Dukane 403-575-00 manual

Intelligent Assembly Solutions www .dukane.com/us ISO 9001:2008 Dukane products ar e manufactured in ISO register ed facilities. Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797– 4900 • F AX (630) 797– 4949 Dukane Part No. 403  – 575  – 00 Series UL TR ASONIC GENERA T OR[...]

Printed in the United States of America. Dukane Part Number: 403-575-00 Dukane ultrasonic equipment is manufactur ed under one or more of the follo wing U.S. P atents: (* = Inactive) 3,780,926 * 4,131,505* 4,277,710* 5,798,599 5,880,580 6,98 4, 921 7, 22 5, 96 5 7 ,4 75 ,80 1 and, 7,819,158 Copyright © 201 1 Dukane Intelligent Assembly Solutions 2[...]

R e vis io n His to r y Revision Revision Number Summary Date - 00 Original release. 08/19/201 1 Page iii Dukane Manual Part No. 403-575-00[...]

This page intentionally left blank Page iv iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

Contents Section 1- Introduction ....................... 1 General User Information ............................. 3 Press System Overview .............................. 4 Key Features ...................................... 4 Section 2 - Health and Safety .................. 5 General Considerations .............................. 7 Plastics Health No[...]

Contents Continued Section 5 - System Operational T esting ......... 71 Section 6 - T roubleshooting .................. 79 Section 7 - Maintenance ...................... 93 Section 8 - Options .......................... 97 Section 9 - Contacting Dukane ............... 103 Section 10 - Specications .................. 107 Outline Drawings ........[...]

SECTION 1 Intr oduction General User Information . . . . . . . . . . . . . . 3 Press System Overview . . . . . . . . . . . . . . . 4 Key Features . . . . . . . . . . . . . . . . . . . . 4 Page 1 Dukane Manual Part No. 403-575-00 Section 1 - Introduction[...]

This page intentionally left blank Page 2 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

General User Information Read This Manual First Before operating your ultrasonic system, read this User ’ s Manual to become familiar with the equipment. This will ensure correct and safe operation. The manual is or ganized to allow you to learn how to safely operate this equipment. The examples given are chosen for their simplicity to il- lustra[...]

Press System Overview An iQ Series Ultrasonic Press System ES consists of these components: the iQ generator , press (with thruster , switches, controls, cables, transducer , booster , horn, and xture ) and iQ Explorer software. The software allows the operator to control the system either remotely or at the press location. The iQ Series ES gene[...]

SECTION 2 Health and Saf ety General Considerations . . . . . . . . . . . . . . . . 7 Plastics Health Notice . . . . . . . . . . . . . . . . . 8 Electrical Safety .............................. 9 Domestic Power Grounding ...................... 9 International Power Grounding .................... 9 Lifting the Equipment ......................... 10 [...]

This page intentionally left blank Page 6 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

Proper Installation - Operate system components only after they are properly installed. No Unauthorized Modications - Do not modify your system in any way unless authorized to do so by Dukane Corporation. Unauthorized modications cou ld cause equipment damage and/or injury to the operator . In ad - dition, unauthorized modications[...]

Pre-trigger Switch Adjustment - The pre-trigger switch option starts the horn vibrating before contacting the part to be welded. T o ensure safe operation, adjust the pre- trigger so the ultrasound signal will not activate if the horn is more than ¼ in (7 mm) from the part to be welded. System Electrical Cabling - Electrical power must be off when[...]

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 CAUTION If there is any question about the grounding of your recep- tacle, have it checked by a qualied electrician. Do not cut off the power cord ground - ing prong, or alter[...]

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 bending at the knees (not your waist). T uck your chin while keeping your back as vertical as possible. Step 3. Get a rm grasp of the object before be - ginning the lift. Begin slowly li[...]

SECTION 3 Installa tion Before Installation ........................... 13 When to Use Lockout/T agout Devices ............... 13 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Placement in a Seismic Zone .................. 16 Rear Panel Layou[...]

This page intentionally left blank Page 12 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

Before Inst allation As you plan for the installation of your generat or , please consider these important subjects as listed below: • When to use lockout / tagout devices • Lifting the generator safely - See Section 2 - Health and Safety , Page 10. When to Use Lockout / T agout Devices The typical kind of LOTO device for this generator is a cl[...]

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 generator's electrical cord from its source. 3. Authorized personnel apply a lockout/ tagout (LOTO) device to the plug end of the generator's electrical cord. Us[...]

Figure 3-3 Generator Front View (typical) Low Prole 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 . P lac e ment Generator placement and cable routing should permit easy access and not interfere with normal system opera-[...]

Placement in a Seismic Region If the iQ generator is to be used in an active seismic region, secure the unit by rack-mounting it or by securing the unit to a benchtop. Rack- Mounting Install the four brackets from Dukane's rack-mount kit to the generator . See T able 3-I, and Figure 3- 4 (showing a low prole unit) below . Mount the generato[...]

Benchtop Mounting If you choose to mount the gen erator on a benchtop follow these instructions: 1) Install the four (4) optional hold down brackets. See Figure 3- 5 below . 2) Secure the slot side of each bracket to the generator's sheet metal cover . 3) Secure the hole side of each bracket to the bench itself. Figure 3-5 Securing iQ Generato[...]

This section provides an overview of the generator rear panel layout, which includes panel areas dedicated to var- ious standard system functions and options that are avail- able. Figure 3-6 illustrates a typical panel layout. AC Power Inlet Panel A IEC Power Inlet Connector – Attaches to an IEC style power cord. B Power Switch – Circuit Breake[...]

AC Power Inlet Panel The standard AC power inlet panel is described in this sec- tion. IEC AC Power Inlet Connector The IEC AC power inlet connector mounted on the system AC power inlet panel requires a properly congured IEC compliant power cord, which enables worldwide system operation by simply changing the power cord. Low prole systems are[...]

Refer to Application Note AN507 (Automation Interface Guidelines) at http://www .dukane.com/us/DL_ApplDa- ta.asp for wiring diagrams of example applications. System Inputs Connector Pinout The SYSTEM INPUTS connector is a HD-15F (high density D-subminiature 15 circuit female) connector . Connector pin numbers for this connector are shown in Figure [...]

System Inputs Signal Descriptions Pin 1 (+22V) This pin can supply +22VDC at up to 250mA to power the user ’ s automation controls. Pin 2 (Power Gnd) Pin 2 is the 22VDC return and is tied to the system chas- sis ground. Pin 3 (Remote Setup Selection Bit 0 Input) Pin 3 is the Remote Setup Selection Bit 0, which is the least signicant bit used t[...]

. Pin 5 (Remote Setup Selection Bit 2 Input) Pin 5 is the Remote Setup Selection Bit 2, which is the third least signicant bit used to select different welding setups with an automation control system. Pin 6 (Remote Setup Selection Bit 3 Input) Pin 6 is the Remote Setup Selection Bit 3, which is the second most signicant bit used to select di[...]

Pin Signal Name Cable Color Code Signal Option Requirements 1 +22V BLK 2 Spare Output WHT 3 +22V Power Ground RED 4 Programmable Status Output 1 GRN 5 Programmable Status Output 2 ORN 6 Ultrasound Active Status Output BLU 7 Any Fault Status Output WHT/BLK 8 Press T rigger Status Output RED/BLK 9 System Overload Status Output GRN/BLK 10 System Onlin[...]

This is at system chassis ground potential (non-isolated). All of the digital output status signals on this connector , are isolated (signals are not referenced to generator chassis ground). When a status output signal is activated, it will sink current (500mA Max. sourced by a 24VDC supply) to isolated common. In automation terms, the outputs are [...]

Pin 9 (System Overload Status Output) Pin 9 is a digital active low status output that activates whenever any overload condition is tripped. Activation of the overload status output signal could be caused by an average overload, a positive peak overload or a negative peak overload condition. After the overload status output activates, it will remai[...]

Pin 17 (Amplitude/Power Regulation Status Output) ( Contact your sales r epr esentative about Power Regulation availability . ) This status signal is most useful when the power regula- tion mode is selected. This Out of Regulation status signal would indicate that due to inadequate pressure agai nst the ultrasonic horn, the power regulation level s[...]

Ultrasound Output Connector The ultrasound output connector used with all standard generators is a high voltage (5000V) coaxial style SHV - BNC connector . This connector provides superior shielding of electrical noise, compared to other types of connectors. The ultrasound output connector mates with fully shielded coaxial ultrasound cables that ar[...]

RF I G roundi ng The iQ Series generator provides the operating power and power returns. Make sure the generator is grounded properly . In addition to the safety considerations, proper grounding is essential for the effective suppression of RFI (Radio Frequency Interference). Every generator co ntains a RFI lter which blocks noise on the AC powe[...]

Co nnect in g Cab l es Step 1. Ground the generator chassis with the supplied 14-Gauge wire, and attach it to the grounding stud. See Figure 3-7. Step 2. Ultrasound (J1 ) - This output connects the Ul- trasound Output of the iQ Series generator to the transducer , through a coaxial cable. The electrical welding signal is transmitted through this ca[...]

Three Congurations The iQ generator , ES models are congured in three basic ways: 1) W ith a pneumatic press/thruster 2) W ith a remote controller and a servo press/thruster 3) W ith a servo press/thruster Diagrams and tables that follow show these three congurations and list the cables used respectively . Page 30 iQ Series Ultrasonic Gene[...]

Figure 3-15 iQ Generator and Pneumatic Press/Thruster - Connections Diagram Connecting Cables Pneumatic Press/Thruster Continued Page 31 Dukane Manual Part No. 403-575-00 Section 3 - Installation J4 J1 CONFIGURATION ULTRASOUND SYSTEM OUTPUTS SYSTEM INPUTS J2 J3 PE LINE VOLTAGE: 200-240 Vac 50/60Hz, 15A U.S. PA TENT 5,880,580 OTHER PA TENTS PENDING [...]

Cable No. Part Number Length Connections Generator Base Thruster HMI 1 200-1556-XXM XX J5 - OPERA TIONAL CONTROL - 2 200-1613-XXM XX J 11 - ENCODER - 3 200-479-XXM XX J1 - UL TRASOUND - 4 200-1545-XXM XX J6 J35 - - 5 200-1553-XXM XX J9 - - ETHERNET 6 One of the following: 200-1541 (240 V AC, 10A, US) 200-1542 (240 V AC, 10A, Europe) 200-1624 (240 V[...]

Continued Servo Press/Thruster (V ersion 1) Figure 3-16 iQ Generator , Remote Controller , and Servo Press/Thruster - Connections Diagram J4 J1 CONFIGURATION ULTRASOUND SYSTEM OUTPUTS SYSTEM INPUTS J2 J3 PE LINE VOLTAGE: 200-240 Vac 50/60Hz, 15A U.S. PA TENT 5,880,580 OTHER PA TENTS PENDING POWER LINE OUTLET MUST BE GROUNDED. DISCONNECT LINE POWER [...]

T able 3-VI iQ Generator , Remote Controller , and Servo Press/Thruster Cables Servo Press/Thruster (V ersion 1) Cable No. Part Number Length (meters) Connections Generator Base Thruster Remote Controller HMI 1 200-1646-XXM XX - - SERVO POWER J100 - 2 200-1647-XXM XX - - THRUSTER I/O J206 - 3 200-1648-XXM XX - - ENCODER J204 - 4 200-1649-XXM XX - -[...]

Figure 3-17 iQ Generator and Servo Press/Thruster - Connections Diagram Servo Press/Thruster (V ersion 2) Continued J4 J1 CONFIGURATION ULTRASOUND SYSTEM OUTPUTS SYSTEM INPUTS J2 J3 PE LINE VOLTAGE: 200-240 Vac 50/60Hz, 15A U.S. PA TENT 5,880,580 OTHER PA TENTS PENDING POWER LINE OUTLET MUST BE GROUNDED. DISCONNECT LINE POWER BEFORE REMOVING COVER.[...]

T able 3-VII iQ Generator and Servo Press/Thruster Cables Servo Press/Thruster (V ersion 2) Cable No. Part Number Length Connections Generator Base Thruster HMI 1 One of the following: 200-1541 (240 V AC, 10A, US) 200-1542 (240 V AC, 10A, Europe) 200-1624 (240 V AC, 10A, India) 200-1576 (120 V AC) 2.4 - - AC INPUT - 2 200-1556-XXM XX J15 - SERVO I/[...]

Net wor king Where several welders are connected, please refer to the iQ Explorer User's Manual , 403-579-00, Section 5 - Multiple W elder Connections. After some introductory material, there is information about: • Simple Stand-alone Conguration • Unique IP Address, and • Connection to Local Area Network Recheck Connect ions Recheck [...]

This page intentionally left blank Page 38 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

SECTION 4 Oper a tion Overview ......................................... 41 Start-up .......................................... 41 Stopping the W eld Cycle ............................ 42 iQ Explorer Support Features ......................... 42 Numeric Pad and Keypad .................................. 42 Help System ...............................[...]

This page intentionally left blank Page 40 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

O ve r v i e w The iQ Series generator , model ES, is usually part of a system. Main components of the system are: • iQ generator , • iQ Explorer (software), • iQ Explorer User Interface (HMI), or computer ( user supplied ), and • iQ Press System. . W ith this type of system, the user controls nearly all aspects of the welding process with [...]

O th er Control F unct ions Other control functions - such as monitoring the weld- ing process and controlling the system are accomplished using the iQ HMI or your computer and Dukane's iQ Explorer software. St opping the W eld C yc l e Normal Conditions The cycle stops when the programmed welding cycle ends or when the rear panel's Cycle[...]

Help System The help system is a reference tool to assist in understand- ing key terms of the ultrasonic welding process. The iQ Explorer help function can be accessed using the top menu bar , or by pressing the F1 key as explained below . T op Menu Bar Help is one of the top menu bar items as shown in Figure 4-3. Clicking on Help and then clicking[...]

Quick S t ar t - Servo Welder Servo Step 1 - Read Section 3, Installation of the iQ Explorer User's Manual 403-579-00. Insure that proper connection of the iQ Explorer software and the servo press are in place. See Figure 4-5 below . It is important that you understand and familiarize your - self with the operation and navigation of the iQ Exp[...]

See Figure 4-7. Figure 4-7 iQ Explorer , Process Settings Process Settings T ab Servo Step 4 - Process Settings > Initiate Mode > Manual 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 Manu[...]

Select Force as the type of trigger . Then program the desired pounds of force. Next, program Max T rigger T ime . This provides a mea - sure of safety insuring the welder will fault if for some reason the welder never achieves the programmed trigger force. See Figure 4-9. NOTE The example shown in Figure 4-9 assumes trigger force for a part with f[...]

On the Process Settings tab, nd Sensing Speed . This is the speed (inches per second) at which actua - tion will move during the approach just before reaching trigger position. Speed range is from 0.001 to 1.00 in/s (inches per second). (A typical base start speed is in the range of 0.20 to 0.40 in/s.) This feature is exclusive to the servo-cont[...]

After pressing T each , you will see a window similar to the one shown in Figure 4-12. Place an unwelded part into the xture. Press both opti- touch activation switches to jog the horn down to within 0.010 - 0.030 inches above the part. The stroke position of the thruster will be shown in the Current Position box. Once you are at the desired pos[...]

On the Process Settings tab, select Weld > Method , Parameter , and Max T ime. Collapse Distance - The distance the welder advances once programmed trigger force is reached. Usually the dis - tance is the height of the ener gy director , or shear joint of the part being welded. Max Time - A seconda r y we ld ch a ra cteristic o f fering a measur[...]

Continuing with the Process Settings tab. . . This is the speed of the thruster during the weld cycle (after T rigger Sensing Speed and Motion Force Decrease have oc- curred). This motion feature is only available on servo- press systems. The speed range is from 0.001 to 1.0 in/s. Motion Control Mode - Select Speed . Motion T ype - Select Constant [...]

Servo Step 13 - Set Amplitude Continuing with the Process Settings tab. . . A typical initial amplitude setting is 100%. The range for this fea - ture is between 20% and 100%. Figure 4-19 iQ Explorer , Amplitude Setting T ypical amplitude setting is 100%. Range is between 20% and 100% . Continue with Post Weld settings on the next page. Page 51 Duk[...]

Servo Step 14 - Post W eld Settings Continuing with the Process Settings tab. . . The post weld phase of the process is often overlooked, however it is important in achieving desired weld results. The iQ Servo W elder has several exclusive post weld control parameters that can improve weld bond strength and process repeatability . Hold There are tw[...]

Hold Static Hold Method If Time has been enabled in the Static Hold Method , the actuator motion will stop at the end of the weld cycle for the programmed interval ( Hold Dwell Time ). When the interval is ended, the actuator motion changes so that it goes upward and travels to the Home position. This unique feature allows for superior consistency [...]

See Figure 4-22. For each limit that is important to your application, use the drop down menu, and select Display . Those limits 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 T ab Page 54 iQ Series Ultrasonic Generator/Power Supply ES[...]

Servo Step 17 - Cycle Data After all the parameters have been programmed, initiate the weld cycle. V iew 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 ][...]

Quick S t ar t - Pneumatic Step 1 - Read Section 4 of the iQ Explorer User's Manual 403-579-00. It is im - portant that you understand and familiarize yourself with the operation and navigation of the iQ Explorer user interface software. Insure that proper connection of the iQ Explorer soft- ware with the pneumatic press is in place. See Figur[...]

Navigate to the Process Settings tab. All welder setup related control parameters are programmed on this tab. The Process Settings page is organized into 8 boxes: 1 - W elder T ype 2 - Initiate Mode 3 - Trigger 4 - W eld 5 - Post W eld 6 - Pressure 7 - Amplitude 8 - Secondary Control These boxes organize the weld process into the events that occur [...]

Pneumatic Step 5 - Process Settings>T rigger T rigger T ype - Select Force as the T rigger T ype. Program a force value. For this example we used values typical for welding an energy director part with approximately 10 inches of linear weld joint. This type of weld may need about 50 pounds of trigger force. See Figure 4-28 . Figure 4-28 Suggeste[...]

Pneumatic Step 6 - Process Settings>T rigger >T ype Continued fr om pr evious page Figure 4-29 iQ Explorer , Process Settings > T rigger >T ype Figure 4-29 below shows T rigger T ype and the other example values discussed on the previous page. Figure 4-30 iQ Explorer , Process Settings > T rigger > Method T rigger , Method - In th[...]

Pneumatic Step 7 - Process Settings> W eld Figure 4-31 iQ Explorer , Process Settings > Weld Mode - Select Single Method . Method 1 - Select Collapse Distance . This is the distance the welder will advance once the programmed trigger force is achieved. Usual ly the di stance is the height of the ener gy director , or shear joint of the part b[...]

Pneumatic Step 8 - Post W eld Settings Figure 4-33 iQ Explorer , Process Settings > Post Weld > Hold Method > Hold T ime Select T ime. Program in a time of 0.500 seconds. See Figure 4-33. After the weld process (In this example setup, Collapse Distance has a programmed value.), the welder will shut off the ultrasound signal and continue to[...]

Pneumatic Step 9 - Process Settings > Pressure Figure 4-34 iQ Explorer > Process Settings > Post Weld > Pressure For systems equipped with the Electronic Pressure Regulator option, weld pressure parameters need to be programmed in this section of the Process Settings page. See Figure 4-34. Downstroke - This is the approach pressure befo[...]

Air Cylinder Size V erify the size of your air cylinder diameter . Use T able 4-I to determine actual force at a given pressure. T able 4-I Pounds of Force Comparison Pressure (psi) Cylinder Diameter (in) 1.5 2.0 2.5 3.0 0 0 0 0 0 5 9 16 25 35 10 18 39 49 71 15 27 47 74 106 20 35 63 98 141 25 44 79 123 177 30 53 94 147 212 35 62 11 0 172 247 40 71 [...]

Pneumatic Step 10 - Process Settings > Pressure Continued fr om Page 62 Hold Pressure - This pressure determines the amount of force applied during Hold . T ypical weld setups have Hold Pressure higher than programmed Weld Pressure . Increasing hold force (pressure) during Hold helps to produce stronger weld bonds. For a basic weld setup, progra[...]

Pneumatic Step 1 1 - Process Settings >Amplitude Figure 4-36 iQ Explorer , Process Settings > Amplitude Amplitude - This refers to the peak-to-peak displacement of the horn at its workface. Amplitude settings are given as a percent of the horn's nominal amplitude in the range of 20% to 100%. Select Local . Then, at Weld , select 100%. Fo[...]

Pneumatic Step 12 - Process Settings >Secondary Control Secondary controls provide additional ways to end the weld portion of a cycle together with the primary control method specied. This means control of the weld process can be accom - plished either by the primary control or by one or more secondary controls. Secondary control is not typic[...]

Navigate to the Process Limits tab. If this is the rst time on this tab (for your selected setup), the status for each parameter will be blank. See Figure 4-38 below . Figure 4-38 iQ Explorer , Process Limits T ab - I Pneumatic Step 14 - Process Limits T ab Continued Page 67 Dukane Manual Part No. 403-575-00 Section 4 - Operation Lab Dukane iQ E[...]

Figure 4-39 iQ Explorer , Process Limits T ab - II Using the drop down menu for each limit that is im - portant to your application, select Display . That limit will be displayed on 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 15 - Cycle Data Navigate to the Cycle Data tab. Begin a weld cycle using the cycle activation switches. • Inspect the weld results of your nished part on the Cycle Data page. • Review weld data to insure the process was done as programmed. • V alues for the completed cycle should be displayed under each programmed parameter [...]

This page intentionally left blank Page 70 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

SECTION 5 System Oper a tional T esting Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Operational T est of the Acoustic Stack ................ 74 Procedure for Cycling the System .................... 77 Page 71 Dukane Manual Part No. 403-575-00 Section 5 - System Operational T esting[...]

This page intentionally left blank Page 72 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

O ve r v i e w An iQ Series generator must be operating and connected to the press/thruster in order to test the system. For efcient operation of a Dukane ultrasonic assembly system, the ultrasound signal from the generator must match the frequency and phase angle (vibrational charac- teristics) of the stack that is being driven. Each stack has [...]

Op erat ional T est of the Acoust ic St ac k The following test procedure is suggested before starting the generator , to verify that the vibrational characteristics of the stack fall within the range of the Digi-T rac. All Dukane stack components are manufactured to tolerance specications within this range. A non-Dukane horn, an improperly asse[...]

b. If an overload fault is displayed, a mis- match has occurred between the genera- tor ’ s ultrasonic output signal and the stack. Refer to the next section, T roubleshooting , and see the Press Error Message tables. Also see Figure 5-3 that shows an example of an error that caused cycling to stop. 4. While pressing the TEST button, lightly touc[...]

5. Turn the generator of f. Check the stack for proper assembly , damaged components, or dirty mating surfaces. Recheck the ultrasound cable for proper connections. Repeat Steps 1 through 4. If the test still fails, go to the next step. 6. T urn the generator off, remove the stack from the thruster , and remove the horn from the stack. Reinstall th[...]

P rocedure for C y cling the S ys t e m 1. Check that you have correctly performed the following: a. Installed the stack in the thruster and have closed the stack access cover securely . b. Secured the xture in place. c. Performed the Operational T est of the Acoustic Stack as detailed on Page 74 of this section. 2. V erify that all controls on [...]

This page intentionally left blank Page 78 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

SECTION 6 T r oubleshooting Page 79 Dukane Manual Part No. 403-575-00 Section 6 - T roubleshooting[...]

This page intentionally left blank Page 80 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

Problem Possible Solution T roubleshoot ing Unit power-up sequence stops, and front panel ON/OFF button is ashing RED rapidly . Operation of the front panel ON/OFF button at power up : • Steady Green - Generator is ready to cycle. • Red - Generator is in standby mode. • Slow Flashing Red - Generator is charging the internal power supplies.[...]

Error Message Description Cause(s) Possible Solution(s) Part detected before reach- ing start sensing distance. Force in excess of 50 lb (220 N) was detected before reaching Sensing Start Distance. 1. Sensing Start Distance is too large. 2. Part(s) not properly loaded. 1. Decrease Sensing Start Distance. 2. Check part placement. Press down travel l[...]

Error Message Description Cause(s) Possible Solution(s) Position Error Allowable servo position following error was exceeded. 1. Force required to maintain pro- grammed speed(s) is too large. 2. T rigger Distance or Sensing Start Distance is too large, causing premature contact of horn with part. 3. Press motion is obstructed. 1a. Reduce weld/hold [...]

T able 6 - II Error Messages, Pneumatic-related iQ Pneumatic Press Error Messages Error Message Description Cause(s) Possible Solution(s) Overload (average) at xxx msecs. Power above generator rating. Power from ultrasonic stack sent to the part exceeds power rating of generator . 1. Excessive pressure applied to the part. 2. Booster size is too la[...]

V eri f ying F eature Op erat ion The iQ ES generator can be congured with several features that provide interfaces from the control board to encoders and transducers outside the system. These features include the following: • Distance Encoder • Power • EPR (electronic pressure regulator) with Pressure T ransducer • Force T ransducer (Lo[...]

Power T o verify operation of this feature perform an acoustic stack test. If no power is displayed, contact Dukane. The electronic pressure regulator and pressure transducer are components of the same system. The electronic pressure regulator accepts commands from the iQ ge n e r a t or and sets the air pressure to the desired user-selected value.[...]

The welding cycle can be divided into a series of segments: Cycle Start, Downstroke, T rigger , W eld Pressure 1, W eld Pressure 2, and Hold. In each of these segments, operator action, rear panel inputs, and process limits can affect the ow of the process. What follows are examples of how some events can alter the ow of the welding process, [...]

The Cycle T erminates During Downstroke The system is in downstroke when the cycle has been successfully started and the head travels towards the part. If the cycle is terminated during downstroke, all trig- ger , weld, and hold characteristics are displayed as zeroes. Figure 6-2 shows results of a cycle terminated during downstroke due to either a[...]

Premature W eld T ermination W eld T ermination Due to End of Weld/Ground Detect An End-of-W eld signal from the thruster limit switches and a Ground Detect signal to the J602 connector cause the W eld portion of the cycle to terminate. A character- istic of this type of weld termination is Hold T ime. If the Hold portion of the cycle is executed, [...]

P ART DOWNSTROKE DOWNSTROKE WELD TIME WELD DIST WELD ENERGY HOLD T OT AL T OTAL COUNT TIME DIST PRESSURE 1 PRESSURE 1 PRESSURE 1 TIME CYCLE TIME STROKE 13 0.994 1.7916 0.038 0.0026 >>20.9 0 1.032 1.7942 Figure 6-8 Weld Segment T erminated by a Bad Part Limit W eld T ermination Due to Secondary Control Secondary controls are additional control[...]

The iQ G ene rato r W on’t C yc l e Just before a weld cycle starts, the iQ generator waits for an initiating signal. If an initiating signal is applied and the system does not begin to cycle, check the following: • Make sure the iQ generator ’ s Initiate Mode in the Process Control menu is set to the appropriate setting: Manual if using acti[...]

This page intentionally left blank Page 92 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

SECTION 7 Maintenance Page 93 Dukane Manual Part No. 403-575-00 Section 7 - Maintenance[...]

This page intentionally left blank Page 94 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

Front and Rear Panels Cleaning • Do not use any solvents or abrasive cleaners to clean any of the panels. • Do not spray or apply cleaner directly on the gen - erator . • Apply a small amount of cleaner on a soft, clean cloth rst. Then, clean the panel with the moistened cloth. Power Button The button responds well to rm, gentle nger[...]

This page intentionally left blank Page 96 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

SECTION 8 Options Power Inlet Options ............................... 99 120V Systems for North American and Japan ............. 99 Electrical Safety .................................. 99 120V Power Ground .................................. 99 AC Power Inlet Panel ............................. 100 AC Power Cord .....................................[...]

This page intentionally left blank Page 98 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

This section of the User ’ s Manual provides a general overview of some options/upgrades, all of which are subject to availability , for the basic ultrasonic gen - erator: Power Inlet Options 120V Systems for North America and Japan 120V systems for North America and Japan have a xed (non-detachable) power cord. This option is available on gen[...]

AC Power Inlet Panel The optional AC power inlet panel is described here. AC Power Cord The AC power cord ( A in Figure 8-2) is appropriately rated and permanently mounted to the power inlet panel. Power Switch/Circuit Breaker The power switch/circuit breaker ( B in Figure 10-2) has a rocker type actuator switch that will activate or deacti- vate t[...]

Press Interface Board This board is also known as the Options Slot Board as shown in Figure 10-4, Interpreting the Model Number . Board location is shown in Figure 3-6. Each option is described in general terms: P4 - Dual Pressure Only P/N 1 10-4426 Dual pressure is a feature that is exclusive to Dukane press systems. It increases clamp force to im[...]

This page intentionally left blank Page 102 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

SECTION 9 Contacting Dukane Page 103 Dukane Manual Part No. 403-575-00 Section 9 - Contacting Dukane[...]

This page intentionally left blank Page 104 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

Contact ing Dukane Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • Model number , line voltage and serial number . • Fault/error indicators from the iQ Explorer . • Software version. • Problem description and steps taken to resolve it. Many problems can be solved [...]

This page intentionally left blank Page 106 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

SECTION 10 Specica tions Generator Outline Drawings ................... 109 W eights, Dimensions, Operating Environment ..... 111 AC Power Requirements ..................... 11 3 Interpreting the Model Number ................. 11 4 Regulatory Agency Compliance ................ 11 5 Page 107 Dukane Manual Part No. 403-575-00 Section 10 - Speci[...]

This page intentionally left blank Page 108 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

Figure 10-1 Layout - Low Prole iQ Generator AC POWER ENTRY UL TRASOUND & SYSTEM I/O'S OPTIONS CARDCAGE P ANELS 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 [...]

Figure 10-2 Layout - High Prole iQ Generator ALLOW 5" BOTH SIDES FOR COOLING. IN (mm) ALLOW 3" IN BACK FOR CABLING. 5.50 [139.78] ALLOW 5" BOT H 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 UL TRASOUND & SYSTEM I/O'S OPTIONS CARDC[...]

Figure 10-3 Layout - High Power iQ Generator WEIGHT 34 LBS UL TRASOUND & I/O CONNECTIONS 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 1 1 1 Dukane M[...]

Operating Environment Operate the equipment within these guidelines: T emperature : 40°F to 100°F (+5°C to +38°C) Air Particulates : Keep the equipment dry . Minimize exposure to moisture, dust, dirt, smoke and mold. Humidity : 5% to 95% Non–condensing @ +5°C to +30°C Nonoperating storage guidelines: T emperature : -4°F to 158°F (-20°C t[...]

AC Power Requirements NOTES: An X used above in the Model Numbers is a “wildcard” character meaning any valid character code combination. Maximum line current requirement is specied at the minimum nominal AC line voltage and the rated power level. T able 10- III AC Power Requirements Operating Frequency Generator Model Number Overload Power [...]

Interpreting the Model Number Inter preting the Model Number 20 HS 120 - 2 A - P6 - C2 P ower Le vel 480 = 4800 W atts 360 = 3600 W atts 240 = 2400 W atts 180 = 1800 W atts 120 = 1200 W atts 090 = 900 W atts 060 = 600 W atts System Process Contr ols A = Blank front panel AC Line Input 2 = 200-240 V for 5.25” tall chassis 1800 W and above 2 = 200-[...]

Regulatory Agency Compliance CAUTION DO NOT make any modi- cations to the generator or associated cables as the changes may result in violating one or more regulations under which this equipment is manufactured. FCC The generator complies with the following Federal Com - munications Commission regulations. • The limits for FCC measurement proc[...]

This page intentionally left blank Page 1 16 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

SECTION 11 A ppendices Appendix A, List of Figures .................... 11 9 Appendix B, List of T ables .................... 122 Page 1 17 Dukane Manual Part No. 403-575-00 Section 1 1 - Appendices[...]

This page intentionally left blank Page 1 18 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

Page 1 19 Dukane Manual Part No. 403-575-00 Section 1 1 - Appendices List of Figures No. Description Page Appendix A Continued 2-1 Example of 220/240 V olt Grounded 3-Prong Receptacle ................................................ 9 2-2 International 220/240 V olt Grounding .........................................................................[...]

Page 120 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00 List of Figures No. Description Page Appendix A Continued Continued 4-15 iQ Explorer , Start Motion After Force Decreases By ..................................................... 49 4-16 iQ Explorer , Motion Control Mode Speed ................[...]

Page 121 Dukane Manual Part No. 403-575-00 Section 1 1 - Appendices List of Figures No. Description Page Appendix A Continued 6-4 Cycle T erminated Due to Pre-trigger Overtravel............................................................88 6-5 Weld T erminated Due to End of Weld/Ground Detect ................................................... 89 6[...]

Page 122 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00 Appendix B List of T ables No. Description Page 2-I iQ Generator Weights ..................................................................................................... 10 3-I Rack Mounted Bracket Part Numbers ...........................[...]

Inde x Page 123 Dukane Manual Part No. 403-575-00 Index[...]

This page intentionally left blank Page 124 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

Index A Acoustic Stack 74 AC Power Cord 95 AC Power Requirements 1 13 Agency Compliance 1 15 CE Ma rking 115 FCC 115 IP (In ternational Pr otection) Rating 115 Air Cylinder Size 63 Amplitude 65 Appendices 1 17 List of Figur es 119 List of T ables 122 C Conguration Port Connector 27 Connecting Cables 29 Cycle Data 55, 69 D Digi-T rac 73 Drawings [...]

Placemen t 15 Placemen t in a Seismic Region 16 When to U se Lo ckou t / T agou t D evices 13 Interpreting the Model Number 1 14 IP (International Protection) Rating 1 15 iQ Explorer He lp System 43 Soware co nnec tion 56 Su pport Featur es N umeric Pad and K ey board 42 Syst em T ab 76 V iew Speed Prole 50 iQ Explorer User's Manual 403-[...]

R Ramp Down T ime 65 Ramp Up T ime 65 RFI Grounding 28 S Specications 107 A C Po wer Requirem ents 113 Dimension s 112 In terpreting the M o del N umber 114 Operating En vironmen t 112 W eights 112 Static Hold Method 53 Stopping the W eld Cycle 42 System 77 Cyc ling 77 System Inputs Connector 19 System Inputs Connector Pinout 20 System Inputs Si[...]

This page intentionally left blank Page 128 iQ Series Ultrasonic Generator/Power Supply ES User ’s Manual Dukane Manual Part No. 403-575-00[...]

Dukane ISO ISO CER TIFICA TION Dukane chose to become ISO 9001:2008 certi - fied in order to demonstrate to our customers our continuing commitment to being a quality vendor . By passing its audit, Dukane can assure you that we have in place a well–defined and systematic approach to quality design, manu- facturing, deliver y and service. This c[...]

Please r ef er to our website a t: www .dukane.com/us/sales/intsales.htm to loca te your local repr esentativ e. Par t No. 403  - 575 - 0 0 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • F AX (630) 797- 4949 Series Ultrasonic Generator/Power Supply ES User's Man[...]