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Pneumatic Safety

A safety isolation lockout valve is installed in series with
the compressed air filter and is capable of isolating the
compressed air supply from the pneumatic cylinder on
the press. This device complies with OSHA regulations.

Always isolate and lockout the compressed air when
performing any maintenance on the press. The isolation
lockout valve is shown in Figure 2–4.

Figure 2–3

Compressed Air Filter

Compressed Air In

Safety Isolation
Lockout Valve

Compressed Air Filter

Filtered Air to Press

Filter Service Indicator -
Green = Filter Element is OKAY;
Red = Replace Filter Element

CAUTION

Lockout valve must be closed
and secured with a padlock be-
fore servicing the press.

Page 10

iQ Series

Ultrasonic Integrated Press System i 220 User’s Manual

Dukane Manual Part No. 403-594-02

Summary of Contents for i220

Page 1: ...elligent Assembly Solutions 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949 Dukane Part No 403 594 02 iQ Series ULTRASONIC INTEGRATED PRESS SYSTEM i220 User s Manual AUTOMATED HAND PROBE PRESS This User s Manual Covers These Models 20122XC0P3 20121XC0P3 20122XC0P5 20121XC0P5 20242XC0P3 20242XC0P5 ...

Page 2: ...copying 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 liabi...

Page 3: ...ion Revision Number Summary Date 00 Original release 06 05 2014 01 Removed Encoder Option and update 10 4 2016 Agency Compliance 02 Added stack surface temperature warning 06 15 2017 Page iii Dukane Manual Part No 403 594 02 ...

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Page 5: ... Screen Basics 40 Press Controls 41 Press Ergonomic Base 45 Section 5 Operation 47 Press Start up Sequence 49 Stopping the Weld Cycle 50 Using the Menus 51 Alarms 69 Section 6 Options 71 Overview 73 Power Inlet Options 74 Distance Encoder 76 Continued General User Information 3 Press System Overview 4 General Considerations 7 Plastics Health Notice 8 Electrical Safety 8 Pneumatic Safety 10 Lifting...

Page 6: ...tion 10 Contacting Dukane 101 Section 11 Specifications 105 Drawings 107 109 Weights Dimensions Operating Environment 110 Compressed Air Requirements 111 AC Power Requirements 111 Models Ultrasonic Pressure 112 Replacement and Repair Parts Lists 113 Regulatory Agency Compliance 114 Section 12 Appendices 115 Appendix A List of Figures 117 Appendix B List of Tables 120 Index 121 Continued Continued ...

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Page 9: ...TION 1 Introduction General User Information 3 Read the Manual First 3 Notes Cautions Warnings 3 Drawings and Tables 3 Press System Overview 4 Page 1 Dukane Manual Part No 403 594 02 Section 1 Introduction ...

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Page 11: ...fy 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 an operator protection issue Caution statements identify conditions or practices that could result in damage to the equipment or other property Warning statements point out ...

Page 12: ...rator has rugged internal ultrasonic cir cuitry and ensures a continuous resonant frequency lock at the start of each weld 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 Page 4 iQ Series Ultrasonic Inte...

Page 13: ...N 2 Health and Safety General Considerations 7 Plastics Health Notice 8 Electrical Safety 8 Domestic Power Grounding 9 International Power Grounding 9 Pneumatic Safety 10 Lifting the Equipment 11 Page 5 Dukane Manual Part No 403 594 02 ...

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Page 15: ...ssembly equipment is used with automatic material handling equip ment in an automated system Foot Switch Do not use a foot switch Using a foot switch in place of the optical touch finger switches activation switches violates OSHA regulations NOTE These recommendations apply to the weld ing system System in this manual refers to a complete group of components associated with the welding of parts al...

Page 16: ...t 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 Plastics Health Notice Certain plastic materials when being processed may emit fumes and or gases that may be ha...

Page 17: ...rdinances that apply See Figures 2 1 and 2 2 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 compatibl...

Page 18: ...performing any maintenance on the press The isolation lockout valve is shown in Figure 2 4 Figure 2 3 Compressed Air Filter Compressed Air In Safety Isolation Lockout Valve Compressed Air Filter Filtered Air to Press Filter Service Indicator Green Filter Element is OKAY Red Replace Filter Element CAUTION Lockout valve must be closed and secured with a padlock be fore servicing the press Page 10 iQ...

Page 19: ...ry spots or other potential hazards Know your limit and don t try to exceed it Ask for help if needed and make any adjustments to the lifting device Know where you are going to set the item down and make sure that placement area and your path are free of obstructions Lift the equipment with the mechanical lift device and move the equipment carefully Lifting the Equipment CAUTION Use a mechanical l...

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Page 21: ...er Inlet Panel 19 System I O Panel 20 Base Abort Connector J6 24 Ground Detect J2 24 EtherNet J9 24 USB J3 24 Base Connections 25 RFI Grounding 26 Connnecting Press Cables 27 Install the Press without Machine Base 30 Automation System 31 Flange Template 32 Page 13 Dukane Manual Part No 403 594 02 Section 3 Installation ...

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Page 23: ...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 Continued Electrical safety hazards exist inside the i220 press chassis Before making a...

Page 24: ... plug end of the 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 press electrical cord into its AC power source 3 Push the press AC power switch breaker to the ON position Utilities Provide for electricity to meet the equipment specifications as shown in ...

Page 25: ...ide any other system components leaving the press on the shipping base 3 Inspect the assembly for any damage before placing it in position Moving the Press into Place 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 ...

Page 26: ... for a protective earth ground System I O Panel I O panel components J1 System I O J6 Base Abort J2 Ground Detect J9 EtherNet J3 USB Figure 3 3 Press Rear View Base Connections J35 Base Interface Connector Base Grounding Stud See Page 24 See Page 25 See Page 19 See Pages 19 23 DUKANE USE ONLY DUKANE USE ONLY Page 18 iQ Series Ultrasonic Integrated Press System i220 User s Manual Dukane Manual Part...

Page 27: ...e AC power to the system The power ON position is marked with the internationally recognized I symbol the power OFF posi tion is marked with the 0 symbol This power switch also integrates an appropriately sized over current protection circuit breaker function in the press If an over current condition trips the circuit breaker it will automatically switch to the OFF position If the overload current...

Page 28: ...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 su...

Page 29: ...atus outputs 12 Not Used BLK WHT 13 Hold Status Output RED WHT Isolated output referenced to Output Common that indicates when in the Hold part of a weld cycle 14 System latch Reset GRN WHT Isolated input referenced to Input Common that resets the Any Fault or System Overload status outputs 15 Input Common BLU WHT Isolated input Common 16 22VDC Power Ground BLK RED 22VDC Power Ground also chassis ...

Page 30: ... Pin 10 Bad Part Status Output Pin 10 is an isolated digital NPN PNP 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 11 Top of Stroke Status Output Pin 11 is an...

Page 31: ...ected In the case of an overload this output stays active until the start of the next cycle or until cleared us ing the front panel keypad or system input Pin 12 System Latch Reset input Faults that will activate the Any Fault output Overload Average Peak or Frequency Overtemperature Fault System Power Fault Pin 22 Output Common Pin 22 is electrically isolated from chassis ground This common line ...

Page 32: ...the ground detect input is activated The weld portion of the cycle is then terminated The system will not start a new cycle until the ground detect input is deactivated EtherNet J9 Dukane Use Only USB J3 Dukane Use Only Isolate the fixture as it is fastened to the press base plate by completing the three numbered steps shown in Figure 3 6 below Figure 3 6 Ground Detect Fixture Installation Base Pl...

Page 33: ...7 It is used to interface the base controls and display to the Base Abort connector J6 on the thruster See Figure 3 4 for the J6 location Grounding Stud This connector is shown as A in Figure 3 7 Use this base connector to insure proper grounding See RFI grounding below and the grounding material on Page 9 Page 25 Dukane Manual Part No 403 594 02 Section 3 Installation ...

Page 34: ...al 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 the grounds Earth Ground 14 Gauge St...

Page 35: ...bout compressed air on the next page This connector is attached to a safety isolation lockout valve and then to an air filter See Pneumatic Safety Page 10 3 Base Abort Cable J6 Connect this cable to the press base plate connector J35 or automation equipment 4 Connect the A C power cord to the IEC power inlet connector on the press and plug the other end into an approved AC outlet Additional Connec...

Page 36: ...0 240V 15A 200 1541 240V 10A Continental Europe 200 1111 240V 16A 200 1542 240V 10A Table 3 II Power Cords The power cord is equipped witha three prong ground ed type plug for your safety Whenever a two slot receptacle is encountered we strongly recom mend that it is replaced with a properly grounded three lead receptacle Have a qualified electrician do the replacement in accordance with the Natio...

Page 37: ...ht Turn the handles clockwise as shown in Figure 3 10b until tight To rotate the handles out of the way without loosen ing or tightening pull the handles outward rotate and release as shown in Figure 3 11 Thruster Support Housing Height Adjustment Handles Counterbalance Spring Figure 3 9 Example of Press Placement Figure 3 10 Using Handles to Make Adjustments Figure 3 11 To Relocate Handles a Loos...

Page 38: ...scale flange template is provided for locating and drilling holes in the supporting structure The template is Figure 3 20 on the next page 2 Operate and E STOP Signals Because there is no machine base as the press is equipped in its standard con figuration operate and emergency stop signals will not be generated by the optical switches and the E STOP Abort switch that are parts of the standard pre...

Page 39: ...ivation Switch 1 N O Normally Open N O dry contact closure to Pin 7 2 Input Activation Switch 2 N O Normally Open N O dry contact closure to Pin 7 3 Input Hardware Abort Power In Normally Closed N C emergency switch contact 4 Input Software Abort Normally Open N O dry contact closure to ground 5 Ground Internal Ground Internal Ground Gnd 6 Input Activation Switch 1 N C Normally Closed N C dry cont...

Page 40: ... inches 57 15 mm 5 inches 57 15 mm inches 5 8 mm 1 5 inches 8 1 mm inches 76 78 mm 875 inches 98 5 mm R R F n e Tem e No Scaling Actual Size Figure 3 12 Flange Template Page 32 iQ Series Ultrasonic Integrated Press System i220 User s Manual Dukane Manual Part No 403 594 02 ...

Page 41: ...e Keys 36 Navigation Keys 37 Soft Keys Bordering the Display 37 Hot Keys 38 System Power Output Level 39 Screen Basics 40 Press Controls 41 Manual Thruster Controls 41 Indicators 43 Press Ergonomic Base 45 Page 33 Dukane Manual Part No 403 594 02 Section 4 Controls ...

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Page 43: ...ly 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 Figure 4 1 Front Panel Controls POWER ABORT TRIGGER LEDs Navigation Keys 4 ENTER Key CANCEL Key INFO Key Hot Keys 8 POWER ABORT TRIGGER AMP PRE WELD WELD POST WELD LIMITS SETUP OPERATE LIVE ENTER ONLINE OFFLINE ...

Page 44: ...g normally the OFFLINE key may be pressed to put the press into the offline mode In this mode the press can not generate an ultrasound signal However the press can still run a cycle while OFFLINE This can be useful to check the rest of the mechanical weld setup including the speed air pressure and trigger point settings The word Offline appears in a white outlined box in the display s upper right ...

Page 45: ...O Figure 4 4 Navigation Keys 4 with Enter Info and Cancel AMP PRE WELD WELD POST WELD OPERATE LIVE SETUPS LIMITS REGIONAL SETTINGS SYSTEM INFO ADVANCED SETTINGS INFO MENU ONLINE Figure 4 5 Info Menu Display Continued 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...

Page 46: ... have their bad part part limits enabled SETUPS This is a display only screen show ing the setup weld parameters 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...

Page 47: ...e right Peak Detect Feature 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 Bar Graph Power Scaling Power scaling is related to amplitude At 100 amplitude the whole graph is lit and the press is operating at 100 power At 50 amplitude the entire graph ...

Page 48: ...on of More Text Figure 4 8 Making Selections Cursor shows selected digit under Distance below White area high lights selected item DISTANCE 0 0000 in 30 000s MAX TIME PRESS ENTER TO ACCEPT PRESS CANCEL TO ABORT DISTANCE TIME ENERGY POSITION GROUND DETECT AMP PRE WELD WELD POST WELD LIVE SETUPS LIMITS OPERATE Display arrow points in direction of more text RESTORE DEFAULTS ADV PROCESS CONTROL FREQUE...

Page 49: ...e horn and or tooling warranty The Mechanical Stop position may be locked by tightening the lock screw located on the left side of the press Once locked it will be difficult or impossible to turn the Mechani cal Stop Adjustment Knob on the front panel Down Speed Adjustment This control adjusts the downward velocity of the press thruster slide assembly Turning the knob clockwise de creases the spee...

Page 50: ... DOWN SPEED PRESSURE MECHANICAL STOP 0 1 2 3 4 5 6 7 8 0 1 2 3 4 5 6 7 8 Page 42 iQ Series Ultrasonic Integrated Press System i220 User s Manual Dukane Manual Part No 403 594 02 Mechanical Stop Adjust Pressure Gauge Down Speed Adjust Weld Trigger Control Knob Thruster Height Adjustment Locking Handle See Section 5 Operation for detail about the LCD front display ...

Page 51: ...to the horn is reached The trigger control adjusts the amount of force needed to close that pressure switch When the switch closes the ultrasound signal starts and the horn begins to vibrate See Figure 4 11 for trigger knob detail To make adjustments grasp the inner knob and turn it to make adjustments This knob can be turned as many as nine revolutions Each revolution advances the outer dial one ...

Page 52: ...ued from Previous Page Loosen or tighten the mechanical stop lock with a M5 Hex wrench Stroke Position Indicator Flag Slot Mechanical Stop Indicator Flag Slot Page 44 iQ Series Ultrasonic Integrated Press System i220 User s Manual Dukane Manual Part No 403 594 02 ...

Page 53: ...xture leveling for alignment with the horn For details on the alignment and leveling of the base plate see Section 7 Acoustic Stack Fixture Setup Right Operate Switch Lower Fixture Lower Fixture E Stop Switch Left Operate Switch Figure 4 13 Ergonomic Base Controls Dimly Lit Red LED Figure 4 15 Right Switch in Operate Mode Both LEDs Brightly Lit Brigtly Lit Red LEDs Figure 4 14 Right Operate Switch...

Page 54: ...r press Pressing the abort switch causes the press to Immediately turn off the ultrasound Remove electrical power from the press and Initiate a software abort sequence Front Panel Status LEDs The function of these LEDs is to indicate the status condi tions of the press POWER A green POWER status light indicates that power is applied to the press and it is ready for operation ABORT When the E STOP ...

Page 55: ...up Sequence 49 Stopping the Weld Cycle 50 Using the Menus 51 AMP 52 PRE WELD 53 WELD 55 POST WELD 56 LIMITS 57 SETUP 58 OPERATE 59 LIVE 60 Using the INFO Menus 62 Alarms 69 Page 47 Dukane Manual Part No 403 594 02 Section 5 Operation ...

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Page 57: ...ayed 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 Figure 5 2 Front Panel with Power On Light Pow...

Page 58: ... the press front panel power light is on GREEN move the rear panel AC breaker switch to the OFF position The front panel power light will go out as power is cut off Automated System Customer supplied external controls provide the means to stop the cycle for an automated system The 200 1546 xxM cable can be used to connect these external controls to the I O panel at connector J6 See Page 30 for mor...

Page 59: ...urst LIMITS From the available process characteristics Select the ones to display and the ones for which limits are to be set for bad parts Display Only Real time Process Characteristics Display Only Amplitude Power Operating Frequency Distance INFO System Info Regional Settings Advanced Settings Menu Access Continued Figure 5 3 i220 Integrated Press Menu Overview Page 52 Page 54 Page 56 Page 57 P...

Page 60: ...ting MODE Automated Press or Manual Press This is the only available menu IF Trigger is either Momentary or Maintained Pre trigger is disabled and Postweld characteristics are disabled If 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 Figure 5 4 ...

Page 61: ...d in the POST WELD menu then the AFTERBURST soft key is also displayed as shown in Figure 5 8 to the right The parameter value last accessed will be highlighted and will be ready to change Figure 5 8 Setting Weld Amplitude with Afterburst Enabled Amplitude Range 20 100 NOTE Figure 5 7 Setting Weld Amplitude 100 WELD AMPLITUDE PRESS ENTER TO ACCEPT PRESS CANCEL TO ABORT ONLINE AMP PRE WELD WELD POS...

Page 62: ... shows the PRE TRIGGER menu with START OF CYCLE selected as the pre trigger TYPE In addition pre trigger amplitude can be adjusted In the example shown in the figure 20 can be raised by pressing the plus key Since amplitude range is 20 100 this value can not be lower than 20 and lowered by pressing the minus key Once the amplitude value has been decided press ENTER to accept it or press CANCEL to ...

Page 63: ...splay seen in Figure 5 15 at the right shows that the TRIGGER type selected is POWER With POWER as trigger type AMPLITUDE POWER Watts and MAX TIME need to be entered Figure 5 15 Pre Weld Menu Trigger Selected is Power MODE TRIGGER ONLINE PRESS ENTER TO SELECT TYPE MAX TIME MAINTAINED 0 000s PRE TRIGGER AMP PRE WELD WELD POST WELD LIVE SETUPS LIMITS OPERATE MODE TRIGGER ONLINE PRESS ENTER TO SELECT...

Page 64: ...ENTER TO CHANGE ONLINE ENERGY GROUND DETECT AMP PRE WELD WELD POST WELD LIVE SETUPS LIMITS OPERATE Figure 5 16 Weld Menu Mode Manual Automated Press Distance not Supported ENERGY 0J 0 000s MAX TIME PRESS ENTER TO ACCEPT PRESS CANCEL TO ABORT ONLINE ENERGY TIME GROUND DETECT AMP PRE WELD WELD POST WELD LIVE SETUPS LIMITS OPERATE Figure 5 18 Weld Menu Mode Manual Automated Press Distance is Supporte...

Page 65: ...enu Figure 5 21 Post Weld Menu Time Setting Figure 5 22 Post Weld Menu Afterburst Disabled Figure 5 23 Post Weld Menu Afterburst Enabled HO AF AM AFTERBURST PRESS ENTER TO CHANGE HOLD AFTERBURST DISABLED ONLINE AMP PRE WELD WELD POST WELD LIVE SETUPS LIMITS OPERATE AFTERBURST HOLD AFTERBURST AMPLITUDE DELAY DURATION ENABLED 100 0 000s 0 000s PRESS ENTER TO ACCEPT PRESS CANCEL TO ABORT ONLINE AMP P...

Page 66: ... Limits Menu Figure 5 25 Limits Menu Bad Soft Key Pressed Figure 5 26 Limits Menu Setting Upper and Lower Limits Figure 5 27 Limits Menu Bad Parts Limits Enabled for Time WELD TIME BAD PART LIMIT DISABLED ENABLED ONLINE AMP PRE WELD WELD POST WELD LIVE SETUPS LIMITS OPERATE DONE UPPER LIMIT LOWER LIMIT 30 000s 0 000s ONLINE WELD TIME BAD PART LIMIT AMP PRE WELD WELD POST WELD LIVE SETUPS LIMITS OP...

Page 67: ... 5 28 displays a typical setup Figure 5 28 Setup Typical Display AFTERBURST MODE WELD ENERGY PRE TRIGGER HOLD ONLINE AUTOMATED PRESS START OF CYCLE 21 POWER 125W 4 000s 10 0 J 0 500s 100 TIME 0 551s 75 0 250s 0 250s AMP PRE WELD WELD POST WELD LIVE SETUP LIMITS OPERATE TRIGGER Page 59 Dukane Manual Part No 403 594 02 Section 5 Operation ...

Page 68: ...cteristics 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 sup ported then the distance related characteristics would not be available Weld Time Peak Power Energy Weld Distance Weld End Position Online Offline E...

Page 69: ...displayed Figure 5 31 In Cycle Screen TEST When the TEST soft key has been pressed and the press is online the screen shown in Figure 5 32 is displayed The screen shows the current value of the parameters shown If DISTANCE is not supported it would not be displayed Figure 5 32 Test Screen ONLINE AMPLITUDE POWER OPERATING FREQUENCY DISTANCE 100 0W 19 900Hz 0 0000in AMP PRE WELD WELD POST WELD LIVE ...

Page 70: ...SETTINGS INFO MENU ONLINE Figure 5 33 Info Menu Display l Continued Figure 5 34 System Info Figure 5 35 Regional Settings Language Menu Figure 5 36 Regional Settings Units Menu REGIONAL SETTINGS MENU LANGUAGE UNITS IMPERIAL METRIC BACK ONLINE AMP PRE WELD WELD POST WELD LIVE SETUPS LIMITS OPERATE DUKANE CORPORATION IAS DIVISION iQ LE SERIES ULTRASONIC GENERATOR Model 20222XCOP5 Serial 236853 Front...

Page 71: ...igure 5 37 Advanced Settings Menu Overview Frequency Tracking Free Run Frequency Freq Lock and Hold System Freq Limits Ramp Up Time Ramp Down Time Buzzer Latch on Bad Part Restore Factory Defaults WARNING ModifyingAdvanced Set tings may damage the unit or ultrasonic stack RESTORE DEFAULTS ADV PROCESS CONTROL FREQUENCY TRACKING FREE RUN FREQUENCY FREQ LOCK AND HOLD SYSTEM FREQ LIMITS RAMP UP TIME R...

Page 72: ...inued from Previous Page Figure 5 39 Restore Defaults Adv Process Controls Figure 5 40 Restore Defaults Confirmed Advanced Process Control YES NO ARE YOU SURE YOU WANT TO RESTORE ALL ADVANCED PROCESS CONTROL SETTINGS TO DEFAULT VALUES ONLINE AMP PRE WELD WELD POST WELD LIVE SETUPS LIMITS OPERATE ADVANCED PROCESS CONTROL SETTINGS HAVE BEEN RESTORED TO DEFAULT VALUES ONLINE AMP PRE WELD WELD POST WE...

Page 73: ...ontrol sub menu Figure 5 41 Advanced Process Control Sub menu Items Moving to the Next Sub menu Continued TRACKING ENABLED ADV PROCESS CONTROL FREQUENCY TRACKING FREE RUN FREQUENCY FREQ LOCK AND HOLD SYSTEM FREQ LIMITS RAMP UP TIME RAMP DOWN TIME DISABLED 20055Hz DISABLED NORMAL 0 150s 0 000s ONLINE TRACKING DISABLED FREE RUN 20000 Hz ADV PROCESS CONTROL DISABLED 20000Hz DISABLED NORMAL 0 150s 0 0...

Page 74: ... Disable this feature 4 System Freq Limits Limits can be Wide Normal Narrow or Manual Wide In wide mode the upper and lower fre quency limits are set to the maximum and mini mum allowed frequencies Normal In Normal mode the upper and lower frequency limits equal the free run frequency plus or minus 500Hz Narrow In Narrow mode the upper and lower frequency limits equal the free run frequency plus o...

Page 75: ...amp 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 Factory setting is 0 150 seconds 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 p...

Page 76: ...S is chosen then another message is displayed as shown to the right Figure 5 44 Miscellaneous Sub menu Items FACTORY DEFAULTS HAVE BEEN RESTORED ONLINE YES NO WARNING ALL SETUPS WILL BE ERASED AND FACTORY DEFAULTS WILL BE RESTORED ARE YOU SURE YOU WANT TO PROCEED ONLINE MISCELLANOUS DISABLE ENABLE BUZZER At TOP OF STROKE AT TRIGGER LATCH ON BAD PART RESTORE FACTORY DEFAULTS DISABLED DISABLED DISAB...

Page 77: ...08 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...

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Page 79: ...SECTION 6 Options Overview 73 Power Inlet Options 74 Page 71 Dukane Manual Part No 403 594 02 Section 6 Options ...

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Page 81: ... of parts This equip ment 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 spe cific...

Page 82: ...L 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 condi tion The cord should have an ...

Page 83: ...ion trips the circuit breaker it will automatically switch to the OFF position If the over load 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 imme diately trips again there is likely an internal system mal function that w...

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Page 85: ...Stack Removal 81 Stack Disassembly 82 Removing a Detachable Tip 82 Stack Assembly and Torque Values 83 Installing a Detachable Tip 84 Installing the Stack 84 Fixture Installation 85 Fixture Alignment 85 Fixture Leveling 86 Page 77 Dukane Manual Part No 403 594 02 Section 7 Acoustic Stack Fixture Setup ...

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Page 87: ...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 component...

Page 88: ...ly 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 BOOSTER TRANSDUCER HORN Spanner Wrench Hole Typical Mounting Ring Mounting Stud Anti Rotation Pins Transducer Housing Contact Button Figure 7 1 Stack Components Page 80 iQ Series Ultrasonic Integrat...

Page 89: ...t switch on the front of the press base 2 Power down the press These two steps are necessary to ensure that no power will be accidently applied while removing the stack 3 While supporting the stack with one hand loosen the two or four socket head screws that secure the stack access door 4 If the door has two screws swing it open If it has four screws remove it completely 5 Pull the stack forward a...

Page 90: ...nents 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 ...

Page 91: ...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 Torque inch lbs foot lbs Nt meters 1 2 in x 20 12 18 1 1 5 1 4 2 3 8 in x 24 12 18 1 1 5 1 4 2 M8 x 1 25 12 18 1 1 5 1 4 2 3 Coat one of the contact surfaces with a thin coat of high pressure grease A small...

Page 92: ...ing 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 th...

Page 93: ...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 Fixture Hold Down Bolts Fixture Holes for 3 Hole Mounting Fixture 12 x 14 Fixture Leveling Screws Hex socket set screws Holes for 4 Hole Mounting Fixture 9 x 9 Figure 7 8 Fixture Base Layout Con...

Page 94: ... stack assembly down to the fixture Allow the horn and the part to align 4 Turn the four jack screws clockwise until a slight re sistance is felt Refer to Figure 7 10 5 Tighten the hold down cap screws by turning them clockwise until a firm resistance is felt Figure 7 9 Loosening the Hold Down Cap Screws and Jack Screws Figure 7 10 Tightening the Hold Down Cap Screws and Jack Screws Fixture Alignm...

Page 95: ...si 6 Set the trigger control on the thruster so that the pres sure switch closes after some pressure is applied 7 Press the ONLINE button on the front panel 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 t...

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Page 97: ...SECTION 8 Stack Maintenance Inspection of the Acoustic Stack Components 91 Reconditioning Stack Components 92 Torque Values 93 Page 89 Dukane Manual Part No 403 594 02 Section 8 Stack Maintenance ...

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Page 99: ...e 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...

Page 100: ...the same number of strokes at each orientation Two strokes per rotation 9 Before reinserting a stud in any horn perform the following for proper engagement of the threads a Visually inspect and clean the stud b Clean the threaded hole using a clean cloth or towel c Tighten the stud to the torque specifications listed in Table 7 I Figure 8 4 Method of Component Resurfacing NOTE The operating effici...

Page 101: ...emoval 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 Torque Values See Section 7 Acoustic Stack Fixture Setup for torque values Table 7 I Stud Torque Values Table 7 II Horn Booster Torque Values Table 7 III Replaceable Tip Torque Values Reconditioning Stack Components Overtightening stack ...

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Page 103: ...SECTION 9 System Maintenance Press Six Month Periodic Maintenance 97 Page 95 Dukane Manual Part No 403 594 02 Section 9 System Maintenance ...

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Page 105: ...ans 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...

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Page 107: ...SECTION 10 Contacting Dukane Page 99 Dukane Manual Part No 403 594 02 Section 10 Contact Dukane ...

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Page 109: ...ated 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 address for the ...

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Page 111: ...Schematic 107 Weights Dimensions Operating Environment 108 Compressed Air Requirements 109 AC Power Requirements 109 Models Ultrasonic Pressure 110 Replacement and Repair Parts 111 Regulatory Agency Compliance 112 Page 103 Dukane Manual Part No 403 594 02 Section 11 Specifications ...

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Page 113: ...2 4 8 1 206 8 1 206 6 61 167 9 6 61 167 9 2X 50 12 7 12 38 314 3 10 88 276 2 14 38 365 1 2 25 57 1 2 63 66 7 2 25 57 2 2 63 66 7 12 00 304 8 B C REF 9 84 249 9 B C REF 7 00 177 8 B C REF 18 6 472 4 69 119 3 80 96 6 16 157 7 00 178 TYPICAL HORN INCHES mm 240 LBS WEIGHT 530 KG ISOMETRIC VIEW HANDLES ADJUSTABLE FRAME SUPPORT HEIGHT BASE DETAIL FIXTURE PLATE MOUNTING HOLES 8X M10x1 5 x 5 13 ULTRASOUND...

Page 114: ...STOMER SUPPLY AIR LINE PROVISION FOR 1 4 AIR LINE INLET 1 4 NPT FEMALE THREAD ON CHECK VALVE GAUGE R1 P1 E E REGULATOR TEE TEE C BAL CYL MAIN VALVE FLOW CONTROL E E E CYLINDER MAIN E E ADJUSTABLE FLOW 2 B P EB EA 4 A 3 5 1 BLUE E E E AIR FILTER SAFETY LOCKOUT E E E E COOLING LINE TO XDCR 20 3 3 30 7 6 4 3 1 6 10 32 1 8 1 8 1 8 8 3 15 5 30 5 15 1 5 2 5 11 5 16 9 5 16 52 Page 106 iQ Series Ultrasoni...

Page 115: ...PRESS E STOP BLUE V BLACK Relay N O J4 1 WHITE Relay N C Safety SW2 Relay C T 2 YELLOW Relay C T N C N O 4 E STOP STATUS 680 1019 1 GROUND 2 22V SOURCE J1 GND BROWN V N O 9 8 7 6 5 4 3 1 2 GROUND 22V_SSW P3 1 2 3 4 5 22V Power 5 Safety SW1 Input 1 N O Safety SW1 Input 2 N C 3 BLUE V BLACK Relay N O J3 1 WHITE Relay N C Safety SW1 Relay C T 2 YELLOW Relay C T N C N O 4 GND BROWN V 110 4993 PRESS ST...

Page 116: ...sing 0 C to 30 C Weights Model Press System Pounds Kilograms 20122XC0P3 530 240 Shipping Add 25 pounds 11 3 Kg to unit weight for packing materials Dimensions in mm Model Number Press includes base and column Height Width Depth 20122XC0P3 60 1 524 20 508 27 685 80 NOTE Add 4 100 mm behind the press for air input line and cable connections Table 11 I Weights Table 11 II Dimensions A representative ...

Page 117: ...Frequency Press Model Number Overload Power Ratings Watts Input AC Power Requirements Nominal AC Volt Maximum RMS Current North America Japan AC Outlet Rating 20kHz 20122XC0P3 1200 100 120V 50 60 Hz 15 Amps 15 Amps 20kHz 20121XC0P3 1200 200 240V 50 60 Hz 8 Amps 20kHz 20122XC0P5 1200 100 120V 50 60 Hz 15 Amps 20kHz 20121XC0P5 1200 200 240V 50 60 Hz 8 Amps 20kHz 20242XC0P3 2400 200 240V 50 60 Hz 15 ...

Page 118: ...stem with Time and Energy 20242XC0P5 iQ Integrated 20kHz 2400 W 240V System with Time Distance and Energy Table 11 V Model Number Descriptions Ultrasonic Pressure Ultrasonic Pressure iQ Generator Models kHz 20 Useful Beam 360 degrees Ultrasonic Pressure Operator s Position dB 140 Ultrasonic Pressure 1 m from the Equipment dB 130 Table 11 VI iQ Generator Ultrasonic Pressure NOTE All measurements ta...

Page 119: ... unavailable Table 11 VII System Replacement Parts System Replacement Parts Part Number Part Description Model 43i220 430 03 0026 iQ main valve assembly X 804 33 Primary air cylinder 2 1 2 bore X 7 X 804 52 Air pressure regulator X 804 63 Counter balance air cylinder 9 16 bore X 11 X 625 37 Optical distance encoder when optional encoder feature is installed X Repair Parts List Dukane recommends th...

Page 120: ...EMC Directive 2014 30 EU 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 2014 35 EU The Machinery Directive 2006 42 EC EN 60204 Safety of Machinery Electrical Equipment of Machines Part 1 General Requirements EN ISO 12100 Safety of machinery General principles of de...

Page 121: ...SECTION 12 Appendices Appendix A List of Figures 115 Appendix B List of Tables 118 Page 113 Dukane Manual Part No 403 594 02 Section 12 Appendices ...

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Page 123: ...12 Flange Template 32 4 1 Front Panel Controls 35 4 2 Display Detail Operating Mode Indicator 36 4 3 Display Detail Power Output Level 36 4 4 Navigation Keys 4 with Enter Info and Cancel 37 4 5 Info Menu Display 37 4 6 Active Soft Keys Example 37 4 7 Display Detail Power Output Level 39 4 8 Making Selections 40 4 9 Arrows Indicate Direction of More Text 40 4 10 Press Controls and Indicators Front ...

Page 124: ...55 5 16 Weld Menu Mode Manual Automated Press Distance Not Supported 56 5 17 Weld Menu Mode Manual Automated Press Energy Selection 56 5 18 Weld Menu Mode Manual Automated Press Distance Is Supported 56 5 19 Weld Menu Mode Manual Automated Press Energy Entry 56 5 20 Post Weld Menu 57 5 21 Post Weld Menu Time Setting 57 5 22 Post Weld Menu Afterburst Disabled 57 5 23 Post Weld Menu Afterburst Enabl...

Page 125: ... Encoder Mounting 76 6 4 Distance Encoder Alignment 77 7 1 Stack Components 82 7 2 Stack Removal 83 7 3 Disassembling Components 84 7 4 Tip Removal 84 7 5 Assembling Components 85 7 6 Tip Assembly 86 7 7 Stack Installation 86 7 8 Fixture Base Layout 87 7 9 Loosening the Hold Down Cap Screws and Jack Screws 88 7 10 Tightening the Hold Down Cap Screws and Jack Screws 88 8 1 Example of Burnished Area...

Page 126: ... Tip Torque Values 86 11 I Weights 110 11 II Dimensions 110 11 III Clamping Pressure 111 11 IV AC Power Requirements 111 11 V Model Number Descriptions 112 11 VI iQ Generator Ultrasonic Pressure 112 11 VII System Replacement Parts 113 11 VIII Repair Parts 113 Page 118 iQ Series Ultrasonic Integrated Press System i220 User s Manual Dukane Manual Part No 403 594 02 List of Tables No Description Page...

Page 127: ...SECTION 13 Index Page 119 Dukane Manual Part No 403 594 02 Section 13 Index ...

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Page 129: ... Base Connector 25 Controls 33 Generator Front Panel Controls Hot Keys 38 Navigation Keys 37 Power On Light 39 Soft Keys 37 System Operating Mode Keys 36 System Power Output Level 39 Manual Thruster Controls Down Speed Adjustment 41 Press Controls 41 Press Ergonomic Base 45 Emergency Stop Abort Switch 46 Screen Basics 40 Interpreting On screen Arrows 40 Thruster Indicators Mechanical Stop Indicato...

Page 130: ...tilities 16 Installing the Press System 17 Placement 17 Press Height Adjustment 29 Without Machine Base 30 Introduction 1 General User Information 3 Key Generator Features 4 Press System Overview 4 IP International Protection Rating 114 L List of Figures 117 M Maintenance Six Month Periodic Maintenance 99 Menus 51 N Navigation Keys 37 Notes Cautions and Warnings 3 O Operate TEST 61 Using the Menus...

Page 131: ...ys 37 Specifications 105 AC Power Requirements 111 Compressed Air Requirements 111 Dimensions 110 Electric Schematic 220 109 Layout 220 Thruster 107 Operating Environment 110 Pneumatic Schematic All iQ LE Presses 108 Ultrasonic Pressure 112 Weights 110 Stack Maintenance 91 Inspection of the Acoustic Stack Components 93 Reconditioning Stack Components 94 Stopping the Weld Cycle 50 System Freq Limit...

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Page 133: ...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 134: ...r local representative Part No 403 594 02 Dukane Intelligent Assembly Solutions 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949 iQ Series Ultrasonic Integrated Press System i220 User s Manual Printed in the United States of America www dukane com us ...

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