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Dukane iQ Series, User Manual

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Intelligent Assembly Solutions

www.dukane.com/us

ISO 9001:2008

Dukane products are manufactured 

in ISO registered facilities.

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

Dukane Part No. 403 

– 

575 

– 

00

Series

ULTRASONIC GENERATOR/POWER SUPPLY

ES

User's Manual

      AUTOMATED  HAND PROBE       

PRESS

Summary of Contents for iQ Series

Page 1: ...s are manufactured in ISO registered facilities Dukane Intelligent Assembly Solutions 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949 Dukane Part No 403 575 00 Series ULTRASONIC GENERATOR POWER SUPPLY ES User s Manual AUTOMATED HAND PROBE PRESS ...

Page 2: ...on 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...

Page 3: ...Revision History Revision Revision Number Summary Date 00 Original release 08 19 2011 Page iii Dukane Manual Part No 403 575 00 ...

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Page 5: ...nstallation 13 Unpacking 15 Placement 15 Placement in a Seismic Region 16 Rear Panel Layout Overview 18 RFI Grounding 28 Connecting Cables 29 Networking 37 Recheck Connections 37 Connect AC Power 37 Section 4 Operation 39 Overview 41 Start up 41 Stopping the Weld Cycle 42 iQ Explorer Support Features 42 Numeric Pad and Keypad 42 Help System 43 Quick Start Servo Welder 44 55 Quick Start Pneumatic W...

Page 6: ... Specifications 107 Outline Drawings 109 Weights Dimensions Operating Environment 112 AC Power Requirements 113 Interpreting the Model Number 114 Regulatory Agency Compliance 115 Section 11 Appendices 117 Appendix A List of Figures 119 Appendix B List of Tables 122 Index 123 Page vi iQ Series Ultrasonic Generator Power Supply ES User s Manual Dukane Manual Part No 403 575 00 ...

Page 7: ...SECTION 1 Introduction General User Information 3 Press System Overview 4 Key Features 4 Page 1 Dukane Manual Part No 403 575 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: ... maintained with any voltage input within the specified range This provides consistent system performance regardless of line voltage fluctuations It also eliminates the need for bulky external constant voltage transformers Load Regulation provides constant ultrasound amplitude automatically regardless of power draw The ultrasonic output amplitude level is held to within 1 to provide weld process c...

Page 11: ...ety General Considerations 7 Plastics Health Notice 8 Electrical Safety 9 Domestic Power Grounding 9 International Power Grounding 9 Lifting the Equipment 10 Page 5 Dukane Manual Part No 403 575 00 Section 2 Health and Safety ...

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Page 13: ...tack System Abort Switch Install a system abort switch at each operator station when ultrasonic plastic assembly equipment is used with automatic material handling equip ment in an automated system Foot Switch Using a foot switch in place of the optical touch finger switches activation switches violates OSHA regulations NOTE These recommendations apply to the welding system System in this manual r...

Page 14: ...s Wear ear protectors to reduce annoying or uncomfortable sounds In addition ultrasound baffles sound enclo sures or materials that absorb sound may be located to surround the system WARNING Keep head hands limbs and body at least six inches 152 mm away from an operating press thruster A vibrating descending horn can cause burns and or crushing injuries CAUTION When making cable connec tions to sy...

Page 15: ...apply 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 compat...

Page 16: ... object below the level of your waist follow the same procedures in re verse order Remember keep your back as vertical as possible and bend at the knees Lifting the Equipment 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 sl...

Page 17: ...nt in a Seismic Zone 16 Rear Panel Layout Overview 18 AC Power Inlet Panel 19 System I O Panel 19 Ultrasound Output Connector 27 Configuration Port Connector 27 RFI Grounding 28 Connecting Cables 29 Networking 37 Recheck Connections 37 Connect AC Power 37 Page 11 Dukane Manual Part No 403 575 00 Section 3 Installation ...

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Page 19: ... 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 Continued Figure 3 1 Lockout Device In Open Position Unlocked Figure 3 2 Bottom Lockout Device In Closed Position Locked WARNING Electrical safety hazards exist...

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

Page 21: ... circulation Allow space between 3 6 inches 8 15 cm at the rear of the chassis for cable clearance The amount of space depends on the chassis type and what rear panel connections there are See Section 10 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 ...

Page 22: ...re 3 4 Rack Mounting iQ Generator System Type Dukane Part Number High Profile 147 4721 Low Profile 147 4720 Table 3 I Rack Mount Bracket Part Numbers 3 82 97 0 3 44 87 4 3 25 82 6 12 57 319 3 12 99 330 0 ALLOW 5 BOTH SIDES FOR COOLING ALLOW 5 BOTH SIDES FOR COOLING ALLOW 3 IN BACK FOR CABLES IN mm 0 25 X 0 50 SLOT 2 PLCS 18 76 476 5 18 16 461 2 17 16 435 9 OPTIONAL RACK MOUNT BRACKETS 147 4720 11 ...

Page 23: ...of each bracket to the bench itself Figure 3 5 Securing iQ Generator to Benchtop 12 54 318 52 0 280 HOLE 18 04 458 22 18 84 478 47 OPTIONAL HOLD DOWN BRACKETS OPTIONAL HOLD DOWN BRACKETS 147 1398 ALLOW 5 BOTH SIDES FOR COOLING IN mm ALLOW 3 IN BACK FOR CABLING 5 50 139 7 ALLOW 5 BOTH SIDES FOR COOLING 5 19 131 83 17 16 435 86 13 20 335 28 1 40 35 6 1 14 29 0 10 00 254 0 Continued from previous pag...

Page 24: ...to modify system parameters Figure 3 6 Generator Rear Panel Pneumatic Press Thruster Options Module Panel H Communications board Shown in the example above are these ports J9 Ethernet and J10 Serial RS232 K Press interface board 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 IN...

Page 25: ... If when resetting the circuit breaker after it has tripped it imme diately 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 System Inputs Connector The SYSTEM ...

Page 26: ...or coding for the system input cable is listed in Table 3 II to assist with custom automation system wir ing and assembly NOTE Refer to Section 8 Options for information on optional features Figure 3 8 System I O Panel standard panel shown 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 i...

Page 27: ...Requirements 1 22V BLK 2 Power Ground WHT 3 Remote Setup Selection Bit 0 Input RED 4 Remote Setup Selection Bit 1 Input GRN 5 Remote Setup Selection Bit 2 Input ORN 6 Remote Setup Selection Bit 3 Input BLU 7 Remote Setup Selection Bit 4 Input WHT BLK 8 Ultrasound Activation Cycle Start Input RED BLK 9 Not Used GRN BLK Not Used 10 Front Panel Control Lock Input ORN BLK Not Used 11 Press Inhibit for...

Page 28: ...edly start a welding cycle that activates a press or thruster to the down position The hand probe cable connector is wired to apply chassis ground to this pin when it is attached to the system which activates a press inhibit relay that disconnects power from the pneu matic press valves This pin must be left open whenever a press control board is installed Connecting this pin to chassis ground will...

Page 29: ... Status Output WHT BLK RED 24 Isolated Common RED BLK WHT 25 Not Used GRN BLK WHT Table 3 III System Output Connector Signals J3 Figure 3 11 DB 25F Generator Output Connector J3 Figure 3 12 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 con...

Page 30: ...DC at up to 250mAto power the user s automation controls Pin 2 Not Used Pin 2 is an open connection Pin 3 22V Power Ground Pin 3 is the 22VDC return and is tied to the system chassis ground Pin 4 Programmable Status Output 1 Pin 4 is a digital active low status output that can be reprogrammed and assigned to other system status sig nals from the available selections from the System tab in iQ Explo...

Page 31: ...mon ground connection for all of the analog monitor signals on Pins 15 and 16 This signal common pin is connected to system chassis ground and is not isolated from the generator chassis This is an analog signal ground connection Do not connect anything to this ground connection except the wiring to the inputs of the analog instrumentation devices used to measure the monitor output signals Pin 14 N...

Page 32: ...be an open circuit when a bad part has not been detected Pin 21 Good Part Status Output Pin 21 is a digital active low status output that activates either momentarily or until the start of the next welding cycle when the welding parameters recorded during the previous welding cycle do not exceed the programmed suspect or bad part limits This output will be an open circuit after a welding cycle whe...

Page 33: ... and will destroy the ultrasound connectors Do not use your generator if there is any evidence of arcing black carbon deposits on either the ultrasound output connector or the ultrasound cable connectors Configuration Port Connector The configuration port connector is a DB 9M standard D subminiature 9 circuit male typically used for RS 232 serial communications This serial port DTE connects to a s...

Page 34: ...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 the grounds Earth Gro...

Page 35: ...0 Connects to the PC RS 232 port Step 7 Base Abort Cable J6 Connects to the press base plate connector J35 or an automation PLC Step 8 Connect the AC power cord to the IEC power inlet connector on the ultrasonic generator and plug the other end into an approved AC outlet Power Cords The AC line cords supplied with the standard generators are matched to the ultrasonic output power rating and the co...

Page 36: ... press thruster 2 With a remote controller and a servo press thruster 3 With a servo press thruster Diagrams and tables that follow show these three configurations and list the cables used respectively Page 30 iQ Series Ultrasonic Generator Power Supply ES User s Manual Dukane Manual Part No 403 575 00 ...

Page 37: ... CONFIGURATION ULTRASOUND SYSTEM OUTPUTS SYSTEM INPUTS J2 J3 PE LINE VOLTAGE 200 240 Vac 50 60Hz 15A U S PATENT 5 880 580 OTHER PATENTS PENDING POWER LINE OUTLET 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 J8 BASE ABORT J9 THRUSTER J11 ENCODER 1 2 3 4 10 11 12 5 6 7 8 Automation Equipment 9 Earth Ground ...

Page 38: ... of the following 200 1110 240 VAC 15A US 200 1111 240 VAC 16A Europe 200 1612 240 VAC 15A India 200 1541 240 VAC 10A US 200 1542 240 VAC 10A Europe 200 1624 240 VAC 10A India for 120 VAC models power cord is integral to generator 2 4 AC INPUT 8 200 1557 5 PE 9 200 1557 5 GRND 10 200 1557 5 PE 11 200 1380 XXM XX J2 12 200 1381 XXM XX J3 Continued from previous page Continued Pneumatic Press Thrust...

Page 39: ... CHARLES IL 60174 MADE IN U S A DUKANE 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 J15 THRUSTER J6 BASE ABORT J11 ENCODER J9 J1...

Page 40: ... 10A US 200 1542 240 VAC 10A 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 10...

Page 41: ...GE 200 240 Vac 50 60Hz 15A U S PATENT 5 880 580 OTHER PATENTS PENDING POWER LINE OUTLET 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 J15 THRUSTER J11 ENCODER 1 2 3 4 10 11 13 12 5 6 7 8 Automation Equipment 9 Earth Ground Page 35 Dukane Manual Part No 403 575 00 Section 3 Installation ...

Page 42: ...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 models power cord is integral to generator 2 4 AC INPUT 9 200 1...

Page 43: ...ne Configuration Unique IP Address and Connection to 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 Page 37 Dukane Manual Part No 403 575 00 Sec...

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Page 45: ...w 41 Start up 41 Stopping the Weld Cycle 42 iQ Explorer Support Features 42 Numeric Pad and Keypad 42 Help System 43 Quick Start Servo 44 55 Quick Start Pneumatic 56 69 Page 39 Dukane Manual Part No 403 575 00 Section 4 Operation ...

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Page 47: ...stack and any tooling are adjusted as necessary For additional information about the other key Dukane components of the system see these User Manuals iQ Explorer Part No 403 579 00 and iQ Press System ES Part No 403 569 00 Start up The main power switch for the iQ Series generator is found on the generator s rear panel When that switch is in the ON position the front panel power button is RED stan...

Page 48: ...ess the button so that the light goes out In addition you may push the power switch on the generator s rear panel to the OFF position Figure 4 2 iQ Explorer Numeric Pad NOTE iQ Explorer provides a touch screen numeric pad and a keyboard for easy parameter entry Select c for the keyboard Select c for the numeric pad Figure 4 2 shows the numeric pad 1 A iQ Explorer Support Features Two support featu...

Page 49: ... Control 3 Process Limits 4 Graph 5 Utilities 6 System 7 Options The Index is an alphabetical list of words and phrases Figure 4 4 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 l...

Page 50: ...anual Section 4 Operation Icon indicates connection has been made Name of the connected welder Figure 4 5 iQ Explorer Start up Figure 4 6 iQ Explorer Start up Hardware Tab Servo Step 2 Hardware Tab 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 4 6 below Hardware Tab Pneumatic W...

Page 51: ...l See Figure 4 8 Figure 4 8 iQ Explorer Process Settings Initiate Mode NOTE This Initiate Mode selection as sumes there is a stand alone benchtop system with manual acti vation switches Select Manual in Initiate Mode Servo Step 3 Navigate to the Process Settings Tab Page 45 Dukane Manual Part No 403 575 00 Section 4 Operation ...

Page 52: ...32 42 lbs of trigger force A 20 inch linear weld may require between 52 70 lbs of trigger force See Figure 4 10 Initial Trigger Force Settings Figure 4 9 iQ Explorer Process Settings Trigger Type Force Max Trigger Time Servo Step 5 Process Settings Trigger Type Figure 4 10 Suggested Initial Trigger Force Setting Page 46 iQ Series Ultrasonic Generator Power Supply ES User s Manual Dukane Manual Par...

Page 53: ... Servo Step 6 Program Sensing Speed See Figure 4 11 Sensing Start Distance is the actual position in the machine travel where motion changes to Sensing Speed To program this distance you must know how far the horn travels to come in contact with the top of the part to be welded If you do not know this position where this contact is made select the Teach button See Figure 4 12 on the next page Sens...

Page 54: ...x Once you are at the desired position press Set to program that distance Select Exit and follow instruc tions to Home the machine Figure 4 13 iQ Explorer Select Trigger Method Select Trigger Method Normal Figure 4 12 iQ Explorer Teach Start Sensing Distance Servo Step 9 Select Trigger Method Still on the Process Settings tab select Normal as the trigger method Servo Step 8 Teach Start Sensing Dis...

Page 55: ...rocess Settings tab See Figure 4 15 This patented feature is found only on Dukane s servo press systems If the feature is selected the system will stop motion once the desired Trigger Force is achieved The ultrasound will be initiated at this moment Once the programmed force drop is detected the motion will continue This is the basis for Dukane s exclusive Melt Match technology Figure 4 15 iQ Expl...

Page 56: ...smetic appearance See Figure 4 17 where Profile was selected as the Motion Type This feature allows creating a speed mo tion profile during the weld cycle The speed motion profile can be created to match the actual melt collapse of the weld joint Figure 4 17 iQ Explorer Speed Motion Type Profile Optimizing the Feature The easiest way to make best use of this feature is to optimize the power draw t...

Page 57: ...amplitude setting is 100 The range for this fea ture is between 20 and 100 Figure 4 19 iQ Explorer Amplitude Setting Typical amplitude setting is 100 Range is between 20 and 100 Continue with Post Weld settings on the next page Page 51 Dukane Manual Part No 403 575 00 Section 4 Operation ...

Page 58: ...ethod During Dynamic Hold with Collapse Distance enabled the actuator will continue to travel the programmed col lapse Distance at the programmed speed with the ultra sound signal turned off This occurs immediately after the weld phase This unique feature provides the ability to collapse the molten plastic after the ultrasonic signal is turned off before material solidification This feature can be...

Page 59: ... overall 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 4 21 below Figure 4 21 iQ Explorer Process Settings Post Weld Static Hold Method Continued from previous page Servo Step 15 Test the Acoustic Stack Run a test of the acoustic stack Please go to Section 5 of this Use...

Page 60: ...will be displayed on the Cycle Data screen and this will be important for future diagnostics of the welder setup Servo Step 16 Navigate to the Process Limits Tab Page 54 iQ Series Ultrasonic Generator Power Supply ES User s Manual Dukane Manual Part No 403 575 00 Figure 4 22 iQ Explorer Process Limits Tab Process Limits Tab ...

Page 61: ...en programmed initiate the weld cycle View the results at the Cycle Data tab to insure all parameters have been achieved See the example shown below in Figure 4 23 Figure 4 23 iQ Explorer Cycle Data Page 55 Dukane Manual Part No 403 575 00 Section 4 Operation ...

Page 62: ...l Servo Welder Quick Start See Pages 44 55 Pneumatic Welder Lab Page 56 iQ Series Ultrasonic Generator Power Supply ES User s Manual Dukane Manual Part No 403 575 00 Icon indicates connection has been made Name of the connected welder Figure 4 24 iQ Explorer Start up Dukane iQ Explorer Welder 1 Figure 4 25 iQ Explorer Start up Hardware Tab Pneumatic Step 2 Hardware Tab After moving to the Hardware...

Page 63: ...ld process Figure 4 26 shows the Welder Type selection Figure 4 26 iQ Explorer Process Settings Welder Type Select Press Pneumatic Step 4 Process Settings Initiate Mode Manual NOTE This Initiate Mode selection as sumes there is a stand alone benchtop system with manual acti vation switches Figure 4 27 iQ Explorer Process Settings Initiate Mode Manual Select Manual Pneumatic Step 3 Process Settings...

Page 64: ...le cycle time from weld initiation until the welder develops the programmed force Max Trigger Time will time the cycle out should the machine for some reason not reach its programmed force value Compensation Point For a basic setup this value can be programmed at zero Typically force values above 10 pounds are programmed at zero See Figure 4 29 on the next page Continued Page 58 iQ Series Ultrason...

Page 65: ...ow shows Trigger Type and the other example values discussed on the previous page Figure 4 30 iQ Explorer Process Settings Trigger Method Trigger Method In the programming example here we have chosen Normal Figure 4 30 below shows this selection Page 59 Dukane Manual Part No 403 575 00 Section 4 Operation Lab Dukane iQ Explorer Welder 1 Setup 4 ...

Page 66: ...ety If the programmed parameter is not achieved as in the example shown in Figure 4 31 within 2 000 seconds the system will terminate the weld process NOTE If the energy director or shear joint collapse value can not be determined See Figure 4 32 and use Time as the initial basic setup Figure 4 32 Suggested Initial Weld Time 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 1 4 1 3 1 2 1 1 95 90...

Page 67: ...ple setup Collapse Distance has a programmed value the welder will shut off the ultrasound signal and continue to apply force for the programmed time This phase is important to insure the molten plastic cre ated during the weld phase has a chance to solidify before pressure is removed from the part Continued Process Settings Post Weld Hold Method Page 61 Dukane Manual Part No 403 575 00 Section 4 ...

Page 68: ... See Table 4 I and Figure 4 35 NOTE Downstroke pressure must be pro grammed so that enough force will be available to achieve the programmed Trigger Force If there is not enough downstroke pressure it may cause the system to fault at Max Trigger Time Continued Figure 4 35 Suggested Initial Weld Force 500 450 400 360 340 320 300 280 260 240 220 200 180 160 140 120 100 80 60 40 20 0 2 4 6 8 10 12 14...

Page 69: ...27 47 74 106 20 35 63 98 141 25 44 79 123 177 30 53 94 147 212 35 62 110 172 247 40 71 126 196 283 45 80 141 221 318 50 89 157 246 354 55 97 173 270 389 60 106 188 295 424 65 115 204 319 460 70 124 220 344 495 75 133 236 368 530 80 142 251 393 566 85 150 267 417 601 90 159 283 442 636 95 168 298 466 672 100 177 314 491 707 105 186 330 516 742 110 195 345 540 778 between Dukane Air Cylinders Page 6...

Page 70: ...am Hold Pressure at 10 psi above Weld Pressure See Figure 4 34 Upstroke Pressure This pressure is applied at the end of the Hold time This is the air pressure that drives the air cylinder to move the system back to its home posi tion Upstroke pressure has little or no effect on weld results However overall cycle time is affected by upstroke travel time For a basic weld setup program Upstroke Press...

Page 71: ...t of the horn s nominal amplitude in the range of 20 to 100 Select Local Then at Weld select 100 For a basic setup leave Ramp Up Time and Ramp Down Time at 0 150 and 0 000 respectively the default settings See Figure 4 36 below NOTE Default settings for Ramp Up Time and Ramp Down Time are dependent on the frequency of the welding system Page 65 Dukane Manual Part No 403 575 00 Section 4 Operation ...

Page 72: ... or by one or more secondary controls Secondary control is not typically needed for basic setup See Figure 4 37 below Figure 4 37 iQ Explorer Process Settings Secondary Control Pneumatic Step 13 Test the Acoustic Stack Run a test of the acoustic stack Please go to Section 5 of this User s Manual System Op erational Testing where the system test procedures are outlined Page 66 iQ Series Ultrasonic ...

Page 73: ...your selected setup the status for each parameter will be blank See Figure 4 38 below Figure 4 38 iQ Explorer Process Limits Tab I Pneumatic Step 14 Process Limits Tab Continued Page 67 Dukane Manual Part No 403 575 00 Section 4 Operation Lab Dukane iQ Explorer Welder 1 Setup 4 ...

Page 74: ... the Cycle Data screen and this will be important for future diagnostics of the welder setup Figure 4 39 shows a typical basic setup with several parameters selected Pneumatic Step 14 Process Limits Tab Continued from previous page Page 68 iQ Series Ultrasonic Generator Power Supply ES User s Manual Dukane Manual Part No 403 575 00 Lab Dukane iQ Explorer Welder 1 Setup 4 ...

Page 75: ...nd bottom parts of the Cycle Data page Because all of the parameters will not fit on one page move the scroll bar right and or left at the bottom to view the entire set of weld parameters NOTE Use the scroll bar at the bottom of the Cycle Data screen to display all of the parameters The bar moves the screen image right and left because a typical display will not show the entire set of parameters a...

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Page 77: ...ECTION 5 System Operational Testing Overview 73 Operational Test of the Acoustic Stack 74 Procedure for Cycling the System 77 Page 71 Dukane Manual Part No 403 575 00 Section 5 System Operational Testing ...

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Page 79: ...tional characteristics of the stack being driven When the ultrasound turns on during each operating sequence the Digi Trac circuit monitors the motion of the stack on a frequency cycle by cycle basis and adjusts the ultrasound signal for the optimum setting Because the Digi Trac continuously monitors each operat ing sequence it compensates for vibrational changes that occur during repeated operati...

Page 80: ...he horn is not under load not in contact with a fixture or part e Verify that the REAR panel AC switch is ON The front panel AC button should be RED 2 Push the generator front panel power button to ON The power button will start to flash RED on and off for LESS THAN 20 seconds It will then turn GREEN This indicates that the system is operating If the power button display stops flashing but re main...

Page 81: ...ts displayed on the graph after the test is between 10 and 20 percent of the power supply s available output The vibration amplitude of the horn and booster and the mass of the horn determine the amount of energy needed to vibrate the stack If the system passes the tests of these four steps proceed to the section called Procedure for Cy cling the System on the next page If one or more of these tes...

Page 82: ...nd applications See Figure 5 4 Consult Dukane Corporation before making adjustments to these settings Figure 5 4 iQ Explorer System 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 ...

Page 83: ...s detailed on Page 74 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 Cycle the system Activate both opti touch switches at the same time to start the system and hold fingers in place until the ultrasound starts Releasing the fingers before ultrasound starts will abort the cycle Page 77 Dukane...

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Page 85: ...SECTION 6 Troubleshooting Page 79 Dukane Manual Part No 403 575 00 Section 6 Troubleshooting ...

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Page 87: ...hing Red AC line over under voltage de tected or internal power supply failure Continued NOTE If troubleshooting does not provide satisfactory re sults please contact Dukane Corporation see Sec tion 9 Contacting Dukane for servicing The iQ ES generator and iQ Explorer are serviceable only by Dukane personnel Unauthorized attempts to service either product will void any warranty See the error messa...

Page 88: ...Amplifier Error Checksum Error Command Error Down Travel Limit Force Duration Exceeded Position Error Servo Error Trigger Sensing start Distance Up Travel Limit See specific error type below See specific error type below Amplifier Error Error occurred with servo amplifier Faulty wiring or damaged amplifier 1 Restart press system 2 Contact DUKANE service Checksum Error Servo controller hardware err...

Page 89: ...eck stack 1 Component failure in the stack 2 Improper stack assembly 3 Incorrect Advanced Hardware settings 1 Check functionality of stack components 2 Disassemble and reassemble stack 3 Check the generator s Advanced Hardware settings Over temperature fault Generator s internal temperature ex ceeds 158º F 70º Celsius 1 Welder duty cycle is too large 2 Weld hold times or forces are too large 3 Thr...

Page 90: ...dam aged 1 Reduce cycle rate 2 Change setup to reduce weld hold forces or decrease weld duration 3 Check if fan is obstructed contact DUKANE service for replacement 4 Contact DUKANE service Overload frequency at xxx msecs Check stack cable or validate ramp up time Generator is unable to lock to the reso nant frequency of the ultrasonic stack 1 Improper stack assembly 2 Defective ultrasound cable 3...

Page 91: ...tance To verify the distance feature go to the Utilities page of iQ Explorer Put a check in the box p for Monitor Encoder Position in order to view the encoder position To check encoder function either remove air pressure from the press or depress the Emergency Stop switch that is grouped with the activation switches As the thruster head moves up or down the displayed value changes The value shoul...

Page 92: ...s force exerted on the part and controls when the ultrasound signal is applied Check the force transducer by looking at the FORCE measurement on the View Parameters menu The measurement should change when upward pressure is applied to the acoustic stack 1 On the Process Settings page select FORCE as the Trigger Type and make sure Trigger Method is Normal 2 Enter a FORCE value perhaps 10 lbs for pu...

Page 93: ... was not interrupted by any I O signal or system error The setup conditions for this process were as follows Normal Trigger Weld by Time for 50 ms Hold by Time for 1 0 sec PART DOWNSTROKE DOWNSTROKE WELD TIME WELD DIST WELD ENERGY HOLD TOTAL TOTAL COUNT TIME DIST PRESSURE 1 PRESSURE 1 PRESSURE 1 TIME CYCLE TIME STROKE 35 0 975 1 7921 0 050 0 0023 28 4 1 000 2 025 1 8090 36 0 879 1 7927 0 050 0 002...

Page 94: ...d the cycle terminated and marked the part as Bad PART DOWNSTROKE DOWNSTROKE WELD TIME WELD DIST WELD ENERGY HOLD TOTAL TOTAL COUNT TIME DIST PRESSURE 1 PRESSURE 1 PRESSURE 1 TIME CYCLE TIME STROKE 12 0 500 0 3462 0 0 0 0 0 500 0 3462 Figure 6 3 Cycle Terminated by High Bad Limit During Downstroke When using pre trigger part contact must occur within 0 75 inch after the application of ultrasound I...

Page 95: ...1 TIME CYCLE TIME STROKE 55 0 882 1 7928 0 015 0 0006 6 5 1 000 1 897 1 8094 Figure 6 5 Weld Termination Due to End of Weld Ground Detect Weld Termination Due to Trigger Lost If the trigger type is set to Maintained loss of the trigger signal causes an immediate termination of the cycle when the ultrasound is applied This results in a shortened weld and zeroes for both HoldTime and Hold Distance F...

Page 96: ...igure 6 7 shows the results using Weld Energy as a secondary control PART DOWNSTROKE DOWNSTROKE WELD TIME WELD DIST WELD ENERGY HOLD TOTAL TOTAL COUNT TIME DIST PRESSURE 1 PRESSURE 1 PRESSURE 1 TIME CYCLE TIME STROKE 3 0 999 1 7915 0 037 0 0024 20 3 1 000 2 036 1 8089 4 0 944 1 7919 0 038 0 0024 20 9 1 000 1 982 1 8089 5 0 906 1 7922 0 038 0 0021 20 9 1 000 1 944 1 8090 Figure 6 7 Weld Segment Ter...

Page 97: ...uitry is operating No Ultrasound To verify that the generator is producing an ultrasonic signal use the acoustic stack test procedure described in Section 5 System Opera tional Testing Verify at the Utilities page that the OFFLINE box is empty not checked Verify pressure settings Review the program There should be aWeld Time P1 and Weld Time P2 if dual pressure is used Set the weld characteristic ...

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Page 99: ...SECTION 7 Maintenance Page 93 Dukane Manual Part No 403 575 00 Section 7 Maintenance ...

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Page 101: ...ge even after the power is shut off Air Ventilation Slots Keep the ventilation 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 Thi...

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Page 103: ...ower Ground 99 AC Power Inlet Panel 100 AC Power Cord 100 Power Switch Circuit Breaker 100 Chassis Ground Stud 100 Press Interface Board 101 P4 Dual Pressure Only 101 P5 Dual Pressure with Distance 101 P6 EPR Load Cell with Distance 101 P7 Servo Board 101 Page 97 Dukane Manual Part No 403 575 00 Section 8 Options ...

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Page 105: ...nt to NEMA 5 15R or 5 20R Figure 8 1 Example of 120 Volt Grounded 3 Prong Receptacle CAUTION If there is any question about the grounding of your recep tacle have it checked by a qualified electrician Do not cut off the power cord ground ing prong or alter the plug in any way If an extension cord is needed use a three wire cord that is in good condition The cord should have an adequate power rat i...

Page 106: ...ircuit 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 and the generator will require service Do not repeatedly try to reset the circuit breaker If it trips this will only cause more...

Page 107: ...on resolu tion to insure exceptional precision and repeatability P6 EPR Load Cell with Distance P N 110 4428 This option offers programmable pressure profiling and force by interfacing with the EPR electronic pressure regulator pressure transducer and load cell Increased control repeatability and consistency are benefits The electronic pressure regulator and pressure transducer are components of t...

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Page 109: ...SECTION 9 Contacting Dukane Page 103 Dukane Manual Part No 403 575 00 Section 9 Contacting Dukane ...

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Page 111: ...cated 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 113: ...rator Outline Drawings 109 Weights Dimensions Operating Environment 111 AC Power Requirements 113 Interpreting the Model Number 114 Regulatory Agency Compliance 115 Page 107 Dukane Manual Part No 403 575 00 Section 10 Specifications ...

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Page 115: ...PTIONS CARDCAGE PANELS ALLOW 3 IN BACK FOR CABLING ALLOW 5 EACH SIDE FOR COOLING ALLOW 5 EACH SIDE FOR COOLING IN mm 3 81 96 8 3 45 87 53 17 16 435 77 13 23 335 92 12 55 318 67 OPTIONAL FRONT POWER SWITCH WEIGHT 20 LBS Page 109 Dukane Manual Part No 403 575 00 Section 10 Specifications ...

Page 116: ...LING 5 50 139 78 ALLOW 5 BOTH SIDES FOR COOLING 5 19 131 83 17 16 435 76 13 20 335 37 12 54 318 61 OPTIONAL FRONT POWER SWITCH WEIGHT 25 LBS AC POWER ENTRY ULTRASOUND SYSTEM I O S OPTIONS CARDCAGE PANELS Page 110 iQ Series Ultrasonic Generator Power Supply ES User s Manual Dukane Manual Part No 403 575 00 ...

Page 117: ...S OPTIONAL I O CONNECTION SLOTS AC POWER INLET CORD 6 29 159 8 5 19 131 8 5 50 139 7 14 51 368 5 3 15 80 0 17 16 435 8 ALLOW 6 150mm BEHIND UNIT FOR CABLE CONNECTIONS ALLOW 2 50mm ON SIDES FOR COOLING AIR FLOW IN mm Page 111 Dukane Manual Part No 403 575 00 Section 10 Specifications ...

Page 118: ...del Height Width Depth Low Profile 3 45 87 5 17 16 435 7 12 55 318 7 High Profile 5 19 131 8 17 16 435 7 12 55 318 7 High Power 5 19 131 8 17 16 435 7 14 51 368 5 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 1270 mm for air flow and cable connections High Profile Low Profile High Power...

Page 119: ...ps 20kHz 20HS180 2A XX XX 1800 200 240V 50 60 Hz 12 Amps 20kHz 20HS240 2A XX XX 2400 200 240V 50 60 Hz 15 Amps 20kHz 20HS360 2A XX XX 3600 200 240V 50 60 Hz 25 Amps 30 Amps 20kHz 20HS480 2A XX XX 4800 200 240V 50 60 Hz 30 Amps 30kHz 30HS090 1A XX XX 900 100 120V 50 60 Hz 8 Amps 15 Amps 30kHz 30HS090 2A XX XX 900 200 240V 50 60 Hz 8 Amps 30kHz 30HS120 1A XX XX 1200 100 120V 50 60 Hz 15 Amps 30kHz 3...

Page 120: ... 30 kHz 40 40 kHz 50 50 kHz Chassis Style HS iQ Series Ultrasonic Press System ES P4 Dual Pressure Only P5 Dual Pressure w Distance P6 EPR Load Cell w Distance P7 Servo Options Slot Board Communications Board The example model number shown here is 20HS120 2A P6 C2 This means A 20kHz generator rated for 1 200 watts horizontal bench 3 5 tall chassis operating on a 200 240 VAC line designed for time ...

Page 121: ...ng interference causing equipment regulations CE stands for Conformité Europeéne European Conformity The equipment complies with the following CE requirements T h e E M C D i r e c t i v e 2 0 0 4 1 0 8 E C for Heavy Industrial EN 61000 6 4 2001 EN 55011 2003 EN 61000 6 2 2001 EN61000 4 2 EN61000 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN61000 4 8 EN61000 4 11 The Low Voltage Directive 2006 95 EC ...

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Page 123: ...SECTION 11 Appendices Appendix A List of Figures 119 Appendix B List of Tables 122 Page 117 Dukane Manual Part No 403 575 00 Section 11 Appendices ...

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Page 125: ... Cable Connector 25 3 13 Ultrasound Output Connector 27 3 14 Configuration Port Connector 27 3 15 iQ Generator and Pneumatic Press Thruster Connection Diagram 31 3 16 iQ Generator Remote Controller and Servo Press Thruster Version 1 Connect 33 3 17 iQ Generator and Servo Press Thruster Version 2 Connection Diagram 35 4 1 Front Panel with Power Button 41 4 2 iQ Explorer Numeric Pad 42 4 3 Help from...

Page 126: ...ess Settings Initiate Mode 57 4 28 Suggested Initial Trigger Force 58 4 29 iQ Explorer Process Settings Trigger Type 59 4 30 iQ Explorer Process Settings Trigger Method 59 4 31 iQ Explorer Process Settings Weld 60 4 32 Suggested Initial Weld Time 60 4 33 iQ Explorer Process Settings Post Weld Hold Method Hold Time 61 4 34 iQ Explorer Process Settings Post Weld Pressure 62 4 35 Suggested Initial We...

Page 127: ...d Ground Detect 89 6 6 Weld Terminated Due to Trigger Lost 89 6 7 Weld Segment Terminated by a Secondary Control 90 6 8 Weld Segment Terminated by a Bad Part Limit 90 8 1 Example of 120 Volt Grounded 3 Prong Receptacle 99 8 2 120VAC Power Inlet Panel 100 10 1 Layout Low Profile iQ Generator 109 10 2 Layout High Profile Generator 110 10 3 Layout High Power iQ Generator 111 10 4 Interpreting the Mod...

Page 128: ...III System Output Communication Signals J3 23 3 IV Power Cords 29 3 V iQ Generator to Pneumatic Press Thruster Cables 32 3 VI Servo Press Thruster Version 1 Connections 34 3 VII Servo Press Thruster Version 2 Connections 36 4 I Pounds of Force Comparison Between Dukane Air Cylinders 63 6 I Error Messages Servo related 82 6 II Error Messages Pneumatic related 84 9 I iQ Generator Weights 112 9 II iQ...

Page 129: ...Index Page 123 Dukane Manual Part No 403 575 00 Index ...

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Page 131: ...uning 4 Flow Through Cooling Tunne 4 High Line Voltage Power Supply 4 ISO 9001 Certification 4 Linear Ramp Soft Start 4 Line Voltage Regulation 4 Load Regulation 4 Low Line Voltage Power Supply 4 Multiple Electronic Overload 4 Process Limits 4 Process Parameters 4 Pulse Width Modulation 4 Rear Panel Expansion Slot 4 RS232 Serial Configuration Port 4 Generator Outline Drawings 109 111 H Health and ...

Page 132: ...erminates During Downstroke 88 Premature Weld Termination 89 Process Limits Tab 54 67 Q Quick Start Pneumatic Welder 56 Air Cylinder Size 63 Cycle Data 69 Hardware Tab 56 Initiate Mode 57 Post Weld Settings 61 Hold Method 61 Process Limits Tab 67 Process Settings 57 60 Amplitude 65 Initial Weld Time 60 Pressure 62 Hold Pressure 64 Initial Weld Force 62 Upstroke pressure 64 Secondary Control 66 Tes...

Page 133: ...ystem Outputs Connector 23 System Outputs Signal Descriptions 24 System Power Output 74 System Tab 76 T TEST button 75 Testing Acoustic Stack 74 System Power Output 74 TEST button 75 Verifying Feature Operation 85 Distance 85 Electronic Pressure Regulator and the Pressure Transducer 86 Force Transducer Load Cell 86 Power 86 Test the Acoustic Stack 53 66 Troubleshooting 79 iQ Generator Won t Cycle ...

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Page 135: ... Infrastructure The ISO 9001 2008 standard establishes a minimum requirement for these requirements and starts transitioning the company from a traditional inspection oriented quality system to one based on partnership for continuous improvement This concept is key in that Du kane no longer focuses on inspection but on individual processes Dukane s quality management system is based on the followi...

Page 136: ...your local representative Part No 403 575 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 ES User s Manual Printed in the United States of America www dukane com us ...

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