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Appendix D

Alarm Messages

Continued from Previous Page

Alarm Code

Alarm Message

Explanation

Solution

U1

10

Power not OK Fault

Problem with incoming

AC line voltage.

Verify that the incoming

AC Line voltage supplied to the

generator is within the range specified for the generator

.

Consult the manual for your generator

U

111

Overtemperature Fault

Generator has exceeded its tempera

-

ture limit.

Check for blockage of air vents on the sides of the genera

-

tor

, restricting air flow to the inside of the generator

.

Check if the internal fan is defective.

U1

12

Frequency Overload Fault 3

(PLL

Limit Exceeded)

The operating frequency was artificially bounded by the system frequency limits for 25 consecutive milliseconds. This is usually due to excessive operat

-

ing frequency drift (operating frequency is “far” from free run frequency) due to heating of the stack.

Execute the following steps to alleviate the problem: Observe the last operating frequency from a test graph. Enable “Advanced Process Settings”. Change “System Frequency Limits” to “Manual” and adjust the of

fending upper/lower frequency limit to an acceptably

safe value for your horn/stack/application.

Often as a horn/stack heats up, it may begin to have trouble starting (Frequency Overload Fault 1) because the operat

-

ing frequency is drifting away from the generator

’s Free Run

Frequency setting.

Adjusting the Free Run Frequency may also be advisable. A sudden shift in frequency (as observed on the graph) im

-

mediately before a Frequency Overload Fault 3, as opposed to a general frequency drift, indicates stack/horn coupling to the part during the weld or an another abrupt change in stack resonance.

This does not imply an operating frequen

-

cy drift issue, but a weld application setup issue.

U200

Servo Controller Fault

One of several possible problems detected on servo controller

.

Cycle power on the generator

.

If alarm persists, contact Dukane.

U201

Force Duration Exceeded

Large amount of force was applied for an excessive amount of time while jogging.

Cycle power on the generator

.

Do not apply large force for long periods of time while in jog mode.

U202

Position Error Limit Exceeded

Servo press was not able to complete the programmed motion due to reach

-

ing its maximum force capability

.

Decrease trigger force, weld and/or hold speed(s). Use alternate press model with larger force capacity

.

U203

Amplifier Error

Indicates a problem with the servo amplifier

.

Cycle power on the generator

.

If alarm persists, contact Dukane.

U204

Command Error

Servo controller program error

.

Cycle power on the generator

.

If alarm persists, contact Dukane.

U205

Checksum Error

Internal servo controller error

.

Cycle power on the generator

.

If alarm persists, contact Dukane.

Table D-I

Servo Press Alarm Message Screens - Page 2 of 4

Continued

Page 158

iQ Series

Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Dukane Manual Part No. 403-587-00

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Summary of Contents for ES

Page 1: ...les Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949 Dukane Part No 403 587 00 AUTOMATED HAND PROBE PRESS Intelligent Assembly Solutions Series ULTRASONIC GENERATOR POWER SUPPLY Servo Systems ES User s Manual ISO 9001 Dukane products are manufactured in ISO registered facilities ...

Page 2: ... 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 t...

Page 3: ...Revision History Revision Revision Number Summary Date 00 Original release November 20 2013 Page iii Dukane Manual Part No 403 587 00 ...

Page 4: ...This page intentionally left blank Page iv iQ Series Ultrasonic Generator Power Supply Servo Systems ES User s Manual Dukane Manual Part No 403 587 00 ...

Page 5: ...lation 11 Before Installation 13 Unpacking 15 Placement 15 Rear Panel Layout Overview 16 AC Power Inlet Panel 17 System I O Panel 17 RFI Grounding 25 Connector Descriptions 26 Power Cords 28 Cable Connections 29 Networking 36 Recheck Connections 36 Connect AC Power 36 Section 4 Control Panel 37 Overview 39 System Operating Mode Keys 40 Navigation Keys 41 System Power Output Level 42 Screen Basics ...

Page 6: ...5 Section 10 Contacting Dukane 131 Section 11 Specifications 135 Generator Outline Drawings 137 Weights Dimensions Operating Environment 140 AC Power Requirements 141 Ultrasonic Pressure 142 Interpreting the Model Number 143 Regulatory Agency Compliance 144 Section 12 Appendices 145 Appendix A List of Figures 147 Appendix B List of Tables 152 Appendix C Sequencing Notes 153 Appendix D Alarm Messag...

Page 7: ...SECTION 1 Introduction General User Information 3 Press System Overview 4 Key Generator Features 4 Page 1 Dukane Manual Part No 403 587 00 Section 1 Introduction ...

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Page 9: ...ements help you to identify and avoid hazards and recognize the conse quences One of three different symbols also accompany the CAUTION and WARNING blocks to indicate whether the notice pertains to a condition or practice an electrical safety issue or a operator protection issue CAUTION Caution statements identify conditions or practices that could result in damage to the equipment or other proper...

Page 10: ...s the need to manually tune the generator Line Voltage Regulation automatically maintains constant amplitude regardless of line voltage devia tion The available output power is maintained with any voltage input within the specified range This provides consistent system performance re gardless of line voltage fluctuations It also elimi nates the need for bulky external constant voltage transformers...

Page 11: ...ety General Considerations 7 Plastics Health Notice 8 Electrical Safety 8 Domestic Power Grounding 9 International Power Grounding 9 Lifting the Equipment 10 Page 5 Dukane Manual Part No 403 587 00 Section 2 Health and Safety ...

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Page 13: ...ic plastic assembly equipment is used with automatic material handling equipment in an automated system Foot Switch Do not use a foot switch Using a foot switch in place of the optical touch finger switches oper ate switches violates OSHA regulations Do not install a foot switch NOTE These recommendations apply to the welding system System in this manual refers to a complete group of components as...

Page 14: ...o Not Operate the Equipment Your judgement or reflexes could be impaired while taking prescription medi cations 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 General Considerations Plastics Health Notice Certain plastic materials when being proc...

Page 15: ...ply See Figures 2 1 and 2 2 Electrical Safety Domestic Power Grounding For safety the power cords used on this product have a three wire grounding type power cord Figure 2 1 il lustrates the appropriate electrical outlet to use with the power cord that is included with systems shipped to North America International Power Grounding The power cable normally provided for international use is compatib...

Page 16: ...o place the object below the level of your waist fol low the same procedures in reverse order Remember keep your back as vertical as possible and bend at the knees CAUTION Take care when lifting the equipment We recommend using a mechanical lift device to assist 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 spot...

Page 17: ...ng 15 Placement 15 Rear Panel Layout Overview 16 AC Power Inlet Panel 17 System I O Panel 17 RFI Grounding 25 Connector Descriptions 26 Power Cords 28 Cable Connections 29 Networking 36 Recheck Connections 36 Connect AC Power 36 Page 11 Dukane Manual Part No 403 587 00 Section 3 Installation ...

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Page 19: ...ver the plug end of the generator electrical cord This effectively prevents access to the energy isolation point See the example of one such device in the figure above The figure to the right shows the lockout device in the closed locked position Figure 3 1 Lockout Device In Open Position Unlocked Figure 3 2 Bottom Lockout Device In Closed Position Locked WARNING Electrical safety haz ards exist i...

Page 20: ...to discharge its electrical energy 5 After taking these steps make the necessary adjustments to the generator Assuming the generator is being put back into service Procedure to use AFTER making any internal adjustments to the generator 1 Authorized personnel remove the lockout tagout device from the plug end of the generator s electrical cord Using a typical clam shell type LOTO device 1 Unlock th...

Page 21: ...chassis type and what rear panel connections there are See Section 11 Specifications for generator drawings CAUTION Allow 5 inches for air ventila tion at the cooling air inlet and at the exhaust air outlet The fan draws in fresh air to cool the internal components reduce thermal gradients and increase component life If excessive dust accumulates in the slots wipe or vacuum them clean Do not use c...

Page 22: ... Communications Board See NOTE below Shown in the example above are these ports J9 Ethernet J10 Serial RS 232 K Press Interface Module See NOTE below Shown in the example above are these ports J6 Base Abort J5 Thruster J11 Encoder REAR VIEW PNEUMATIC PRESS THRUSTER J4 J1 CONFIGURATION ULTRASOUND SYSTEM OUTPUTS SYSTEM INPUTS J2 J3 J9 ETHERNET J10 RS 232 J5 THRUSTER J6 BASE ABORT J11 ENCODER LINE VO...

Page 23: ...ely trips again there is likely an internal system mal function 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 sec tion See Figure 3 6 on the next page System Inputs Connector The SYSTEM INPUTS connector mounted on the sys tem ...

Page 24: ... the system input cable is listed in Table 3 II to assist with custom automation system wir ing and assembly NOTE Refer to Section 9 Options for information on optional features Note that a simple switch closure relay contact con nected to a control input can not activate the input with out adding an external power supply to power the input Adding jumper connections to pins available on the Sys te...

Page 25: ...Generator Input Cable Connector 1 2 3 4 5 6 10 11 12 13 14 15 5 4 3 2 1 5 4 3 2 1 15 14 13 12 11 15 14 13 12 11 6 6 10 10 Table 3 I Generator Input Signals J2 System Inputs Signal Descriptions Pin 1 22VDC Power Supply This pin can supply 22VDC at up to 250mA to power the user s automation controls Pin 2 22VDC Power Ground Pin 2 is the 22VDC return and is tied to the system chas sis ground Pin 3 Re...

Page 26: ...es a press or thruster to the down position The hand probe cable connector is wired to apply chassis ground to this pin when it is attached to the system which activates a press inhibit relay that disconnects power from the pneu matic press valves This pin must be left open whenever a press control board is installed Connecting this pin to chassis ground will inhibit press operation Pin 12 System ...

Page 27: ...Part Status Output WHT BLK RED 24 Isolated Common RED BLK WHT 25 Not Used GRN BLK WHT Table 3 II System Output Connector Signals J3 Figure 3 9 DB 25F Generator Output Connector J3 Figure 3 10 DB 25M Generator Output Cable Connector 1 3 5 7 9 11 13 15 17 19 21 23 25 13 11 9 7 5 3 1 25 23 21 19 17 15 System Outputs Connector The SYSTEM OUTPUTS connector mounted on the gen erator I O panel includes c...

Page 28: ...s listed in Table 3 II System Outputs Signal Descriptions Pin 1 22VDC Power Supply This pin can supply 22VDC at up to 250mA to power the user s automation controls Pin 2 Not Used Pin 2 is an open connection Pin 3 22VDC Power Ground Pin 3 is the 22VDC return and is tied to the system chassis ground Pin 4 Programmable Status Output 1 Pin 4 is a digital active low status output that can be re assigne...

Page 29: ... 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 Pin 15 Power Signal Monitor Output Pin 15 is an analog output signal used to monitor the pow...

Page 30: ...ctivates 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 sy...

Page 31: ...RFI from the press run an additional grounding wire from the press base ground ing 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 cur rents ground the chassis as shown Use a STAR con figuration illustrated below Do not DAISY CHAIN th...

Page 32: ...put 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 au tomation controller The user can determine which signals are appropriate for each welding application Continued Connector Descriptions Figure ...

Page 33: ... configuration port features J6 Base Abort The Base Abort connector accepts the operate and emergency stop signals from the optical operate switches and abort switch on the base If you are using custom automation you may have separate operate and abort switches but these still connect to this connector on the generator J9 Ethernet This port is used for Ethernet communication between the generator ...

Page 34: ...h a properly grounded three lead recep tacle Have a qualified electrician do the replacement in accordance with the National Electrical Code and local codes and ordinances DO NOT cut off the power cord grounding prong or alter the plug in any way Continent of Use Power Cord Part Number Power North America 200 1110 240V 15A 200 1541 240V 10A Continental Europe 200 1111 240V 16A 200 1542 240V 10A Ta...

Page 35: ...t customer supplied electricity using cables 10 11 and 12 Connect the power cords last but do not turn on the power yet 5 Recheck all connections When they are secure you are ready to connect electrical power 6 Finally connect electrical power See Section 11 Specifications for AC power requirements Before connecting or disconnecting cables Put power switches for the iQ generator press remote contr...

Page 36: ...CORP WARNING SERVO POW ER J100 GENERATOR I O J202 ENCODER IN J204 SERVO FEEDBACK J205 THRUSTER I O J206 ENCODER OUT J201 LINE VOLTAGE 90 240 Vac 50 60 Hz 10A PE W ARNING POW ER LINE OUTLET M UST BE G ROUNDED DISCONNECT LINE POW ER BEFORE REM OVING COVER DUKANE CORPORATION ST CHARLES IL M ADE IN U S A WWW DUKANE COM J5 THRUSTER J6 BASE ABORT J11 ENCODER J9 J10 RS 232 ETHERNET 1 2 3 4 10 11 12 13 14...

Page 37: ...J1 ULTRASOUND 6 200 1556 XXM XX J5 J202 7 200 1613 XXM XX J11 J201 8 200 1545 XXM XX J6 J35 9 200 1553 XXM XX J9 ETHERNET 10 One of the following 200 1110 240 VAC 15A US 200 1111 240 VAC 16A Europe 200 1612 240 VAC 15A India 2 4 AC INPUT 11 One of the following 200 1541 240 VAC 10A US 200 1542 240 VAC 10A Europe 200 1624 240 VAC 10A India 200 1576 120 VAC 2 4 AC INPUT 12 Power cord is integral to ...

Page 38: ...0A Europe 200 1624 240 VAC 10A India 200 1576 120 VAC 2 4 AC INPUT 11 One of the following 200 1541 240 VAC 10A US 200 1542 240 VAC 10A Europe 200 1624 240 VAC 10A India 200 1576 120 VAC 2 4 AC INPUT 12 One of the following 200 1110 240 VAC 15A US 200 1111 240 VAC 16A Europe 200 1612 240 VAC 15A India 200 1541 240 VAC 10A US 200 1542 240 VAC 10A Europe 200 1624 240 VAC 10A India for 120 VAC models...

Page 39: ... they are secure you are ready to connect electrical power 6 Finally connect electrical power See Section 11 Specifications for AC power requirements Before connecting or dis connecting cables Put power switches for the iQ generator press and any user supplied automation equipment in the OFF position Turn off electrical power RemoveAC power cords from their receptacles CAUTION DO NOT operate the g...

Page 40: ...TLET MUST BE GROUNDED DISCONNECT LINE POWER BEFORE REMOVING COVER ST CHARLES IL 60174 MADE IN U S A DUKANE CORP WARNING J9 J10 RS 232 ETHERNET J6 BASE ABORT J5 THRUSTER J11 ENCODER 1 2 3 4 10 11 13 12 5 6 7 8 Automation Equipment 9 Earth Ground NOTE Separate cables 1 7 and 8 from other cables DO NOT bundle these with other cables Continued from Previous Page Page 34 iQ Series Ultrasonic Generator ...

Page 41: ...TRASOUND 5 200 1545 XXM XX J6 J35 6 200 1553 XXM XX J9 ETHERNET 7 One of the following 200 1541 240 VAC 10A US 200 1542 240 VAC 10A Europe 200 1624 240 VAC 10A India 200 1576 120 VAC 2 4 AC INPUT 8 One of the following 200 1110 240 VAC 15A US 200 1111 240 VAC 16A Europe 200 1612 240 VAC 15A India 200 1541 240 VAC 10A US 200 1542 240 VAC 10A Europe 200 1624 240 VAC 10A India for 120 VAC 3600 W or 4...

Page 42: ...d a local area network Recheck Connections Recheck all cabling connections for the iQ ES Generator Remote Controller Press Thruster Connections to Local Area Network Connect AC Power When all cabling connections have been made and they have been systematically rechecked connectAC line power to your system Any modifications to the Emergency Stop Switch also known as the E STOPorAbort Switch circuit...

Page 43: ...SECTION 4 Control Panel Overview 39 System Operating Mode Keys 40 Navigation Keys 41 System Power Output Level 42 Screen Basics 43 Page 37 Dukane Manual Part No 403 587 00 Section 4 Control Panel ...

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Page 45: ... identification Figure 4 1 iQ Generator Display and Control Keys Color Display Lighted Power Indicator Navigation Keys 4 System Operating Mode Keys 3 Soft Keys 8 CANCEL Key ENTER Key Page 39 Dukane Manual Part No 403 587 00 Section 4 Control Panel NOTE Do not touch the display Touch only the System Operating Mode Keys the Navigation Keys and the Soft Keys to the left and right of the display Clean...

Page 46: ...this mode the generator can not generate an ultrasound signal The display has a YELLOW background and the word Offline appears in a yellow box in the lower right corner of the display See Figure 4 3 to the right The display has a RED background and the word E STOP appears in a red box in the lower right corner of the display If a transducer is not connected to the ultrasound output con nector the ...

Page 47: ...Display 8 Use the eight keys that border the display to make selec tions from the choices shown on the display Not all keys will be active on any given screen Example 1 For the display shown on the right three of the eight soft keys are active Administrator Password Erase and Done Figure 4 5 Active Soft Keys Example 1 Active Key C A NCEL EN T E R EN T E R C A NCEL Navigation Key 4 Example 2 At tim...

Page 48: ...tput Power Level red overload indicator is lit that means there is an overload fault If this hap pens verify that the ultrasonic stack is not damaged System Power Output Level Bar Graph A bar graph displays the percentage of ultrasonic power being drawn by the load The display uses LED s that show GREEN normal operation YELLOW warning of potential overload RED warning that an overload condition ex...

Page 49: ...he arrow points Two examples are shown in Figure 4 9 below For the screen on the left the up or down navigation keys are used to move the display For the screen on the right active soft keys are used to move the display left or right See Active Soft Keys Figure 4 6 Display arrows point in the direction of more text Page 43 Dukane Manual Part No 403 587 00 Section 4 Control Panel Screen Basics Figu...

Page 50: ...entification can be seen in the lower right corner of the screen The example shown in Figure 4 11 illustrates that setup control is by automation Auto and that Setup 1 pro gram has been selected for the generator Setup can also be controlled by iQ System iQ or by se quencing A pair of numbers that resemble a ratio such as 2 3 appears In this example 2 is the number for the seg ment and 3 is the nu...

Page 51: ...ence 47 Stopping the Weld Cycle 48 Using the Menus 49 Process Setup 50 Process Limits 62 Utilities Hardware 68 Operate Screen 84 Current Setup 84 Graph 85 Help 87 Security 88 Set up Guidelines 93 Page 45 Dukane Manual Part No 403 587 00 Section 5 Operation ...

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Page 53: ...N See Figure 5 1 when the generator is activated 3 After the generator is activated the LCD displays an image that identifies the Dukane iQ Series type The sequence ends when the Main Menu screen is displayed as shown in Figure 5 2 NOTE Press acoustic stack and tooling will require their own individual adjustments as those components are integrated into your particular system Helpful information o...

Page 54: ...nt panel lighted power indicator goes out showing that power has been turned off NOTE Automated System External Controls Customer supplied external controls pro vide the means to stop the cycle for an automated system An auxiliary cable connects these external controls to the iQ generator at connector J2 Activating the System Input called Automa tion Cycle Stop will stop the weld process or the co...

Page 55: ...gineer has logged in the screen looks like that shown in Figure 5 3 If Setup has logged in the screen looks like that shown in Figure 5 4 The screens look identical with one exception The Administrator Process Engineer screen has Utilities Hardware while the Setup screen has Select Setup Go to the pages referenced for more detail about each sub menu NOTE Security detail can be found on Pages 88 92...

Page 56: ...e Until Force Reached Dynamic Hold Speed Hold Distance Max Hold Time DynamicHoldPeakForce Dynamic Hold Speed Max Hold Time Hold Time Segmented Constant Constant Weld Speed Enable Melt Detect After Force Drops By Speed Enable Melt Detect After Force Drops By Enable Disable Enable Disable Distance Increment Speed Force Advanced Servo Settings Top of Stroke Position Acceleration Deceleration Weld Mot...

Page 57: ...here are two ways the latch can be cleared Remove the LATCHED Message from the Display 1 Go to the Main Menu 2 Go to Utilities and then to Part Count Settings 3 Enable Clear Bad Part See Figure 5 7 to the right When these three steps are completed the operator can press the ENTER key to clear the latch or Activate the System Latch Reset Input The System Latch Reset Input signal Pin 12 of J2 the Sy...

Page 58: ... Trigger Type is the next Process Setup submenu Trigger defines the type of event that turns on the ultra sound signal This event can be a force level from the force load cell a power level reached by the generator or a position reached by the thruster Types can be Force Power Position Trigger Type Use extreme caution when using the Momentary trigger type Opening the trigger switch will NOT termin...

Page 59: ...rom Previous Page Figure 5 9 Trigger Type Position Position The factory default setting for Trigger Type is Position After the system has completed the initiate mode the press head travels down at the Sense Speed until it has reached the trigger position After the trigger position is reached it then changes to the programmed welding speed The figure to the right shows the Process Setting menu appe...

Page 60: ...rate switches so that the servo thruster can move Once it is moved the Sensing Start Position can be set Sensing Start Position is the actual position in the ma chine travel where the system begins to sense for the trigger force to be achieved As the horn approaches the Sensing Start Position the servo changes to the Sensing Speed setting Sensing Start Position Figure 5 12 Teaching Sensing Start P...

Page 61: ...p of stroke to the part quickly However you will find that the medium speed satisfies most needs Direction The direction to jog the servo press up or down can be changed as well During the teaching process the user will get feedback on force and current position from the on screen display Move to Saved Position If a previous position has been set the user can press the Move to Saved Position butto...

Page 62: ...Peak Power measured in Watts has a 0 1 Watt resolution Peak Power range is dependent on the generator s maxi mum output power rating Primary Weld Method Figure 5 14 Primary Weld Method Submenu Diagram Secondary Weld Method Secondary Weld Method is the next item to consider in the Process Setup menu The secondary weld method defines an alternative control to terminate the ultrasound signal after it...

Page 63: ... length of each of the profile segments to track when to transition from one profile segment to the next Enable Melt Detect Enabling Melt Detect allows for greater control of the part s collapse speed profile When enabled another parameter must be addressed After Force Drops By After Force Drops By The melt detect portion of the weld is linked to the force applied by the press but only after the i...

Page 64: ...m time prevents infinite holding due to an unreachable distance Distance This setting determines the distance the press travels following the weld process Depending on the mo tion control mode the user defined force or speed will be applied to the part Auser specified maximum time prevents infinite holding due to an unreachable distance Process Setup Continued Process Setup Continued from Previous...

Page 65: ...nes the amount of time the press position is held following the dynamic hold process if enabled or the weld process if dynamic hold is disabled Disabled Choose Disabled when no static hold method is needed Time This setting determines the amount of time the press position is held following the dynamic hold process if enabled or the weld process if dynamic hold is disabled See the Figure 5 24 to th...

Page 66: ...terburst feature can be turned off by choosing Dis abled or it can be turned on by choosing Enabled When enabled the delay and duration times and the ampli tude are then entered See the figure to the right Weld Amplitude WeldAmplitude is the next parameter to select This refers to the peak to peak excursion of the horn at its workface Amplitude settings are given as a percent of the horn s nominal...

Page 67: ...ased on the maximum stroke distance of the press CAUTION DO NOT make any adjust ments to Acceleration or Deceleration unless you have first contacted qualified Dukane personnel for guidance in making any necessary adjust ments Weld Motion Control This is the last of theAdvanced Servo Settings This setting determines whether force or speed is controlled by the servo during the weld process Figure 5...

Page 68: ...e g strength appearance Results of this evaluation are correlated to the process characteristics Limits for the characteristics related to part quality are calculated Other limits are determined by the system itself For instance Total Cycle Time limits may be established to end the cycle before an index table moves Downstroke Distance may be set to detect a misload or incomplete assembly Process L...

Page 69: ...at Trigger Weld Time Weld Distance Weld Energy Weld Peak Power Weld End Position Weld Peak Force Hold Time Hold Distance Total Cycle Time Total Stroke Distance Alarm Status Time Date Setup OFF ON Low Limits Bad Limits Suspect Limits Display Only High Limits OFF ON Low Limits High Limits Force at Trigger Display OFF ON Force Suspect Force Bad Disabled Display Trigger Delay Time Trigger Delay Distan...

Page 70: ...relative to the home position of the mounted distance encoder at the instant of the end of the weld Weld Peak Force This is the highest instantaneous force that is measured during the weld method Hold Time This is the time the horn maintains pressure on the part after the ultrasound signal has stopped Hold Distance This is the distance the press travels while maintaining pressure during the hold p...

Page 71: ...circumstance as Suspect or as Bad Whatever designation is given to the part it will be carried on to become an item in the part record Figure 5 31 on the right shows with the red square symbol that Force Bad has been chosen as the option for Alarm Status 4 Display Whenever a system alarm happens the ultrasonic generator indicates this on the display s Operate screen A square green indicator appear...

Page 72: ...haracteristic is displayed during normal op eration on the Operate screen Bad Limits This is also known as Bad Part Limits Figure 5 34 shows that Peak Power is the selected char acteristic Bad Limits are ON and Low Limits and High Limits need to be set The Bad part limits are used to establish boundaries that de fine unacceptable results for parts that are being processed If a bad limit is either ...

Page 73: ...r Page 80 The iQ ES suspect part output is activated SUSPECT is displayed in the part cycle data In Figure 5 34 the selected characteristic is Peak Power Both Suspect Limits and Bad Limits are ON for which both Low Limits and High Limits need to be entered Part Cycle Data The weld characteristics chosen to be displayed can be seen in real time using the Operate Screen See OPERATE SCREEN on Page 84...

Page 74: ...ure Manual P1 Manual P2 Hold Dynamic Trigger Down Speed Flow Control Mechanical Stop HSC Setting HSC Start Position Pre trigger EOW Flags Serial Port System Status I O Auto Start Input Auto Stop Input Enabled J3 pin 4 Output Duration Output Format LF After CR Output Mode Baud Rate Serial Limit Indicators Serial Headers Restore System I O Defaults Adv Process Settings Buzzer Text Keyboard Adv Trigg...

Page 75: ... methods that define where control for a particular setup originates iQ System Control originates through the iQ generator and its program Sequencing Control originates through the sequence definition as programmed through the iQ generator See more on Sequencing in Appendix C Automation Control originates from an external source connected to the generator s System Input J2 8 The ul trasonics outpu...

Page 76: ...ice Security Access If Security access has been established then menu access can be limited depending on what Secu rity access level is active If the Setup Security is active then the main screen would look like it does in Figure 5 43 to the right To choose a setup in this case press the Select Setup soft key As with System Control a list of setups is displayed Highlight a setup from the list and ...

Page 77: ...ist Press the Copy Setup soft key and the display shown in Figure 5 45 appears Choose setups Copy From and Copy To Then press the soft key Press Here to Copy The display will appear as it does in Figure 5 46 Process Utilities Continued from Previous Page Process Utilities Continued Figure 5 45 Copy Setup 2 Figure 5 46 Copy Setup 3 Page 71 Dukane Manual Part No 403 587 00 Section 5 Operation ...

Page 78: ... Part Enable this to allow the opera tor to clear a Bad Part Limit Exceeded message displayed on the front panel Allowing the operator to clear the bad part message will also reset the bad part latch See Figure 5 48 to the right Language The language displayed by the front panel is made through this utility Base Units Select either Imperial or Metric units with this utility Date Format The date ut...

Page 79: ...etup time will be much shorter when trying to create the same or similar setup Figure 5 49 Notes Setup Name Horn Booster Fixture Manual P1 Manual P2 Hold Dynamic Trigger Down Speed Flow Control Mechanical Stop HSC Setting HSC Start Position Pre trigger EOW Flags Notes HSC Hydraulic Speed Control EOW End of Weld Process Utilities Continued from Previous Page Process Utilities Continued NOTE Althoug...

Page 80: ...ation about the serial data format LF after CR Each line of output ends with a carriage return CR Some devices automatically insert a line feed LF to advance the paper while others do not Enabling the LF After CR function makes it possible to insert a line feed at the end of an output string Output Mode Use Output Mode to determine the type of data that will appear in the part record Selections ar...

Page 81: ... been exceeded Two greater than signs mean that an upper limit Bad value has been exceeded The less than sign means that a lower limit Suspect value has not been reached Two less than signs mean that a lower limit Bad value has been exceeded Select Disable if the limit indicator might confuse a pro gram that is running an SPC or data collection application Select Enable to allow use of the limit i...

Page 82: ...he Auto Input signal This setting is typically used when a relay is used to activate the Auto Input Choosing Mechanical presents another choice That is Switch Debounce Time which is configurable to 5ms 10ms or 25ms Auto Stop Input Enabled This function can be disabled or enabled The default set ting is Enabled and set to End of Cycle When Auto Stop Input is enabled the operator is prompt ed to cho...

Page 83: ... is Amplitude Regulation It can be programmed to provide Amplitude Regulation Teaching or Servo Alarm Output Duration Use the Output Duration function to decide on how long the output signal should be Maintained or 100ms Pulse The default setting is Maintained Restore System I O Defaults Choose this function to restore the original system input output defaults Once Restore is chosen a secondary sc...

Page 84: ...gs because the system could be damaged in some way Before changes are allowed a warning screen displays an alert See Figure 5 54 Descriptions of each of the settings are shown below Free Run Frequency Free run is the frequency at which the generator drives the ultrasound output pulses until a valid feedback sig nal is detected Typically this value should be below the operating frequency of the sta...

Page 85: ...y Limits Wide In wide mode the upper and lower frequency limits are set to the maximum and minimum allowed frequencies for the generator These values are depen dent on the system frequency of the generator Normal In Normal mode the upper and lower fre quency limits equal the free run frequency 500Hz Narrow In Narrow mode the upper and lower fre quency limits equal the free run frequency 200Hz Manu...

Page 86: ...k stress Ramp Down Time Although the Ramp Down time is factory set it is vari able and can be adjusted to account for characteristics of a particular stack Ramp Down Time decreases the amplitude linearly to zero in the programmed time period following the end of the weld when ultrasound is shutting off The stack is brought down from its weld amplitude reducing shock stress Restore Advance Process ...

Page 87: ...ive elements 1 DHCP These initials stand for Dynamic Host Con figuration Protocol The protocol was established for assigning dynamic IPaddresses to devices on a network DHCP should be enabled if connecting multiple genera tors when using an Ethernet router or switch DHCPcan be enabled or disabled depending on customer requirements 2 IPAddress This Internet Protocol address is a num ber unique to a...

Page 88: ... Trigger Function Key to Trigger Function Figure 5 59 Trigger Function Basic and Advanced Trigger Type Power Force Force at Trigger Max Trigger Time Pre trigger Pre trigger Position Enabled Trigger Delay Not a choice if Pre trigger is Enabled Sensing Start Position Disabled Delay by Distance Position Max Trigger Time Trigger Position Disabled Trigger Delay Pre trigger Amplitude Trigger Delay Dista...

Page 89: ...ring the generator software to the factory default settings Before this is allowed however an intermediate screen questioning the action appears See Figure 5 61 Important Performing a Restore Factory Defaults can not be reversed If the user is directly connecting to a laptop or PC the PC s IP address should be set to 169 254 0 x x must be 2 255 The x_ in the computer s IP address can not be the sa...

Page 90: ...ber in the cycle data Pressing the Part soft key displays a search screen after a minimum of 10 parts are in the cycle data Search by Time Press this soft key to search for a part know to have been welded at a specific time in the cycle data Search by Date Press this soft key to search for a specific part welded on a specific date in the cycle data Previous Bad Press this soft key to search for a ...

Page 91: ...ges to show press characteristics for the current setup and weld cycle The possible characteristics are Force Distance Power Frequency and Speed Characteristics displayed depend on system configuration Process Limits Press the soft key next to Process Limits and the process limits list similar to the one shown in Figure 5 65 is dis played Adjustments to the list of process characteristics can be m...

Page 92: ...ight side of the graph Figure 5 69 shows the graph setup screen used to choose a starting point for the graph 3 Choose one of the active soft keys representing the event that starts the graphing procedure The events are Cycle Start Trigger or Weld Start Figure 5 70 shows the graph setup screen used to select the end point for the graph 4 Chose one of the active soft keys representing one of two ev...

Page 93: ... 72 Locating Help on the Main Menu Figure 5 71 Example Graph Following Test Graph Continued from Previous Page The figure below shows a completed graph This particular image resulted after pressing the TEST key Completed Graph Red Vertical Axis Power Blue Vertical Axis Frequency Horizontal Axis Time Page 87 Dukane Manual Part No 403 587 00 Section 5 Operation NOTE Color Front Panel v1 11 02 will a...

Page 94: ... Security menu is to yield allow or deny access to the programming features of the iQ generator under certain conditions This feature is most useful when a remote user using iQ Explorer II software and a user at the generator might both want to control the generator A request for control by either user shows on the generator display and on the remote computer display See Figure 5 85 Page 92 If no ...

Page 95: ...ply Changes when finished The next screen to appear looks like Figure 5 77 Because the screen message says Security Enabled Currently Logged Out theAdministrator must enter the Login Password to activate access to security features Once the Administrator password has been entered the screen appears as shown in Figure 5 78 Note the change in the Security Screen from what is seen in Figure 5 75 The ...

Page 96: ... 80 Security Screen Logged Out Continued Security Continued from Previous Page At this point the Administrator typically has four options Logout Press the soft key next to Logout and the Administrator will be logged out None of the security levels will be active Done Press the soft key next to Done to exit and return to the main menu Erase Select Administrator Password En abled in the list Press t...

Page 97: ...g with the available menus Available menus for Setup Eng are Select Setup Operate Screen Graph Help and Security 4 When finished working with the generator press Security to get to the Security Screen again Then press the soft key next to Logout to quit 5 Finally press Done so that the main menu screen is displayed when the session is complete NOTE When using the Security feature only one person c...

Page 98: ...ess can be granted by pressing the Yield Control soft key Deny access by pressing the Deny Control soft key Forgotten Password Contact Dukane if the password has been forgotten See Section 10 Contacting Dukane Figure 5 84 Security Prompt for Setup Access Figure 5 83 Security Prompt for Process Engineer Access Security Continued from Previous Page Process Eng Access Required Please Log In Setup Acc...

Page 99: ...thod Distance Distance Distance Distance Distance Weld Distance 0 0150 0 0100 0 0075 0 0050 0 0050 Max Weld Time 2 000 2 000 2 000 2 000 2 000 Weld Secondary Method Disabled Disabled Disabled Disabled Disabled Weld Profile Constant Constant Constant Constant Constant Weld Profile Speed 0 0500 0 0400 0 0300 0 0200 0 0200 Melt Detect Enabled Enabled Enabled Enabled Enabled Force Drop 5 5 5 5 2 Dynam...

Page 100: ...s a Process Setup submenu item and can be customized for your process Refer to Pages 50 61 for more information about working with the Process Setup menu Changing Default Settings Page 94 iQ Series Ultrasonic Generator Power Supply Servo Systems ES User s Manual Dukane Manual Part No 403 587 00 ...

Page 101: ...al Control Other Control Functions 97 Stopping the Weld Cycle 97 Software Support Features 97 Quick Start Using iQ Explorer II 99 Unique Features 111 Page 95 Dukane Manual Part No 403 587 00 Section 6 Optional Control ...

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Page 103: ...gency Conditions 1 Press the rear panel AC breaker switch to OFF 2 The front panel power light will go out This means the generator s power has been turned off Figure 6 1 iQ Explorer II Keyboard and Numeric Pad Software Support Features Two support features in corporated into your iQ Explorer II software are its virtual numeric pad key board and its help system Numeric Pad and Keyboard NOTE iQ Exp...

Page 104: ...7 System 8 Options The Index is an alphabetical list of words and phrases Figure 6 3 illustrates that the term Trigger was found through both Contents and the Index Using the F1 Key The F1 key can be pressed to activate Help when 1 the cursor is positioned in an item that can be edited such as a text box drop down list or check box and 2 that item is linked to Help Using the Index in Help Using Co...

Page 105: ...er to the iQ Explorer II User s Manual Section 4 Operation Name of the connected welder Figure 6 5 iQ Explorer II Start up Hardware Tab Step 2 Select Unused Setup After moving to the Hardware tab click on the Setup File Name box and select an unused setup This will ensure that you do not overwrite a pre existing setup See Figure 6 5 Names of active welders in the network appear when Show Welders t...

Page 106: ...ode selection as sumes there is a stand alone benchtop system with manual oper ate switches Step 3 Navigate to the Process Settings Tab Figure 6 6 iQ Explorer II Process Settings Tab and Initiate Mode Select Manual in Initiate Mode Page 100 iQ Series Ultrasonic Generator Power Supply Servo Systems ES User s Manual Dukane Manual Part No 403 587 00 ...

Page 107: ...ce Setting Step 5 Specify Trigger Settings Select Force as the type of trigger Then program the desired amount of force the press is to apply before ultrasound is initiated Next program Max Trigger Time This provides a measure of safety insuring the welder will fault if for some reason the welder never achieves the programmed trigger force See Figure 6 7 Force pounds Linear Weld Joint inches 110 1...

Page 108: ...e servo controlled systems and allows for precise accurate trigger forces See Figure 6 10 Sensing Start Position is the actual position in the machine travel where the system begins to sense for the trigger force to be achieved By the time the horn reaches the Sensing Start Position it is already moving at the programmed Sensing Speed If you do not know the position where this contact is made sele...

Page 109: ...es above the part The stroke position of the thruster will be shown in the Current Position box Once you are at the desired position press Set to pro gram that distance Select Exit and follow instructions to home the machine Page 103 Dukane Manual Part No 403 587 00 Section 6 Optional Control NOTE By default there is a 50 lbs limit on the amount of force a 20K servo will produce while teaching a p...

Page 110: ...ved within this time window 2 seconds as shown in the example of Figure 6 12 the system will terminate the weld cycle Figure 6 13 iQ Explorer II Process Settings Weld Secondary Weld Method Secondary Method Continue programming weld characteristics by selecting one of the Secondary Methods available Position Energy or Peak Power The purpose of the secondary method is to end the weld phase if the se...

Page 111: ...the horn will resume the pro grammed weld motion For example for a Trigger Force of 40 lbs and a value of 5 for After Force Drops By the press would stop once the Trigger Force is achieved and resume motion after the force drops by 2 lbs 5 of 40 lbs below the Trigger Force or 38 lbs A starting value of After Force Drops By is typically in the 5 10 range The benefit of this option is significantly ...

Page 112: ...cle This can be done by manipulat ing the Speed Profile until the Power Graph shows a smooth constant result See Figure 6 17 at right for a view of a Seg mented Speed Profile To program the desired speeds first select the segment by clicking on the square block under the down arrow then type in the speed value in the numerical entry box Repeat this process for the remaining seg ments View Speed Pr...

Page 113: ...el at the programmed hold speed with the ultrasound turned off This feature provides the ability to collapse the molten plastic after the ultrasonic signal is turned off before material solidification This feature can be beneficial in producing superior weld strength and appearance To program Dynamic Hold find Post Weld Dynamic Hold Method and select Distance Then enter the de sired Hold Distance ...

Page 114: ...rall part height This is unlike a pneumatic press that continues to compress the part during the hold phase In addition Static Hold can contribute to stronger weld bonds See Figure 6 20 below Continued from Previous Page Step 14 Test the Acoustic Stack Run a test of the acoustic stack to confirm proper operation before welding parts Please go to Section 7 of this User s Manual System Opera tional ...

Page 115: ...settings are fully developed for the application the Process Limits can be set to Suspect and or Bad to identify part assemblies of inferior weld quality Step 15 Specify Process Limits Behavior Figure 6 21 iQ Explorer II Process Limits Tab Process Limits Tab Show No Limits Sets all of the process limits to not display any limits Show All Sets all of the process limits to be Displayed Page 109 Duka...

Page 116: ...meters have been achieved See the example shown below in Figure 6 22 Detailed performance graphs for select parameters may also be reviewed by selecting the Graph tab Figure 6 22 iQ Explorer II Cycle Data Tab Step 17 View Weld Results Page 110 iQ Series Ultrasonic Generator Power Supply Servo Systems ES User s Manual Dukane Manual Part No 403 587 00 ...

Page 117: ...If the thruster is moved up or down when going to a new program Sensing Start Distance or Trigger Position and Travel Limit have to be adjusted accordingly One instance of the use of this feature is as follows A file is created for the setup of Part 1 and another file for the setup of Part 2 After running a batch of parts with the Part 1 setup a switch to running parts for the Part 2 setup can be ...

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Page 119: ...SECTION 7 System Operational Testing Overview 115 Operational Test of the Acoustic Stack 116 Cycling the System 119 Page 113 Dukane Manual Part No 403 587 00 Section 7 System Operational Testing ...

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Page 121: ...s of the stack being driven When the ultrasound turns on during each operating sequence the Digi Trac circuit monitors the frequency of the stack on a cycle by cycle basis and adjusts the ultrasound signal for the optimum efficiency Because the Digi Trac continuously monitors each operat ing sequence it compensates for frequency changes that occur during repeated operations due to heating of the s...

Page 122: ...h a fixture or part 2 Push the generator REAR panel AC breaker switch to ON Then the FRONT panel power indicator will flash on start up and finally turn a steady GREEN This indicates that the system is operational If the power indicator stops flash ing but remains RED do not go any further there is a problem with an internal power supply 3 Using iQ Explorer II go to the Utilities tab Press the TES...

Page 123: ... vibrate the stack If the system passes the tests of these four steps proceed to the section called Cycling the System on Page 119 If one or more of these tests have failed go to the next step Figure 7 2 iQ Explorer II TEST Screen Display NOTE Note the Frequency and Power values in the graph above You have the option of saving the test data for future reference Continued Acoustic Stack Test Contin...

Page 124: ...I Process Settings Tab Advanced Hardware If any failure indications are present with the horn removed check the booster and the transducer for the following Any visible damage Loose or cracked stud Pitted or dirty mating surfaces Make any necessary repairs or adjustments Go to Step 7 7 Repeat Steps 1 through 6 If the failure indications disappear reassemble the horn to the stack and repeat Steps 2...

Page 125: ...on Page 116 of this section 2 Verify that all controls on the Press Thruster and the generator are set as required for this operation 3 Place a part in the fixture 4 Manually cycle the system Activate both operate switches at the same time to start the system and hold fingers in place until the ultrasound starts Releasing the fingers before ultra sound starts will abort the cycle Page 119 Dukane M...

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Page 127: ...SECTION 8 Maintenance Page 121 Dukane Manual Part No 403 587 00 Section 8 Maintenance ...

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Page 129: ...ion slots free from obstructions If exces sive dust or dirt collects on the slots wipe or vacuum them clean Do not use compressed air to clean them as this may force the dirt inside the chassis Allow 5 inches 127 mm of clearance outside each ventila tion slot The air intake is on the right and the exhaust is on the left This is shown in Figure 3 3 Page 15 I O Connector The Input Output connector h...

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Page 131: ...r Inlet Options 127 120V Systems for North American and Japan 127 240V Systems 127 Data Transfer 128 Ethernet Port J9 128 RS 232 Port J10 128 Part Data Indexes 129 Page 125 Dukane Manual Part No 403 587 00 Section 9 Options ...

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Page 133: ...ble on generators with power ratings up to 1200 Watts 240V Systems Generators with power ratings above 2400 Watts also have fixed power cords See Table 11 II in Section 11 Specifications NOTE Refer to Section 2 Health and Safety Pages 8 and 9 for information about Elec trical Safety including grounding Page 127 Dukane Manual Part No 403 587 00 Section 9 Options ...

Page 134: ... This allows a program to identify each characteristic and store it in an appropriate file regardless of the order in which the characteristic is received Figure 9 1 shows an example of this output format and Table 9 I on the next page gives the Part Data Index numbers and descriptions 7 4 1 Part Number 417 0 0 0 1 0 CR LF Downstroke Time 0 101 second eld 1 Distance 0 0100 inch eld 1 Energy 210 0 ...

Page 135: ... Stroke 50 Time Format HH MM SS 51 Date Formats DD MM YYYY MM DD YYYY YYYY MM DD 52 Setup Number 53 Error Code U Number without the U Table 9 I Part Data Indexes NOTE Individual data records are separated by a comma tab or semicolon The character used is set in the Hardware Settings screen See page 74 for setting the Output Format character The indexes are printed as 4 characters 0 pad ded and the...

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Page 137: ...SECTION 10 Contacting Dukane Page 131 Dukane Manual Part No 403 587 00 Section 10 Contacting Dukane ...

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Page 139: ...elephone located near the equipment Intelligent Assembly Solutions Mailing Address Dukane Ultrasonics 2900 Dukane Drive St Charles IL 60174 US Phone 630 797 4900 E mail ussales dukane com Fax Main 630 797 4949 Service 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 addr...

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Page 141: ...e Drawings 137 Weights Dimensions Operating Environment 140 AC Power Requirements 141 Ultrasonic Pressure 142 Interpreting the Model Number 143 Regulatory Agency Compliance 144 Page 135 Dukane Manual Part No 403 587 00 Section 11 Specifications ...

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Page 143: ...ROLS ULTRASOUND SYSTEM I O PRESS CONTROL COMMUNICATION OPTIONS CARDS AC POWER ENTRY ALLOW 5 BOTH SIDES FOR COOLING ALLOW 5 BOTH SIDES FOR COOLING ALLOW 3 IN BACK FOR CABLES IN mm 18 76 476 5 18 16 461 3 17 16 435 9 OPTIONAL RACK MOUNT BRACKETS 147 4720 11 37 288 8 0 81 20 6 0 12 3 1 0 25 x 0 50 SLOT 2 PLCS Page 137 Dukane Manual Part No 403 587 00 Section 11 Specifications ...

Page 144: ...OWER ENTRY ALLOW 5 BOTH SIDES FOR COOLING ALLOW 5 BOTH SIDES FOR COOLING 4 31 109 5 LIGHTED POWER INDICATOR OPTIONAL OPERATOR DISPLAY AND CONTROLS ALLOW 3 IN BACK FOR CABLES OPTIONAL RACK MOUNTS 147 4721 0 203 5 16 DIA 0 25 X 0 50 SLOT IN mm WEIGHT 25 lbs 11 34 kg Figure 11 2 Layout High Profile iQ Generator Page 138 iQ Series Ultrasonic Generator Power Supply Servo Systems ES User s Manual Dukane...

Page 145: ... SIDE FOR COOLING ALLOW 6 IN BACK FOR CABLING ALLOW 5 EA SIDE FOR COOLING LIGHTED POWER INDICATOR OPERATOR CONTROLS OPERATOR DISPLAY IN mm ULTRASOUND SYSTEM I O S OPTIONS CARDCAGE PANELS AC POWER ENTRY WEIGHT 34 lbs 15 42 kg COOLING FAN POWER SWITCH Page 139 Dukane Manual Part No 403 587 00 Section 11 Specifications ...

Page 146: ... Width Depth Low Profile 3 45 87 6 17 16 435 9 12 55 318 8 High Profile 5 19 131 8 17 16 435 9 12 55 318 8 High Power 5 19 131 8 17 16 435 9 14 51 368 6 NOTE Add approximately 0 4 10 mm to height when the generator is equipped with factory installed feet Add between 3 and 6 76 152 mm behind the generator and 5 127 mm for air flow and cable connections High Profile Low Profile High Power lb kg lb k...

Page 147: ...Q XX XX 3600 200 240V 50 60 Hz 25 Amps 30 Amps 1400 VAC Nominal 5 A Nominal 20kHz 20HS480 2 Q XX XX 4800 200 240V 50 60 Hz 30 Amps 30kHz 30HS090 1 Q XX XX 900 100 120V 50 60 Hz 8 Amps 15 Amps 700 1300 VAC Nominal 1 5 3 A Nominal 30kHz 30HS090 2 Q XX XX 900 200 240V 50 60 Hz 8 Amps 30kHz 30HS120 1 Q XX XX 1200 100 120V 50 60 Hz 15 Amps 30kHz 30HS120 2 Q XX XX 1200 200 240V 50 60 Hz 8 Amps 30kHz 30H...

Page 148: ... Ultrasonic Pressure 1 m from the Equipment dB 110 130 110 105 110 Table 11 IV iQ Generator Ultrasonic Pressure NOTE All measurements taken with Data Physics Dynamic 4 Channel Signal Analyzer with calibrated 377C01 Microphone and 426B02 Preamplifier Page 142 iQ Series Ultrasonic Generator Power Supply Servo Systems ES User s Manual Dukane Manual Part No 403 587 00 ...

Page 149: ...Watts 240 2400 Watts 180 1800 Watts 120 1200 Watts 060 600 Watts 090 900 Watts 024 240 Watts 018 180 Watts 012 120 Watts System Process Controls Press System Q ES Graphics Color LCD w Press Card Supports the iQ Explorer II Software AC Line Input 2 200 240V for 5 25 Tall chassis 1800W and 2400 W only 2 200 240V for 3 5 Short chassis 1200W and below 1 100 120V for 5 25 Tall chassis 1200W and below f...

Page 150: ...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 2005 EN61000 4 2 EN61000 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN61000 4 8 EN61000 4 11 The Low Voltage Directive 2006 95 EC The Machinery Directive 2006 42 EC EN 60204 2006 Safety of Machinery Electrical Equipment of Machines Part 1 General Require...

Page 151: ...ppendix A List of Figures 147 Appendix B List of Tables 152 Appendix C Sequencing Notes 153 Appendix D Alarm Messages 156 Appendix E Menu Structure Diagrams 161 Page 145 Dukane Manual Part No 403 587 00 Section 12 Appendices ...

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Page 153: ...utput Connector 26 3 12 Configuration Port Connector 27 3 13 iQ Generator Remote Controller Servo Press Thruster Connections Version 1 30 3 14 iQ Generator and Servo Press Thruster Connections Version 2 34 4 1 iQ Generator Display and Control Keys 39 4 2 Display Detail Operating Mode Indicator 40 4 3 Generator in Offline Condition 40 4 4 Navigation Keys 4 with Enter and Cancel 41 4 5 Active Soft K...

Page 154: ...Control Submenu Diagram 61 5 30 Process Limits Menu Diagram 63 5 31 Process Limits Alarm Status 65 5 32 Process Limits No Display 66 5 33 Process Limits Display Only 66 5 34 Process Limits Bad Limits 66 5 35 Process Limits Suspect Limits 67 5 36 Utilities Hardware Menu Diagram 68 5 37 Setup Control 69 5 38 Setup Control Select a Method 69 5 39 Setup Control Sequencing Chosen 69 5 40 Defining the S...

Page 155: ...itional Hardware Settings Diagram 78 5 54 Advanced Process Settings Warning 78 5 55 Scan Stack Warning 79 5 56 Scan Stack Results 80 5 57 Buzzer Enabled 80 5 58 Test at Power Up 81 5 59 Trigger Function Basic and Advanced 82 5 60 Network Settings 83 5 61 Restore Factory Defaults 83 5 62 Main Operate Screen 84 5 63 Part Number Screen 84 5 64 Current Setup 85 5 65 A Process Limits List 85 5 66 Real ...

Page 156: ... up Hardware Tab 99 6 6 iQ Explorer II Process Settings Tab and Initiate Mode 100 6 7 iQ Explorer II Process Settings Tab Trigger Type Force Max Trigger Time 101 6 8 Suggested Initial Trigger Force Setting 101 6 9 iQ Explorer II Process Settings Sensing Speed 102 6 10 iQ Explorer II Process Settings Sensing Start Position 102 6 11 iQ Explorer II Teach Start Sensing Position 103 6 12 iQ Explorer II...

Page 157: ... Process Settings Window 118 9 1 CVS Output Format 128 11 1 Layout Low Profile iQ Generator 137 11 2 Layout High Profile Generator 138 11 3 Layout High Power iQ Generator 139 11 4 Interpreting the Model Number 143 List of Figures No Description Page Appendix A C 1 What is a Sequence 153 C 2 Insertion Sequence Example 154 C 3 Sequence Definition 155 E 1 Process Setup Menu Diagram 161 E 2 Process Li...

Page 158: ...Generator Remote Controller and Servo Press Thruster Cables 43S215 31 3 V iQ Generator Remote Controller and Servo Press Thruster Cables 43S245 AX 32 3 VI iQ Generator and Servo Press Thruster Cables Version 2 35 5 I Security Access to Main Menu Item 88 9 I Part Data Indexes 128 11 I iQ Generator Weights 140 11 II iQ Generator Dimensions 140 11 III Generator AC Power Requirements 141 11 IV iQ Gene...

Page 159: ...sed This order of operations determines the order of the segments in the sequence definition See Sequence Definition Page 155 The figure below gives a graphic representation of a se quence The figure shows that a sequence is a process having from 1 to 8 seg ments and each of those segments has from 1 to 255 cycles See Page 69 Process Utilities Setup Control NOTE Figure C 1 What is a Sequence Segme...

Page 160: ...es are finished the sequence is reset to begin processing another part The figure below gives a graphic representation of what this sequence might look like on an X Y table Appendix C Sequencing Notes Setup 01 Cycle 1 Setup 02 Cycle 3 Setup 02 Cycle 2 Setup 02 Cycle 1 Setup 02 Cycle 4 Setup 01 Cycle 3 Setup 01 Cycle 4 Start Point Stop Point Setup 01 Cycle 2 Figure C 2 Insertion Sequence Example Pa...

Page 161: ...Sequence Current Cycle Choose 1 8 Current Segment Choose 1 8 Process Cycles for a Given Segment Choose 1 255 Appendix C Sequencing Notes Sequence Length 1 8 Segments Cycle or Sequence Current Cycle 1 8 Current Segment 1 8 Process Cycles for a Given Segment 1 255 Figure C 3 Sequence Definition Page 155 Dukane Manual Part No 403 587 00 Section 12 Appendices Continued from Previous Page ...

Page 162: ...s containing a generator with a color front panel display Q Series or iQ Explorer II software Information on particular alarms may also be obtained on the Dukane Easy Alarm web page http www dukane com us DL_EasyAlarm asp Page 156 iQ Series Ultrasonic Generator Power Supply Servo Systems ES User s Manual Dukane Manual Part No 403 587 00 ...

Page 163: ...nabling a pre trigger source that allows for full ramp up time to elapse still in air before contacting the part should eliminate all Frequency Overload Fault 1 occurrences for a properly maintained stack If the above steps do not resolve problem contact Dukane U105 Frequency Overload Fault 2 PLL Lock Lost The stack may be coupling the part to the fixture Attempt to decouple vibrations from fixtur...

Page 164: ...ing Adjusting the Free Run Frequency may also be advisable A sudden shift in frequency as observed on the graph im mediately before a Frequency Overload Fault 3 as opposed to a general frequency drift indicates stack horn coupling to the part during the weld or an another abrupt change in stack resonance This does not imply an operating frequen cy drift issue but a weld application setup issue U20...

Page 165: ... U213 Servo Communication Error Communication between the servo controller and the motherboard has been compromised Contact Dukane U214 Obstruction at Top of Stroke The press is unable to reach the Top of Stroke position Remove obstruction detected at Top of Stroke Adjust Top of Stroke position to be defined higher than obstruction U216 Excessive Force at Idle The press system senses an excessive ...

Page 166: ...or pneumatic press the distance from pre trigger to posi tion of trigger is required to be less than 0 75 inches or 19 05 millimeters U411 Part Detected Too Early Contact between the horn and part was detected before reaching the Sensing Start Position Adjust Sensing Start Position to be above contact with part Account for variation of heights of unassembled parts NOTE Repeated occurrences of this...

Page 167: ...amic Hold Method Enable Disable Distance Until Force Reached Dynamic Hold Speed Hold Distance Max Hold Time DynamicHoldPeakForce Dynamic Hold Speed Max Hold Time Hold Time Segmented Constant Constant Weld Speed Enable Melt Detect After Force Drops By Speed Enable Melt Detect After Force Drops By Enable Disable Enable Disable Distance Increment Speed Force Advanced Servo Settings Top of Stroke Posi...

Page 168: ... Weld Peak Power Weld End Position Weld Peak Force Hold Time Hold Distance Total Cycle Time Total Stroke Distance Alarm Status Time Date Setup OFF ON Low Limits Bad Limits Suspect Limits Display Only High Limits OFF ON Low Limits High Limits Force at Trigger Display OFF ON Force Suspect Force Bad Disabled Display Trigger Delay Time Trigger Delay Distance Limits available when Trigger Delay is enab...

Page 169: ... Setup Name Horn Booster Fixture Manual P1 Manual P2 Hold Dynamic Trigger Down Speed Flow Control Mechanical Stop HSC Setting HSC Start Position Pre trigger EOW Flags Serial Port System Status I O Auto Start Input Auto Stop Input Enabled J3 pin 4 Output Duration Output Format LF After CR Output Mode Baud Rate Serial Limit Indicators Serial Headers Restore System I O Defaults Adv Process Settings B...

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Page 171: ...Index Page 165 Dukane Manual Part No 403 587 00 Index ...

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Page 173: ...ted Configuration 33 Remote Controller Configuration 29 CE Certification 4 CE Marking 144 Changing Default Settings 94 Connect AC Power 36 Connector Descriptions 26 Control Functions 97 Control Panel Navigation Keys 41 Operating Mode Keys 40 Overview 39 Screen Basics 43 Interpreting On Screen Arrows 43 Making Selections 43 System Operating Mode Keys 40 System Power Output Level 42 Virtual Keyboard...

Page 174: ...6 Health and Safety 5 Electrical Safety 8 Domestic Power Grounding 9 International Power Grounding 9 General Considerations 7 How to Lift Safely 10 Lifting the Equipment 10 Plastics Health Notice 8 Recommendations 7 Help 87 Help System 98 F1 Key 98 Hold Distance 64 Hold Time 64 I Initiate Mode 51 Installation 11 AC Power Inlet Panel 17 Before Installation 13 When to Use Lockout Tagout Devices 13 C...

Page 175: ...eal Time Data 85 Operating Environment 140 Operation 45 Changing Default Settings 94 Dynamic Hold Method 58 Generator Start up Sequence 47 Graph 86 Graph Setup 86 Hardware Setup 74 Help 87 Menus 49 Process Setup 51 Operate Screen 84 Part Number History 84 Overview 47 Primary Weld Method 56 Process Limits 62 Process Setup 51 Process Utilities 69 Secondary Weld Method 56 Security 88 Remote User Requ...

Page 176: ...p 15 Specify Process Limits Behavior 109 Step 16 Run Weld Cycle 110 Step 17 View Weld Results 110 R Ramp Down Time 80 Ramp Up Time 80 Real Time Data 85 Rear Panel Expansion Slot 4 Rear Panel Layout Overview 16 Recheck Connections 36 Regulatory Agency Compliance 144 Remote User Request for Control 92 Remote User Timeout 88 Restore Advance Process Defaults 80 Restore Factory Defaults 83 Restore Syst...

Page 177: ...Stroke Position 61 Total Cycle Time 64 Total Stroke Distance 64 Travel Limit 51 61 Trigger Advanced Trigger Settings 81 Trigger Type 52 Troubleshooting Alarm Messages 156 TUV Certification 4 U UL 144 Using iQ Explorer II 99 Enable Melt Detect 105 Navigate to the Process Settings Tab 100 Post Weld Settings 107 Program Sensing Speed 102 Program Sensing Start Position 102 Program Weld Characteristics...

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Page 179: ...nimum requirement for these requirements and starts transitioning the company from a traditional inspection oriented quality system to one based on partnership for continuous improve ment 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 ...

Page 180: ...cal representative Part No 403 587 00 Dukane Intelligent Assembly Solutions 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949 Series Ultrasonic Generator Power Supply Servo Systems ES User s Manual Printed in the United States of America www dukane com us ...

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