Dukane iQ LE Pneu User Manual

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Dukane iQ LE Pneu User Manual | Manualzz

Intelligent Assembly Solutions

iQ

Series

ULTRASONIC PRESS SYSTEM

LE

AUTOMATED HAND PROBE PRESS

User's Manual

Dukane Part No. 403–586-00

Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797–4900 • FAX (630) 797–4949

ISO 9001:2008 Dukane products are manufactured in ISO registered facilities www.dukane.com/us

iQ

Series Ultrasonic Press System LE User’s Manual

Copyright © 2012

2900

Dukane Intelligent Assembly Solutions

Drive

St. Charles, IL 60174 USA

Notice of Rights :

All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical, photocopying, recording, or by any information storage and retrieval system, without written permission from Dukane Corporation.

Notice of Liability :

The information contained in this manual is distributed on an “As is” basis, without warranty.

While every precaution has been taken in the preparation of this manual, Dukane Corporation shall not have any liability to any person or entity with respect to any liability, loss, or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual, or by the hardware products described herein.

Specifications subject to change 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: 403-586-00

Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Paten ts:

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

Page ii Dukane Manual Part No. 403-586-00

Revision History

Revision Revision

Number Summary Date

Dukane Manual Part No. 403-586-00

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Page iv Dukane Manual Part No. 403-586-00

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 . . . . . . . . . . . . . . . . . . . . . . . 39

Screen Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Press Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Press Ergonomic Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Section 5 - Operation . . . . . . . . . . . . . . . . . . . . . . . . 53

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Generator Start-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . 55

Stopping the Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Using the Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Dukane Manual Part No. 403-586-00

Continued

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Series Ultrasonic Press System LE User’s Manual

Contents

Continued

Section 6 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Power Inlet Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Press Interface Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Hydraulic Speed Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Distance Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Insertion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Stacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Continuous Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Section 10 - System Maintenance . . . . . . . . . . . . . 133

Press/Thruster Six-Month Periodic Maintenance . . . . . . . . . 135

Section 11 - Contacting Dukane . . . . . . . . . . . . . . 137

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Continued

Dukane Manual Part No. 403-586-00

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

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Page viii Dukane Manual Part No. 403-586-00

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

Page 1

Dukane Manual Part No. 403-586-00

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Page 2 Dukane Manual Part No. 403-586-00

Section 1 - Introduction

General User Information

Read This Manual First

Before operating your ultrasonic system, read this User’s

Manual to become familiar with the equipment. This will ensure correct and safe operation. The manual is organized to allow you to learn how to safely operate this equipment.

The examples given are chosen for their simplicity to 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 S eries LE press system.

Particular models are listed in Section 12 - Specifications .

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.

NOTE

Note statements provide additional information or highlight procedures.

CAUTION

practices that could result in damage to the equipment or other property.

Caution statements identify conditions or

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)

Dukane Manual Part No. 403-586-00

Page 3

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.

• 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.

Page 4 Dukane Manual Part No. 403-586-00

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

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Page 6 Dukane Manual Part No. 403-586-00

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

Corporation. 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 Corporation. The generator produces hazardous electrical voltages which could cause injury.

Grounded Electrical Power - Operate this equipment only with a grounded electrical connection.

See Electrical Safety for grounding instructions, Page 9.

Comply with Regulations - You may be required to add accessories to bring the system into compliance with applicable regulations (OSHA in the USA) for machine guarding and noise exposure.

Use Eye Protection - Wear ANSI approved safety 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.

Dukane Manual Part No. 403-586-00

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 Corporation 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

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Series Ultrasonic Press System LE User’s Manual

Continued from Previous Page

General Considerations

Pre-trigger Switch Adjustment - The pre-trigger switch option starts the horn vibrating before contacting the part to be welded. To ensure safe operation, adjust the pretrigger so the ultrasound signal will not activate if the horn is more than ¼ in (7 mm) from the part to be welded.

System Electrical Cabling - Electrical power must be off when connecting or disconnecting electrical cables.

Do Not Wear Loose Clothing or Jewelry - They can become caught in moving parts.

Stay Alert - Watch what you are doing at all times. Use common sense. Do not operate the press when you are tired or distracted from the job at hand.

Do not Operate the Equipment - Your judgement or reflexes could be impaired while taking prescription medications. If so, do not operate the equipment. Be familiar with warning labels and recommended activity restrictions that accompany your prescription medications. If you have any doubt, do not operate the equipment.

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

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 .

Plastics Health Notice

Certain plastic materials, when being processed, may emit fumes and/or gases that may be hazardous to the operator’s health. Proper ventilation of the work station should be provided where such materials are processed.

Inquiries should be made to the U.S. Department of Labor concerning OSHA regulations for a particular plastic prior to processing with Dukane ultrasonic equipment .

Electrical Safety

The iQ Series generator provides the operating power and power returns. Make sure the generator is grounded properly.

In addition to the safety considerations, proper grounding is essential for the effective suppression of RFI (Radio

Frequency Interference). Every generator contains a RFI filter which blocks noise on the AC power line from entering the generator control circuitry. This filter also prevents ultrasonic RFI from being fed back into the AC power line.

If you experience problems with RFI from the press, run an additional grounding wire from the press base grounding stud to the nearest grounded metal pipe or equivalent earth ground by means of a ground clamp. Use at least 14

AWG wire for the connection to the press base.

CAUTION

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

Page 8 Dukane Manual Part No. 403-586-00

Section 2 - Health and Safety

Domestic Power Grounding

Continued from Previous Page

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.

Typical Outlet

Provided Cable

Figure 2–2 International 220/240V Grounding

100/120 Volt Systems (North America or

Japan)

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.

Dukane Manual Part No. 403-586-00

Page 9

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:

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.

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 .

Page 10 Dukane Manual Part No. 403-586-00

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

Dukane Manual Part No. 403-586-00

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Page 12 Dukane Manual Part No. 403-586-00

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.

Dukane Manual Part No. 403-586-00

Figure 3-2 Bottom Lockout Device In

Closed Position, Locked

Continued

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Series Ultrasonic Press System LE User’s Manual

Lockout/Tagout

Continued from Previous Page

Utilities

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.

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

Assuming the generator is being put back into service.

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.

Procedure to use AFTER making any internal adjustments to the generator:

1. Authorized personnel remove the lockout/tagout device from the plug end of the generator's electrical cord. Using a typical clam shell type LOTO device:

1) Unlock the protective shell.

2) Open the shell, exposing the electrical cord end.

3) Remove the LOTO device, and set it aside.

2. Plug the generator's electrical cord into its AC power source.

3. Push the generator's AC power switch/breaker to the

ON position.

Page 14 Dukane Manual Part No. 403-586-00

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

High Profile

Low Profile

Dukane Part Number

147-4721

147-4720

Table 3- I Rack Mount Bracket Part Numbers

ALLOW 3" IN BACK FOR CABLES

ALLOW 5"

BOTH

SIDES

FOR

COOLING

NOTE

The figure shows how a typical iQ generator is rack mounted. Your generator’s appearance may be different from what is shown here .

IN

[mm]

OPTIONAL RACK

MOUNT BRACKETS

147-4720

Figure 3-3 Rack Mounting iQ Generator - Representative Low-Profile Model Shown

Dukane Manual Part No. 403-586-00

Continued

Page 15

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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 5" BOTH

SIDES

FOR COOLING.

ALLOW 3" IN BACK FOR CABLING.

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]

OPTIONAL HOLD

DOWN BRACKETS

Figure 3-4 Securing iQ Generator to Benchtop - Representative High-Profile Model Shown

Page 16 Dukane Manual Part No. 403-586-00

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.

B

I

0

LINE VOLTAGE:

200-240 Vac

50/60Hz, 15A

-WARNING-

POWER LINE OUTLET

MUST BE GROUNDED.

DISCONNECT LINE POWER

BEFORE REMOVING COVER.

J6 BASE/ABORT J5 THRUSTER

A

PE

DUKANE CORP

ST. CHARLES IL 60174

MADE IN U.S.A.

U.S. PATENT 5,880,580

OTHER PATENTS PENDING

C H

Figure 3-5 Typical iQ LE Generator Rear Panel Layout

J11 ENCODER

K

D

G

SYSTEM INPUTS

J2

SYSTEM OUTPUTS

J3

CONFIGURATION

ULTRASOUND

J1

J4

E

F

AC Power Inlet Panel

A IEC Power Inlet Connector – Attaches to an IEC style power cord.

B Power Switch – Circuit Breaker – Used to switch system power ON and OFF.

C Chassis Grounding Stud – Chassis connection for a protective earth ground.

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.

Options Module Panel

H Expansion Boards

K Press Interface Module (See NOTE below.)

Shown in the example above are these ports:

J6 - Base/Abort

J11 - Encoder

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

Dukane Manual Part No. 403-586-00

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.

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

C

PE

Figure 3-6 IEC AC Power Inlet Connector

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.

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. 403-586-00

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.

Dukane Manual Part No. 403-586-00

Continued

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Series Ultrasonic Press System LE User’s Manual

Continued from Previous Page

Pin Signal Name

1 +22V

6

7

8

9

4

5

2

3

Power Ground

Remote Setup Selection Bit 0 Input

Remote Setup Selection Bit 1 Input

Remote Setup Selection Bit 2 Input

Remote Setup Selection Bit 3 Input

Remote Setup Selection Bit 4 Input

Ultrasound Activation/Cycle Start Input

Not Used

10 Front Panel Control Lock Input

11 Press Inhibit for Hand Probes

12 System Latch Reset Input

13 Isolated Common

14 Not Used

15 Automation Cycle Stop Input

Table 3-II Generator Input Signals (J2)

Cable Color Code

BLK

WHT

RED

GRN

ORN

BLU

WHT/BLK

RED/BLK

GRN/BLK

ORN/BLK

BLU/BLK

BLK/WHT

RED/WHT

GRN/WHT

BLU/WHT

Signal Option Requirements

Not Used

Not Used

Hand Probe

System Inputs Signal Descriptions

Pin 1 (+22V)

This pin can supply +22VDC at up to 250mA to power the user’s automation controls.

Pin 2 (Power Gnd)

Pin 2 is the 22VDC return and is tied to the system chassis ground.

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.

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.

Figure 3-8 HD-15F, Generator Input Connector

1 2 3 4 5

6

10

11 12 13 14 15

Figure 3-9 HD-15M, Generator Input Cable

Connector

Page 20

Continued

Dukane Manual Part No. 403-586-00

Section 3 - Installation

Continued from Previous Page

Pin 5 (Remote Setup Selection Bit 2 Input) Pin 12 (System Latch Reset Input)

Pin 5 is the Remote Setup Selection Bit 2, which is the third least significant bit used to select different welding setups with an automation control system.

Pin 6 (Remote Setup Selection Bit 3 Input)

Pin 6 is the Remote Setup Selection Bit 3, which is the second most significant bit used to select different welding setups with an automation control system.

Pin 7 (Remote Setup Selection Bit 4 Input)

Pin 12 is used to reset the Any Fault or System Overload status outputs (See Status Output descriptions.). If a fault occurs during a weld cycle, these outputs will normally remain active until the next weld cycle is initiated. Activating this input will reset the status output faults and may simplify automation programming.

Pin 13 (Isolated Common)

Pin 7 is the Remote Setup Selection Bit 4, which is the most significant bit used to select different welding setups with an automation control system.

Pin 8 (Ultrasound Activation/ Cycle Start

Input)

Pin 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 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 9 (Not Used)

Pin 10 (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 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.

Dukane Manual Part No. 403-586-00

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Series Ultrasonic Press System LE User’s Manual

Pin

9

10

6

7

8

4

5

1

2

3

19

20

21

22

23

24

25

16

17

18

11

12

13

14

15

Signal Name

+22V

Spare Output

+22V Power Ground

Programmable Status Output 1

Programmable Status Output 2

Ultrasound Active Status Output

Any Fault Status Output

Press Trigger Status Output

System Overload Status Output

System Online Status Output

Press Top of Stroke Status Output

Current Loop OK Status Output

Analog Monitor Signal Common

Not Used

Power Signal Monitor Output

Amplitude Monitor Output

Amplitude/Power Regulation Status Output

MPC Ready Status Output

System Power OK Status Output

Bad Part Status Output

Good Part Status Output

System Ready Status Output

Suspect Part Status Output

Isolated Common

Not Used

Table 3-III System Output Connector Signals (J3)

Cable Color Code Signal Option Requirements

BLK

WHT

RED

GRN

ORN

BLU

WHT/BLK

RED/BLK

GRN/BLK

ORN/BLK

BLU/BLK

BLK/WHT

RED/WHT

GRN/WHT

BLU/WHT

BLK/RED

WHT/RED

ORN/RED

BLU/RED

RED/GRN

ORN/GRN

BLK/WHT/RED

WHT/BLK/RED

RED/BLK/WHT

GRN/BLK/WHT

Not Used

Not Used

13 11 9 7 5 3 1

System Outputs Connector

The SYSTEM OUTPUTS connector mounted on the generator I/O panel includes connections for all of the basic system status and monitor output signals, which will typically connect to an automated control system. The cable attached to this connector includes all of the available system output signals, which will be read or monitored by a digital input card or analog inputs on the user-supplied automation controller.

The user can determine which signals are appropriate for each welding application.

25 23 21 19 17 15

Figure 3–10 DB-25F, Generator Output Connector (J3)

1 3 5 7 9 11 13

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).

15 17 19 21 23 25

Figure 3–11 DB-25M, Generator Output Cable

Connector

Continued

Page 22 Dukane Manual Part No. 403-586-00

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.

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)

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 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.

Dukane Manual Part No. 403-586-00

Continued

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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 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 12 (Not Used)

Pin 13 (Analog Monitor Signal Common)

Pin 15 is an analog output signal used to monitor the power output from the welding system. The scaling on this output signal is as shown below:

15kHz, 20kHz, 30kHz and 40kHz systems

1 Watt = 0.001 VDC (1mV per Watt)

50kHz and higher systems

1 Watt = 0.010 VDC (10mV per Watt)

Examples: 20kHz system measures 0.525 VDC on

Power Monitor Output = 525 Watts

50kHz system measures 0.525 VDC on

Power Monitor Output = 52.5 Watts

Pin 16 (Amplitude Monitor Output)

Pin 16 is an analog output signal used to monitor the system amplitude setting. The scaling on this output signal is 100% amplitude = 10.0 VDC, or 0.1 VDC per 1% amplitude. This monitor signal output would typically be used when a remote control option board is installed in the system. The automation control system will adjust the system’s amplitude setting remotely, using a 4-20mA current loop attached to the input of the remote control board. Using this monitor output, the control system can verify that the amplitude is set to the expected programmed amplitude level.

Pin 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.

Page 24

Continued

Dukane Manual Part No. 403-586-00

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.

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.

Dukane Manual Part No. 403-586-00

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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 SHV-

BNC connector. This connector provides superior shielding of electrical noise, compared to other types of connectors.

The ultrasound output connector mates with fully shielded coaxial ultrasound cables that are secured with a simple and reliable quarter-turn bayonet style attachment mechanism.

Figure 3-12 Ultrasound Output Connector

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.

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.

Page 26

Figure 3-13 Configuration Port Connector

Dukane Manual Part No. 403-586-00

Section 3 - Installation

RFI Grounding

The iQ Series properly.

generator provides the operating power and power returns. Make sure the generator is grounded

In addition to the safety considerations, proper grounding is essential for the effective suppression of RFI (Radio

Frequency Interference). Every generator contains a RFI filter which blocks noise on the AC power line from entering the generator control circuitry. This filter also prevents ultrasonic RFI from being fed back into the AC power line.

If you experience problems with RFI from the press, run an additional grounding wire from the press base grounding stud to the nearest grounded metal pipe or equivalent earth ground by means of a ground clamp. Use at least 14

AWG wire for the connection to the press base.

CAUTION

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.

Fixed Probe Mount

or 2nd Chassis

Grounding Stud

#14 Gauge

Stranded or

Solid Wire

Earth

Ground

3rd Chassis

Grounding

Stud

Dukane Manual Part No. 403-586-00

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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

Power Cord

Part Number

200 - 1110

200 - 1541

Continental Europe

200 - 1111

200 - 1542

Table 3-IV Power Cords

Power

240V, 15A

240V, 10A

240V, 16A

240V, 10A

Page 28 Dukane Manual Part No. 403-586-00

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.

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.

CAUTION

CAUTION

DO NOT

LIFT the p r e s s manually.

Lifting and/or moving the press manually could result in personal injury. Use mechanical means to move and place the press.

See Section 2, Health and Safety,

Page 10 on safe lifting practices.

Page 29

Dukane Manual Part No. 403-586-00

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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

Height

Adjustment

Handles

Thruster

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

Page 30

Figure 3-16 To Relocate Handles

Dukane Manual Part No. 403-586-00

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.

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.

Mounting

Holes

Washers

Mounting Bolts

*

Rigid

Mounting

* ( 2) Hex head Mounting Bolts

M10-1.5 x 40mm

Distance from horn to work surface should be less than 7 inches.

Figure 3-17 Example of Mounting the Thruster

to a Rigid Structure

NOTE

Total Stroke = 7 inches (177.800mm)

This is the thruster's maximum available distance of travel.

Page 31

Dukane Manual Part No. 403-586-00

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 Cable

(optional)

Ultrasound

Cable

J207 J1

• 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.

Grounding Stud

Operation

Control

Cable

J201

1/4 NPT

Threaded Air

Connector

Filtered Air to Thruster

Air Filter

NOTE

Under normal usage, do not apply more than 24 VDC @ 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.

• 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.

Air Filter In

Air Supply

Source

Air

Supply to Filter

Air Shut

Off Valve

Encoder

Cable

Base Control

Cable

J35

Figure 3-18 Press Connector Locations

Grounding Stud

Page 32 Dukane Manual Part No. 403-586-00

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 (J7) 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.

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.

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 J7 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

J7 receptacle.

iQ generator's

See Table 3-V.

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)

Ultrasound

Cable

1/4 NPT Threaded

Air Connector

Grounding Stud

J207 J1

J201

Filtered Air to Thruster

Operation Control

Cable

Figure 3-19 Thruster Connector Locations

Cable/Signal Generator Press Thruster

Ultrasound

Operational Control

Press Base

J1

J5

J7

J1

J201

J1

J201

J35

***

Built-in Built-in Distance Encoder J11

Top of Stroke Customer supplied control

J207 J207

***

Dukane's cable (Part Number 200-1546-03) is installed in the iQ generator's J7 receptacle.

Table 3-V Generator to Press/Thruster Cables

Dukane Manual Part No. 403-586-00

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Series Ultrasonic Press System LE User’s Manual

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Page 34 Dukane Manual Part No. 403-586-00

3.875 inches

(98.425 mm)

FRONT

7.75 inches

(196.85 mm)

3.023 inches (76.783 mm

1.50 inches (38.10 mm

2.625 inches

(66.675 mm)

2.625 inches

(66.675 mm)

Section 3 - Installation

2.00 inches (50.80 mm

2.25 inches

(57.15 mm)

2.25 inches

(57.15 mm)

Figure 3-20 Flange Template

No Scaling - Actual Size

REAR

Flange Template

Dukane Manual Part No. 403-586-00

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Page 36 Dukane Manual Part No. 403-586-00

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

Page 37

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Page 38 Dukane Manual Part No. 403-586-00

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

4-1 below are discussed.

• These screen basics are introduced:

— Making selections,

— Interpreting on-screen arrows,

— Taking a look at setup identification.

NOTE

Do not touch the display.

Touch only the keys that are on the front panel.

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.

Online/Offline/E-Stop Status

System Power Output Level

INFO Key

Soft Keys (3)

Active Hot Key Indicator

Navigation Keys (4)

Power On Light

System

Operating

Mode

Keys (3)

AUTO 01

Process

Statistics

SETUP #01

Part Count:

ONLINE

PART COUNT: 0

ENERGY: 0J

PEAK POWER : 0 W

DISTANCE 0in

COL Dist: 0.000in

Hot Keys (8)

Figure 4-1 iQ Generator Display and Control Keys

ENTER Key CANCEL Key

Page 39

Dukane Manual Part No. 403-586-00

iQ

Series Ultrasonic Press System LE User’s Manual

System Operating Mode Keys

ON LINE - After AC power has been activated and the generator is operating normally, ON LINE 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 generator is operating normally, in the ON LINE 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.

Figure 4-2 Display Detail, Operating Mode Indicator

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.

Operating Mode Indicator

Online condition shown

AUTO 01 SETUP #01 ONLINE

PART COUNT: 0

WELD TIME : 0.000s

ENERGY: 0J

PEAK POWER : 0 W

DISTANCE 0in

PROCESS

STATISTICS

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.

System Power Output Level

Bar Graph

The word, Offline appears in a white outlined box in the display's upper right corner.

AUTO 01 SETUP #01 ONLINE

PART COUNT: 0

WELD TIME : 0.000s

ENERGY: 0J

PEAK POWER : 0 W

DISTANCE 0in

PROCESS

STATISTICS

Figure 4-3 Display Detail, Power Output Level

Page 40 Dukane Manual Part No. 403-586-00

Section 4 - Controls

Navigation Keys

(4)

Moving the Cursor - Press the left and right naviga-

( ) keys to move the display’s cursor 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.

INFO

ENTER  

CANCEL

Navigation Key (4)

Figure 4-4 Navigation Keys (4), with Enter, Info and

Cancel

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.

SYSTEM INFO

INFO MENU ONLINE    

REGIONAL SETTINGS

ADVANCED SETTINGS

AMP  

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 4-5 Info Menu Display

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 .

NOTE

For more information about the INFO menus, please see Section 5 - Operation .

Active Keys

AMPLITUDE

WELD

AFTERBURST

AMP  

PRE  

WELD   WELD  

ONLINE      

100%

PRESS ENTER TO ACCEPT

PRESS CANCEL TO ABORT

LIMITS   SETUPS   OPERATE   LIVE  

Figure 4-6 Active Soft Keys, Example

Dukane Manual Part No. 403-586-00

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 displayed, 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.)

See the next section, OPERATION for more detail on the functions of these hot key sub-menus.

NOTE

The white bar along the bottom of the LCD display indicates what Hot Key menu is being displayed.

Page 42 Dukane Manual Part No. 403-586-00

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.

System Power Output Level

Bar Graph

Peak Detect Feature

AUTO 01

To indicate the maximum peak power achieved during a weld cycle, the segment in the bar graph corresponding to the peak level remains on (for about one second) after the weld cycle has been completed.

PROCESS

STATISTICS

SETUP #01 ONLINE

PART COUNT: 0

WELD TIME : 0.000s

ENERGY: 0J

PEAK POWER : 0 W

DISTANCE 0in

Figure 4-7 Display Detail, Power Output Level 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.

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.

NOTE

Go to Section 5 - Operation, Start-up

Sequence for an explanation of the generator start-up sequence.

Dukane Manual Part No. 403-586-00

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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.

White area highlights selected item

DISTANCE

0.0000 in

MAX TIME

30.000s

AMP  

>

TIME

ENERGY

DISTANCE

POSITION

GROUND DETECT

PRESS ENTER TO ACCEPT

PRESS CANCEL TO ABORT

LIMITS   SETUPS   OPERATE   LIVE  

Figure 4-8 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 Arrows Indicate Direction of More Text

> # 1 - SETUP# 1

# 2 - SETUP# 2

# 3 - SETUP# 3

# 4 - SETUP# 4

# 5 - SETUP# 5

# 6 - SETUP# 6

# 7 - SETUP# 7

ONLINE      

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Page 44 Dukane Manual Part No. 403-586-00

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.

This is the name of the setup being edited if in Automation mode.

Otherwise, the setup shown is the one in use.

AUTO 01

PROCESS

STATISTICS

AMP  

SETUP #01 ONLINE

PART COUNT: 0

WELD TIME : 0.000s

ENERGY: 0J

PEAK POWER : 0 W

DISTANCE 0in

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 4-10 Main Menu Detail - Setup Identification

Section 4 - Controls

Dukane Manual Part No. 403-586-00

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 (177.800mm)

This is the thruster's maximum available distance of travel.

Page 46

Continued

Dukane Manual Part No. 403-586-00

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.

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.

CAUTION

Do not allow the horn to contact the fixture while ultrasonic power is applied to the horn.

M e t a l – t o – m e t a l c o n tact can void the horn and/or tooling warranty.

Dukane Manual Part No. 403-586-00

Continued

Page 47

iQ

Series Ultrasonic Press System LE User’s Manual

Regulator Select

Switch

Pressure Gauge

Stroke Position

Indicator Flag

Mechanical

Stop Indicator

Flag

Slow Speed

Indicator Flag

3

5

6

7

INCREASE

INCREASE

30

2

40

3

50

4

60

5

10

1

0 7

6

100

90

70

Mechanical Stop Adjust

Down Speed Adjust

Pressure 1 Regulator

Pressure 2 Regulator

Ultrasound Active Status Light

2

3

0

1

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

Adjustment

(Velocity

Damping)

20

LOWERS

SPEED CONTROL

TRIGGER

3 5 0

LOOSEN THE

THUMBSCREW TO

UNLOCK KNOB

Hydraulic Slow Speed

Position Adjustment

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. 403-586-00

Section 4 - Controls

Continued from Page 47

Pre-Trigger Control (Optional)

The pre-trigger control turns the ultrasound on at a preset point in the thruster downstroke. This control is normally used in staking and inserting applications. This control should be set for a distance of approximately 6.25 mm

(.25 inch) above the part.

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

End-of-Weld Control

(Optional

)

This adjustment is set at the point in the stroke of horn travel (absolute distance) where the ultrasound turns off.

NOTE

The pre-trigger switch option starts the horn vibrating before contacting the part to be welded. To ensure safe operation, adjust the pre-trigger so the ultrasound signal will not activate if the horn is more than ¼ in

(7 mm) from the part to be welded.

Dukane Manual Part No. 403-586-00

Continued

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 .

Left

Operate

Switch

E–Stop Switch

Figure 4-12 Ergonomic Base Controls

Right

Operate

Switch

Page 50 Dukane Manual Part No. 403-586-00

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

Dukane Manual Part No. 403-586-00

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 Corporation does not assume any responsibility or liability for circuitry modifications made by the customer or by any third party manufacturer .

Page 51

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,

• 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 green READY status light indicates that power is applied to the press and it is ready for operation.

• ABORT - When the abort switch is pushed in, the red ABORT status indicator illuminates. Press operation is no longer possible.

• IN CYCLE - When both activation switches are pressed, the IN CYCLE display of the status indicator is ON for the duration of the finger switch activation.

POWER

IN CYCLE

ABORT

Twist to Re set

Figure 4-15 Setting and Resetting the E–STOP

WARNING

Any modifications to the

Emergency Stop Switch (also known as the E-STOP or Abort

Switch) circuit must comply with all OSHA and ANSI requirements .

Compliance with all local building and electrical codes is also required .

Dukane Corporation does not assume any responsibility or liability for circuitry modifications made by the customer or by any third party manufacturer .

Page 52 Dukane Manual Part No. 403-586-00

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

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This page intentionally left blank

Page 54 Dukane Manual Part No. 403-586-00

Section 5 - Operation

Overview

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.

With this type of system, the user controls nearly all aspects of the welding process through the front panel of the iQ LE generator.

Generator Start-up

Sequence

1) Press the rear panel AC breaker switch to ON . See

Figure 5-1.

2) The front panel power on light (See Figure 5-2.) will flash RED a few times, then will glow a steady GREEN .

The display's initial screen identifies the Dukane iQ

Series generator and its major components.

The start-up sequence ends when the OPERATE screen is displayed.

NOTE

Press, acoustic stack, and tooling will require their own individual adjustments as those components are integrated into your particular system.

Helpful information on a wide variety of assembly equipment, processes and techniques can be found at the Dukane website: http://www .dukane .com/us/PPL_upa .htm

(ON)

(OFF)

Figure 5–1 Rear Panel AC Breaker Switch

Power On Light

Figure 5–2 Front Panel with Power On Light

Dukane Manual Part No. 403-586-00

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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. 403-586-00

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

Page 60

Page 64

AMP

PRE-WELD

WELD

Weld

Afterburst

Pre-trigger

Start

Operating Mode

Pre-trigger

Trigger

Time

Energy

Distance

Position

Ground Detect

Page 66 POST-WELD

Hold

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.

Page 69

Page 72

SETUPS

OPERATE

Setup Control

Name Setup

Copy Setup

Erase Setup

Display Only -

Real time Process

Characteristics.

iQ System

Automation

Edit Setup

Page 74

LIVE

Display Only -

Amplitude, Power,

Frequency, Position.

Figure 5-3 Generator Menu Overview

Dukane Manual Part No. 403-586-00

INFO

Page 75

System Info

Regional Settings

Advanced Settings

NOTE

The unique hardware configuration of the generator determines what menus are available.

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.

AMPLITUDE

ONLINE      

100%

WELD

This is the only menu available if MODE is set to AUTO-

MATED PROBE.

This same menu is displayed if MODE is set to iQ CON-

TROLLED PROBE MODE , and TRIGGER BY POWER is disabled, or if PRE-TRIGGER is disabled in either of the press modes.

AMP  

PRE  

WELD   WELD  

PRESS ENTER TO ACCEPT

PRESS CANCEL TO ABORT

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-4 Setting Weld Amplitude

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.

WELD

AMPLITUDE

ONLINE      

100%

AFTERBURST

AMP  

POST  

WELD  

PRESS ENTER TO ACCEPT

PRESS CANCEL TO ABORT

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-5 Setting Weld Amplitude with Afterburst

Enabled

Page 58

Continued

Dukane Manual Part No. 403-586-00

Section 5 - Operation

Continued from Previous Page

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.

PRE-TRIGGER

WELD

AMPLITUDE

Online  

100%

AMP  

PRE  

WELD   WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-6 Setting Weld Amplitude, Pre-Trigger

Available

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 .

START

WELD

AMPLITUDE

ONLINE      

100%

PRESS ENTER TO ACCEPT

PRESS CANCEL TO ABORT

LIMITS   SETUPS   OPERATE   LIVE   AMP  

Figure 5-7 Setting Weld Amplitude with Trigger By

Power Enabled

NOTE

Amplitude Range = 20 -100%

Dukane Manual Part No. 403-586-00

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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

PROBE DELAY

AMP  

AUTOMATED PROBE iQ CONTROLLED PROBE

MANUAL PRESS

AUTOMATED PRESS

ONLINE      

PRESS ENTER TO SELECT

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-8 Pre Weld Menu, Mode is Automated Probe

MODE

TIME

ONLINE      

0.0000s

PROBE DELAY menu is shown in Figure 5-9 at right.

PROBE DELAY

AMP  

PRESS ENTER TO SELECT

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-9 Pre Weld Menu, Probe Delay

NOTE

PROBE DELAY is only available in AUTO-

MATED PROBE MODE.

Page 60

Continued

Dukane Manual Part No. 403-586-00

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

ONLINE      

TRIGGER

AMP  

POST  

WELD  

PRESS ENTER TO SELECT

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-10 Pre Weld Menu, Mode is iQ Controlled

Probe

MODE

TYPE

ONLINE      

DISABLED

The TRIGGER menu is shown in Figure 5-11.

TRIGGER

AMP  

PRESS ENTER TO CHANGE

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-11 Pre Weld Menu, Trigger Menu

MODE

ONLINE      

DISABLED

POWER

Making the selection of trigger type is shown in Figure

5-12.

TRIGGER

AMP  

PRESS ENTER TO CHANGE

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-12 Pre Weld Menu, Trigger Selection

TRIGGER BY POWER has been chosen as the trigger type as shown in Figure 5-13.

MODE

TYPE

AMPLITUDE

POWER

MAX TIME

ONLINE      

POWER

100%

0W

0.000s

TRIGGER

AMP  

PRESS ENTER TO CHANGE

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-13 Pre Weld Menu, Trigger By Power

Selected

Dukane Manual Part No. 403-586-00

Continued

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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   WELD  

AUTOMATED PROBE iQ CONTROLLED PROBE

MANUAL PRESS

AUTOMATED PRESS

ONLINE      

PRESS ENTER TO SELECT

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.

MODE

TYPE

MAX TIME

ONLINE      

MAINTAINED

0.000s

PRE-TRIGGER

TRIGGER

AMP  

PRE  

WELD   WELD  

PRESS ENTER TO SELECT

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.

MODE

ONLINE      

MAINTAINED

MOMENTARY

POWER

PRE-TRIGGER

TRIGGER

AMP  

PRE  

WELD   WELD  

PRESS ENTER TO SELECT

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.

MODE

PRE-TRIGGER

TRIGGER

AMP  

ONLINE      

MAINTAINED

MOMENTARY

WHEN MOTION STOPS

POWER

POSITION

PRESS ENTER TO SELECT

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-17 Pre Weld Menu, Press Supports Distance

Page 62

Continued

Dukane Manual Part No. 403-586-00

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 .

MODE

PRE-TRIGGER

The PRE WELD menu shown in Figure 5-19 shows the PRE-TRIGGER menu, but the press does not support DISTANCE .

DISABLED

ONLINE      

TRIGGER

AMP  

PRE  

WELD   WELD  

PRESS ENTER TO CHANGE

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-18 Pre Weld Menu, Pre-Trigger Disabled

MODE

ONLINE      

DISABLED

TIME

PRE-TRIGGER

TRIGGER

AMP  

PRESS ENTER TO CHANGE

POST  

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 .

The PRE WELD menu shown in Figure 5-21 shows the PRE-TRIGGER menu, when TIME is selected.

MODE

ONLINE      

DISABLED

POSITION

TIME PRE-TRIGGER

TRIGGER

AMP  

PRE  

WELD   WELD  

PRESS ENTER TO CHANGE

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-20 Pre Weld Menu, Pre-Trigger Enabled,

Press Supports Distance

MODE

PRE-TRIGGER

DISABLED

TIME

AMPLITUDE

ONLINE      

0.000s

20%

TRIGGER

AMP  

PRESS ENTER TO CHANGE

POST  

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 selecte d.

MODE

DISABLED

POSITION

AMPLITUDE

ONLINE      

0.0000in

20% PRE-TRIGGER

TRIGGER

AMP  

PRESS ENTER TO CHANGE

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-22 Pre-Trigger Menu, Position Selected

Dukane Manual Part No. 403-586-00

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WELD

The WELD menu seen in Figure 5-23, shows the message that is displayed if the MODE was set to AUTOMATED

PROBE .

WELD CONTROLLED BY AUTOMATION

ONLINE      

AMP   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

0.000s

>

TIME

ENERGY

ONLINE      

USE +/- TO SELECT

PRESS ENTER TO CHANGE

LIMITS   SETUPS   OPERATE   LIVE   AMP  

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

0.000s

>

TIME

ENERGY

GROUND DETECT

ONLINE      

USE +/- TO SELECT

PRESS ENTER TO CHANGE

LIMITS   SETUPS   OPERATE   LIVE   AMP  

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 has been selected, and a value for energy will be entered.

ENERGY

0J

MAX TIME

0.000s

>

TIME

ENERGY

GROUND DETECT

ONLINE      

AMP  

PRE  

WELD   WELD  

PRESS ENTER TO ACCEPT

PRESS CANCEL TO ABORT

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-26 Weld Menu, Mode: Manual/Automated

Press, Energy Selection

Page 64

Continued

Dukane Manual Part No. 403-586-00

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

AMP  

PRE  

WELD   WELD  

> TIME

ENERGY

DISTANCE

POSITION

GROUND DETECT

ONLINE      

USE +/- TO SELECT

PRESS ENTER TO CHANGE

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

0 J

MAX TIME

30.000s

AMP  

>

TIME

|||||  

DISTANCE

POSITION

GROUND DETECT

ONLINE      

PRESS ENTER TO ACCEPT

PRESS CANCEL TO ABORT

POST  

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. 403-586-00

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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 AUTO-

MATED PROBE MODE using the PRE WELD display .

HOLD

ONLINE      

AFTERBURST

DISABLED

TIME

DISTANCE

DISABLED

DISABLED

AMP  

USE +/- TO SELECT

PRESS ENTER TO CHANGE

POST  

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.

HOLD

AFTERBURST

AMP  

PRE  

WELD   WELD  

ONLINE      

DISABLED

TIME

DISTANCE

0.000s

DISABLED

PRESS ENTER TO ACCEPT

PRESS CANCEL TO ABORT

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-30 Post Weld Menu, Time Setting

HOLD

ONLINE      

AFTERBURST

AMP  

PRE  

WELD   WELD  

DISABLED

TIME

DISTANCE

0.000s

DISABLED

PRESS ENTER TO ACCEPT

PRESS CANCEL TO ABORT

LIMITS   SETUPS   OPERATE   LIVE  

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

AFTERBURST

AFTERBURST

ONLINE      

DISABLED

PRESS ENTER TO CHANGE

AMP  

PRE  

WELD   WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-31 Post Weld Menu, Afterburst Disabled

The menu to the right in Figure 5-32, is displayed when

AFTERBURST is enabled.

HOLD

AFTERBURST

AMP  

PRE  

WELD   WELD  

AFTERBURST

AMPLITUDE

DELAY

DURATION

ONLINE      

ENABLED

|||||  

100%

0.000s

0.000s

PRESS ENTER TO ACCEPT

PRESS CANCEL TO ABORT

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-32 Post Weld Menu, Afterburst Enabled

Page 66 Dukane Manual Part No. 403-586-00

Section 5 - Operation

LIMITS

The LIMITS menu seen in Figure 5-33, shows what is displayed when in a PROBE MODE (either iQ CON-

TROLLED PROBE or AUTOMATED PROBE ).

In the example shown to the right, the DISPLAY EN-

ABLED soft key was pressed to select ENABLED . Press the key again to select DISABLED .

BAD

DISABLED

SUSPECT

DISABLED

DISPLAY

ENABLED

AMP  

> TIME

ENERGY

ONLINE      

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-33 Limits Menu, in Probe Mode

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

SUSPECT

DISABLED

DISPLAY

ENABLED

AMP  

>

DOWNSTROKE TIME

TRIGGER DELAY TIME

TIME

ENERGY

HOLD TIME

TOTAL CYCLE TIME

ONLINE      

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

>

DOWNSTROKE TIME

DOWNSTROKE DIST

TIME

ENERGY

WELD DISTANCE

WELD END POSITION

TOTAL CYCLE TIME DISPLAY

ENABLED

AMP  

PRE  

WELD   WELD  

POST  

WELD  

LIMITS  

ONLINE      

SETUPS   OPERATE   LIVE  

Figure 5-35 Limits Menu, Press Mode, Distance Is

Supported

Dukane Manual Part No. 403-586-00

Continued

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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

ENABLED

WELD TIME

BAD PART LIMIT

ONLINE      

Selecting ENABLED will change the menu to what is shown in Figure 5-37.

AMP  

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-36 Limits Menu, Bad Soft Key Pressed

.

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.

UPPER LIMIT

30.000s

LOWER LIMIT

0.000s

DONE

AMP  

PRE  

WELD   WELD  

WELD TIME

BAD PART LIMIT

LIMITS   SETUPS  

ONLINE      

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

PEAK POWER

ENERGY

ONLINE      

AMP  

PRE  

WELD   WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-38 Limits Menu, Bad Parts Limits Enabled for

Time

Page 68 Dukane Manual Part No. 403-586-00

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.

If AUTOMATION is selected, the bottom soft key would be: EDIT SETUP .

IQ SYSTEM

AUTOMATION

>

SETUP CONTROL

NAME SETUP

COPY SETUP

ERASE SETUP

ONLINE      

SELECT SETUP

AMP  

PRE  

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.

When the > is next to the desired setup, press the

SETUP soft key, or the ENTER key.

SELECT

SELECT SETUP

> # 1 - SETUP# 1

# 2 - SETUP# 2

# 3 - SETUP# 3

# 4 - SETUP# 4

# 5 - SETUP# 5

# 6 - SETUP# 6

# 7 - SETUP# 7

ONLINE      

AMP   LIMITS   SETUPS   OPERATE   LIVE  

Then, the previous screen will be displayed.

Pressing CANCEL would display the previous screen without any setup being chosen.

Figure 5-40 Setups Menu, Select Setup

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).

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.

SETUP NAME

SETUP #1

>

SETUP CONTROL

NAME SETUP

COPY SETUP

ERASE SETUP

ONLINE      

ERASE NAME

AMP  

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-41 Setups Menu, Name Setup

NOTE

A total of 8 (eight) setups can be made.

Dukane Manual Part No. 403-586-00

Continued

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Continued from Previous Page

Copying a Setup

COPY FROM

SETUP# 1

Move the

5-42.

> next to COPY SETUP as shown in Figure

COPY TO

SETUP# 2

COPY SETUP

The current setup being used or edited is displayed under

COPY FROM.

AMP  

>

SETUP CONTROL

NAME SETUP

COPY SETUP

ERASE SETUP

ONLINE    

POST  

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.

Use the + and - keys to scroll through the list.

Press ENTER to make the setup the COPY FROM selection.

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.

Press ENTER to make the setup the COPY TO selection.

SELECT SETUP

> # 1 - SETUP# 1

# 2 - SETUP# 2

# 3 - SETUP# 3

# 4 - SETUP# 4

# 5 - SETUP# 5

# 6 - SETUP# 6

# 7 - SETUP# 7

ONLINE      

AMP   LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-43 Setups Menu, Copy From/To Setup

SETUP COPIED

ONLINE      

When the COPY SETUP soft key is pressed, the screen shown in Figure 5-44 is displayed - for about 5 seconds.

The next screen displayed is the COPY SETUP screen as shown in Figure 5-42 above.

AMP  

PRE  

WELD   WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-44 Setups Menu, Setup Copied Confirmation

Page 70

Continued

Dukane Manual Part No. 403-586-00

Section 5 - Operation

Continued from Previous Page

Erase Setup

Move the >

Figure 5-45.

next to ERASE SETUP as shown in the

CURRENT SETUP

ALL SETUPS

SETUP CONTROL

NAME SETUP

>

COPY SETUP

ERASE SETUP

ONLINE    

The current setup or all setups can be erased.

AMP  

PRE  

WELD   WELD  

POST  

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.

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

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.

If ALL SETUPS was chosen in the setup menu, the message would be: ALL SETUPS ERASED.

YES

NO

ARE YOU SURE YOU WANT TO

ERASE THIS SETUP?

ONLINE    

AMP  

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-46 Setups Menu, Question Erase

SETUP ERASED

ONLINE      

AMP  

PRE  

WELD   WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-47 Setups Menu, Confirm Erase

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OPERATE

Name of setup being edited if in

Automation Mode, Otherwise the setup is in use.

Operating Mode

Online/Offline/E-Stop Status

System Power

Output Level

AUTO 01 SETUP #01

PART COUNT

WELD TIME

ENERGY

PEAK POWER

DISTANCE

PROCESS

STATISTICS

AMP  

PRE  

WELD   WELD  

LIMITS   SETUPS   OPERATE  

ONLINE

0

0.000s

0.0J

0W

0.000IN

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

Page 72

Continued

Dukane Manual Part No. 403-586-00

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.

AUTO 01 PROCESS STATISTICS

PART COUNT

GOOD

BAD

SUSPECT

Online

0 |

0 0%

0 0%

0 0%

BACK

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.

AMP   LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-49 Operate Screen - II

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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.

If distance is not supported, it would not be displayed.

AUTO 01

SETUP #01

AMPLITUDE

POWER

OPERATING FREQUENCY

DISTANCE

ONLINE

100%

0W

19,900Hz

0.0000in

AMP  

PRE  

WELD   WELD  

Figure 5-50 Live Data Screen

LIMITS   SETUPS   OPERATE   LIVE  

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

ONLINE

100%

0W

19,900Hz

0.0000in

AMP  

POST  

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.

AUTO 01 TEST

SETUP #01

AMPLITUDE

POWER

OPERATING FREQUENCY

DISTANCE The screen shows the current value of the parameters shown.

AMP  

If DISTANCE is not supported, it would not be displayed.

Figure 5-52 Test Screen

ONLINE

100%

0W

19,900Hz

0.0000in

LIMITS   SETUPS   OPERATE   LIVE  

Page 74 Dukane Manual Part No. 403-586-00

Section 5 - Operation

Using the INFO Menus

Press the INFO key, and the menu shown to the right in

Figure 5-53 appears.

SYSTEM INFO

INFO MENU ONLINE    

REGIONAL SETTINGS

ADVANCED SETTINGS

AMP  

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-53 Info Menu Display l

SYSTEM INFO - To display information about the generator hardware, press the SYSTEM INFO button. Figure 5-54 shows an example display of that information.

DUKANE CORPORATION/IAS DIVISION iQ LE SERIES ULTRASONIC GENERATOR

Model# 20HS2401ZP5 Serial# 236853

Front Panel Code v1.00.00

ONLINE      

Motherboard Code vXX.XX.XX www.dukane.com/us

Boot Code: MB v1.03 / FP v1.00

AMP  

PRE  

WELD   WELD  

POST  

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

UNITS

ENGLISH

FRENCH

GERMAN

ONLINE      

BACK

AMP  

PRE  

WELD   WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-55 Regional Settings, Language Menu

UNITS - To set up preference for units press the

INFO ke y, go to the REGIONAL SETTINGS

MENU , and then to the UNITS key.

See Figure 5-56.

LANGUAGE

REGIONAL SETTINGS MENU

IMPERIAL

METRIC

UNITS

ONLINE      

BACK

AMP  

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-56 Regional Settings, Units Menu

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Continued from Previous Page

ADVANCED SETTINGS - This part of the INFO menu gives access to the three sub-menus, Adv Process Control , System Status IO , and Miscellaneous and their menu items as shown below in Figure 5-57.

• Adv Process Control

Phase Shift

Free Run Freq

Freq Lock and Hold

System Freq Limits

Ramp Up Time

Ramp Down Time

WARNING

Modifying Advanced Settings may damage the unit or ultrasonic stack .

• System Status IO

Auto Start Input

Auto Stop Input

J3 Pin 4

J3 Pin 5

Output Duration

• Miscellaneous

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

> ADV PROCESS CONTROL

PHASE SHIFT

FREE RUN FREQ

FREQ LOCK AND HOLD

SYSTEM FREQ LIMITS

RAMP UP TIME

RAMP DOWN TIME

AMP  

PRE  

WELD   WELD  

LIMITS   SETUPS   OPERATE  

ONLINE      

20000Hz

DISABLED

NORMAL

0.150s

0.000s

 

LIVE  

Figure 5-58 Advanced Process Control Menu

Page 76

Continued

Dukane Manual Part No. 403-586-00

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.

YES

NO

ARE YOU SURE YOU WANT TO

RESTORE ALL ADVANCED

PROCESS CONTROL SETTINGS TO

DEFAULT VALUES?

ONLINE      

AMP  

PRE  

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.

After that, the display will once again appear as it does in Figure 5-58.

ONLINE      

ADVANCED PROCESS CONTROL

SETTINGS HAVE BEEN RESTORED TO

DEFAULT VALUES

AMP  

PRE  

WELD   WELD  

POST  

WELD  

LIMITS   SETUPS   OPERATE   LIVE  

Figure 5-60 Restore Defaults, Confirmed,

Advanced Process Control

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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) Phase Shift

Phase shift is used to adjust the timing of the ultrasound output driving pulses. A positive number delays the start of the output pulses and a negative number causes the signal output to start earlier.

Phase Shift range is + 20° to - 20°

2) Free Run Freq

Free run is the frequency at which the generator drives the ultrasound output pulses until a valid feedback signal is detected. Typically this value should be below the operating frequency of the stack

Adjust manually within the prescribed limitations for your particular generator model.

3) Freq Lock and Hold

When frequency lock and hold is disabled the frequency of the stack is tracked by changing the frequency of the ultrasound driving pulses to match the 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.

Enable or Disable this feature.

PHASE

ADV PROCESS CONTROL

> PHASE SHIFT

FREE RUN FREQ

FREQ LOCK AND HOLD

SYSTEM FREQ LIMITS

RAMP UP TIME

RAMP DOWN TIME

FREE RUN

20000 Hz

ADV PROCESS CONTROL

>

PHASE SHIFT

FREE RUN FREQ

FREQ LOCK AND HOLD

SYSTEM FREQ LIMITS

RAMP UP TIME

RAMP DOWN TIME

ENABLE

DISABLE

ADV PROCESS CONTROL

PHASE SHIFT

FREE RUN FREQ

> FREQ LOCK AND HOLD

SYSTEM FREQ LIMITS

RAMP UP TIME

RAMP DOWN TIME

LIMITS

NORMAL

UPPER

20400Hz

LOWER

19400Hz

ADV PROCESS CONTROL

PHASE SHIFT

FREE RUN FREQ

>

FREQ LOCK AND HOLD

SYSTEM FREQ LIMITS

RAMP UP TIME

RAMP DOWN TIME

TIME

0.150s

ADV PROCESS CONTROL

PHASE SHIFT

FREE RUN FREQ

FREQ LOCK AND HOLD

SYSTEM FREQ LIMITS

> RAMP UP TIME

RAMP DOWN TIME

TIME

0.000s

ADV PROCESS CONTROL

PHASE SHIFT

FREE RUN FREQ

FREQ LOCK AND HOLD

SYSTEM FREQ LIMITS

RAMP UP TIME

> RAMP DOWN TIME

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

Figure 5-61 Advanced Process Control Sub-menu Items

Continued

Dukane Manual Part No. 403-586-00

ONLINE      

20000Hz

DISABLED

NORMAL

0.150s

0.000s

 

ONLINE      

20000Hz

DISABLED

NORMAL

0.150s

0.000s

 

ONLINE      

20000Hz

DISABLED

NORMAL

0.150s

0.000s

 

ONLINE      

20000Hz

DISABLED

NORMAL

0.150s

0.000s

 

ONLINE      

20000Hz

DISABLED

NORMAL

0.150s

0.000s

 

ONLINE      

20000Hz

DISABLED

NORMAL

0.150S

0.000s

 

Continued from Previous Page

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 equal the free run frequency -

500Hz.

Narrow - In Narrow mode the upper and lower frequency limits equal the free run frequency -

200Hz.

Manual - In Manual mode the user sets the upper and lower frequency limits. To be valid, the settings must be within the maximum and minimum values for the generator and at least

25Hz greater than the "upper" free run frequency and 25Hz less than "lower" free run frequency.

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

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.

Section 5 - Operation

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SYSTEM STATUS I/O Sub-menu

The SYSTEM STATUS I/O submenu 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.

YES

NO

ONLINE      

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.

After that, the display will once again appear as it does in Figure 5-62.

SYSTEM STATUS I/O SETTINGS HAVE

BEEN RESTORED TO DEFAULT VALUES

ONLINE      

Figure 5-64 System Status I/O Defaults Restored

Page 80

Continued

Dukane Manual Part No. 403-586-00

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

Mechanical - If this is chosen, a value (0.000 to

0.100 seconds) must be given for Debounce.

SOLID SYSTEM STATUS I/O ONLINE      

STATE

MECHANICAL

> AUTO START INPUT SOLID STATE

AUTO STOP INPUT END OF CYCLE

J3 PIN 4 E-STOP

J3 PIN 5 HOLD

OUTPUT DURATION MAINTAINED

2) Auto Stop Input

Choose to Disable this, or select End of Weld , or

End of Cycle .

DISABLED

END OF

WELD

END OF

CYCLE

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

3) J3 Pin 4

Choose the output signal for J3 Pin 4:

E-Stop , or Overtemp

E-STOP

OVERTEMP

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

4) J3 Pin 5

Choose the output signal for J3 Pin 5:

Hold , In Cycle, or In Cycle No AB

HOLD

IN

CYCLE

IN CYCLE

NO AB

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

5) Output Duration

Choose either Maintained , or 100mS Pulse .

Moving to the Next Sub-menu

When > is next to OUTPUT DURATION , and the down key (minus) is pressed, the next sub-menu for MISCEL-

LANEOUS replaces the SYSTEM STATUS IO submenu.

MAINTAINED

100 ms

PULSE

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

Figure 5-65 System Status I/O Sub-menu Items

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Continued from Previous Page

Miscellaneous Sub-menu Items

The three sub-menu items and their corresponding displays (Figure 5-66) are shown below:

1) Buzzer

Set the audible buzzer to sound:

At Top of Stroke - Enable or Disable , or

At Trigger - Enable or Disable

DISABLE

ENABLE

MISCELLANOUS

> BUZZER

At TOP OF STROKE

AT TRIGGER

EXTERNAL CONTROL

LATCH ON BAD PART

RESTORE FACTORY DEFAULTS

ONLINE      

DISABLED

DISABLED

DISABLED

DISABLED

2) External Control

Choices are:

Disabled ,

Serial , or

Profibus (Range of 1 to 125)

DISABLE

ENABLE

>

MISCELLANOUS

BUZZER

AT TOP OF STROKE

AT TRIGGER

EXTERNAL CONTROL

LATCH ON BAD PART

RESTORE FACTORY DEFAULTS

ONLINE      

DISABLED

DISABLED

DISABLED

DISABLED

3) Restore Factory Defaults

Choose Restore to erase ALL setups and factory defaults.

RESTORE MISCELLANOUS

BUZZER

AT TOP OF STROKE

AT TRIGGER

EXTERNAL CONTROL

LATCH ON BAD PART

> RESTORE FACTORY DEFAULTS

ONLINE      

DISABLED

DISABLED

DISABLED

DISABLED

An intermediate display allows for confirmation.

YES

NO

ONLINE      

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 5-66 Miscellaneous Sub-menu Items

Page 82 Dukane Manual Part No. 403-586-00

Section 5 - Operation

ALARMS

Terminology : Alarm refers to any fault, or error the generator might produce.

An alarm condition may occur. Figure 5-67 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

AMP  

Figure 5-67 Alarm Message Screen

PRESS ENTER TO CLEAR

LIMITS   SETUPS   OPERATE   LIVE  

FAULTS:  

       U100        Configura3on  Fault  (Default  Setup  Corrupted,  Model  Number  Incorrect,  Serial  Number  Incorrect,  

                                   Feedback  Scaling  Incorrect,  etc)  

       U103        Hardware  Fault  (Hardware  Changed,  Remote  Amp  Card  removed?)  

       U104        Frequency  Overload  Fault  1  (PLL  Lock  Fail)  

       U105        Frequency  Overload  Fault  2  (PLL  Lock  Lost)  

       U106        POS  Peak  Overload  Fault  

       U107        NEG  Peak  Overload  Fault  

       U108        Average  Overload  Fault  

       U109        Bad  Current  Loop  Fault  

       U110        Power  not  OK  Fault  

       U111        Over  Temperature  Fault  

       U112        Frequency  Overload  Fault  3  (PLL  Limit  Exceeded)  

INITIATE  ERRORS:  

       U300        Operate  Switch  1  Pressed  before  Cycle  Start  

       U301        Operate  Switch  2  Pressed  before  Cycle  Start  

       U302        Auto  In  switch  closed  at  End  of  Cycle  

       U304        Trigger  switch  closed  before  Cycle  Start  

       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  

PROCESS  ERRORS:  

       U400        Weld  Limits  enabled  for  con3nuous  Opera3on  

       U401        Weld  Time  set  to  Zero  

       U402        Weld  Power  set  to  Zero  

       U403        Weld  Energy  set  to  Zero  

       U404        Weld  Distance  set  to  Zero  

       U405        Weld  Posi3on  set  to  Zero  

       U406        Max  Trigger  Time  set  to  Zero  

       U407        Forced  Shutdown  Fault  

       U408        Trig  Lost  Early  Fault  

       U409        Trig  Lost  Weld  Fault  

       U410        Pre-­‐trigger  Overtravel  Fault  

       U412        Max  Pre-­‐trigger  Time  exceeded  

       U413        Max  Trigger  Time  exceeded  

       U414        Max  Trigger  Delay  Time  exceeded  

Table 5-I Alarm Messages

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Page 84 Dukane Manual Part No. 403-586-00

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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Page 86 Dukane Manual Part No. 403-586-00

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. 403-586-00

Section 6 - Options

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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 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.

Page 88 Dukane Manual Part No. 403-586-00

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.

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.

B

A LINE VOLTAGE:

100-120 Vac

50/60Hz, 10A

PE

C

120 Volt line cord

Figure 6 - 2 120VAC Power Inlet Panel

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Press Interface Module

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.

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.

Welding with Two Pressures and

Distance

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.

Dukane's linear optical encoder has a one-micron resolution to insure exceptional precision and repeatability.

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 press base control.

- Provides the signal for the

(Dukane Cable P/N 200-1545-XXM) iQ Series

The iQ Series module, P5, adds support for distance, and that requires a third connector:

• 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.)

Ultra Series

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 - Base/Abor t press base control.

- Provides the signal for the

(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)

Ultra Series

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 200-1613-

XXM.)

Press Interface Modules

Generator

Series iQ

Ultra

Two Pressure

(No Distance)

Weld Options

Distance

(Two Pressure + Distance)

P4 (P/N 110-4426)

P8 (P/N 110-4854)

Table 6- I Press Interface Modules

P5 (P/N 110-4427)

P9 (P/N 110-4855)

Page 90 Dukane Manual Part No. 403-586-00

Section 6 - Options

Hydraulic Speed Control

SLOW SPEED Control and

Indicator Flags

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.

The knob and the indicator flag are part of the optional

Hydraulic Speed Control Kit.

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).

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.

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.

5 6

7

INCREASE

INCREASE

10

30

2

40

3

50

4

60

5

1 6

0 7

100

70

90

20

LOWERS

SPEED CONTROL

TRIGGER

3 5 0

LOOSEN THE

THUMBSCREW TO

UNLOCK KNOB

}

NOTE

Slow Speed range is limited to 1" (2.5 cm) above the Stroke

Position set point.

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

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Continued from Previous Page

Hydraulic Speed Control Kit Operation

Turning the SLOW SPEED knob rotates the rod.

Threaded

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.

Plunger

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.

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

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.

• 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.

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.

20

20

Contact Block

13

16

17

14

15

18

2

3

4

5

0

1

Indicator Flag

Hydraulic

Cylinder

Speed Adjustment

Figure 6-4 Location of the Hydraulic Control

Components

Decrease

Increase

Figure 6-5 Adjustment Using the Hole

20

Decrease

Increase

Figure 6-6 Adjustment Using the Slot

Page 92 Dukane Manual Part No. 403-586-00

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

• 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.)

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.

4. Connect the encoder cable to the generator connector

J-11 (Encoder).

5. Replace the rear panel on the press.

Right Side Panel

Encoder Scale

Encoder

Head

Figure 6-7 Distance Encoder Mounting

Continued

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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

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.

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:

• 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.

Figure 6-8 Distance Encoder Alignment

WARNING

.039 in (1 mm)

Gap

Stationary

Encoder

Head

1.375”

Keep hands and clothing away from an activated press .

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Continued

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Continued from Previous Page

Alignment

7. Set the gap between the encoder scale and head, using the feeler gauge .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 ±.005. This is a range of from .034 to .044 inches (.864 to 1.12 mm).

9. Tighten all the screws and check the measurements again.

10. Replace the press/thruster right side panel.

Section 6 - Options

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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

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Page 98 Dukane Manual Part No. 403-586-00

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.

Section 7 - Acoustic Stack/Fixture Setup

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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

BOOSTER

Contact Button

HORN

Transducer Housing

Anti–Rotation Pins

Mounting Stud

Mounting Ring

Spanner Wrench Hole (Typical)

Figure 7-1 Stack Components

Page 100 Dukane Manual Part No. 403-586-00

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.

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.

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.

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

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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.

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.

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.

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.

B

Figure 7-3 Disassembling Components

A

CAUTION

To avoid possible injury, press down on the spanner wrench with the palm of the hand.

Figure 7-4 Tip Removal

Page 102 Dukane Manual Part No. 403-586-00

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 Ultrasonics 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

1/2 in. x 20

3/8 in. x 24

M8 x 1.25

Torque inch-lbs foot-lbs Nt-meters

12-18

12-18

12-18

Table 7-I Stud Torque Values

1 - 1.5

1 - 1.5

1 - 1.5

1.4 - 2

1.4 - 2

1.4 - 2

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).

4. Thread the components together and tighten (Refer to

Table 7-II) by applying torque as follows:

Stack

kHz

15

20

30

40 inch-lbs

540

420

216

216

Torque foot-lbs Nt-meters

45

35

18

18

Table 7-II Horn/Booster Torque Values

61

47.5

24.4

24.4

NOTE

Do not apply any grease or lubricant to the stud.

Figure 7-5 Assembling Components

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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.

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

1/2 in. x 20

3/8 in. x 24

5/16 in. x 24

1/4 in. x 28

Torque inch-lbs foot-lbs Nt-meters

360

336

300

240

30

28

25

20

Table 7-III Replaceable Tip Torque Values

40.7

37.9

33.9

27.1

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.

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!

NOTE

Do not apply any lubricant to the tip threads.

Figure 7-6 Tip Assembly

A

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. 403-586-00

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.

WARNING

Any fixture manufactured by a third party must comply with all OSHA and ANSI requirements . All fixtures must be guarded as necessary .

Dukane Corporation does not assume any responsibility or liability for fixtures manufactured by the customer or any third party manufacturer .

Fixture

Fixture

Hold Down Bolts

Fixture Leveling Screws

(Hex socket set screws)

Holes for 3–Hole

Mounting Fixture

(12" x 14")

Holes for 4–Hole

Mounting Fixture

(9" x 9")

Figure 7-8 Fixture/Base Layout

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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.

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.

NOTE

S o m e a p p l i c a t i o n s m a y r e q u i r e t h e h o r n t o b e a f e w 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.

Figure 7-9 Loosening the Hold–Down

Cap Screws and Jack Screws

Figure 7-10 Tightening the Hold–Down

Cap Screws and Jack Screws

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Continued

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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.

Section 7 - Acoustic Stack/Fixture Setup

Figure 7-10 Tightening the Hold–Down

Cap Screws and Jack Screws

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Page 108 Dukane Manual Part No. 403-586-00

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 .0005 inch

Booster .0005 inch

Horn .0005 inch

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.

Burnished

Area

Figure 8-1 Example of Burnished Area

Crown

Straight

Edge

Gap

Figure 8-2 Example of Crowning

Gap

Straight

Edge

Figure 8-3 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.

4. If necessary, remove the mounting studs.

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.

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:

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.

CAUTION

Use extreme care to avoid tilting the part. Loss of flatness of interface surfaces may render t h e w e l d i n g s y s t e m inoperative.

Figure 8-4 Method of Component Resurfacing 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.

Page 112

CAUTION

Use extreme care to avoid multiple strokes at each 1/3 rotation of the part. Loss of flatness the centering axis of the part may render the welding system inoperative.

and perpendicularity of the interface surface to

Continued

Dukane Manual Part No. 403-586-00

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:

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.

Table 7-I - Stud Torque Values

Table 7-II - Horn/Booster Torque Values

Table 7-III - Replaceable Tip Torque Values

NOTE

Overtightening stack components may result in horn/ booster studs loosening and unexplained overloads.

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Page 114 Dukane Manual Part No. 403-586-00

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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Page 116 Dukane Manual Part No. 403-586-00

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 or altering the position of the

End-of-Weld limit switch, 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

Time

Distance

Position

Energy

Equipment Requirements

Generator with a digital timer or process controller with a time function.

Process controller with a distance measurement function and a press / thruster equipped with an optical distance encoder.

Process controller with a distance measurement function and a press/thruster equipped with an optical distance encoder, or a press/ thruster with an End-of-Weld limit switch installed.

Process controller with an energy measurement function.

Table 9- I Weld Characteristics and Equipment Requirements

End-of-Weld Limit Switch

The End-of-Weld limit switch is used to terminate the ultrasound power burst during a weld cycle as determined by the stroke position of the press head.

The switch is generally not used with a system that contains a process controller with a distance measurement function or a press/thruster equipped with an optical distance encoder.

Section 9 - Troubleshooting

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Welding

__________________________________________________________________________________

Problem

Flash ( See also: Uneven Welding )

Probable Cause

Energy director is too large.

Solution

Reduce the size of the energy director.

Reduce the weld time/primary weld characteristic.

Reduce the air pressure.

Use an interrupted energy director.

Reduce the amount of interference.

Shear interference is too great.

Weld time is too long.

Non-uniform joint dimensions.

Reduce the weld time.

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.

Improper support in the fixture.

Wall flexure.

Design a means of alignment into the tooling (fixturing).

Add a means of alignment (e.g., pins and sockets) to the mating part halves.

Redesign the fixture for proper support.

Add ribs or gussets to the part.

With a resilient fixture, if large sections of urethane are deflecting, add a rigid backup.

Re-dimension the parts.

Joint design is not properly dimensioned.

Incorrect part tolerance/poor molding. Tighten the part tolerance.

Check the processing conditions.

__________________________________________________________________________________

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Continued

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Section 9 - Troubleshooting

Welding

_______________________________________________________________________________

Problem

Internal components are welding together.

Probable Cause

The internal components are made of the same material.

Solution

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

Excessive horn amplitude.

Excessive exposure to ultrasound.

Improper gate location/design/thin- wall sections.

Solution

Reduce the horn amplitude.

Dampen the welding area to absorb the amplitude.

Reduce the weld time and increase the horn amplitude and/or air pressure.

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

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Welding

__________________________________________________________________________________

Problem

Internal components of work piece damaged during welding.

Probable Cause

Excessive horn amplitude

Excessive exposure to ultrasound.

Too much energy transmitted into the part.

The components are improperly mounted (e.g., parts are mounted too close to the joint area).

Solution

Reduce the horn amplitude by changing to a lower gain booster.

Dampen the excess horn amplitude.

Reduce the primary weld time and increase the horn amplitude by changing to a higher gain booster.

Reduce the horn amplitude.

Reduce the air pressure.

Reduce the weld time/primary weld characteristic.

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.

Excessive horn amplitude.

A long weld time.

Radius all sharp corners.

Dampen motion for any damaged area, if possible.

Reduce the horn amplitude by changing to a lower gain booster.

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.

__________________________________________________________________________________

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Section 9 - Troubleshooting

Welding

_______________________________________________________________________________

Problem

Underwelding

Probable Cause

Insufficient energy is being transmitted to the part.

Energy is being absorbed into the fixture.

Solution

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.

Change the type of fixture being used.

_______________________________________________________________________________

Problem

Uneven welding

Probable Cause

Warped part(s).

The energy director varies in height.

Lack of parallelism between the horn, the fixture, and the part.

Solution

Check part dimensions.

Check the molding conditions.

Use a higher trigger pressure.

Use a higher hold pressure.

Redesign the energy director to ensure uniform height.

Use an interrupted energy director.

Make sure the thruster is perpendicular to the part.

Check the part dimensions.

Wall flexure is occurring.

The knockout pin location is in the joint area

Add ribs to the part.

Modify the fixture to prevent outward flexure

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

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Welding

_________________________________________________________________________________

Problem Continued from Previous Page

Uneven welding

Probable Cause Solution

Part dimensions are incorrect.

The parts are improperly aligned.

There is a lack of intimate contact around the joint area.

Check the part dimensions.

Re-dimension the part, if necessary.

Check the molding conditions.

Check for part shifting during welding.

Check the alignment of mating parts.

Check for parallelism of the horn, the part, and/or the fixture.

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.

Mold release is on the joint surface(s).

There is a non-uniform distribution of filler in the plastic material.

The joint design is incorrect.

There is a material or resin grade incompatibility problem.

There is a regrind problem.

Check the fit of the part to the horn.

Check for proper support in the fixture.

Clean the mating surfaces.

Check the molding conditions.

Check the mold design.

Redesign the joint.

Consult with the resin supplier(s).

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.

_________________________________________________________________________________

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Section 9 - Troubleshooting

Welding

________________________________________________________________________________

Problem

The parts are marking.

Probable Cause

The horn heats up.

Solution

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.

Use of raised lettering.

The part does not fit the fixture properly.

Oxide from the horn is being transferred to the part.

The parts contain fillers.

Check the part dimensions.

Check the fit of the horn to the part.

Use recessed lettering or relieve the horn around the lettering.

Check the fixture for proper support.

Check for cavity-to-cavity variations.

Redesign the fixture.

Place polyethylene film between the horn and the part.

Use a chrome-plated horn and/or fixture.

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.

Incorrect part tolerances.

Clean the mating surfaces.

If a mold release agent is necessary, use a paintable/printable grade.

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.

________________________________________________________________________________

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Welding

__________________________________________________________________________________

Problem Continued 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.

The resin contains regrind or degraded plastic.

Perform a statistical study to see if a pattern develops with certain cavity combinations.

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.

Fluctuations in the air line pressure.

The plastic’s filler content is too high.

The horn doesn’t fit the part correctly.

The weld cycle is too long.

There is a lack of parallelism between the horn, part, and/or fixture.

Upgrade to a generator with line regulation.

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.

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).

Check the part dimensions.

Check for cavity-to-cavity variations.

Obtain a new horn.

Reduce the weld cycle time and increase the horn amplitude or air pressure.

Increase the dynamic trigger force.

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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Section 9 - Troubleshooting

Insertion

_______________________________________________________________________________

Problem

The insert pulls out easily in use.

Probable Cause

There is insufficient interference between the hole and the insert.

The screw bottoms out in the hole.

Solution

Reduce the size of the molded hole in the plastic.

Use a shorter screw. (Applies to internally- threaded insert).

The insert gets pushed into the plastic before the plastic melts.

Deepen the hole.

Use hydraulic speed control.

Increase the horn amplitude and/or decrease the air pressure.

Use pre-triggering.

Decrease the primary weld characteristic.

The ultrasound remains on after insertion is complete.

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

The plastic is not melting consistently around all inserts.

Solution

Increase the horn amplitude.

Inserts are pushed into the plastic before the plastic has melted.

Inserts are seated at different heights within the same part.

Use hydraulic speed control.

Reduce the down speed.

Use pre-triggering.

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

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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.

The gauge pressure is set too high.

The boss wall is too thin.

Reduce the down speed, air pressure, and/or horn amplitude.

Use pre-triggering.

Reduce the air pressure.

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

The ultrasound is not on long enough.

Solution

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

There is insufficient ultrasonic power or the generator overloads.

There is too much interference between the hole and the insert.

The area of the part being inserted is not being rigidly supported.

The down speed is slow.

Solution

If using a power control, increase the power.

Use a more powerful generator.

Increase the hole diameter, if possible.

Use a smaller insert.

Support the part directly under the boss.

Install a metal post directly under the part being inserted.

Increase the down speed.

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Continued

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Section 9 - Troubleshooting

Insertion

_________________________________________________________________________________

Problem

Plastic flows over the top of the insert.

Probable Cause

The weld time is too long.

The insert is being driven too deep.

Solution

Decrease the primary weld characteristic.

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.

There is too much interference between the hole and the insert.

Use a shorter insert or make the hole deeper.

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.

The volume of plastic in the stud is insufficient.

Change to a smaller cavity in the horn.

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.

The volume of plastic in the stud is excessive.

The stud is not centered in the horn cavity.

Use a larger cavity in the horn.

Decrease the stud height and/or diameter.

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

The hole diameter relative to the stud diameter is too large.

Solution

Reduce the hole diameter.

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Continued

Dukane Manual Part No. 403-586-00

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

The holding force was removed before the stud head could solidify.

Insufficient force is being applied to the staked head during the hold time.

Solution

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.

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.

The stud is not centered in the horn cavity.

The base is melting before the head forms.

Radius the stud at the base.

Center the stud under the horn cavity.

Use a knurled tip

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.

The horn amplitude is insufficient.

Reduce the trigger force.

Pre-trigger the ultrasound.

Increase the amplitude.

The downstroke speed is too fast. Use hydraulic speed control.

Use a slower downstroke speed.

_________________________________________________________________________________

Continued

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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. 403-586-00

Section 9 - Troubleshooting

Continuous Welding

_____________________________________________________________________________

Problem

Seal not meeting strength requirements.

Probable Cause Solution

Material traveling too quickly.

Not enough horn amplitude.

Decrease speed.

Increase booster ratio.

Inconsistent blends of synthetic material. Evaluate material.

________________________________________________________________________________

Problem

Inconsistent welding.

Probable Cause Solution

Non-uniform amplitude horn.

Variations in anvil (fixture).

Have horn analyzed for amplitude uniformity.

Check fixture design and dimensions.

Inconsistency of material. Evaluate material.

________________________________________________________________________________

Problem

Seal area too great, causing flash.

Probable Cause Solution

Material traveling too slow.

Too much amplitude.

Increase speed.

Reduce booster ratio.

Excessive air pressure. Reduce air pressure.

________________________________________________________________________________

Problem

Transducer and/or horn heating up.

Probable Cause

Not enough air flow to dissipate heat buildup.

Solution

Continuous duty applications require cooling air (refrigerated air, in some applications).

Supply air to the stack interfaces and the horn tips.

________________________________________________________________________________

Continued

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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

Loose stack components.

Horn failure.

Transducer failure

Solution

Disassemble, clean and reassemble stack.

Replace horn.

Replace transducer.

Booster failure. Replace booster.

Stack operating frequency shifted out of tolerance.

Cool stack with air.

_________________________________________________________________________________

**

NOTE

Table 5-I, Page 83, shows alarm messages that indicate generator status, and appear only on display-capable generators.

Page 132 Dukane Manual Part No. 403-586-00

Section 10 - System Maintenance

SECTION 10

System Maintenance

Press/Thruster Six-Month Periodic Maintenance . . . 135

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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.

Section 10 - System Maintenance

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Section 11 - Contacting Dukane

SECTION 11

Contacting Dukane

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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 Ultrasonics

Drive

St. Charles, IL 60174 US

Phone:

E-mail:

(630) 797–4900 [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/us/

You can locate your local representative at: www.dukane.com/us/sales/intsales.htm

Dukane Manual Part No. 403-586-00

Section 11 - Contacting Dukane

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Page 140 Dukane Manual Part No. 403-586-00

Section 12 - Specifications

SECTION 12

Specifications

Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143-148

Pneumatic Schematic. . . . . . . . . . . . . . . . . . . . . . . . 145

Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 146

Weights, Dimensions, Operating Environment. . . . . 149

Compressed Air Requirements. . . . . . . . . . . . . . . . . 150

AC Power Requirements . . . . . . . . . . . . . . . . . . . . . 150

Interpreting the Model Number Codes . . . . . . . . . . . 151

Replacement Parts. . . . . . . . . . . . . . . . . . . . . . . . . . 153

Regulatory Agency Compliance . . . . . . . . . . . . . . . . 154

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Page 142 Dukane Manual Part No. 403-586-00

OPTIONAL IQ

GENERATOR

Section 12 - Specifications

Figure 12-1 Layout - 220 Thruster

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(PART HEIGHT+FIXTURE)

15.00

MAX.

[381]

STROKE

7.00

MAX.

[178]

TYPICAL HORN

5.38

[137]

Figure 12-2 Layout - 220 Press

Page 144 Dukane Manual Part No. 403-586-00

Section 12 - Specifications

Figure 12-3 Pneumatic Schematic (All iQ LE Presses)

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4

2

Figure 12-4 Electric Schematic 220

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Section 12 - Specifications

Figure 12-5 iQ LE Basic Generator Layout

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Figure 12-6 iQ LE 4800W Generator Layout

Page 148 Dukane Manual Part No. 403-586-00

Weights

Model Number

43Q220

Press (includes base and column)

Pounds

170

Kilograms

77

Thruster

Pounds

45

Kilograms

20

Shipping : Add 10 pounds (2.3 kg) to unit weight for packing materials

Table 12- I Weights

Section 12 - Specifications

Dimensions

Dimensions - in (mm)

Model Number

43Q220

Press (includes base and column)

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

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Compressed Air Requirements

For all press/thruster models, Dukane recommends 80-110 psi of clean, dry air.

Maximum available clamping pressure:

Model Force Generated at

110 psi (lb)

43Q220 540

Table 12- III Clamping Pressure

Standard Air Cylinder

Diameter (in)

2.50

AC Power Requirements

T he 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

20kHz

20kHz

20kHz

20kHz

20XX120-1X-XX-XX

20XX120-2X-XX-XX

20XX240-2X-XX-XX

20XX360-2X-XX-XX

Table 12- IV AC Power Requirements

Overload

Power

Ratings

(Watts)

1200

1200

2400

3600

Input AC Power Requirements

Nominal AC Volt

@ Maximum RMS Current

100-120V 50/60 Hz @ 15 Amps

200-240V 50/60 Hz @ 8 Amps

200-240V 50/60 Hz @ 15 Amps

200-240V 50/60 Hz @ 25 Amps

North America/

Japan

AC Outlet Rating

15 Amps

30 Amps

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.

Page 150 Dukane Manual Part No. 403-586-00

Section 12 - Specifications

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 . 2 Z - P4 H3 . S -

Nominal U/S Frequency

20 = 20 kHz

Power Level

24 = 2400 Watts

18 = 1800 Watts

12 = 1200 Watts

Example System Number Shown Above:

2024.2Z - P4H3.S

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.

Controller

Z = Graphic front panel

Custom Code

LC = Less Cables

Press Card

P4 = iQ Dual Pressure Card

P5 = iQ Distance Card

P8 = Ultra Dual Pressure Card

P9 = Ultra Distance Card

CS3 = SUWSI LITE Board

AC Line Input

E = 220-240 VAC (Europe)

N = 220/240 VAC (India)

2 = 200-240 V

1 = 100-120 V

Press Options

H = Hydraulic Speed Control

3 = 3” Air Cylinder

Support Options

T = Thruster Only

S = Standard Press

4 = 4 foot. Column

5 = 5 foot Column

6 = 6 foot Column

L = Less Base

Figure 12- 7 System Model Numbers

Model

Number

iQ Series LE Press/Thruster

Standard Options

Power

D P H S

43Q220 20kHz X X X X

Table 12-V Interpreting the Thruster Model Number

X = available

D - Distance encoder

P - Basic dual air pressure

H - Hydraulic speed control

S - Pre-trigger/end of weld limit

switches

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Figure 12- 8 Generator Model Numbers

Page 152 Dukane Manual Part No. 403-586-00

Section 12 - Specifications

Replacement Parts - iQ Series LE Presses

Part Number Part Description

474-33 High pressure grease packet

403-586 User's Manual iQ Series Ultrasonic Press System LE

430-03-0026 iQ main valve assembly

697-113 Air pressure gauge (NOT needed if standard option E is installed)

721-31-00056 Transducer door hex key 43Q220/43Q340

721-68

804-33

43Q215 / 43Q220 spanner wrench

Primary air cylinder, 2 1/2 " bore X  7"

804-52

804-62

804-63

804-71

Air pressure regulator (NOT needed if standard option E is installed)

Primary air cylinder 3" bore X 7"

Counter balance air cylinder 9/16" bore X 11"

Counter balance air cylinder 1 1/16 bore X 11"

Press Model

43Q215 43Q220

X

O

X

O

X

X

X

O

X

X

X

X

X

X

X

X

X

X

X

O

X

O

625-18 Optical distance encoder (when optional E feature is installed)

430-03-0045 Dual pressure valve assembly (when optional P feature is installed)

430-03-0035 Dual pressure valve assembly (when optional P feature is installed)

804-18 Hydraulic speed control cylinder (when optional H feature is installed)

Table 12-VI Replacement Parts

X

X

O

O

X

O

X

X

X = available

O = unavailable

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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.

• T h e E M C D i r e c t i v e 2 0 0 4 / 1 0 8 / E C for Heavy Industrial —

EN 61000-6-4: 2001

EN 55011: 2003

EN 61000-6-2: 2001

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.

• The Machinery Directive 2006/42/EC.

EN 60204: 2006

Safety of Machinery - Electrical Equipment of

Machines Part 1: General Requirements.

IP (International Protection)

Rating

The iQ generator has an IP rating from the IEC (International Electrotechnical Commission).

The rating is IP2X, in compliance with finger-safe industry standards.

CAUTION

DO NOT make any modifications to the generator or associated cables as the changes may result in violating one or more regulations under which this equipment is manufactured.

Page 154 Dukane Manual Part No. 403-586-00

Section 13 - Appendices

SECTION 13

Appendices

Appendix A, List of Figures. . . . . . . . . . . . . . . . . . . . 157

Appendix B, List of Tables . . . . . . . . . . . . . . . . . . . . 161

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Page 156 Dukane Manual Part No. 403-586-00

Appendix A

No. Description

2-1

2-2

Section 13 - Appendices

List of Figures

Page

Example of 220/240 Volt, Grounded, 3-Prong Receptacle ..............................................9

International 220/240V Grounding ..................................................................................9

3-5

3-6

3-7

3-8

3-1

3-2

3-3

3-4

Lockout Device In Open Position, Unlocked .................................................................13

Bottom Lockout Device In Closed Position, Locked ......................................................13

Rack Mounting iQ Generator - Representative Low-Profile Model Shown ...................15

Securing iQ Generator to Benchtop - Representative High-Profile Model Shown ........16

Typical iQ LE Generator Rear Panel Layout .................................................................17

IEC AC Power Inlet Connector ......................................................................................18

System I/O Panel (Standard Panel Shown) ..................................................................19

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

4-2

4-3

4-4

4-5

4-6

4-7 iQ Generator Display and Control Keys ........................................................................39

Display Detail, Operating Mode Indicator ......................................................................40

Display Detail, Power Output Level ...............................................................................40

Navigation Keys (4) with Enter, Info and Cancel ...........................................................41

Info Menu Display ..........................................................................................................41

Active Soft Keys, Example ............................................................................................41

Display Detail, Power Output Level ...............................................................................43

4-8

4-9

Making Selections .........................................................................................................44

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

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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

5-2

5-3

5-4

Rear Panel AC Breaker Switch .....................................................................................55

Front Panel with Power On Light ...................................................................................55

Generator Menu Overview ............................................................................................57

Setting Weld Amplitude .................................................................................................58

5-5

5-6

5-7

5-8

5-9

Setting Weld Amplitude with Afterburst Enabled ...........................................................58

Setting Weld Amplitude, Pre-Trigger Available ..............................................................59

Setting Weld Amplitude, with Trigger by Power Enabled ..............................................59

Pre Weld Menu, Mode is Automated Probe ..................................................................60

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. 403-586-00

Appendix A

No. Description

Section 13 - Appendices

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

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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

8-1

8-2

8-3

8-4

6-1

6-2

6-3

6-4

6-5

6-6

6-7

6-8

Example of 120 Volt, Grounded, 3-prong Receptacle ...................................................88

120VAC Power Inlet Panel ............................................................................................89

Example of Slow Speed Setting ....................................................................................91

Location of the Hydraulic Control Components .............................................................92

Adjustment Using the Hole ............................................................................................92

Adjustment Using the Slot .............................................................................................92

Distance Encoder Mounting ..........................................................................................93

Distance Encoder Alignment .........................................................................................94

7-1

7-2

7-3

7-4

7-5

7-6

7-7

7-8

Stack Components ......................................................................................................100

Stack Removal ............................................................................................................101

Disassembling Components ........................................................................................102

Tip Removal ................................................................................................................102

Assembling Components ............................................................................................103

Tip Assembly ...............................................................................................................104

Stack Installation .........................................................................................................104

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

Example of Burnished Area ......................................................................................... 111

Example of Crowning .................................................................................................. 111

Example of Center Depression ................................................................................... 111

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. 403-586-00

Appendix B

No. Description

Section 13 - Appendices

List of Tables

Page

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

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Page 162 Dukane Manual Part No. 403-586-00

Section 14 - Index

SECTION 14

Index

Dukane Manual Part No. 403-586-00

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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

Dukane Manual Part No. 403-586-00

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

End-of-Weld Control

(Optional) 49

Hydraulic Slow Speed Adjustment 47

Mechanical Stop Adjustment 47

Pressure 1 Regulator 47

Pressure 2 Regulator 49

Pre-Trigger Control (Optional) 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

Section 14 - Index

Continued

Page 165

iQ

Series Ultrasonic Press System LE User’s Manual

D

Digi-Trac 4

Distance Encoder 93

Drawings and Tables 3

Dukane 137

Address 139

Contacting 137

E-mail 139

Fax 139

Intelligent Assembly Solutions 139

Mailing Address 139

Phone 139

Website 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

End-of-Weld Limit Switch 117

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

Page 166

Process Limits 4

Pulse Width Modulation 4

Rear Panel Expansion Slot 4

RS232 Serial Configuration Port 4

Generator Menu Overview 57

Generator Start-up

Sequence 55

H

Health and Safety 5

General Considerations 7

No Unauthorized Modifications 7

How to Lift Safely 10

Plastics Health Notice 8

Recommendations 7

Hot Keys 42

Hydraulic Speed Control 91

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

Continued

Dukane Manual Part No. 403-586-00

L

Linear Ramp Soft-Start 4

Line Voltage Regulation 4

List of Figures 157

List of Tables 161

Load Regulation 4

Low Line Voltage Power Supply 4

M

Maintenance

Six-Month Periodic Maintenance 135

Menus 57

Model Number Codes 151

Generator Model Numbers 152

System Model Numbers 151

Multiple Electronic Overload 4

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

Dukane Manual Part No. 403-586-00

Options 85

AC Power Inlet Panel 89

Distance Encoder 93

Hydraulic Speed Control 91

Power Inlet Options 88

Press Interface Board 90

Press Interface Module 90

P

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

Section 14 - Index

Continued

Page 167

iQ

Series Ultrasonic Press System LE User’s Manual

S

Screen Basics 44

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

T

TEST 74

Torque Values 113

Troubleshooting 115

Continuous Welding 131

End-of-Weld Limit Switch 117

Insertion 125

Primary Weld Characteristics 117

Staking 128

Welding 118

U

Ultrasound Output Connector 26

Using the Menus 57

Utilities 14

W

Weld

Weld Cycle

MAX TIME 65

Stopping 56

Page 168 Dukane Manual Part No. 403-586-00

Dukane ISO

ISO CERTIFICATION

Dukane chose to become ISO 9001:2008 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 9001:2008 certification, you must prove to one of the quality system registrar groups that you meet three requirements:

1. Leadership

2. Involvement

3. Quality in Line Organizations and Quality

System Infrastructure.

The ISO 9001:2008 standard establishes a minimum requirement for these requirements and starts transitioning the company from a traditional inspection–oriented quality system to one based on partnership for continuous improvement. This concept is key in that 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.

ISO 9001:2008

C E R T I F I E D

Dukane products are manufactured in ISO registered facilities.

Please refer to our website at: www .dukane .com/us/sales/intsales .htm

to locate your local representative

.

iQ Series Ultrasonic Press System LE User's Manual

Part No. 403 – 586–  00 www.dukane.com/us

Printed in the United States of America

Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949

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