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Dukane 403-574-01 manual

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Table of contents for the manual

  • Page 1

    ISO 9001:2008 Products ar e manufactured in ISO register ed facilities. Intelligent Assembly Solutions www .dukane.com/us Dukane Part No. 403-574-01 Series UL TRASONIC GENER A TOR/ POW ER SUP P L Y LS User ’ s Manual Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (63[...]

  • Page 2

    Page  ii Dukane Manual Part No. 403-574-01 Copyright © 2010 Notice of Rights: All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical, photocopying, recording, or by any information storage and retrieva[...]

  • Page 3

    Page  iii Dukane Manual Part No. 403-574-01 R e vi s io n Hist or y Revision Revision Number Summary Date - 00 Original release. 01/25/2008 - 01 Add High Power models. 09/21/2010 Update system I/O pin descriptions. Add T rigger by Power . Add iQ LinQ TM . W eb address revised. Revise Regulatory Agency Compliance statement. Health and Safe[...]

  • Page 4

    Page  iv Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 5

    Page  v Dukane Manual Part No. 403-574-01 Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General User Information Read the Manual First Notes, Cautions and W arnings Drawings and T ables Generator Overview Key Generator Features Section 2 - Health and Safety . . . . . . . . . . . . . . . . . . . .[...]

  • Page 6

    Page  vi Dukane Manual Part No. 403-574-01 Contents Continued Section 6 - Process Control Settings . . . . . . . . . . . . . . . . . 45 User-Provided Process Control Overview Manual W elding Automated W elding Automated Process Control Input Signals Status Output Signals Screen Navigation Basics Programming the Generator - Some Examples S[...]

  • Page 7

    Page  1 Section 1 – Intr oduction Dukane Manual Part No. 403-574-01 SECTION 1 Intr oduction General User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 R e a d t h e M a n u a l F i r s t ..................................... 3 Notes, Cautions and W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 8

    Page  2  iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 9

    Page  3 Section 1 – Intr oduction Dukane Manual Part No. 403-574-01 General User Information Read the Manual First Before operating your ultrasonic generator , read this User ’ s Manual to become familiar with the equipment. This will ensure correct and safe operation. The manual is organized to allow you to learn how to safely operat[...]

  • Page 10

    Page  4  iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Generator Overview This generator is designed for basic ultrasonic applications that use either manually operated hand probes or ultrasonic probes controlled by automation systems. Using the avail- able system control i[...]

  • Page 11

    Page  5 Section 2 – Health & Safety Dukane Manual Part No. 403-574-01 SECTION 2 Health and Saf ety G e n e r a l C o n s i d e r a t i o n s .............................. 7 P l a s t i c s H e a l t h N o t i c e ................................ 7 E l e c t r i c a l S a f e t y .................................... 8 D o m e s t i [...]

  • Page 12

    Page  6          iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 13

    Page  7 Section 2 – Health & Safety Dukane Manual Part No. 403-574-01 General Considerations Ple ase obs erve these hea lth and saf et y rec ommen datio ns for safe , ef ci ent , and inju ry-fr ee op erati on of your equi p - men t. In th is man ua l, t he ter m sy stem r ef ers to a com plete gro up of co mpone nt s as so cia te[...]

  • Page 14

    Page  8          iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Approved 2 pole, 3 wir e grounding receptacle HUBBELL No. 5652 or equivalent to NEMA 6–15R or 6–20R Figure 2 - 1 Example of 220/240 V olt, Grounded, 3-Prong Receptacle C A UTION If th ere i s any qu [...]

  • Page 15

    Page  9 Section 2 – Health & Safety Dukane Manual Part No. 403-574-01 St ep 1. Stand close to the load with your feet spread apart about shoulder width, with one foot slightly in front of the other for balance. Step 2. Squat down bendin g at the knee s (not your waist). Tuc k your chin while keepin g your back as vertical as possibl[...]

  • Page 16

    Page  10                  iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 17

    Page  1 1 Section 3 – Installation Dukane Manual Part No. 403-574-01 SECTION 3 Installa tion B e f o r e I n s t a l l a t i o n ........................... 1 3 When to Use Lockout/T agout Devices . . . . . . . . . . . . . . . 13 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Placement . . . . .[...]

  • Page 18

    Page  12                  iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 19

    Page  13 Section 3 – Installation Dukane Manual Part No. 403-574-01 Bef ore Insta ll atio n As yo u pla n for t he in stal latio n of y our g ener ator, please consider these important subjects as listed below: • When to use lockout / tagout devices • Lifting the generator safely - See Section 2 - Health and Safety , P . 9 When to U[...]

  • Page 20

    Page  14                  iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Lockout/T agout Procedur e to use BEFORE making any internal adjustments to the generator: 1. Push the generator's AC power switch/ breaker to the OFF position. 2. Unplug the genera[...]

  • Page 21

    Page  15 Section 3 – Installation Dukane Manual Part No. 403-574-01 Unpacking Carefully open your shipping container , and make sure it contains the items shown on the shipping documents. Inspect all items, and report any damage immediately . Placement Generator placement and cable routing should permit easy access and not interfere wit[...]

  • Page 22

    Page  16                  iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Placing the Generator when Used in an Active Seismic Region If the iQ gener ato r is to be use d in an acti ve seismic regi on, secure the unit by rack-mounting it or by securing the uni[...]

  • Page 23

    Page  17 Section 3 – Installation Dukane Manual Part No. 403-574-01 Benchtop Mounting If you choose to mount the generator on a benchtop follow these instructions: 1) Install the four (4) optional hold down brackets. See Figure 3-5 below . 2) Secure one side of each L backet to the generator's sheet metal cover . 3) Secure the othe[...]

  • Page 24

    Page  18                  iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 RFI Grounding In addition to the safety considerations previously men- tioned, proper grounding at the generator power cord is essential for the effective suppression of electrical noise[...]

  • Page 25

    Page  19 Section 3 – Installation Dukane Manual Part No. 403-574-01 C A UTION T he po w e r co rd i s e q u i pp e d w it h a three-prong , gro un d- ed-type plu g for you r safe t y . W h e n e v e r a t w o - s l o t r e - c e p t a c l e i s e n c o u n t e r e d , w e s t r o n g l y r e c o m m e n d t h a t i t i s r e p l a c e d[...]

  • Page 26

    Page  21 Page  20                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Figure 3 - 6 Generator - Rear View (low prole model) Automation Controlled Probe System Step 1. Gro und the gene rat or cha ssis usin g the supp lied 14- Gauge wire , and att[...]

  • Page 27

    Page  21 Page  20                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 SECTION 4 Standar d Connections Rear Panel Layout Overview . . . . . . . . . . . . . . . . . . . . . . . . 23 A C P o w e r I n l e t P[...]

  • Page 28

    Page  23 Page  22                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page  23 Page  22                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua[...]

  • Page 29

    Page  23 Page  22                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page  23 Page  22                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka[...]

  • Page 30

    Page  25 Page  24                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page  25 Page  24                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua[...]

  • Page 31

    Page  25 Page  24                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page  25 Page  24                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka[...]

  • Page 32

    Page  27 Page  26                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page  27 Page  26                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua[...]

  • Page 33

    Page  27 Page  26                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page  27 Page  26                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka[...]

  • Page 34

    Page  29 Page  28                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page  29 Page  28                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua[...]

  • Page 35

    Page  29 Page  28                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page  29 Page  28                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka[...]

  • Page 36

    Page  31 Page  30                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page  31 Page  30                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua[...]

  • Page 37

    Page  31 Page  30                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page  31 Page  30                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka[...]

  • Page 38

    Page  33 Page  32                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page  33 Page  32                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua[...]

  • Page 39

    Page  33 Page  32                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page  33 Page  32                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka[...]

  • Page 40

    Page  34                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 41

    Page  35 Section 5 – Standar d System Status and Controls Dukane Manual Part No. 403-574-01 SECTION 5 Standar d System Sta tus and Contr ols F r o n t P a n e l O v e r v i e w .............................. 3 7 S y s t e m D i s p l a y s .................................. 3 7 System Power Output Level (Bar Graph) . . . . . . . . . . .[...]

  • Page 42

    Page  36                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 43

    Page  37 Section 5 – Standar d System Status and Controls Dukane Manual Part No. 403-574-01 Front Panel Overview This section provides an overview of the front panel’ s two main functions: monitoring (with the system displays), and controlling the system (with the user navigation control keys). LOAD 80 60 100 OVER 40 0 20 SYSTEM POWER[...]

  • Page 44

    Page  38                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Control Keys Keys Left of the Display INFO After the primary weld method has been chosen, you can press the INFO key to go directly to the “Hot Key” screen where frequently used [...]

  • Page 45

    Page  39 Section 5 – Standar d System Status and Controls Dukane Manual Part No. 403-574-01 TEST Hold the TEST key momentarily to activate ultrasound and view system operating parameters. The LCD screen will show the real time settings for Amplitude, Power (does not appear with T ime Only generators) , and Operating Frequency . This inf[...]

  • Page 46

    Page  40                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Start-up Sequence After all connections have been completed, 1. Push the rear panel AC breaker switch to ON . The generator begins its self-diagnostics sequence. 2. POWER TEST ash[...]

  • Page 47

    Page  41 Section 5 – Standar d System Status and Controls Dukane Manual Part No. 403-574-01 S t o p p i n g t h e W e l d C y c l e Normal Conditions The cycle stops when the programmed welding cycle ends. Emergency Conditions Manual System Press OFFLINE to stop the ultrasound signal. This may be done under any condition. Automated Syst[...]

  • Page 48

    Page  42                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 System Parameter Settings Overview This section provides the default system settings programmed at the factory . Some of these system parameter settings are dependent on the nominal [...]

  • Page 49

    Page  43 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 Continued Setting Description User Adjustment Limit Setting Ranges for All Frequencies Minimum Maximum Amplitude Setting 20% 100% Free Run Frequency *** Default Free Run Frequency minus 500 Hz Default Free Run Frequency plus 500 Hz Ramp-up T ime 0.010 secon[...]

  • Page 50

    Page  44                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 51

    Page  45 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 Section 6 Pr ocess Contr ol Settings User-Provided Process Control Overview . . . . . . . . . . . . . . 47 M a n u a l W e l d i n g .................................. 4 7 A u t o m a t e d W e l d i n g ............................... 4 7 Automated Process[...]

  • Page 52

    Page  46                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 53

    Page  47 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 User- Provided Process Control Overview The generator includes a process control system to control welding process. The basic “B models” can be programmed to weld by time. “E model” generators can weld by time and ener gy . See Figure 1 1-5 for mode[...]

  • Page 54

    Page  48                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Sc ree n N avi ga tio n B asi cs This section gives you a step-by-step guide to navigating through some of the basic menu structure. AMPLITUDE 50 % FREE RUN FRQ 20000 Hz OPERA TE MOD[...]

  • Page 55

    Page  49 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 1. Press CANCEL until you see the Main Menu screen as it is shown here. Move the selection indicator to PROCESS SETUP . 2. Press ENTER and you will see the screen as shown here. 3. Select PROCESS CONTROL , and press ENTER . W ith no option boards installed [...]

  • Page 56

    Page  50                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 HOW TO - W eld by Time 1. Press CANCEL until you see the Main Menu screen as it is shown here. Move the selection indicator to PROCESS SETUP . 2. Press ENTER and you will see the scr[...]

  • Page 57

    Page  51 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 HOW TO - W eld by Energy (Available only if generator has energy option.) 1. Press CANCEL until you see the Main Menu screen as it is shown here. Move the selection indicator to PROCESS SETUP . 2. Press ENTER and you will see the screen as shown here. 3. Se[...]

  • Page 58

    Page  52                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 HOW TO - Adjust Amplitude 1. Press CANCEL until you see the Main Menu screen as it is shown here. Move the selection indicator to PROCESS SETUP . 2. Press ENTER and you will see the [...]

  • Page 59

    Page  53 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 HOW TO - Adjust Ramp Up/Down Times The Ramp Up feature , also called soft start , applies amplitude at the beginning of the weld cycle to start the stack assem bly (transd ucer , booster , hor n) line arly , rather than in two instantaneous surges. The stac[...]

  • Page 60

    Page  54                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 61

    Page  55 Section 7 – System Operational T esting Dukane Manual Part No. 403-574-01 SECTION 7 System Oper a tional T esting System V erication T ests ........................... 5 7 P r e l i m i n a r y S e t u p ....................................... 5 7 T esting the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 62

    Page  56                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 63

    Page  57 Section 7 – System Operational T esting Dukane Manual Part No. 403-574-01 System V erication T ests Preliminary Setup Step 1. Plug in the AC line cord to the correct AC power outlet. See T able 1 1 -II for the model power requirements. Step 2. Attach a compatible ultrasonic probe to the ultrasound output connector - J1. Step[...]

  • Page 64

    Page  58                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 System T est T o test the system’ s ultrasound operation, perform the following steps. Step 1. For this test, the generator must be ONLINE. If the OFFLINE LED is showing yellow ( D[...]

  • Page 65

    Page  59 Section 7 – System Operational T esting Dukane Manual Part No. 403-574-01 Probe Operation 1. If the generator is not online, press the ON/OFFLINE mode key , labeled C in Figure 7-6. The System Op- erating Mode ONLINE indicator ( G in Figure 7-5) will be green. 2. Hand Probe – Apply the probe tip to the components to be ultras[...]

  • Page 66

    Page  60                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 67

    Page  61 Section 8 – T r oubleshooting Dukane Manual Part No. 403-574-01 SECTION 8 T r oubleshooting N o U l t r a s o n i c O u t p u t .............................. 6 3 P r o b e ................................................. 6 3 C a b l e s ................................................ 6 3 G e n e r a t o r ...................[...]

  • Page 68

    Page  62                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 69

    Page  63 Section 8 – T r oubleshooting Dukane Manual Part No. 403-574-01 No Ultrasonic Output Probe Make sure that the probe coaxial cable is connected to the generator ultrasonic output connector J1. Basic generator models have the BNC connector on the rear panel. Also, make sure the probe stack was properly assembled. Cables Make sure[...]

  • Page 70

    Page  64                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 System Power Output Level: Red Red - Fault Condition When the SYSTEM POWER OUTPUT LEVEL turns red (arrow on the right end of the bar graph), there is an overload condition that disab[...]

  • Page 71

    Page  65 Section 9-Maintenance Dukane Manual Part No. 403-574-01 W elding Problems W eak W elds W eak welds, or underwelding, is caused by insufcient energy being transmitted to the part. Y ou can increase the weld pressure, increase the weld time or change to a higher gain booster to increase the amplitude to increase the energy deliv[...]

  • Page 72

    Page  66                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Pop-up Status Screens System Status Signal Status T ext Displayed System Status or Fault Explanation Average Overload OVERLOAD - A VERAGE A T X.XXX SECONDS POWER ABOVE GENERA TOR RA [...]

  • Page 73

    Page  67 Section 9-Maintenance Dukane Manual Part No. 403-574-01 SECTION 9 Maintenance F r o n t a n d R e a r P a n e l s ............................ 6 9 C l e a n i n g .............................................. 6 9 D i s p l a y ............................................... 6 9 C o n t r o l K e y s / B u t t o n s .............[...]

  • Page 74

    Page  68                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 75

    Page  69 Section 9-Maintenance Dukane Manual Part No. 403-574-01 Front and Rear Panels Cleaning • Do not use any solvents or abrasive cleaners on the any of the panels (including the LCD display). • Do not spray any cleaning product directly on the pan- els. T o remove dust, rst try gently dusting with a micro - ber cleaning clo[...]

  • Page 76

    Page  70                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 77

    Page  71 Section 10 - Options Dukane Manual Part No. 403-574-01 SECTION 10 Options P o w e r I n l e t O p t i o n s ............................... 7 3 120V Systems for North American and Japan . . . . . . . . . . . . . 73 E l e c t r i c a l S a f e t y .................................. 7 3 1 2 0 V P o w e r G r o u n d ...............[...]

  • Page 78

    Page  72                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 79

    Page  73 Section 10 - Options Dukane Manual Part No. 403-574-01 This section of the User ’ s Manual provides a general overview of some options/upgrades, all of which are sub- ject to availability , for the basic ultrasonic generator: Power Inlet Options 120V Systems for North America and Japan 120V systems for North America and Japan h[...]

  • Page 80

    Page  74                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 AC Power Inlet Panel The optional AC power inlet panel is described here. AC Power Cord The AC power cord ( A in Figure 10-2) is appropriately rated and permanently mounted to the po[...]

  • Page 81

    Page  75 Section 10 - Options Dukane Manual Part No. 403-574-01 I/O Panel Options Single Connector System I/O Panel See B in Figure 10-4 where the I/O panel is set up for the single I/O connector , a HD15F type. The generator label for this connector is, SYSTEM INPUTS/OUTPUTS . Another label identies the connector as J12. The I/O panel[...]

  • Page 82

    Page  76                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Optional MPC Interface Connections Complete Steps 1 - 4 of the basic connections as de- scribed on Pages 19-20. These involve: • Grounding (optional), • Ultrasound Output, • Sy[...]

  • Page 83

    Page  77 Section 10 - Options Dukane Manual Part No. 403-574-01 Pin Signal Name Connector 3 Setup Bit 0 Input J2 (Page 20) 4 Setup Bit 1 Input 5 Setup Bit 2 Input 6 Setup Bit 3 Input 18 MPC Ready Out J3 (Page 25) T able 10 - II MPC I/O Connector Signals MPC I/O Connections Signal names and Pin numbers and the connectors re- lated to the M[...]

  • Page 84

    Page  78                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 MPC Interface Installation Guide The MPC interface is designed for assembly systems where one ultrasonic generator is sequenced to as many as 16 ultrasonic probes. The MPC interface [...]

  • Page 85

    Page  79 Section 10 - Options Dukane Manual Part No. 403-574-01 Connecting Cables For stand-alone interfaces and securely installed panel mounted interfaces: Rear Connections Refer to Figure 10 -7 below , and complete these connections. 1. Earth ground - Connect one end of a user-supplied 14-Gauge ground wire to the ground connection at t[...]

  • Page 86

    Page  80                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 MPC Interface Status LEDs System Status When the system is powered and ready , the front panel SYSTEM ST A TUS LED lights up, and becomes GREEN ( E in Figure 10 - 9). If this LED is [...]

  • Page 87

    Page  81 Section 10 - Options Dukane Manual Part No. 403-574-01 Confirm probes are retracted from weld position. Load part to be welded. Move part to the welding position. Move probes to the welding position. MPC Ready Status Output active? PLC activates generator ’s binary code inputs to select active probe. W ait 40 mS to confirm bina[...]

  • Page 88

    Page  82                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Remote Amplitude Control M o d u l e Part Number - 1 10- 4183 This optional module enables remote control of output amplitude of the iQ system. The control interface is a 4–20mA cu[...]

  • Page 89

    Page  83 Section 10 - Options Dukane Manual Part No. 403-574-01 AMPLITUDE CONTROL AMPLITUDE SETTING RAMP UP / DOWN TIME AMPLITUDE SETTING 90 % CHANGE V ALUE SELECT DIGIT AMPLITUDE SETTING AMPLITUDE CONTROL BY iQ SYSTEM AUTOMA TION This menu av ailable only with Remote Amplitude Control option. Figure 10-13   Amplitude Control Menu Detai[...]

  • Page 90

    Page  84                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Automation Thruster Control M o d u l e Part Number - 1 10- 4206 This optional module enables the iQ system to control a Dukane iQ thruster . The module is illustrated in Figure 10-1[...]

  • Page 91

    Page  85 Section 10 - Options Dukane Manual Part No. 403-574-01 T o enable the thruster , Pins 3 and 9 must be shorted together through a safety circuit (see T able 10-V) during normal operation. During an abort or emergency stop condition, the connection between Pins 3 and 9 must open to disable movement of the thruster . In addition to [...]

  • Page 92

    Page  86                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 NPN T O PNP CONVERSION SPECIFICA TIONS: INPUTS: MINIMUM VOL T AGE: 5.0 Vdc CURRENT : 1.5mA @ 5.0 Vdc / 9.5mA @ 24.0 Vdc MAXIMUM VOL T AGE: 30.0 Vdc MAXIMUM CURRENT : 50mA MAXIMUM VOL[...]

  • Page 93

    Page  87 Section 10 - Options Dukane Manual Part No. 403-574-01 PNP TO NPN CONVERSION SPECIFICA TIONS: INPUTS: MINIMUM VOL T AGE: 5.0 Vdc CURRENT : 1.5mA @ 5.0 Vdc / 9.5mA @ 24.0 Vdc MAXIMUM VOL T AGE: 30.0 Vdc MAXIMUM CURRENT : 50mA MAXIMUM VOL T AGE: 30.0 Vdc MINIMUM VOL T AGE: 5.0 Vdc OUTPUTS: VOL T AGE DROP ( + T O - ): 1.0 Vdc MAX NO[...]

  • Page 94

    Page  88                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 +5V T O +24V PNP CONVERSION +5V IN 1 @ 0V = ON IN 1 @ 5V = OFF GND IN 2 @ 5V = ON IN 2 @ 0V = OFF IN 3 @ 0V = ON IN 3 @ 5V = OFF ACTIVE HIGH TTL ACTIVE LOW TTL OPEN COLLECTOR WITH PU[...]

  • Page 95

    Page  89 Section 10 - Options Dukane Manual Part No. 403-574-01 iQLinQ communication options allow automated systems to monitor and change settings in iQ generators. These options provide machine builders the ability to integrate the generator into an electrical cabinet and to use the machine’ s HMI to program or monitor weld settings. [...]

  • Page 96

    Page  90                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 J2 U/S I 0 LINE VOLT AGE: 200-240 Vac 50/60Hz, 15A PE J3 J4 J1 BUS ERROR PROFIBUS J16 i Q Li nQ ™ PR OF IB U S Co mm un ic a t i on s Mo du l e P a rt N um be r - 1 10 -4 55 4 The [...]

  • Page 97

    Page  91 Section 10 - Options Dukane Manual Part No. 403-574-01 iQ LinQ TM Ethernet/IP TM Module Part Number - 1 10- 4644 The EtherNet/IP option module allows the iQ generator to connect to an EtherNet/IP network. The option module is an external DIN-rail mounted device that acts as a bridge between the automation network and an iQ genera[...]

  • Page 98

    Page  92                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 99

    Page  93 Section 1 1 - Specications Dukane Manual Part No. 403-574-01 SECTION 11 Specica tions D r a w i n g s ......................................... 9 5 Low Prole Chassis ....................................... 9 5 High Prole Chassis ...................................... 9 6 High Power (3600W) Chassis . . . . . . . . . . [...]

  • Page 100

    Page  94                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 101

    Page  95 Section 1 1 - Specications Dukane Manual Part No. 403-574-01 Figure 1 1-1 Low Prole Chassis Drawing LOAD 80 60 100 OVER 40 0 20 SYSTEM POWER OUTPUT LEVEL SYSTEM OPERATING MODE ON LINE OFF LINE POWER TEST OPERA TOR CONTROLS AC POWER ENTRY UL TRASOUND & SYSTEM I/O'S OPTIONS P ANEL ALLOW 3" IN BACK FOR CABLING. A[...]

  • Page 102

    Page  96                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Figure 1 1- 2 High Prole Chassis Drawing SYSTEM OPERATING MODE SYSTEM POWER OUTPUT LEVEL 20 0 40 OVER 100 60 80 LOAD POWER TEST OFF LINE ON LINE AC POWER ENTRY OPERA TOR CONTROLS [...]

  • Page 103

    Page  97 Section 1 1 - Specications Dukane Manual Part No. 403-574-01 Figure 1 1- 3 High Power (3600W) Chassis Drawing ALLOW 3" IN BACK FOR CABLING. AC POWER ENTRY UL TRASOUND & SYSTEM I/O'S AC POWER ENTRY 5.19 [131.8] 5.50 [139.7] 17.16 [435.8] ALLOW 5" EACH SIDE FOR COOLING 12.51 [317.8] 3.15 [80.0] IN [mm] ALLOW 5[...]

  • Page 104

    Page  98                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Figure 1 1- 4 High Power (4800W) Chassis Drawing ALLOW 5" EACH SIDE FOR COOLING ALLOW 5" EACH SIDE FOR COOLING ALLOW 3" IN BACK FOR CABLING. AC POWER ENTRY UL TRASOUND[...]

  • Page 105

    Page  99 Section 1 1 - Specications Dukane Manual Part No. 403-574-01 Operating Environment Operate the generator within these guidelines: T emperature : 40° F to 10 0°F (+4°C to + 38° C) Air Particulates : Keep the equipment dry Minimize exposure to moisture, dust, dirt, smoke and mold Humidity : 5% to 95% Non–condensing @ +5°C[...]

  • Page 106

    Page  100                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 AC Power Requirements The AC input power requirements depend on the frequency and output power rating of the generator . T able 1 1-II below , lists both the AC requirements (maximu[...]

  • Page 107

    Page  101 Section 1 1 - Specications Dukane Manual Part No. 403-574-01 Inter preting the Model Number 20 HB 120 - 2 E- R1 P o wer Le vel 480 = 4800 W atts 360 = 3600 W atts 240 = 2400 W atts 180 = 1800 W atts 120 = 1200 W atts 060 = 600 W atts System Process Contr ols A = Advanced Weld Controller (time and energy) AC Line Input 2 = 200[...]

  • Page 108

    Page  102                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Regulatory Agency Compliance C A UTION DO NO T mak e an y modi- cations to the gene rat or o r a s s o c i at e d c a b le s a s the changes ma y resu lt in viol ati ng one or mo[...]

  • Page 109

    Page  103 Section 12 - Contacting Dukane Dukane Manual Part No. 403-574-01 SECTION 12 Contacting Dukane[...]

  • Page 110

    Page  104                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 111

    Page  105 Section 12 - Contacting Dukane Dukane Manual Part No. 403-574-01 Co ntacting Du kane Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • Model number , line voltage and serial number • Fault/error indicators from the LCD display • Software version (P[...]

  • Page 112

    Page  106                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 113

    Page  107 Appendices Dukane Manual Part No. 403-574-01 APPENDICES L i s t o f F i g u r e s .................................... 1 0 9 L i s t o f T a b l e s ..................................... 1 1 0 Guide to iQ Generator Menu Structure. . . . . . . . . . . . . . 1 1 1-127[...]

  • Page 114

    Page  108                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 115

    Page  109 Appendices Dukane Manual Part No. 403-574-01 List of Figures 2-1 Example of 220 V olt, Grounded, 3-prong Receptacle ..................................................... 8 2-2 International 220/240V Grounding ..................................................................................8 3-1 Lockout Device in Open Position, [...]

  • Page 116

    Page  1 10                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 No. Description Page 2-I iQ Generator W eights ....................................................................................................... 9 3-I Rack Mount Bracket Part[...]

  • Page 117

    Page  1 1 1 Appendices Dukane Manual Part No. 403-574-01 Menus Page Number Time Only Operate 1 13 Process Setup - Automated Probe 1 14 Process Setup - Hand Probe 1 15 Process Setup - MPC Probe 1 16 Process Setup - Process Limits 1 17 Process Setup - Utilities 1 18 Time and Energy Operate 1 19 Process Setup - Automated Probe 120 Process Se[...]

  • Page 118

    Page  1 12                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 119

    Page  1 13 Appendices Dukane Manual Part No. 403-574-01 # 1 P ART COUNT XXXXX WELD TIME 0.0000 S OPERA TE T ime Only Menus Page 1 of 15 “Rxx” = Remote Setup Number and #xx = Local Setup Number OPERA TE MODE PROCESS DA T A PROCESS ST A TISTICS SYSTEM P ARAMETERS P ART COUNT XXXXX GOOD XXXXX XXX% BAD SUSPECT XXXXX XXX% XXXXX XXX% AMPLIT[...]

  • Page 120

    Page  1 14                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime Only Menus Page 2 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES No option boards installed Automated Probe AUTOMA TED PROBE WELD CONTROL BY AUTOM[...]

  • Page 121

    Page  1 15 Appendices Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime Only Menus Page 3 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Hand Probe HAND PROBE WELD CONTROL BY HAND PROBE SWITCH iQ SYSTEM HAND PROBE Weld Control Amplitude Control Weld T ime Hand Probe Detected See Amplitude Control Menu See Amplitude Contr[...]

  • Page 122

    Page  1 16                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime Only Menus Page 4 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES MPC Probe MPC PROBE WELD CONTROL BY AUTOMA TION WELD CONTROL MPC Probe AMPLITUDE [...]

  • Page 123

    Page  1 17 Appendices Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime Only Menus Page 5 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Process Limits Disable Maximum Weld T ime Minimum Weld T ime PROCESS LIMITS SUSPECT P ART BAD P ART WELD TIME LIMIT Enable Disable Maximum Weld T ime Minimum Weld T ime WELD TIME LIMIT [...]

  • Page 124

    Page  1 18                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime Only Menus Page 6 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Utilities UTILITIES SETUP CONTROL SETUP UTILITIES SETUP UTILITIES NAME CURRENT SE[...]

  • Page 125

    Page  1 19 Appendices Dukane Manual Part No. 403-574-01 OPERA TE T ime and Energy Menus Page 7 of 15 “Rxx” = Remote Setup Number and “#xx” = Local Setup Number OPERA TE MODE PROCESS DA T A PROCESS ST A TISTICS SYSTEM P ARAMETERS R 1 P ART COUNT WELD TIME PEAK POWER ENERGY 0.000 S 0 W 0 J P ART COUNT XXXXX GOOD XXXXX XXX% BAD SUSPE[...]

  • Page 126

    Page  120                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy Menus Page 8 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES No option boards installed Automated Probe AUTOMA TED PROBE WELD CONTROL BY [...]

  • Page 127

    Page  121 Appendices Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy Menus Page 9 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Hand Probe HAND PROBE WELD CONTROL BY HAND PROBE SWITCH iQ SYSTEM WELD CONTROL Weld by T ime Weld by Peak Power Weld by Energy Weld T ime Weld Peak Power Weld Energy Max Weld T ime[...]

  • Page 128

    Page  122                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy Menus Page 10 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES MPC Probe MPC PROBE WELD CONTROL BY AUTOMA TION iQ SYSTEM WELD CONTROL MPC [...]

  • Page 129

    Page  123 Appendices Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy Menus Page 1 1 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Process Limits Disable Maximum Weld T ime Minimum Weld T ime PROCESS LIMITS SUSPECT P ART BAD P ART SUSPECT P ART LIMITS WELD TIME WELD PEAK POWER WELD ENERGY BAD P ART LIMITS WE[...]

  • Page 130

    Page  124                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy (and T ime Only) Menus Page 12 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Utilities UTILITIES SETUP CONTROL SETUP UTILITIES SETUP UT[...]

  • Page 131

    Page  125 Appendices Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy (and T ime Only) Menus Page 13 of 15 AMPLITUDE CONTROL AMPLITUDE SETTING RAMP UP / DOWN TIME Amplitude Control WARNING MODIFIED SETTINGS MA Y EFFECT OPERA TION OF UNIT Amplitude Ramp T ime Ramp Up T ime Ramp Down Time AMPLITUDE SETTING 90 % CHANGE V ALUE[...]

  • Page 132

    Page  126                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 I/O PORT SETUP CONFIGURE INPUTS CONFIGURE OUTPUTS RESTORE DEF AUL TS HARDW ARE T ime and Energy Menus Page 14 of 15 #1: SETUP NAME OPERA TE MODE PROCESS SETUP HARDWARE SETUP PORT SE[...]

  • Page 133

    Page  127 Appendices Dukane Manual Part No. 403-574-01 ADV ANCED HARDW ARE T ime and Energy Menus Page 15 of 15 #1: SETUP NAME OPERA TE MODE PROCESS SETUP HARDWARE SETUP I/O PORT SETUP ADV ANCED HARDWARE SYSTEM RESTORE TRIGGER BY POWER ADV ANCED HARDWARE: SETTINGS RESTORE DEF AULTS FREQ LOCK/HOLD SYSTEM FREQ LIMITS Wide 21000-19000 Phase [...]

  • Page 134

    Page  128                    iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 This page intentionally left blank[...]

  • Page 135

    Dukane ISO ISO CER TIFICA TION Duka ne chose to become ISO 9001:20 08 certi- fied in order to demonstrate to our customers our continuing commitment to being a quality ve nd or . By pass ing its audi t, Duka ne can as su re you that we have in place a well–defined and systematic approach to quality design, manu - facturing, deliver y and ser vi[...]

  • Page 136

    Part No. 403-574 -01 Dukane Intel ligent Assembl y Solu tions • 2900 Dukan e Driv e • St . Char les, I llinoi s 6017 4 USA • TEL (630) 797-49 00 • F AX (630) 797–4 949 Series, LS Generators, User's Manual Printed in the United States of America www .dukane.com/us Please r ef er to our website a t: www .dukane.com/us/sales/intsales.ht[...]