) J3 Pin 5
Choose the output signal for J3 Pin 5:
Hold, In Cycle, or In Cycle No AB
END OF
WELD
END OF
CYCLE
E-STOP
OVERTEMP
HOLD
IN
CYCLE
IN CYCLE
NO AB
SYSTEM STATUS I/O
ONLINE AUTO START INPUT SOLID STATE
> AUTO STOP INPUT END OF CYCLE
J3 PIN 4
E-STOP
J3 PIN 5
HOLD
OUTPUT DURATION
MAINTAINED
ONLINE SYSTEM STATUS I/O
AUTO START INPUT
AUTO STOP INPUT
> J3 PIN 4
J3 PIN 5
OUTPUT DURATION
SOLID STATE
END OF CYCLE
E-STOP
HOLD
MAINTAINED
SYSTEM STATUS I/O
AUTO START INPUT
AUTO STOP INPUT
J3 PIN 4
> J3 PIN 5
OUTPUT DURATION
SOLID STATE
END OF CYCLE
E-STOP
HOLD
MAINTAINED
ONLINE 5) Output Duration
Choose either Maintained, or 100mS Pulse.
MAINTAINED
100 ms
PULSE
Moving to the Next Sub-menu
SYSTEM STATUS I/O
ONLINE AUTO START INPUT SOLID STATE
AUTO STOP INPUT END OF CYCLE
J3 PIN 4
E-STOP
J3 PIN 5
HOLD
MAINTAINED
> OUTPUT DURATION
When > is next to OUTPUT DURATION, and the down
key (minus) is pressed, the next sub-menu for NETWORK replaces the SYSTEM STATUS IO sub-menu.
Figure 5-65 System Status I/O Sub-menu Items
Continued
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
Network Submenu
The Network Settings screen as seen in Figure 6-66 has
five elements:
1. DHCP - These initials stand for Dynamic Host Configuration Protocol. The protocol was established for assigning
dynamic IP addresses to devices on a network.
DHCP is enabled by default, this ensures no network address contention will happen in the event that the generator
is plugged into a network before the user assigns a static
address. Most commonly DHCP is disabled and a statically assigned IP addresses are used in industrial networks.
When DHCP is enabled, the static IP address/subnet mask
setting is ignored. You may need to contact your network
administrator if you do not know whether to enable or
disable DHCP.
DHCP
ENABLED
NETWORK
> DHCP
IP ADDRESS
DHCP
DISABLED SUBNET MASK
EIP CONN:
Figure 6-66
ONLINE ENABLED 172. 16.100.111
255.255 0. 0.
NONE Network Settings
2. 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. This field
is editable when DHCP is disabled.
You may need to contact your network administrator if you
do not know what address to use.
3. SUBNET MASK - defines the subset of the network
address which applies to the locally defined subnetwork. Generally, this setting must match other entities on
the network. This field is editable when DHCP is disabled.
You may need to contact your network administrator if you
do not know what mask to use.
4. EIP CONN: - Indicates the IP address of the controlling Ethernet/IP connection.
5. LINK: - Indicates the state of the Ethernet link. (up/
down (plugged in or not), 10/100 Mbps, half/full duplex)
Moving to the Next Sub-menu
When > is next to LINK: and the down key (minus) is
pressed, the MISCELLANEOUS sub-menu screen appears. See the next page.
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Dukane Manual Part No. 403-586-03
Section 5 - Operation
Continued from Previous Page
Miscellaneous Sub-menu Items
The three sub-menu items and their corresponding displays (Figure 5-67) are shown below:
1) Buzzer
Set the audible buzzer to sound:
At Top of Stroke - Enable or Disable, or
At Trigger - Enable or Disable
2) External Control
Choices are:
Disabled,
Serial, or
Profibus (Range of 1 to 125)
DISABLE
ENABLE
DISABLE
ENABLE
RESTORE
3) Restore Factory Defaults
Choose Restore to erase ALL setups and factory
defaults.
An intermediate display allows for confirmation.
ONLINE MISCELLANOUS
BUZZER
At TOP OF STROKE
AT TRIGGER
EXTERNAL CONTROL
LATCH ON BAD PART
RESTORE FACTORY DEFAULTS
DISABLED
DISABLED
DISABLED
DISABLED
MISCELLANOUS
BUZZER
AT TOP OF STROKE
AT TRIGGER
>
EXTERNAL CONTROL
LATCH ON BAD PART
RESTORE FACTORY DEFAULTS
DISABLED
DISABLED
DISABLED
DISABLED
>
MISCELLANOUS
BUZZER
AT TOP OF STROKE
AT TRIGGER
EXTERNAL CONTROL
LATCH ON BAD PART
> RESTORE FACTORY DEFAULTS
ONLINE ONLINE DISABLED
DISABLED
DISABLED
DISABLED
ONLINE YES
NO
WARNING: ALL SETUPS WILL BE
ERASED AND FACTORY DEFAULTS WILL
BE RESTORED. ARE YOU SURE YOU
WANT TO PROCEED?
If confirmed, then another message is displayed as
shown to the right.
ONLINE FACTORY DEFAULTS HAVE BEEN RESTORED.
Figure 5-67 Miscellaneous Sub-menu Items
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
ALARMS
Terminology: Alarm refers to any fault, or error the generator might produce.
An alarm condition may occur. Figure 6-67 shows the
format for a typical alarm display.
The list below gives general reference information for
each alarm condition.
FREQUENCY OVERLOAD FAULT 1 ONLINE FAULT ID # Uxxx
SERIAL # xxxxxx
VISIT WWW.DUKANE.COM/EASYFAULT FOR
FAULT AND TROUBLESHOOTING TIPS,
OR CONSULT YOUR MANUAL
PRESS ENTER TO CLEAR
AMP PRE WELD POST WELD WELD LIMITS SETUPS OPERATE LIVE Figure 5-67 Alarm Message Screen
FAULTS:
U100
PROCESS ERRORS:
Configura3on Fault (Default Setup Corrupted, Model Number Incorrect, Serial Number Incorrect, Feedback Scaling Incorrect, etc)
U400
Weld Limits enabled for con3nuous Opera3on
U103 Hardware Fault (Hardware Changed, Remote Amp Card removed?)
U401 Weld Time set to Zero
U104 Frequency Overload Fault 1 (Lock Fail)
U402 Weld Power set to Zero
U106 POS Peak Overload Alarm
U404 Weld Distance set to Zero
U108 Average Overload Alarm
U405 Weld Posi3on set to Zero
U109 Bad Current Loop Alarm
U406 Max Trigger Time set to Zero
U110 Power not OK Alarm
U407 Forced Shutdown Fault
U111 Over Temperature Alarm
U408 Trig Lost Early Fault
U116 Over Voltage Alarm
INITIATE ERRORS:
U409 Trig Lost Weld Fault
U300 Operate Switch 1 Pressed before Cycle Start
U410 Pre-­‐trigger Over travel Fault
U301 Operate Switch 2 Pressed before Cycle Start
U412 Max Pre-­‐trigger Time exceeded
U302 Auto In switch closed at End of Cycle
U413 Max Trigger Time exceeded
U304 Trigger switch closed before Cycle Start
U414 Max Trigger Delay Time exceeded
U305 Pre-­‐trigger switch closed before Cycle Start
U306 End Weld input enabled before Cycle Start
U307 Ground Detect input enabled before Cycle Start
U308 Generator or Press Not Ready
Table 5-I
Page
84
Alarm Messages
Dukane Manual Part No. 403-586-03
Section 6 - Options
SECTION 6
Options
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Power Inlet Options . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Press Interface Module . . . . . . . . . . . . . . . . . . . . . . . 90
Hydraulic Speed Control . . . . . . . . . . . . . . . . . . . . . . 91
Distance Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
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Dukane Manual Part No. 403-586-03
Section 6 - Options
Overview
This section of the User’s Manual provides a general
overview of some options/upgrades for the basic ultrasonic generator and for the press/thruster, all of which
are subject to availability.
These options/upgrades are:
Generator
•
Power Inlet
•
Press Interface Module
Press/Thruster
•
Hydraulic Speed Control
•
Distance Encoder
Additional Options
Dukane can provide high-quality automation equipment
for efficient handling and assembly of parts. This equipment is tailored specifically to your needs. Some of the
available options include pick and place automation,
rotary tables, in-line indexing, conveyors, and walking
beams.
Dukane can also provide standard and custom sound
enclosures. The additional options are not covered in this
manual due to their specialized applications.
Contact your local Dukane representative for more specific information, or visit the Dukane website:
www.dukane.com/us/PCU_custom.htm
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Power Inlet Options
120V Systems for North America and
Japan
120V systems for North America and Japan have a fixed
(non-detachable) power cord.
This option is available on generators with power ratings
of 1200 watts or less and with operating frequencies of
20kHz, 30kHz, or 40kHz.
See Table 12-II in Section 12, Specifications.
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.
Electrical Safety
120V Power Ground
For safety, the power cords used on all Dukane products have a three-prong, grounding-type plug.
Approved 2 pole, 3 wire grounding
receptacle HUBBELL No. 5262 or
equivalent to NEMA 5–15R or 5–20R
Figure 6 - 1
Page
88
Example of 120 Volt,
Grounded, 3-Prong Receptacle
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.
Dukane Manual Part No. 403-586-03
Section 6 - Options
AC Power Inlet Panel
The optional AC power inlet panel is described here.
AC Power Cord
The AC power cord (A in Figure 6-2) is appropriately
rated and permanently mounted to the power inlet panel.
Power Switch/Circuit Breaker
The power switch/circuit breaker (B in Figure 6-2) 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 0 symbol. This
power switch also integrates an appropriately sized overcurrent 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.
B
A
LINE VOLTAGE:
100-120 Vac
50/60Hz, 10A
PE
C
120 Volt line cord
Figure 6 - 2 120VAC Power Inlet Panel
Chassis Ground Stud
The chassis ground stud is used to attach a protective
earth ground to the generator. This will aid in the suppression of electrical interference or radio frequency interference (RFI) that is common in an industrial environment. The chassis ground stud is C in Figure 6-2. Proper
system grounding is discussed on Page 9.
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Press Interface Module
Welding with Two Pressures and
Distance
This module is also known as the Options Slot Module.
Module location is shown on Page 17, Figure 3-5.
Modules support two different press series: iQ Series,
and Ultra Series, and those modules are described here
in general terms.
The P5 or P9 module enhances the P4 or P8 module
respectively by adding a distance mode.
The 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.
Welding with Two Pressures
With modules P4 or P8 (as shown in the table below),
two pressures can be used to create strong, reliable
welds. Clamp force is increased to improve the plastic
melt and flow during the weld portion (Pressure 1) of
a cycle, and this assures tight assembly during the hold
portion (Pressure 2) by welding parts at one pressure
and holding them together at a second, higher pressure.
Dukane's linear optical encoder has a one-micron resolution to insure exceptional precision and repeatability.
iQ Series
iQ Series
The iQ Series module, P4, supports press system operation through two connectors:
• J5 - Thruster - Provides control for thruster
operation.(Dukane Cable P/N 200-1556-XXM)
• J6 - Base/Abort - Provides the signal for the
press base control.
(Dukane Cable P/N 200-1545-XXM)
The iQ Series module, P5, adds support for distance,
and that requires a third connector:
Ultra Series
Ultra Series
• J11 - Encoder - This connector is configured to
deliver control for the distance encoder.
(An extender cable, that is required in some applications: Dukane Cable P/N 200-1613-XXM.)
The P8 module offers connectivity for Dukane Ultra
Series systems. It supports three connectors:
• J7 - Thruster - Provides control for thruster
operation. (Dukane Cable P/N 200-1556-XXM)
• J8 - Safety Switch - Provides the signal for the
press base control.
(Dukane Cable P/N 200-1545-XXM)
• TOS (Top of Stroke) - Provides the signal for
top of stroke - when thruster is fully retracted.
(Dukane Cable P/N 200-1545-XXM)
The P9 module adds support for distance, and that requires
a third connector:
• J12 - Encoder - This connector is configured
to deliver control for the distance encoder.
(An extender cable, that is required in some
applications: Dukane Cable P/N 200-1613XXM.)
Press Interface Modules
Generator
Series
Two Pressure
(No Distance)
Distance
(Two Pressure + Distance)
iQ
P4 (P/N 110-4426)
P5 (P/N 110-4427)
Ultra
P8 (P/N 110-4854)
P9 (P/N 110-4855)
Table 6- I
Page
90
Weld Options
Press Interface Modules
Dukane Manual Part No. 403-586-03
Section 6 - Options
Hydraulic Speed Control
SLOW SPEED Control and
Indicator Flags
6
5
8
4
7
The thruster has a knob labelled SLOW SPEED near the
bottom of the front panel and a SLOW SPEED indicator
flag. Refer to Figure 6-3.
3
The knob and the indicator flag are part of the optional
Hydraulic Speed Control Kit.
I
E
NC
REAS
50
60
4
0
7
5
10
1
6
90
3
80
20
30
40
2
REAS
E
I
NC
70
The purpose of the hydraulic speed control is to match
the downstroke speed to the material melt flow. This will
produce the strongest joint. The Slow Speed Setting knob
adjusts the point along the 7 inch (177.8 mm) downstroke
distance at which the hydraulic speed control will engage.
It should be set to engage just before the horn contacts
the part. The maximum distance over which this kit can
control the downstroke speed is 1 inch (25.4 mm).
0
10
The middle of the indicator flag, when referenced to the
scale beside the flag slot, shows where the 1 inch (25.4
mm) of slow speed is set to begin.
NOTE
}
Hydraulic Speed Control Kit
Operation
The hydraulic speed control kit, shown in Figure 6-4, is a
combination impact absorber and hydraulic check valve.
The kit contains a sealed hydraulic cylinder with an external plunger. The cylinder is mounted to the stationary
part of the thruster.
The kit also has a contact block that is mounted to the
slide assembly of the thruster. When the slide assembly
descends, the contact block descends until it engages the
plunger of the stationary hydraulic cylinder and pushes the
plunger down into the cylinder. The design of the cylinder
resists the downward motion of the plunger by metering
the pure silicone fluid through an adjustable internal flow
aperture, resulting in a constant speed of the slide assembly.
The hydraulic cylinder is mounted in a clamping block.
The block is threaded onto a long rod.
Slow Speed
range is limited to 1" (2.5
cm) below
the Stroke
Position set
point.
LOOSEN THE
THUMBSCREW TO
UNLOCK KNOB
20
LOWERS
SPEED CONTROL
TRIGGER
3 5 0
Figure 6-3 Example of Slow Speed Setting
NOTE
The optional air cylinders (1.5", 2", and
3" in diameter) are factory installed and
do not require any field adjustments.
Continued
Dukane Manual Part No. 403-586-03
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91
iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
Hydraulic Speed Control Kit Operation
Turning the SLOW SPEED knob rotates the rod.
This in turn causes the contact block to ride up or down
on the rod, moving the contact point closer to or further
from the hydraulic cylinder at rest.
This distance determines how far the contact block, and
therefore the slide assembly, must travel before the block
contacts the plunger of the hydraulic cylinder.
The plunger has a maximum travelling distance of one inch
(25.4 mm). The first 1/4 inch (6.4 mm) of travel decelerates
the speed of the slide assembly. The remaining 3/4 inch
(19.1 mm) of travel allows the slide assembly to descend
at a constant slow speed set by the operator.
Threaded
Rod
Contact Block
Plunger
13
Rotating this shaft adjusts the internal metering aperture
which regulates the flow of the silicone fluid. There are
two ways to adjust the hydraulic speed control setting. First
make sure that the slide assembly is fully retracted (up position). This will uncover the hydraulic damper and shaft.
•
•
3
16
2
17
1
18
0
Indicator Flag
20
Hydraulic
Cylinder
Speed Adjustment
Figure 6-4
Insert the end of a small screwdriver or similar tool
into the hole (Figure 6-5) in the adjustment shaft of
the hydraulic cylinder, OR,
Locate the slot on the bottom of the cylinder (Figure
6-6). Insert a screwdriver in the slot and adjust the
setting.
4
15
Clamping
Collar
The slide assembly can only travel downward a maximum
of one inch (25.4 mm) after the block contacts the plunger.
Hydraulic Speed Control
Adjustment
5
14
Location of the Hydraulic Control
Components
20
Decrease
Increase
Figure 6-5
Just above the shaft is a scale with 30 divisions. On
the adjustment shaft is a vertical groove that indicates where along the scale the speed is set. Zero (0)
is the fastest setting, and thirty (30) is the slowest setting.
Adjustment Using the Hole
20
Decrease
Increase
Figure 6-6
Page
92
Adjustment Using the Slot
Dukane Manual Part No. 403-586-03
Section 6 - Options
Distance Encoder
Purpose
To install and calibrate the distance encoder in order to
accurately measure the distance of thruster travel.
Requirements
Parts
Kit (P/N 438-783) consisting of the following:
• Encoder (two pieces; P/N 625-18),
• Encoder head cable cover bracket, and
• Mounting screws and hardware.
Tools
Right Side Panel
• Phillips-head screwdriver
• Feeler gauge set (0-.050 inches) or metric equivalent
• 6 inch ruler or metric equivalent
Installation Instructions
Dismantling
1. Facing the front of the press, remove the panel from
the right side of the press. (See Figure 6-7.)
Encoder Scale
Reassembly
1. Mount the cable cover bracket from the kit and secure
it with flat head screws.
2. Attach the encoder scale to the mounting screw holes
in the right side of the thruster with pan-head screws.
Do not tighten.
3. Remove the back panel from the press and route the
encoder head cable, being careful not to interfere with
the press movement.
Encoder
Head
Figure 6-7 Distance Encoder Mounting
4. Connect the encoder cable to the generator connector
J-11 (Encoder).
5. Replace the rear panel on the press.
Continued
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Continued from Previous Page
Reassembly
6. Gently slide the encoder head down until the mounting screw holes in the press support base appear in
the head’s mounting slots.
7. Center the screw holes in the mounting slots. Secure
the encoder head with the two pan-screws but do not
tighten them yet.
Alignment
The purpose of this alignment is to set the internal reference mark for the encoder. This reference mark resets
the distance register in the generator after each thruster
cycle and ensures repeatable distance measurements from
cycle to cycle.
Moving
Encoder
Scale
.039 in (1 mm)
Gap
Stationary
Encoder
Head
1. Check the position of the encoder scale’s mounting
hole slots using the 6" ruler. Measure the distance
from the center of the screw to the edge of the slot
in both directions. When the screws are centered
horizontally, carefully tighten the screws.
2. Measure a vertical distance of 1.375 inches (34.92
mm) up from the bottom edge of the encoder scale,
as shown in Figure 6-8.
3. Adjust the bottom edge of the encoder head to align
to this distance and tighten the screws on the encoder
head.
1.375”
Figure 6-8
Distance Encoder Alignment
4. Push in the ABORT button (on the press base).
Turn on the generator, and set it to measure distance.
5. Set the air pressure to the desired level.
6. Perform the following procedure to test the encoder
for the proper setting:
WARNING
Keep hands and clothing
away from an activated
press.
• Pull out the ABORT button (on the press
base). Allow the thruster to return to top of
stroke.
• If the encoder position reads -0.06" to 0.30",
then the encoder is set correctly.
• Secure the two screws. Proceed to Step 7.
Continued
Page
94
Dukane Manual Part No. 403-586-03
Section 6 - Options
Continued from Previous Page
Alignment
7. Set the gap between the encoder scale and head, using
the feeler gauge 0.039 inch (1 mm) blade.
8. Measure the gap at the top and bottom of the stroke.
Allowable tolerance, as specified by the encoder
manufacturer, is ± 0.005. This is a range of from 0.034
to 0.044 inches (0.864 to 1.12 mm).
9. Tighten all the screws and check the measurements
again.
10. Replace the press/thruster right side panel.
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Dukane Manual Part No. 403-586-03
Section 7 - Acoustic Stack/Fixture Setup
SECTION 7
Acoustic Stack/Fixture Setup
Overview . . . . . . . . . . . . . . . . . . . . . . 99
Stack Description. . . . . . . . . . . . . . . . .
100
Changing Stack Components. . . . . . . . . . . 101
Stack Removal . . . . . . . . . . . . . . . . . . . . 101
Stack Disassembly . . . . . . . . . . . . . . . . . . 102
Removing a Detachable Tip. . . . . . . . . . . . . 102
Stack Assembly and Torque Values. . . . . . . . . 103
Installing a Detachable Tip . . . . . . . . . . . . . . 104
Installing the Stack . . . . . . . . . . . . . . . . . . 104
Fixture Installation. . . . . . . . . . . . . . . . . 105
Fixture Alignment . . . . . . . . . . . . . . . . . . 105
Fixture Leveling. . . . . . . . . . . . . . . . . . . 106
Dukane Manual Part No. 403-586-03
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Dukane Manual Part No. 403-586-03
Section 7 - Acoustic Stack/Fixture Setup
Overview
A Dukane press/thruster and a iQ Series generator can be
used to assemble an unlimited variety of parts for every
conceivable market segment, including Automotive,
Medical, Appliance, Consumer, Packaging and Toy
industries. Various techniques and processes, such as
welding, staking, swaging, inserting, and spot welding
can be used for the different applications.
This variety is made possible through the interchange of
some system components. Of these components, the horn
and fixture are usually custom-made for each application,
and the booster that is selected for a job depends on the
required horn output amplitude. Also, the press/thruster
controls are specifically adjusted for each application.
This section provides instructions for setting up these
components of the system in a new installation or when
changing applications.
Dukane Manual Part No. 403-586-03
Page
99
iQ Series Ultrasonic Press System LE User’s Manual
Stack Description
The acoustic stack shown in Figure 7-1 consists of three
parts:
•
•
•
Transducer
Booster
Horn
The transducer and the booster are normally shipped
assembled and installed in the press. The horn and/or the
fixture may be shipped separately.
The stack is easily removed from or installed in the
press/thruster. This makes it possible to change the horn
or booster. It also makes it easier to perform regular
inspections and/or maintenance of the stack components.
TRANSDUCER
Contact Button
BOOSTER
Transducer Housing
Anti–Rotation Pins
Mounting Stud
Mounting Ring
HORN
Spanner Wrench Hole (Typical)
Figure 7-1
Page
100
Stack Components
Dukane Manual Part No. 403-586-03
Section 7 - Acoustic Stack/Fixture Setup
Changing Stack Components
Stack Removal
Before removing the stack, perform the following steps:
1. Activate the E-STOP (Abort) switch on the
front of the press base.
2. Power down the generator.
These two steps are necessary to ensure that no
power will be accidently applied while removing
the stack.
3. While supporting the stack with one hand,
loosen the two or four socket-head screws that
secure the stack access door.
4. If the door has two screws, swing it open. If it
has four screws, remove it completely.
5. Pull the stack forward and down until the
transducer clears the electrical contact. Refer
to Figure 7-2.
6. Lift the stack out of the housing.
CAUTION
The stack access door on
the press/thruster holds
the stack components in
the stack housing. Hold
the stack by the HORN or the exposed
part of the BOOSTER when removing
or installing the access door. This will
prevent the stack from falling out and
being damaged.
NOTE
When changing or inspecting any of
the stack components, ALWAYS remove the stack from the thruster.
CAUTION
There may be an electrical charge stored in the
transducer. To avoid any
electrical shock, do not
touch the contact button when removing the stack.
Figure 7-2
Stack Removal
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Stack Disassembly
To separate the stack component carefully follow the
instructions below:
1. Use the two spanner wrenches (wrench A and B)
provided with the press. Place wrench A on the
component to be removed (Refer to Figure 7-3) and
wrench B on the one next to it. Turn wrench A in the
direction indicated.
A
B
Once the component is loose, it can be removed by
hand.
2. To maintain structural integrity, NEVER hold a
transducer by the housing or the booster by the
mounting rings while separating components. Doing
so will result in damage to the unit.
Figure 7-3
Disassembling Components
CAUTION
3. Use only the tools recommended by Dukane.
NEVER clamp a horn, booster, or transducer in a
vise or use tools such as pliers, visegrips, etc. Doing
so will result in scratches and/or gouges, resulting
in stress areas on the surface. This condition will
affect the stack operation and could lead to failure
of each stack component.
To avoid possible injury,
press down on the
spanner wrench with the
palm of the hand.
Removing a Detachable Tip
If the horn has a detachable tip, do the following:
1. Use a spanner wrench to hold the horn, as shown in
Figure 7-4.
2. Turn a properly sized open end wrench to loosen the
tip.
NEVER clamp the horn or use a vise to hold it.
Figure 7-4
Page
102
Tip Removal
Dukane Manual Part No. 403-586-03
Section 7 - Acoustic Stack/Fixture Setup
Stack Assembly
Before assembling a stack, inspect all of the components
for possible damage — especially the surfaces that are to
be joined. Look for non-flat surfaces (concave, convex),
stress cracks, chips, or gouges. Any of these irregularities
will affect the operation of the stack and could cause
further damage. Contact the Dukane Tooling Department
concerning a damaged component.
When the components have been inspected and are found to
be free of any damage, continue with the following steps:
1. Inspect the contact surfaces for smoothness and
cleanliness. Pitting or a buildup of old grease and dirt
on the surface will interfere with the transfer of energy
from one component to another.
2. Remove any foreign matter from the threaded stud
and the mating hole. Tighten the stud in the stack
component that is most distant from the transducer
according to the following stud torque values:
Stud Thread
Size
inch-lbs
foot-lbs
Torque
Nt-meters
1/2 in. x 20
12-18
1 - 1.5
1.4 - 2
3/8 in. x 24
12-18
1 - 1.5
1.4 - 2
M8 x 1.25
12-18
1 - 1.5
1.4 - 2
Table 7-I Stud Torque Values
3. Coat one of the contact surfaces with a thin coat of
high-pressure grease. A small packet is supplied with
the system. We recommend Dow–Corning #4 (or #111
as an alternate).
NOTE
Do not apply any grease or lubricant to
the stud.
4. Thread the components together and tighten (Refer to
Table 7-II) by applying torque as follows:
Torque
Stack
kHz
inch-lbs
foot-lbs
15
540
45
61
20
420
35
47.5
30
216
18
24.4
40
216
18
24.4
Nt-meters
Table 7-II Horn/Booster Torque Values
Figure 7-5
Dukane Manual Part No. 403-586-03
Assembling Components
Page
103
iQ Series Ultrasonic Press System LE User’s Manual
Installing a Detachable Tip
If the horn has a detachable tip, do the following:
1. Inspect the surfaces of the tip and the horn for any
stress cracks, chips or gouges.
NOTE
Do not apply any lubricant to the tip
threads.
2. Coat one of the contact surfaces with a thin coat of
high-pressure grease or lubricant. We recommend
Dow–Corning #4 (or #111 as an alternate).
3. Thread the tip into the horn. To tighten the tip, use the
open-end wrench for the tip and a spanner wrench to
hold the horn, as shown in Figure 7-6.
Tighten the tip to the following specifications:
Tip Stud
Thread
Size
Torque
inch-lbs
foot-lbs
Nt-meters
1/2 in. x 20
360
30
40.7
3/8 in. x 24
336
28
37.9
5/16 in. x 24
300
25
33.9
1/4 in. x 28
240
20
27.1
Figure 7-6
Tip Assembly
Table 7-III Replaceable Tip Torque Values
Installing the Stack
1. With the stack at the angle shown in Figure 7-7, rest the
booster mounting ring on the pin of the stack housing.
2. Brace the stack at point A in Figure 7-7, and swing
the stack to a vertical position. The ultrasound contact
button on the transducer should snap under the
electrical contact leaf of the housing.
3. While still supporting the stack in this vertical position,
install the stack access door, and thread the two or four
socket-head bolts (that hold the door closed) into their
holes.
A
4. If the horn is not properly aligned with the fixture,
rotate the stack to align the horn with the fixture.
5. Finish tightening the socket head bolts until snug.
DO NOT OVER-TIGHTEN!
Figure 7-7
Stack Installation
NOTE
When all door screws are tightened, a small
gap between the door and stack housing is
normally present.
Page
104
Dukane Manual Part No. 403-586-03
Section 7 - Acoustic Stack/Fixture Setup
Fixture Installation
There are three steps involved in installing a fixture.
• Aligning the fixture with the horn,
• Leveling the fixture to provide the necessary support,
and
• Rigidly securing the fixture to the mounting surface.
Fixture Alignment
To safely align the fixture under the horn, use the following
procedure. (Refer to Figure 7-8.)
1. Depress the E-STOP (Abort) switch. This allows the
acoustic stack assembly to be lowered by hand and
prevents the system from accidentally cycling.
2. Turn off the power to the generator to prevent accidental ultrasound operation.
3. Place the fixture, with parts, under the horn.
4. Initially align the two slots in the fixture over two of
the seven mounting holes on the base plate.
5. Install the two hold-down bolts with washers, and
finger tighten.
Figure 7-8
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.
Fixture/Base Layout
Continued
Dukane Manual Part No. 403-586-03
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Continued from Previous Page
Fixture Alignment
6. Place a part in the fixture.
7. Grasping the horn firmly, pull the acoustic stack assembly down until the horn is as close to the part as
necessary to align the fixture.
8. Align the fixture with the horn, and tighten the holddown bolts, or cap screws, to prevent the fixture from
moving.
9. Adjust the mechanical stop of the press so that the horn
stops above the fixture. This prevents pinch points and
avoids horn damage if the acoustic stack assembly
descends when a part is not in the fixture.
NOTE
The fixture should be flat on the base.
If the fixture is equipped with leveling
jack screws, adjust the screws so that
they do not interfere with seating of the
fixture on the base plate.
Fixture Leveling
For most applications, the fixture must be mounted so
that the contacting surfaces on the horn are parallel to the
contacted surfaces on the plastic part. This ensures that a
consistent, even weld will result. To level the fixture, do
the following:
1. Place a part in the fixture.
2. Loosen (turn counterclockwise) the hold-down bolts
or cap screws and the four leveling jack screws on
the fixture plate. Refer to Figure 7-9.
3. Pull the acoustic stack assembly down to the fixture.
Allow the horn and the part to align.
4. Turn the four jack screws clockwise until a slight resistance is felt. Refer to Figure 7-10.
NOTE
Some applications may require the horn to be a few
thousandths of an inch from contact
with the fixture.
Special applications may require the
Mechanical (MEC) stop to be lowered
so the horn makes contact with the
fixture or anvil. When this is required,
a ground-detect circuit is needed to
terminate the weld cycle.
5. Tighten the hold-down cap screws by turning them
clockwise until a firm resistance is felt.
NOTE
Do not overtighten the cap screws.
This may flex the fixture plate.
Figure 7-9
Loosening the Hold–Down
Cap Screws and Jack Screws
Figure 7-10
Tightening the Hold–Down
Cap Screws and Jack Screws
Continued
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106
Dukane Manual Part No. 403-586-03
Section 7 - Acoustic Stack/Fixture Setup
Continued from Previous Page
Fixture Leveling
6. If any readjustment is necessary, loosen the hold-down
screws first. Then readjust the jack screws.
The following procedure may be helpful in leveling the
fixture in some applications. To perform this procedure,
use a piece of carbon paper and a piece of white paper.
1. Place a sample part in the fixture.
2. Place a piece of white paper on top of the sample part.
3. Place a piece of carbon paper, carbon side down, on
top of the white paper.
4. Enter the following parameters into the generator:
Weld Time = 0.05
Hold Time = 0.00
System parameters = Use default settings. See examples on Application Setup Worksheet.
5. Set pressure to a value from 20 to 40 psi.
6. Set the trigger control on the thruster so that the pressure switch closes after some pressure is applied.
7. Press the ONLINE button on the generator.
8. Cycle the equipment by activating both finger switches
on the base or by triggering the automation switch.
When one cycle is completed, the pressure developed
between the horn and the sample part will have left marks
from the carbon paper on the white paper. If the fixture
is not level, the carbon markings will be darker in some
areas than in others. All carbon markings will be uniform
when all adjustments have been made properly.
Adjust the leveling of the fixture and repeat this procedure
as necessary until you are confident that the fixture is level.
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Dukane Manual Part No. 403-586-03
Section 8 - Stack Maintenance
SECTION 8
Stack Maintenance
Inspection of the Acoustic Stack Components . . . . . 111
Reconditioning Stack Components . . . . . . . . . . . . . . 112
Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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Section 8 - Stack Maintenance
Inspection of the Acoustic Stack Components
It is essential that the mating faces between an ultrasonic
transducer/booster and a booster/horn be absolutely flat
and parallel. If there is any air gap, there will be a loss in
power output and efficiency. Coupling may be so poor as
to prevent the startup of vibration from the stack, due to
the excessive power draw at the mating surfaces.
The condition of excessive crowning, or uneven contact
surfaces, is normally made evident by a burnished
appearance around the bolt hole areas of the contact
surfaces. This condition indicates that contact between the
parts occurs only at the burnished areas and not across the
full faces of the mating surfaces. (See Figure 8-1.)
The following flatness tolerances are specified for
Dukane transducers, boosters, and horns used in 20 kHz
applications:
Transducer
0.0005 inch
Booster
0.0005 inch
Horn
0.0005 inch
Burnished
Area
Figure 8-1
Crown
To check if there may be a flatness problem, first
disassemble the stack and look at the mating surfaces.
If there are burnished areas at the periphery of a contact
surface, that surface may be crowned in the center. Place
a straight edge along the face. Refer to Figure 8-2. If light
can be seen along the edges, it is crowned.
The surface may also be depressed in the bolt area. Refer
to Figure 8-3. In this case, there will be contact only at
the peripheral edges and light will be visible beneath the
straight edge in the center region.
Example of Burnished Area
Straight
Edge
Gap
Figure 8-2
Example of Crowning
Gap
Straight
Edge
Figure 8-3
Dukane Manual Part No. 403-586-03
Example of Center Depression
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Reconditioning Stack
Components
To restore the interface to the proper condition, do the
following:
1. Disassemble the transducer/booster/horn stack and
wipe interfaces with a clean cloth or paper towel.
2. Examine all interfaces. If any interface is corroded or
shows a dark, hard deposit, it should be reconditioned.
3. If the interfaces appear to be in good condition, go to
Step 11.
NOTE
The operating efficiency of the
equipment will be greatly affected
if the mating interfaces of the transducer/booster/horn stack are not flat,
make poor contact with each other,
or become corroded. A poor contact condition wastes power output,
makes tuning difficult, can affect the
noise level, and can cause possible
heat damage to the transducer.
4. If necessary, remove the mounting studs.
CAUTION
5. Tape a clean sheet of #400 grit (or finer) silicon carbide
wet-or-dry paper to a clean, smooth, flat surface. A
piece of plate glass is usually suitable.
Use extreme care to
avoid tilting the part. Loss
of flatness of interface
surfaces may render
the welding system
inoperative.
6. Hold the part to be conditioned at its lower end with
your thumb over a spanner wrench hole. Carefully
stroke the part once in one direction (toward you)
across the abrasive paper, as shown in Figure 8- 4.
Do not apply downward pressure. The component’s
weight alone provides sufficient pressure. Perform a
second stroke.
7. Rotate the part 120° (1/3 rotation) to the next
spanner wrench hole. Repeat the procedure outlined
in Step 6.
8. Rotate the part the remaining 120° and repeat. Be
certain to perform the same number of strokes at each
orientation: Two strokes per rotation.
9. Before reinserting a stud in any horn, perform the
following for proper engagement of the threads:
a. Visually inspect and clean the stud.
b. Clean the threaded hole using a clean cloth or
towel.
c. Tighten the stud to the torque specifications listed
in Table 7-I.
Figure 8-4
Method of Component Resurfacing
CAUTION
Use extreme care to
avoid multiple strokes at
each 1/3 rotation of the
part. Loss of flatness
and perpendicularity of
the interface surface to
the centering axis of the
part may render the welding system
inoperative.
Continued
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Dukane Manual Part No. 403-586-03
Section 8 - Stack Maintenance
Continued from Previous Page
Reconditioning Stack Components
10. Reexamine the interface surface and repeat Steps
6 through 9 until most of the contaminate has been
removed. This should not take more than 2 or 3
complete rotations of the part being reconditioned.
11. Reassemble and install the stack, using the procedure
in Section 7 of this manual. Recheck the power supply
tuning.
Torque Values
See Section 7, Acoustic Stack/Fixture Setup for torque
values:
Table 7-I - Stud Torque Values
Table 7-II - Horn/Booster Torque Values
Table 7-III - Replaceable Tip Torque Values
Dukane Manual Part No. 403-586-03
NOTE
Thread deformation may occur
if the studs are overtightened.
Removal of the stud could
damage the threads in the
horn. If this occurs, re-tap the
horn threads and replace the
stud with a new one. Use studs
recommended by Dukane.
NOTE
Overtightening stack components may result in horn/
booster studs loosening and
unexplained overloads.
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Dukane Manual Part No. 403-586-03
Section 9 - Troubleshooting
SECTION 9
Troubleshooting
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Primary Weld Characteristics . . . . . . . . . . . . . . . . . . . . 117
End of Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Staking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Continuous Welding . . . . . . . . . . . . . . . . . . . . . . . . 131
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Dukane Manual Part No. 403-586-03
Section 9 - Troubleshooting
Overview
The Troubleshooting section of this manual contains
a listing of problems that may occur when using this
equipment along with probable causes and recommended
solutions for the problems.
Regarding solutions, please note the following:
Where the solutions section refers to changing a setting
for a primary weld characteristic, these adjustment
capabilities and controls must be available on your
equipment.
Primary Weld Characteristics
Primary weld characteristics refers to methods used
to control the welding process. The characteristics
include Time, Distance, Position and Energy.
To be functional in your system, each characteristic
needs corresponding hardware/software support from
the generator.
Table 9-I shows each characteristic and its equipment
requirements.
Primary Weld
Characteristic
Equipment Requirements
Time
Generator with a digital timer or process controller with a time
function.
Distance
Process controller with a distance measurement function and a
press / thruster equipped with an optical distance encoder.
Position
Process controller with a distance measurement function and a
press/thruster equipped with an optical distance encoder.
Energy
Process controller with an energy measurement function.
Table 9- I
Weld Characteristics and Equipment Requirements
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Welding
__________________________________________________________________________________
Problem
Flash (See also: Uneven Welding)
Probable Cause
Solution
Energy director is too large.
Reduce the size of the energy director.
Reduce the weld time/primary weld characteristic.
Reduce the air pressure.
Use an interrupted energy director.
Shear interference is too great.
Reduce the amount of interference.
Weld time is too long.
Reduce the weld time.
Non-uniform joint dimensions.
Re-dimension the joint.
Redesign the joint to be a shear joint or
a tongue-in-groove joint. Contact Dukane's Applications
Lab.
Check the processing conditions.
Part fit or tolerances.
Loosen the part fit.
Loosen the part tolerances.
__________________________________________________________________________________
Problem
Misalignment of the welded assembly
Probable Cause
Solution
Parts are not self-aligning.
Design a means of alignment into the
tooling (fixturing).
Add a means of alignment (e.g., pins
and sockets) to the mating part halves.
Improper support in the fixture.
Redesign the fixture for proper support.
Wall flexure.
Add ribs or gussets to the part.
With a resilient fixture, if large sections
of urethane are deflecting, add a rigid
backup.
Joint design is not properly dimensioned.
Re-dimension the parts.
Incorrect part tolerance/poor molding.
Tighten the part tolerance.
Check the processing conditions.
__________________________________________________________________________________
Continued
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Dukane Manual Part No. 403-586-03
Section 9 - Troubleshooting
Welding
_______________________________________________________________________________
Problem
Internal components are welding together.
Probable Cause
Solution
The internal components are made
of the same material.
Make the internal components out of
different materials.
Carefully lubricate the internal parts.
Use less horn amplitude by changing to a lower gain booster.
_______________________________________________________________________________
Problem
Diaphragm Damage
Probable Cause
Solution
Excessive horn amplitude.
Reduce the horn amplitude.
Dampen the welding area to absorb the
amplitude.
Excessive exposure to ultrasound.
Reduce the weld time and increase the horn
amplitude and/or air pressure.
Improper gate location/design/thinwall sections.
Check gate placement.
Change the shape of the gate.
Add stiffening ribs to the part.
Increase the thickness of the material on
the underside of the gate area.
If using a 20 kHz system, consider using
a 30 kHz or 40 kHz system.
The type of horn and/or its placement.
Check for the proper horn/part fit.
Change the horn.
_______________________________________________________________________________
Problem
Overwelding
Probable Cause
Solution
Too much energy is being transmitted
to the part.
Reduce the air pressure.
Reduce the weld time/primary weld
characteristic.
Change to a lower gain booster to reduce the horn
amplitude.
Reduce downstroke speed.
_______________________________________________________________________________
Continued
Dukane Manual Part No. 403-586-03
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Welding
__________________________________________________________________________________
Problem
Internal components of work piece damaged during welding.
Probable Cause
Solution
Excessive horn amplitude
Reduce the horn amplitude by changing to a lower gain
booster.
Dampen the excess horn amplitude.
Excessive exposure to ultrasound.
Reduce the primary weld time and
increase the horn amplitude by changing to a higher gain
booster.
Too much energy transmitted into
the part.
Reduce the horn amplitude.
Reduce the air pressure.
Reduce the weld time/primary weld characteristic.
The components are improperly
mounted (e.g., parts are mounted
too close to the joint area).
Ensure that internal components are mounted properly.
Isolate internal components from the part.
Move the internal components away from areas of high
energy.
Use an external device to dampen energy locally.
__________________________________________________________________________________
Problem
Melting or fracturing of the part (outside of the joint area).
Probable Cause
Solution
Sharp internal corners/thin sections.
Radius all sharp corners.
Dampen motion for any damaged area, if possible.
Excessive horn amplitude.
Reduce the horn amplitude by changing to a lower gain
booster.
A long weld time.
Decrease the weld time and
increase the horn amplitude and/or
the air pressure.
Inherent stress.
Check the molding conditions.
Check the part design.
Reduce the horn amplitude.
__________________________________________________________________________________
Continued
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Dukane Manual Part No. 403-586-03
Section 9 - Troubleshooting
Welding
_______________________________________________________________________________
Problem
Underwelding
Probable Cause
Solution
Insufficient energy is being transmitted
to the part.
Increase the air pressure.
Increase the weld time/primary weld characteristic.
Change to a higher gain booster to increase the horn
amplitude.
Use a more powerful assembly system.
Energy is being absorbed into the fixture.
Change the type of fixture being used.
_______________________________________________________________________________
Problem
Uneven welding
Probable Cause
Solution
Warped part(s).
Check part dimensions.
Check the molding conditions.
Use a higher trigger pressure.
Use a higher hold pressure.
The energy director varies in height.
Redesign the energy director to ensure uniform
height.
Use an interrupted energy director.
Lack of parallelism between the horn,
the fixture, and the part.
Make sure the thruster is perpendicular
to the part.
Check the part dimensions.
Wall flexure is occurring.
Add ribs to the part.
Modify the fixture to prevent outward flexure
The knockout pin location is in the
joint area
Redesign the part so the knockout pin
is not in the joint area (Make sure knockout pins are
flush with the surface)
There is insufficient support in
the fixture.
Redesign the fixture to improve the
support in critical areas.
Change to a rigid fixture.
If large sections of urethane are deflecting with a
resilient fixture, add a rigid backup.
_______________________________________________________________________________
Continued
Dukane Manual Part No. 403-586-03
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Welding
_________________________________________________________________________________
Problem Continued from Previous Page
Uneven welding
Probable Cause
Solution
Part dimensions are incorrect.
Check the part dimensions.
Re-dimension the part, if necessary.
Check the molding conditions.
The parts are improperly aligned.
Check for part shifting during welding.
Check the alignment of mating parts.
Check for parallelism of the horn, the part, and/or the
fixture.
There is a lack of intimate contact
around the joint area.
Check the part dimensions.
Check the part tolerances.
Check for knockout pin marks in the joint area.
Check for misalignment of the mating part halves.
Check for sinks.
Non-uniform horn contact is occurring.
Check the fit of the part to the horn.
Check for proper support in the fixture.
Mold release is on the joint surface(s).
Clean the mating surfaces.
There is a non-uniform distribution of
filler in the plastic material.
Check the molding conditions.
Check the mold design.
The joint design is incorrect.
Redesign the joint.
There is a material or resin grade
incompatibility problem.
Consult with the resin supplier(s).
There is a regrind problem.
Check with the molder.
Check the molding conditions.
There is moisture in the molded parts.
Specify the parts to be “dry as molded”.
Dry the parts by heating them prior to welding.
_________________________________________________________________________________
Continued
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Dukane Manual Part No. 403-586-03
Section 9 - Troubleshooting
Welding
________________________________________________________________________________
Problem
The parts are marking.
Probable Cause
Solution
The horn heats up.
Check for a loose stud, tighten if loose.
Loosen and then retighten the horn tip.
(Refer to Section 7).
Reduce the weld time.
Ensure that the horn and booster are coupling well.
(Refer to Section 7).
Visually check the horn for cracks.
There are high spots in the part.
Check the part dimensions.
Check the fit of the horn to the part.
Use of raised lettering.
Use recessed lettering or relieve the horn around the
lettering.
The part does not fit the fixture
properly.
Check the fixture for proper support.
Check for cavity-to-cavity variations.
Redesign the fixture.
Oxide from the horn is being
transferred to the part.
Place polyethylene film between the horn
and the part.
Use a chrome-plated horn and/or fixture.
The parts contain fillers.
Check the processing conditions.
Reduce the amount of filler in the plastic.
________________________________________________________________________________
Problem
Welding process not in control (inconsistent weld results on a part-to-part basis).
Probable Cause
Solution
A mold release agent is used.
Clean the mating surfaces.
If a mold release agent is necessary, use a
paintable/printable grade.
Incorrect part tolerances.
Tighten the part tolerances.
Check the part dimensions.
Check the molding dimensions.
There are cavity-to-cavity variations.
Check the part dimensions and tolerances.
Check for cavity wear.
Check the molding conditions.
________________________________________________________________________________
Continued
Dukane Manual Part No. 403-586-03
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Welding
__________________________________________________________________________________
ProblemContinued from Previous Page
Welding process not in control (inconsistent weld results on
a part-to-part basis).
Probable Cause
Solution
Part dimensions vary due to mold
cavity variations.
Perform a statistical study to see if a pattern
develops with certain cavity combinations.
The resin contains regrind or degraded
plastic.
Consult with the molder.
Check the molding conditions.
Reduce the percentage of regrind.
Improve the quality of the regrind.
Fluctuations in the AC line voltage
supplied to the generator.
Upgrade to a generator with line
regulation.
Fluctuations in the air line pressure.
Upgrade to a system with electronic pressure regulation.
Add a surge tank with a check valve to the air line.
Raise the compressor output pressure.
The plastic’s filler content is too high.
Reduce the percentage of filler in the plastic.
Check the processing conditions.
Change the type of filler (e.g., from short to long glass
fibers).
The horn doesn’t fit the part correctly.
Check the part dimensions.
Check for cavity-to-cavity variations.
Obtain a new horn.
The weld cycle is too long.
Reduce the weld cycle time and increase the horn
amplitude or air pressure.
Increase the dynamic trigger force.
There is a lack of parallelism between
the horn, part, and/or fixture.
Check for parallelism between the horn,
part, and fixture.
Check the horn/part fit.
Check the part/fixture fit.
Level the fixture, where necessary.
Rigid fixture reflects vibratory energy.
Dampen the energy by using teflon, neoprene, cork, or
urethane in the nest of the fixture.
__________________________________________________________________________________
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Dukane Manual Part No. 403-586-03
Section 9 - Troubleshooting
Insertion
_______________________________________________________________________________
Problem
The insert pulls out easily in use.
Probable Cause
Solution
There is insufficient interference between
the hole and the insert.
Reduce the size of the molded hole in
the plastic.
The screw bottoms out in the hole.
Use a shorter screw. (Applies to internallythreaded insert).
Deepen the hole.
The insert gets pushed into the plastic
before the plastic melts.
Use hydraulic speed control.
Increase the horn amplitude and/or decrease the air
pressure.
Use pre-triggering.
The ultrasound remains on after insertion
is complete.
Decrease the primary weld characteristic.
The horn retracts before the plastic
around the insert is solidified.
Increase the hold time.
_______________________________________________________________________________
Problem
Inconsistent insertion of multiple inserts on the same part.
Probable Cause
Solution
The plastic is not melting consistently
around all inserts.
Increase the horn amplitude.
Inserts are pushed into the plastic
before the plastic has melted.
Use hydraulic speed control.
Reduce the down speed.
Use pre-triggering.
Inserts are seated at different heights
within the same part.
Evaluate the support provided by the
fixture. If required, re-level or shim the
fixture.
Measure the horn tip length to check for dimensional
consistency. If a varying length is found, send the
horn to Dukane for modification.
_______________________________________________________________________________
Continued
Dukane Manual Part No. 403-586-03
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Insertion
________________________________________________________________________________
Problem
The boss or the plastic around the boss cracks after insertion.
Probable Cause
Solution
The insert is pushed in before the
plastic has melted.
Reduce the down speed, air pressure,
and/or horn amplitude.
Use pre-triggering.
The gauge pressure is set too high.
Reduce the air pressure.
The boss wall is too thin.
Increase the thickness of the boss wall.
There is too much interference between
the insert and the hole.
Increase the hole diameter.
Use a smaller insert.
________________________________________________________________________________
Problem
The insert is not driven to the desired depth.
Probable Cause
Solution
The ultrasound is not on long enough.
Increase the primary weld characteristic. Check the
bottom stop setting.
Increase the depth of the hole.
Flash fills the hole.
(Applies to an internally-threaded insert.)
There is insufficient air pressure and/or
ultrasonic power.
Increase the air pressure, the ultrasonic
power, or the horn amplitude.
________________________________________________________________________________
Problem
The cycle time is too long.
Probable Cause
Solution
There is insufficient ultrasonic power
or the generator overloads.
If using a power control, increase the
power.
Use a more powerful generator.
There is too much interference
between the hole and the insert.
Increase the hole diameter, if possible.
Use a smaller insert.
The area of the part being inserted
is not being rigidly supported.
Support the part directly under the boss.
Install a metal post directly under the part being
inserted.
The down speed is slow.
Increase the down speed.
Continued
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Dukane Manual Part No. 403-586-03
Section 9 - Troubleshooting
Insertion
_________________________________________________________________________________
Problem
Plastic flows over the top of the insert.
Probable Cause
Solution
The weld time is too long.
Decrease the primary weld characteristic.
The insert is being driven too deep.
Reset the bottom stop.
Decrease the primary weld characteristic.
There is too much interference
between the hole and the insert.
Increase the hole diameter, if possible.
Use smaller inserts.
_________________________________________________________________________________
Problem
Melted plastic fills the hole (applies to internally-threaded inserts).
Probable Cause
Solution
The insert is too long or the hole is
too shallow.
Use a shorter insert or
make the hole deeper.
There is too much interference
between the hole and the insert.
Increase the hole diameter.
Use smaller inserts.
The insert is being driven too deep.
Reset the bottom stop.
Decrease the primary weld characteristic.
_________________________________________________________________________________
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Staking
________________________________________________________________________________
Problem
A ragged or irregularly shaped stake head is formed.
Probable Cause
Solution
The staking cavity is too large.
Change to a smaller cavity in the horn.
The volume of plastic in the stud is
insufficient.
Increase the stud height/diameter.
The stud is melting at the base.
See the problem section that follows entitled
“The base is melting before the head forms.”
________________________________________________________________________________
Problem
There is excessive flash around the stake head.
Probable Cause
Solution
The staking cavity is too small.
Use a larger cavity in the horn.
The volume of plastic in the stud
is excessive.
Decrease the stud height and/or
diameter.
The stud is not centered in the
horn cavity.
Center the stud under the horn cavity.
________________________________________________________________________________
Problem
The surface below the stake head is distorted.
Probable Cause
Solution
The part is not supported directly
beneath the stud being staked.
Support the fixture with a metal post
beneath the stud being staked.
The trigger force is too high.
Reduce the trigger force.
Use pre-triggering.
________________________________________________________________________________
Problem
There is a loose fit between the staked head and the part being attached.
Probable Cause
Solution
The hole diameter relative to
the stud diameter is too large.
Reduce the hole diameter.
Continued
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Dukane Manual Part No. 403-586-03
Section 9 - Troubleshooting
Staking
_________________________________________________________________________________
Problem Continued from Previous Page
There is a loose fit between the staked head and the part being attached.
Probable Cause
Solution
The holding force was removed before
the stud head could solidify.
If using a dual pressure system, use
Pressure 2 in the hold portion of the weld cycle
(Pressure 2 should be higher than
Pressure 1).
Increase the hold time/distance.
Increase the stud diameter.
Reduce the size of the staking cavity.
Insufficient force is being applied to
the staked head during the hold time.
Lower the bottom stop for the horn’s
travel.
_________________________________________________________________________________
Problem
The stud is collapsing at its base.
Probable Cause
Solution
There is a sharp corner near the base
of the stud.
Radius the stud at the base.
The stud is not centered in the
horn cavity.
Center the stud under the horn cavity.
Use a knurled tip
The base is melting before the
head forms.
See the problem section below entitled
“The base is melting before the head forms.”
Too much pressure is applied before
the ultrasound is activated.
Use pre-triggering.
_________________________________________________________________________________
Problem
The base is melting before the head forms.
Probable Cause
Solution
The trigger force is too high.
Reduce the trigger force.
Pre-trigger the ultrasound.
The horn amplitude is insufficient.
Increase the amplitude.
The downstroke speed is too fast.
Use hydraulic speed control.
Use a slower downstroke speed.
_________________________________________________________________________________
Continued
Dukane Manual Part No. 403-586-03
Page
129
iQ Series Ultrasonic Press System LE User’s Manual
Staking
_________________________________________________________________________________
Problem
The formed stud head stays in the staking cavity as the horn retracts.
Probable Cause
Solution
The stud head has not solidified before
the horn retracts.
Increase the hold time.
The horn tip is heating and not
allowing the stud to solidify.
Cool the horn tip.
Use afterburst.
_________________________________________________________________________________
NOTE
The use of a knurled horn
tip and a pointed stud
can help solve many of
the above problems.
Page
130
Dukane Manual Part No. 403-586-03
Section 9 - Troubleshooting
Continuous Welding
_____________________________________________________________________________
Problem
Seal not meeting strength requirements.
Probable Cause
Solution
Material traveling too quickly.
Decrease speed.
Not enough horn amplitude.
Increase booster ratio.
Inconsistent blends of synthetic material.
Evaluate material.
________________________________________________________________________________
Problem
Inconsistent welding.
Probable Cause
Solution
Non-uniform amplitude horn.
Have horn analyzed for amplitude uniformity.
Variations in anvil (fixture).
Check fixture design and dimensions.
Inconsistency of material.
Evaluate material.
________________________________________________________________________________
Problem
Seal area too great, causing flash.
Probable Cause
Solution
Material traveling too slow.
Increase speed.
Too much amplitude.
Reduce booster ratio.
Excessive air pressure.
Reduce air pressure.
________________________________________________________________________________
Problem
Transducer and/or horn heating up.
Probable Cause
Solution
Not enough air flow to dissipate
heat buildup.
Continuous duty applications require
cooling air (refrigerated air, in some applications). Supply air to the stack interfaces and the horn tips.
________________________________________________________________________________
Continued
Dukane Manual Part No. 403-586-03
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131
iQ Series Ultrasonic Press System LE User’s Manual
Continuous Welding
_________________________________________________________________________________
Problem
Excessive horn wear.
Probable Cause
Solution
Metal-to-metal contact between
the horn and anvil.
Use carbide inserts or have horn face
carbide-coated.
Reduce metal-to-metal contact.
_________________________________________________________________________________
Problem
Overloading generators.** See the NOTE below.
Probable Cause
Solution
Loose stack components.
Disassemble, clean and reassemble stack.
Horn failure.
Replace horn.
Transducer failure
Replace transducer.
Booster failure.
Replace booster.
Stack operating frequency shifted
out of tolerance.
Cool stack with air.
_________________________________________________________________________________
**
Page
132
NOTE
Table 5-I, Page 83, shows
alarm messages that indicate
generator status, and appear
only on display-capable
generators.
Dukane Manual Part No. 403-586-03
Section 10 - System Maintenance
SECTION 10
System Maintenance
Press/Thruster Six-Month Periodic Maintenance . . 135
Dukane Manual Part No. 403-586-03
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Dukane Manual Part No. 403-586-03
Section 10 - System Maintenance
Press/Thruster Six-Month
Periodic Maintenance
1. Disconnect the generator AC power cord from the AC
line receptacle. Then, remove the thruster left and right
side covers.
2. Check that all socket-head cap screws in the press/
thruster are tight. Check the air cylinder mounting.
3. Wipe or blow away all dirt and grease in the press/
thruster.
4. Wipe away all excess oil and any dirt accumulation,
especially at the exhaust openings in the transducer
housing. There should be very little, if any, oil accumulation at the air exhaust opening. We recommend
that no oil get into the press/thruster pneumatics.
Regular accumulation of oil at the air exhaust opening
means that some oil is getting into the pneumatics. To
rectify this problem, route the air for the press/thruster
through an “oil mist reclassifier”.
5. Check the press/thruster slide operation for smooth
downward motion. Wipe away any accumulated
grease, but do not apply any solvents. If movement is
not smooth, the lower bearing may be greased with
AFB lithium grease in the standard grease fitting
provided.
6. Ensure that all wire and cable connections are secure
in the press/thruster and are not rubbing or showing
wear. If they do show wear or rubbing then reroute to
eliminate the problem.
7. Remount and secure the press/thruster covers and
reconnect the generator AC power cord to the AC line
receptacle.
Dukane Manual Part No. 403-586-03
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Dukane Manual Part No. 403-586-03
Section 11 - Contacting Dukane
SECTION 11
Contacting Dukane
Dukane Manual Part No. 403-586-03
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Dukane Manual Part No. 403-586-03
Section 11 - Contacting Dukane
Contacting Dukane
Identify Equipment
When contacting Dukane about a service–related problem,
be prepared to give the following information:
• Model number, line voltage and serial number.
• Alarm indicators from the generator display.
• 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. 403-586-03
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Dukane Manual Part No. 403-586-03
Section 12 - Specifications
SECTION 12
Specifications
Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143-147
Press Dimentions . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Pneumatic Schematic . . . . . . . . . . . . . . . . . . . . . . . 145
Weights, Dimensions, Operating Environment . . . . 148
Compressed Air Requirements . . . . . . . . . . . . . . . . 149
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . 149
Interpreting the Model Number Codes . . . . . . . . . . 150
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . 152
Regulatory Agency Compliance . . . . . . . . . . . . . . . 153
Dukane Manual Part No. 403-586-03
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Dukane Manual Part No. 403-586-03
Section 12 - Specifications
32.00
[813]
5.19
[132]
q
17.18
17.18
[436]
[436]
1.75
1.75
[47]
[47]
DETAIL 1
SEE SEE
DETAIL
1
10.82
10.82
[275]
[275]
q
[100]
3.94
3.94
[100]
[31]
1.22
1.22
[31]
1.26
1.26
[32]
[32]
IN
[MM]
7.00
[178]
STROKE
2.45
[62]
DETAIL 1
1.94
[49]
7.0 ONLY WITH OPTIONAL
7.0/178
[178]
HYDRAULIC SPEED CONTROL
14.17
[360]
[360]
14.17
SEE NOTE 1
AIR IN
12.99
12.99
[330]
[330]
BNC
7.48
7.48
[190]
[190]
U/SU/S
BNC
AIR IN
1.26
1.26
[32]
[32]
1.18
1.18
[30]
[30]
.99
.99
[25]
[25]
143
Page
Dukane Manual Part No. 403-586-03
7.77
.77
[197]
[197]
1.31
1.31
[33]
[33]
13.68
13.68
[347]
[347]
q
2.58
2.58
[66]
[66]
Layout - 220 Thruster
Figure 12-1
5.60
5.60
[142]
[142]
OPTIONAL IQ
GENERATOR
iQ Series Ultrasonic Press System LE User’s Manual
9.29
[236]
12.43
[316]
7.0 [178]
1.75
[44]
17.14
[435]
ONLY WITH
OPTIONAL HYDRAULIC SPEED CONTROL
31.94
[811]
1.45
[37]
7.00 MAX.
5.38
[137]
STROKE
TYPICAL HORN
[381]
OPTIONAL
GENERATOR
XGT MODEL
SHOWN
4.75
[121]
15.00 MAX.
12.38
[314]
14.75
[375]
12.38
[314]
24.84
[631]
23.70
[602]
17.09
[434]
44.09
[1120]
14.00
[356]
12.38
[314]
16 . 50
[419]
8. 250
[210]
Dukane Manual Part No. 403-586-03
144
Page
7.24
[184]
5.19
[132]
18.58
[472]
(PART HEIGHT+FIXTURE)
[178]
Figure 12-2 Layout - 220 Press
Section 12 - Specifications
Figure 12-3
Pneumatic Schematic (All iQ LE Presses)
Dukane Manual Part No. 403-586-03
Page
145
iQ Series Ultrasonic Press System LE User’s Manual
13.94
[354.05]
ALLOW 5"
EA SIDE FOR
COOLING
5.19
[131.90]
OPERATOR
DISPLAY
NOTE:
17.16
[435.76]
POWER LIGHT
ALLOW 3" IN BACK FOR CABLING
OPERATOR
CONTROLS
IN
[mm]
13.40
[340.40]
ALLOW 5"
EA SIDE FOR
COOLING
5.51
[139.90]
WEIGHT: 25 LBS
POWER SWITCH
AC POWER
ENTRY
COOLING FAN
ULTRASOUND &
SYSTEM I/O'S
OPTIONS CARDCAGE
PANELS
Dukane Manual Part No. 403-586-03
146
Page
iQ LE Basic Generator Layout
Figure 12-5
17.16
[435.76]
POWER LIGHT
ALLOW 6" IN BACK FOR CABLING
OPERATOR
CONTROLS
IN
[mm]
18.23
[462.97]
ALLOW 5"
EA SIDE FOR
COOLING
5.51
[140.00]
WEIGHT: 34 LBS
POWER SWITCH
COOLING FAN
ULTRASOUND &
SYSTEM I/O'S
OPTIONS CARDCAGE
PANELS
AC POWER
ENTRY
147
Page
Dukane Manual Part No. 403-586-03
15.14
[384.47]
ALLOW 5"
EA SIDE FOR
COOLING
5.19
[131.83]
OPERATOR
DISPLAY
NOTE:
iQ LE 4800W Generator Layout
Figure 12-6
iQ Series Ultrasonic Press System LE User’s Manual
Weights
Press (includes base and column)
Model Number
43Q220
Thruster
Pounds
Kilograms
Pounds
Kilograms
170
77
45
20
Shipping: Add 10 pounds (2.3 kg) to unit weight for packing materials
Table 12- I
Weights
Dimensions in (mm)
Press (includes base and column)
Model Number
43Q220
Height
Width
Depth
56.94 (1450)
18.6 (475)
24.8 (630)
NOTE: Add 4" (100 mm) behind the press/thruster for air input line and cable connections.
Table 12- II
Dimensions
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
Non Operating storage guidelines:
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
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Dukane Manual Part No. 403-586-03
Section 12 - Specifications
Compressed Air Requirements
For all press/thruster models, Dukane recommends 80-110 psi of clean, dry air.
Maximum available clamping pressure:
Model
43Q220
Table 12- III
Force Generated at
110 psi (lb)
Standard Air Cylinder
Diameter (in)
540
2.50
Clamping Pressure
AC Power Requirements
The press/thruster uses 24VDC @ 2 Amps, obtained from the iQ Series generator to which
it is connected. The AC line voltage and current needed depend on whichever generator has
been chosen for your system. See the table below.
Operating
Frequency
Generator
Model Number
Overload
Power
Ratings
(Watts)
Input AC Power Requirements
Nominal AC Volt
@ Maximum RMS Current
20kHz
20XX120-1Z-XX-XX
1200
100-120V 50/60 Hz @ 15 Amps
20kHz
20XX120-2Z-XX-XX
1200
200-240V 50/60 Hz @ 8 Amps
20kHz
20XX240-2Z-XX-XX
2400
200-240V 50/60 Hz @ 15 Amps
20kHz
20XX360-2Z-XX-XX
3600
200-240V 50/60 Hz @ 25 Amps
Table 12- IV
North America/
Japan
AC Outlet Rating
15 Amps
30 Amps
AC Power Requirements
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.
Dukane Manual Part No. 403-586-03
Page
149
iQ Series Ultrasonic Press System LE User’s Manual
Interpreting the Model Number Codes
Model numbers use combinations of letters and numbers to identify each system
and its major components. Codes are given here for:
• iQ Series LE - Overall System Models (See Figure 12-7 below),
• Thruster Models (See Table 12-V below), and
• Generator Models (See Figure 12-8 on the next page).
iQ Series LE - Overall System Model Number Codes
20
24 .
Nominal U/S Frequency
2
P4 H3 . S Custom Code
Controller
Power Level
24 = 2400 Watts
18 = 1800 Watts
12 = 1200 Watts
20 = 20 kHz
Z-
LC = Less Cables
Z = Graphic front panel
Press Card
P4 = iQ Dual Pressure Card
P5 = iQ Distance Card
P8 = Ultra Dual Pressure Card
P9 = Ultra Distance Card
CS3 = SUWSI LITE Board
Example System Number Shown Above:
AC Line Input
2024.2Z - P4H3.S
E = 220-240 VAC (Europe)
N = 220/240 VAC (India)
2 = 200-240 V
1 = 100-120 V
System Detailed Description:
20kHz, 2,400 Watt, 220-240 VAC, generator
with graphic front panel, module for dual
pressure, hydraulic speed control, with 3” air
cylinder, and a standard press column.
Figure 12- 7
Support Options
T = Thruster Only
S = Standard Press
4 = 4 foot. Column
5 = 5 foot Column
6 = 6 foot Column
L = Less Base
Press Options
H = Hydraulic Speed Control
3 = 3” Air Cylinder
System Model Numbers
iQ Series LE Press/Thruster
Model
Number
43Q220
Table 12-V
Power
20kHz
Standard Options
D
P
H
X
X
X
Interpreting the Thruster Model Number
D - Distance encoder
P - Basic dual air pressure
H - Hydraulic speed control
X = available
Page
150
Dukane Manual Part No. 403-586-03
Section 12 - Specifications
1 2 0
Power Level
H S
Nominal U/S Frequency
2 0
15 = 15 kHz
20 = 20 kHz
30 = 30 kHz
40 = 40 kHz
50 = 50 kHz
70 = 70 kHz
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
P 4
Options Slot #2
LE Series Controller Options (Z)
P4 = Press Interface Board
P5 = Press Interface Board w/ Distance
P8 = Ultra Press Board
P9 = Ultra Press Board w/ Distance
C3 = SUWSI LITE Board
ES Series Options (A and Q)
P4 = Press Interface Board
P5 = Press Interface Board w/ Distance
P6 = Press Interface Board w/ Distance & Press Options
P7 = Servo Press Interface Board
C2 = Communications Board (A only))
C3 = SUWSI Board
iQ Generator Model Number Codes
Q
Options Slot #1
ES Series Options (A and Q)
P4 = Press Interface Board
P5 = Press Interface Board w/ Distance
P6 = Press Interface Board w/ Distance & Press Options
P7 = Servo Press Interface Board
C2 = Communications Board (A only)
C3 = SUWSI Board
System Process Control
Press System Options
A = ES Blank Front Panel w/ iQ Explorer (Time & Energy)
Q = ES Graphics Color LCD w/ iQ Explorer (Time & Energy)
Z = LE Graphics LCD (Time & Energy)
LE Series Controller Options (Z)
P4 = Press Interface Board
P5 = Press Interface Board w/ Distance
P8 = Ultra Press Board
P9 = Ultra Press Board w/ Distance
C3 = SUWSI LITE Board
151
Page
Dukane Manual Part No. 403-586-03
2 = 200-240V for 5.25" Tall Chassis
1800 W and 2400 W only
2 = 200-240 for 3.5" Short Chassis
1200 W and below
1 = 100-120V for 5.25" Tall Chassis
1200 W and below(fixed power cord)
Example System Number shown above:
20HS120-2Q-P4
System Assembly Detailed Description:
20kHz 1,200 Watt Press System in a 5.25" tall chassis which operates on a 100-120V AC Line with a rear panel mounted
breaker, a Time and Energy Weld Controller and a Pressure Press option board. The system power cord (if needed) is listed as
a separate line item on the sales order to match the user’s specific AC line power outlet configuration.
Generator Model Numbers
Figure 12- 8
iQ Series Ultrasonic Press System LE User’s Manual
Replacement Parts - iQ Series LE Presses
Part Number
Press Model
Part Description
43Q215
43Q220
High pressure grease packet
X
X
403-586-02
User's Manual iQ Series Ultrasonic Press System LE
X
X
430-03-0026
iQ main valve assembly
X
X
Air pressure gauge (NOT needed if standard option E is installed)
X
X
O
X
474-33
697-113
721-31-00056 Transducer door hex key 43Q220/43Q340
721-68
43Q215 / 43Q220 spanner wrench
X
X
804-33
Primary air cylinder, 2 1/2 " bore X 7"
O
X
804-52
Air pressure regulator (NOT needed if standard option E is installed)
X
X
804-62
Primary air cylinder 3" bore X 7"
X
O
804-63
Counter balance air cylinder 9/16" bore X 11"
O
X
804-71
Counter balance air cylinder 1 1/16 bore X 11"
X
O
625-18
Optical distance encoder (when optional E feature is installed)
X
X
430-03-0045
Dual pressure valve assembly (when optional P feature is installed)
X
O
430-03-0035
Dual pressure valve assembly (when optional P feature is installed)
O
X
Hydraulic speed control cylinder (when optional H feature is installed)
O
X
804-18
Table 12-VI
Replacement Parts
X = available
O = unavailable
Page
152
Dukane Manual Part No. 403-586-03
Section 12 - Specifications
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 61010-1, and
National Standards of Canada:
CAN/CSA C22.2 No. 61010-1-12
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.
CAUTION
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.
Dukane Manual Part No. 403-586-03
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.
Page
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Dukane Manual Part No. 403-586-03
Section 13 - Appendices
SECTION 13
Appendices
Appendix A, List of Figures . . . . . . . . . . . . . . . . . . . 157
Appendix B, List of Tables . . . . . . . . . . . . . . . . . . . . 161
Dukane Manual Part No. 403-586-03
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Dukane Manual Part No. 403-586-03
Section 13 - Appendices
Appendix A
No.
Description
List of Figures
Page
2-1
Example of 220/240 Volt, Grounded, 3-Prong Receptacle...............................................9
2-2
International 220/240V Grounding...................................................................................9
3-1
Lockout Device In Open Position, Unlocked..................................................................13
3-2
Bottom Lockout Device In Closed Position, Locked.......................................................13
3-3
Rack Mounting iQ Generator - Representative Low-Profile Model Shown....................15
3-4
Securing iQ Generator to Benchtop - Representative High-Profile Model Shown.........16
3-5
Typical iQ LE Generator Rear Panel Layout..................................................................17
3-6
IEC AC Power Inlet Connector.......................................................................................18
3-7
System I/O Panel (Standard Panel Shown)...................................................................19
3-8
HD-15F, Generator Input Connector..............................................................................20
3-9
HD-15M, Generator Input Cable Connector...................................................................20
3-10
DB-25F, Generator Output Connector (J3).....................................................................22
3-11
DB-25M, Generator Output Cable Connector................................................................22
3-12
Ultrasound Output Connector.........................................................................................26
3-13
Configuration Port Connector.........................................................................................26
3-14
Example of Press Placement.........................................................................................30
3-15
Using Handles to Make Adjustments..............................................................................30
3-16
To Relocate Handles......................................................................................................30
3-17
Example of Mounting the Thruster to a Rigid Structure.................................................31
3-18
Press Connector Locations............................................................................................32
3-19
Thruster Connector Locations........................................................................................33
3-20
Flange Template.............................................................................................................35
4-1
iQ Generator Display and Control Keys.........................................................................39
4-2
Display Detail, Operating Mode Indicator.......................................................................40
4-3
Display Detail, Power Output Level................................................................................40
4-4
Navigation Keys (4) with Enter, Info and Cancel............................................................41
4-5
Info Menu Display...........................................................................................................41
4-6
Active Soft Keys, Example.............................................................................................41
4-7
Display Detail, Power Output Level................................................................................43
4-8
Making Selections..........................................................................................................44
4-9
Arrows Indicate Direction of More Text...........................................................................44
4-10
Main Menu Detail- Setup Identification...........................................................................45
4-11
(Manual) Press/Thruster Controls and Indicators (Model 220 Shown)..........................48
Continued
Dukane Manual Part No. 403-586-03
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iQ Series Ultrasonic Press System LE User’s Manual
Appendix A
No.
Description
List of Figures
Page
4-12
Ergonomic Base Controls...............................................................................................50
4-13
Right Operate Switch in Standby Mode.........................................................................51
4-14
Right Operate Switch in Operate Mode..........................................................................51
4-15
Setting and Resetting the E-Stop Switch.......................................................................52
5-1
Rear Panel AC Breaker Switch......................................................................................55
5-2
Front Panel with Power On Light....................................................................................55
5-3
Generator Menu Overview.............................................................................................57
5-4
Setting Weld Amplitude..................................................................................................58
5-5
Setting Weld Amplitude with Afterburst Enabled............................................................58
5-6
Setting Weld Amplitude, Pre-Trigger Available...............................................................59
5-7
Setting Weld Amplitude, with Trigger by Power Enabled...............................................59
5-8
Pre Weld Menu, Mode is Automated Probe...................................................................60
5-9
Pre Weld Menu, Probe Delay.........................................................................................60
5-10
Pre Weld Menu, Mode is iQ Controlled Probe...............................................................61
5-11
Pre Weld Menu, Trigger Menu.......................................................................................61
5-12
Pre Weld Menu, Trigger Selection..................................................................................61
5-13
Pre Weld Menu, Trigger by Power Selected..................................................................61
5-14
Pre Weld Menu, Manual Press Mode.............................................................................62
5-15
Pre Weld Menu, Maintained Trigger Selected................................................................62
5-16
Pre Weld Menu, Press Does Not Support Distance.......................................................62
5-17
Pre Weld Menu, Press Supports Distance.....................................................................62
5-18
Pre Weld Menu, Pre-Trigger Disabled............................................................................63
5-19
Pre Weld Menu, Pre-Trigger Menu, Press Does Not Support Distance.........................63
5-20
Pre Weld Menu, Pre-Trigger Enabled, Press Supports Distance...................................63
5-21
Pre-Trigger Menu, Time Selected...................................................................................63
5-22
Pre-Trigger Menu, Position Supported...........................................................................63
5-23
Weld Menu, Mode: Automated Probe............................................................................64
5-24
Weld Menu, Mode: iQ Controlled Probe.........................................................................64
5-25
Weld Menu, Mode: Manual/Automated Press, Distance Not Supported........................64
5-26
Weld Menu, Mode: Manual/Automated Press, Energy Selection...................................64
5-27
Weld Menu, Mode: Manual/Automated Press, Distance is Supported...........................65
5-28
Weld Menu, Mode: Manual/Automated Press, Energy Entry.........................................65
5-29
Post Weld Menu, Mode: Automated Probe....................................................................66
5-30
Post Weld Menu, Time Setting.......................................................................................66
Continued
Page
158
Dukane Manual Part No. 403-586-03
Section 13 - Appendices
Appendix A
No.
Description
List of Figures
Page
5-31
Post Weld Menu, Afterburst Disabled.............................................................................66
5-32
Post Weld Menu, Afterburst Enabled.............................................................................66
5-33
Limits Menu, in Probe Mode...........................................................................................67
5-34
Limits Menu, Press Mode, Distance Not Supported.......................................................67
5-35
Limits Menu, Press Mode, Distance Is Supported.........................................................67
5-36
Limits Menu, Bad Soft Key Pressed...............................................................................68
5-37
Limits Menu, Setting Upper and Lower Limits................................................................68
5-38
Limits Menu, Bad Parts Limits Enabled for Time............................................................68
5-39
Setups Menu, Default Display........................................................................................69
5-40
Setups Menu, Select Setup............................................................................................69
5-41
Setups Menu, Name Setup............................................................................................69
5-42
Setups Menu, Copy Setup.............................................................................................70
5-43
Setups Menu, Copy From/To Setup...............................................................................70
5-44
Setups Menu, Setup Copied Confirmation.....................................................................70
5-45
Setups Menu, Erase Setup............................................................................................71
5-46
Setups Menu, Question Erase.......................................................................................71
5-47
Setups Menu, Confirm Erase.........................................................................................71
5-48
Operate Screen - I..........................................................................................................72
5-49
Operate Screen - II.........................................................................................................73
5-50
Live Data Screen............................................................................................................74
5-51
In Cycle Screen..............................................................................................................74
5-52
Test Screen....................................................................................................................74
5-53
Info Menu Display...........................................................................................................75
5-54
System Info....................................................................................................................75
5-55
Regional Settings, Language Menu...............................................................................75
5-56
Regional Settings, Units Menu.......................................................................................75
5-57
Advanced Settings Menu Overview...............................................................................76
5-58
Advanced Process Control Menu...................................................................................76
5-59
Restore Defaults, Advanced Process Controls..............................................................77
5-60
Restore Defaults, Confirmed, Advanced Process Controls............................................77
5-61
Advanced Process Control Sub-menu Items.................................................................78
5-62
System Status I/O Sub-menu.........................................................................................80
5-63
System Status I/O Restore Defaults?.............................................................................80
5-64
System Status I/O Defaults Restored.............................................................................80
Continued
Dukane Manual Part No. 403-586-03
Page
159
iQ Series Ultrasonic Press System LE User’s Manual
Appendix A
No.
Description
List of Figures
Page
5-65
System Status I/O Sub-menu Items...............................................................................81
5-66
Miscellaneous Sub-menu Items.....................................................................................82
5-67
Alarm Message Screen..................................................................................................83
6-1
Example of 120 Volt, Grounded, 3-prong Receptacle....................................................88
6-2
120VAC Power Inlet Panel.............................................................................................89
6-3
Example of Slow Speed Setting.....................................................................................91
6-4
Location of the Hydraulic Control Components..............................................................92
6-5
Adjustment Using the Hole.............................................................................................92
6-6
Adjustment Using the Slot..............................................................................................92
6-7
Distance Encoder Mounting...........................................................................................93
6-8
Distance Encoder Alignment..........................................................................................94
7-1
Stack Components.......................................................................................................100
7-2
Stack Removal.............................................................................................................101
7-3
Disassembling Components.........................................................................................102
7-4
Tip Removal.................................................................................................................102
7-5
Assembling Components.............................................................................................103
7-6
Tip Assembly................................................................................................................104
7-7
Stack Installation..........................................................................................................104
7-8
Fixture/Base Layout.....................................................................................................105
7-9
Loosening the Hold Down Cap Screws and Jack Screws............................................106
7-10
Tightening the Hold Down Cap Screws and Jack Screws............................................106
8-1
Example of Burnished Area.......................................................................................... 111
8-2
Example of Crowning................................................................................................... 111
8-3
Example of Center Depression.................................................................................... 111
8-4
Method of Component Resurfacing............................................................................. 112
12-1
Layout 220 Thruster.....................................................................................................143
12-2
Layout 220 Press.........................................................................................................144
12-3
Pneumatic Schematic (All iQ LE Presses)...................................................................145
12-4
Electrical Schematic 220..............................................................................................146
12-5
iQ LE Basic Generator Layout......................................................................................147
12-6
iQ LE 4800W Generator Layout...................................................................................148
12-7
System Model Numbers...............................................................................................151
12-8
Generator Model Numbers...........................................................................................152
Continued
Page
160
Dukane Manual Part No. 403-586-03
Section 13 - Appendices
Appendix B
List of Tables
No.
Description
3-I
Rack Mount Bracket Part Numbers................................................................................. 15
3-II
Generator Input Signals (J-2)........................................................................................... 20
3-III
System Output Connector Signals (J-3).......................................................................... 22
3-IV
Power Cords.................................................................................................................... 28
3-V
Generator to Press/Thruster Cables................................................................................ 33
5-I
Alarm Messages.............................................................................................................. 83
6-I
Press Interface Modules.................................................................................................. 90
7-I
Stud Torque Values........................................................................................................ 103
7-II
Horn/Booster Torque Values.......................................................................................... 103
7-III
Replaceable Tip Torque Values...................................................................................... 104
9-I
Weld Characteristics and Equipment Requirements...................................................... 117
12-I
Weights.......................................................................................................................... 149
12-II
Dimensions.................................................................................................................... 149
12-III
Clamping Pressure........................................................................................................ 150
12-IV
AC Power Requirements............................................................................................... 150
12-V
Interpreting the Thruster Model Number........................................................................151
12-VI
Replacement Parts........................................................................................................153
Dukane Manual Part No. 403-586-03
Page
Page
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Page
162
Dukane Manual Part No. 403-586-03
Section 14 - Index
SECTION 14
Index
Dukane Manual Part No. 403-586-03
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Page
164
Dukane Manual Part No. 403-586-03
Section 14 - Index
Index
A
Acoustic Stack/Fixture Setup 97
Fixture Installation 105
Fixture Alignment 105
Fixture Leveling 106
Installing a Detachable Tip 104
Installing the Stack 104
Removing a Detachable Tip 102
Stack Assembly 103
Stack Description 100
Stack Disassembly 102
AC Power Inlet Panel 18
Chassis Grounding Stud 18
IEC AC Power Inlet Connector 18
Power Switch/Circuit Breaker 18
AC Power Inrush 4
Activation (Operate) Switches 51
Advanced Process Control
Buzzer 82
External Control 82
Free Run Freq 78
Freq Lock and Hold 78
Phase Shift 78
Ramp Down Time 79,?81,?82
Ramp Up Time 79
Restore Factory Defaults 82
System Freq Limits 79
SYSTEM STATUS I/O 80
ALARMS 83
Amplitude 40,42
AMP 58
Power Scaling 43
Range 59
B
Base Plate 50
Base Status Display 52
Benchtop Mounting 16
C
CE Certification 4
CE Marking 154
Configuration Port Connector 26
Connecting Cables 28
Connecting Generator Cables 28
Connecting Press Cables
Thruster Only 33
Controls 37
Base Status Display 52
Generator Front Panel Controls 39
Hot Keys 42
Navigation Keys 41
Power On Light 43
Soft Keys 41
System Operating Mode Keys 40
System Power Output Level 43
Manual Hydraulic Controls
Hydraulic Slow Speed Control 46
Manual Thruster Controls
Down Speed Adjustment 46
Hydraulic Slow Speed Adjustment 47
Mechanical Stop Adjustment 47
Pressure 1 Regulator 47
Pressure 2 Regulator 49
Regulator Select Switch 47
Trigger Control 49
Press Controls 46
Press Ergonomic Base 50
Activation (Operate) Switches 51
Base Status Display 52
Emergency Stop (Abort) Switch 52
Screen Basics 44
Interpreting On-screen Arrows 44
Setup Identification 45
Thruster Indicators 50
Mechanical Stop Indicator Flag 50
Pressure Gauge 50
Slow Speed Indicator Flag (Optional) 50
Stroke Position Indicator Flag 50
Ultrasound Active Status Light 50
D
Digi-Trac 4
Continued
Dukane Manual Part No. 403-586-03
Page
165
iQ Series Ultrasonic Press System LE User’s Manual
Distance Encoder 93
Drawings and Tables 3
Dukane 137
Address 139
Contacting 137
E-mail 139
Fax 139
Intelligent Assembly Solutions
Mailing Address 139
Phone 139
Website 139
Generator Menu Overview 57
Generator Start-up
Sequence 55
H
139
E
Electrical Safety 8
100/120 Volt Systems 9
Domestic Power Grounding 9
International Power Grounding 9
E-mail 139
Emergency Stop (Abort) Switch 52
F
FCC 154
Fixture Alignment 105
Flange Template 35
Flow Through Cooling Tunnel 4
Free Run Freq 78
Freq Lock and Hold 78
G
General User Information 3
Drawings and Tables 3
Notes, Cautions and Warnings 3
Read This Manual First 3
Generator Features 4
AC Power Inrush 4
CE Certification 4
Digi-Trac Tuning 4
Flow Through Cooling Tunne 4
High Line Voltage Power Supply 4
ISO 9001 Certification 4
Linear Ramp Soft-Start 4
Line Voltage Regulation 4
Load Regulation 4
Low Line Voltage Power Supply 4
Multiple Electronic Overload 4
Process Limits 4
Pulse Width Modulation 4
Rear Panel Expansion Slot 4
RS232 Serial Configuration Port 4
Health and Safety 5
General Considerations 7
No Unauthorized Modifications
How to Lift Safely 10
Plastics Health Notice 8
Recommendations 7
Hot Keys 42
Hydraulic Speed Control 91
7
I
Installation 11
Before Installation 13
When to Use Lockout /
Tagout Devices 13
Connecting Cables 28
Placement 14
Active Seismic Region 15
Power Cords 28
Rear Panel 17
AC Power Inlet Panel 18
Chassis Grounding Stud 18
IEC AC Power Inlet Connector 18
Power Switch/Circuit Breaker 18
System I/O Panel 18
System Inputs Connector 18
Unpacking 29
Utilities 14
Installing the Press System 29
Connecting
Press Cables 32
Placement 29
Press Height Adjustment 30
Without Machine Base 30
Installing the Thruster 31
Introduction 1
General User Information 3
Key Generator Features 4
Press System Overview 4
IP (International Protection) Rating 154
ISO 9001 Certificatio 4
L
Linear Ramp Soft-Start 4
Line Voltage Regulation 4
Continued
Page
166
Dukane Manual Part No. 403-586-03
Section 14 - Index
List of Figures 157
List of Tables 161
Load Regulation 4
Low Line Voltage Power Supply 4
Power Inlet Options 88
Press Interface Board 90
Press Interface Module 90
P
M
Maintenance
Six-Month Periodic Maintenance
Menus 57
Model Number Codes 151
Generator Model Numbers 152
System Model Numbers 151
Multiple Electronic Overload 4
135
N
Navigation Keys 41
Notes, Cautions and Warnings 3
O
Operate
TEST 74
Using the Menus
IN CYCLE 74
LIVE 74
Operation 53
ALARMS 83
Generator Start-up
Sequence 55
Overview 55
Start-up 55
Stopping the Weld Cycle 56
Using the Menus 57
AMP 58
Generator Menu Overview 57
INFO 75
ADVANCED SETTINGS 76
REGIONAL SETTINGS 75
SYSTEM INFO 75
UNITS 75
LIMITS 67
OPERATE 72
POST-WELD 66
PRE-WELD 60
SETUPS 69
WELD 64
Options 85
AC Power Inlet Panel 89
Distance Encoder 93
Hydraulic Speed Control 91
Phase Shift 78
Power Cords 28
Press Controls 46
Manual Thruster Controls 46
Press Ergonomic Base 50
Press Height Adjustment 30
Press Interface Module 90
Press System Overview 4
Primary Weld Characteristics 117
Process Limits 4
Pulse Width Modulation 4
R
Rack Mount Bracket Part Numbers 15
Rack Mounting 15
Ramp Down Time 79
Ramp Up Time 79
Rear Panel AC Breaker Switch 55
Rear Panel Expansion Slot 4
Rear Panel Layout 17
Configuration Port Connector 26
Rear Panel AC Breaker Switch 55
Ultrasound Output Connector 26
Reconditioning Stack Components 112
Regulatory Agency
Compliance 154
Regulatory Agency Compliance
CE Marking 154
FCC 154
IP (International Protection) Rating 154
Replacement Parts 153
RFI Grounding 27
RS232 4
S
Screen Basics 44
Continued
Dukane Manual Part No. 403-586-03
Page
167
iQ Series Ultrasonic Press System LE User’s Manual
Setup
Control 69
Copying 70
Erase 71
Identification 45
Name 69
Stack/Fixture 97
Total Number 69
Soft Keys 41
Specifications 141
AC Power Requirements 150
Compressed Air Requirements 150
Dimensions 149
Electric Schematic 220 146
iQ LE 4800W Generator Layout 148
iQ LE Basic Generator Layout 147
Layout - 220 Press 144
Layout - 220 Thruster 143
Operating Environment 149
Pneumatic Schematic (All iQ LE Presses) 145
Weights 149
Stack Maintenance 109
Inspection of the Acoustic Stack Components 111
Reconditioning Stack Components 112
Stopping the Weld Cycle 56
Stroke 31
Downstroke distance 46
System Freq Limits 79
System Inputs Connector 18
System Inputs Connector Pinout 19
System I/O Panel 18
System Inputs Connector 18
System Inputs Connector Pinout 19
System Outputs Connector 22
System Outputs Connector Pinout 23
System Maintenance 133
System Outputs Connector 22
System Outputs Connector Pinout 23
System Outputs Signal Descriptions 23
System Power Output Level 43
System Status I/O
Auto Start Input 81,?82
Auto Stop Input 81
J3 Pin 4 81
J3 Pin 5 81
Output Duration 81
SYSTEM STATUS I/O 80
Page
168
T
TEST 74
Torque Values 113
Troubleshooting 115
Continuous Welding 131
Insertion 125
Primary Weld Characteristics
Staking 128
Welding 118
117
U
Ultrasound Output Connector 26
Using the Menus 57
Utilities 14
W
Weld
Weld Cycle
MAX TIME 65
Stopping 56
Dukane Manual Part No. 403-586-03
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.
iQ Series Ultrasonic Press System LE User's Manual
Part No. 403 – 586– 03
www.dukane.com
Printed in the United States of America
Dukane • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797-4900