Intelligent Assembly Solutions Series ULTRASONIC GENERATOR/POWER SUPPLY ES AUTOMATED HAND PROBE PRESS User's Manual Dukane 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 ISO 9001:2008 Dukane products are manufactured in ISO registered facilities. www.dukane.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Copyright © 2011 Dukane Intelligent Assembly Solutions 2900 Dukane Drive St. Charles, IL 60174 USA Notice of Rights: All rights reserved.
Revision History Revision Number Revision Summary Date - 00 Original release. 08/19/2011 Dukane Manual Part No.
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Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . . 1 General User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Press System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Section 2 - Health and Safety . . . . . . . . . . . . . . . . . . . 5 General Considerations . . . . . . . . . . . . . . .
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Contents Continued Section 5 - System Operational Testing . . . . . . . . . 71 Section 6 - Troubleshooting . . . . . . . . . . . . . . . . . . . 79 Section 7 - Maintenance . . . . . . . . . . . . . . . . . . . . . . 93 Section 8 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Section 9 - Contacting Dukane . . . . . . . . . . . . . . . .
Section 1 - Introduction SECTION 1 Introduction General User Information . . . . . . . . . . . . . . 3 Press System Overview. . . . . . . . . . . . . . . 4 Key Features . . . . . . . . . . . . . . . . . . . . . 4 Dukane Manual Part No.
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Section 1 - Introduction 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 organized to allow you to learn how to safely operate this equipment. The examples given are chosen for their simplicity to illustrate basic operation concepts.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual 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 fixture) and iQ Explorer software. The software allows the operator to control the system either remotely or at the press location. • Load Regulation provides constant ultrasound amplitude automatically regardless of power draw.
Section 2 - Health and Safety SECTION 2 Health and Safety General Considerations . . . . . . . . . . . . . . . . 7 Plastics Health Notice. . . . . . . . . . . . . . . . . 8 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Domestic Power Grounding . . . . . . . . . . . . . . . . . . . . . . . 9 International Power Grounding . . . . . . . . . . . . . . . . . . . . 9 Lifting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . .
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Section 2 - Health and Safety General Considerations Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your equipment. Proper Installation - Operate system components only after they are properly installed. No Unauthorized Modifications - Do not modify your system in any way unless authorized to do so by Dukane Corporation. Unauthorized modifications could cause equipment damage and/or injury to the operator.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual General Considerations Continued from previous page Pre-trigger Switch Adjustment - The pre-trigger switch option starts the horn vibrating before contacting the part to be welded. To ensure safe operation, adjust the pretrigger 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 connecting or disconnecting electrical cables.
Section 2 - Health and Safety 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 illustrates the appropriate electrical outlet to use with the power cord that is included with systems shipped to North America. CAUTION If you have a two-prong electrical receptacle, we strongly recommend that you replace it with a properly grounded three-prong type.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Lifting the Equipment High Profile Low Profile lb kg lb kg Generator Only 25 11.3 20 9.1 Generator + Packing Materials 30 13.6 25 11.3 Table 2–I iQ Generator Weights How to Lift Safely • Before lifting, take a moment to think about what you’re about to do. • Examine the object for sharp corners, slippery spots or other potential hazards. Know your limit and don’t try to exceed it.
Section 3 - Installation SECTION 3 Installation Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 When to Use Lockout/Tagout Devices . . . . . . . . . . . . . . . 13 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Placement in a Seismic Zone . . . . . . . . . . . . . . . . . . 16 Rear Panel Layout Overview . . . . . . . . . . . . . . . . . . . 18 AC Power Inlet Panel . .
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Section 3 - Installation Before Installation As you plan for the installation of your generator, 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 / Tagout Devices Figure 3-1 Lockout Device In Open Position, Unlocked The typical kind of LOTO device for this generator is a clam shell type device (with lockout capability).
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Lockout/Tagout Continued from previous page Procedure 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. Using a typical clam shell type LOTO device: 1) Open the clam shell.
Section 3 - Installation 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 with normal system operation. Allow at least 5 inches (13 cm) of space on both ends of the generator chassis for air circulation.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Continued from previous page 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 Table 3-I, and Figure 3- 4 (showing a low profile unit) below. Mount the generator to a 19-inch equipment rack.
Section 3 - Installation Continued from previous page 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 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. 18.84 [478.47] 18.04 [458.22] 0.280 HOLE ALLOW 3" IN BACK FOR CABLING. 1.14 [29.0] 13.20 [335.28] ALLOW 5" BOTH SIDES FOR COOLING. 10.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Rear Panel Layout Overview This section provides an overview of the generator rear panel layout, which includes panel areas dedicated to various standard system functions and options that are available. Figure 3-6 illustrates a typical panel layout. B K D -WARNING- POWER LINE OUTLET MUST BE GROUNDED. DISCONNECT LINE POWER BEFORE REMOVING COVER.
Section 3 - Installation AC Power Inlet Panel The standard AC power inlet panel is described in this section. IEC AC Power Inlet Connector The IEC AC power inlet connector mounted on the system AC power inlet panel requires a properly configured IEC compliant power cord, which enables worldwide system operation by simply changing the power cord. Low profile systems are equipped with a 10 amp rated IEC inlet connector. The high profile systems include a 16/20 amp rated IEC inlet connector.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Continued from previous page Note that a simple switch closure (relay contact) connected to a control input can not activate the input without adding an external power supply to power the input. Adding jumper connections to pins available on the System Inputs connector, can configure switch closure inputs to operate referenced to generator chassis ground (nonisolated), without adding a separate power supply, if desired.
Section 3 - Installation Pin Signal Name Cable Color Code Signal Option 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
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Continued from previous page Pin 5 (Remote Setup Selection Bit 2 Input) . Pin 5 is the Remote Setup Selection Bit 2, which is the third least significant 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 significant bit used to select different welding setups with an automation control system.
Section 3 - Installation Pin Signal Name Cable Color Code 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 7 Any Fault Status Output 8 Press Trigger Status Output RED/BLK 9 System Overload Status Output GRN/BLK 10 System Online Status Output ORN/BLK 11 Press Top of Stroke Status Output BLU/BLK 12 Current Loop OK Status Output BLK/WHT 13 Analog Monitor Signal Com
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Continued from previous page 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.
Section 3 - Installation Continued from previous page 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 remain active until the next ultrasound activation cycle begins and this output will automatically reset.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Continued from previous page Pin 17 (Amplitude/Power Regulation Status Output) (Contact your sales representative about Power Regulation availability.) This status signal is most useful when the power regulation mode is selected.
Section 3 - Installation Ultrasound Output Connector The ultrasound output connector used with all standard generators is a high voltage (5000V) coaxial style SHVBNC 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 are secured with a simple and reliable quarter-turn bayonet style attachment mechanism.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual RFI Grounding 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 contains a RFI filter which blocks noise on the AC power line from entering the generator control circuitry.
Section 3 - Installation Connecting Cables 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 Ultrasound Output of the iQ Series generator to the transducer, through a coaxial cable. The electrical welding signal is transmitted through this cable. Step 3. Operational Control (J201) - This cable runs from J201 on the thruster to the generator's Thruster connector (J5).
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Three Configurations The iQ generator, ES models are configured in three basic ways: 1) With a pneumatic 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 Dukane Manual Part No.
6 Figure 3-15 Dukane Manual Part No. 403-575-00 PE LINE VOLTAGE: 200-240 Vac 50/60Hz, 15A U.S. PATENT 5,880,580 OTHER PATENTS PENDING ST. CHARLES IL 60174 MADE IN U.S.A. DUKANE CORP -WARNING- POWER LINE OUTLET MUST BE GROUNDED. DISCONNECT LINE POWER BEFORE REMOVING COVER.
Page 32 Table 3-V AC INPUT - - - - PE - - - GRND - - AC INPUT PE J2 J3 2.4 2.
Figure 3-16 Dukane Manual Part No. 403-575-00 LINE VOLTAGE: 90-240 Vac 50/60 Hz, 10A W ARNING: POW ER LINE OUTLET M UST BE G ROUNDED. DISCONNECT LINE POW ER BEFORE REM OVING COVER. 11 PE J100 SERVO POW ER 1 ST. CHARLES, IL M ADE IN U.S.A. WWW.DUKANE.
Page Table 3-VI 34 200-479-XXM 200-1556-XXM 200-1613-XXM 200-1545-XXM 200-1553-XXM One of the following: 5 6 7 8 9 13 14 15 16 17 18 12 11 10 200-1649-XXM 4 (for 120 VAC models, power cord is integral to generator) 200-1557 200-1557 200-1557 200-1557 200-1380-XXM 200-1381-XXM 200-1624 (240 VAC, 10A, India) 200-1542 (240 VAC, 10A, Europe) 200-1541 (240 VAC, 10A, US) 200-1612 (240 VAC, 15A, India) 200-1111 (240 VAC, 16A, Europe) 200-1110 (240 VAC, 15A, US) 200-1576 (120 VAC) One of the follo
7 8 6 Figure 3-17 Dukane Manual Part No. 403-575-00 PE LINE VOLTAGE: 200-240 Vac 50/60Hz, 15A U.S. PATENT 5,880,580 OTHER PATENTS PENDING ST. CHARLES IL 60174 MADE IN U.S.A. DUKANE CORP -WARNING- POWER LINE OUTLET MUST BE GROUNDED. DISCONNECT LINE POWER BEFORE REMOVING COVER.
Page Table 3-VII 36 9 10 11 12 13 8 7 2 3 4 5 6 1 Cable No.
Section 3 - Installation Networking Where several welders are connected, please refer to the iQ Explorer User's Manual, 403-579-00, Section 5 - Multiple Welder Connections.
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Section 4 - Operation SECTION 4 Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Stopping the Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 iQ Explorer Support Features . . . . . . . . . . . . . . . . . . . . . . . . . 42 Numeric Pad and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Help System . . .
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Section 4 - Operation Overview 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. . With this type of system, the user controls nearly all aspects of the welding process with the iQ Explorer User Interface (HMI) or a computer (user supplied), using iQ Explorer.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Other Control Functions Other control functions - such as monitoring the welding process and controlling the system are accomplished using the iQ HMI or your computer and Dukane's iQ Explorer software. Stopping the Weld Cycle Normal Conditions The cycle stops when the programmed welding cycle ends or when the rear panel's Cycle Stop input is activated.
Section 4 - Operation Help System The help system is a reference tool to assist in understanding 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. Top Menu Bar Help is one of the top menu bar items as shown in Figure 4-3. Clicking on Help and then clicking on iQ Explorer Help will open the Help window. A Contents tab and an Index tab are two entry points to the help file information.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Quick Start - 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. Pneumatic Welder Quick Start See Pages 56-69 It is important that you understand and familiarize yourself with the operation and navigation of the iQ Explorer user interface software.
Section 4 - Operation Servo Step 3 - Navigate to the Process Settings Tab See Figure 4-7. Process Settings Tab ] Figure 4-7 iQ Explorer, Process Settings Servo Step 4 - Process Settings > Initiate Mode > Manual See Figure 4-8. NOTE This Initiate Mode selection assumes there is a stand-alone, benchtop system with manual activation switches. ] Select Manual in Initiate Mode. Figure 4-8 iQ Explorer, Process Settings > Initiate Mode Dukane Manual Part No.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Servo Step 5 - Process Settings > Trigger > Type Select Force as the type of trigger. NOTE Then program the desired pounds of force. The example shown in Figure 4-9 assumes trigger force for a part with four linear inches of weld would need between 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. Next, program Max Trigger Time.
Section 4 - Operation Servo Step 6 - Program Sensing Speed On the Process Settings tab, find Sensing Speed. This is the speed (inches per second) at which actuation 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-controlled systems and allows for precise, accurate trigger forces.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Servo Step 8 - Teach Start Sensing Distance After pressing Teach, you will see a window similar to the one shown in Figure 4-12. Place an unwelded part into the fixture. Press both optitouch 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 position, press Set to program that distance.
Section 4 - Operation Servo Step 10 - Program Weld Characteristics On the Process Settings tab, select Weld > Method, Parameter, and Max Time. Collapse Distance - The distance the welder advances once programmed trigger force is reached. Usually the distance is the height of the energy director, or shear joint of the part being welded. Max Time - A secondary weld characteristic offering a measure of safety.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Servo Step 12 - Select Motion Control Mode > Speed > Constant Continuing with the Process Settings tab. . . This is the speed of the thruster during the weld cycle (after Trigger Sensing Speed and Motion Force Decrease have occurred). This motion feature is only available on servopress systems. The speed range is from 0.001 to 1.0 in/s. Motion Control Mode - Select Speed. Motion Type - Select Constant. Speed - Program speed.
Section 4 - Operation Servo Step 13 - Set Amplitude Continuing with the Process Settings tab. . . A typical initial amplitude setting is 100%. The range for this feature is between 20% and 100%. Typical amplitude setting is 100%. Range is between 20% and 100%. Figure 4-19 iQ Explorer, Amplitude Setting Continue with Post Weld settings on the next page. Dukane Manual Part No.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Servo Step 14 - Post Weld 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 Welder has several exclusive post weld control parameters that can improve weld bond strength and process repeatability. Hold There are two types of hold - Dynamic Hold and Static Hold. These types can be used together or separately.
Section 4 - Operation Continued from previous page 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 on overall part height.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Servo Step 16 - Navigate to the Process Limits Tab 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. Process Limits Tab ] Figure 4-22 iQ Explorer, Process Limits Tab Page 54 Dukane Manual Part No.
Section 4 - Operation Servo Step 17 - Cycle Data After all the parameters have been 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 Dukane Manual Part No.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Quick Start - Pneumatic Welder Pneumatic Step 1 - Read Section 4 of the iQ Explorer User's Manual 403-579-00. It is important 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 software with the pneumatic press is in place. See Figure 4-24 and Section 3 of the iQ Explorer User's Manual.
Section 4 - Operation Pneumatic Step 3 - Process Settings 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 - Welder Type 2 - Initiate Mode 3 - Trigger 4 - Weld 5 - Post Weld 6 - Pressure 7 - Amplitude 8 - Secondary Control These boxes organize the weld process into the events that occur during the weld process. Figure 4-26 shows the Welder Type selection.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Pneumatic Step 5 - Process Settings>Trigger Trigger Type - Select Force as the Trigger Type. 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.
Section 4 - Operation Continued from previous page Pneumatic Step 6 - Process Settings>Trigger >Type Figure 4-29 below shows Trigger Type and the other example values discussed on the previous page. Dukane iQ Explorer - [Welder 1- Setup 4] Lab Figure 4-29 iQ Explorer, Process Settings > Trigger >Type Trigger, Method - In the programming example here, we have chosen Normal. Figure 4-30 below shows this selection. Figure 4-30 iQ Explorer, Process Settings > Trigger > Method Dukane Manual Part No.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Pneumatic Step 7 - 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. Usually the distance is the height of the energy director, or shear joint of the part being welded. NOTE Max Time - Max Time is a secondary weld characteristic offering a measure of safety.
Section 4 - Operation Pneumatic Step 8 - Post Weld Settings Process Settings > Post Weld > Hold Method Select Time. 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 apply force for the programmed time. This phase is important to insure the molten plastic created during the weld phase has a chance to solidify before pressure is removed from the part.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Pneumatic Step 9 - Process Settings > 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 before Trigger. For a basic setup, program a value here equal to Pressure 1.
Section 4 - Operation Air Cylinder Size Verify the size of your air cylinder diameter. Use Table 4-I to determine actual force at a given pressure. Pressure (psi) 1.5 2.0 2.5 3.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Pneumatic Step 10 - Process Settings > Pressure Continued from Page 62 Hold Pressure - This pressure determines the amount of force applied during Hold. Typical 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, program Hold Pressure at 10 psi above Weld Pressure. See Figure 4-34.
Section 4 - Operation Pneumatic Step 11 - 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%. For a basic setup, leave Ramp Up Time and Ramp Down Time at 0.150 and 0.000 respectively (the default settings).
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual 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 specified. This means control of the weld process can be accomplished either by the primary control or by one or more secondary controls. Secondary control is not typically needed for basic setup. See Figure 4-37 below.
Section 4 - Operation Pneumatic Step 14 - Process Limits Tab Navigate to the Process Limits tab. If this is the first time on this tab (for your selected setup), the status for each parameter will be blank. See Figure 4-38 below. Lab Dukane iQ Explorer - [Welder 1- Setup 4] Figure 4-38 iQ Explorer, Process Limits Tab - I Continued Dukane Manual Part No.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Pneumatic Step 14 - Process Limits Tab Continued from previous page Using the drop down menu for each limit that is important 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.
Section 4 - Operation 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 finished part on the Cycle Data page. • Review weld data to insure the process was done as programmed. • Values for the completed cycle should be displayed under each programmed parameter. Figure 4-40 below shows the top and bottom parts of the Cycle Data page.
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Section 5 - System Operational Testing SECTION 5 System Operational Testing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Operational Test of the Acoustic Stack . . . . . . . . . . . . . . . . . 74 Procedure for Cycling the System . . . . . . . . . . . . . . . . . . . . . 77 Dukane Manual Part No.
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Section 5 - System Operational Testing Overview An iQ Series generator must be operating and connected to the press/thruster in order to test the system. For efficient operation of a Dukane ultrasonic assembly system, the ultrasound signal from the generator must match the frequency and phase angle (vibrational characteristics) of the stack that is being driven. Each stack has unique vibrational characteristics dependent on the combination of stack components.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Operational Test of the Acoustic Stack 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-Trac. All Dukane stack components are manufactured to tolerance specifications within this range.
Section 5 - System Operational Testing Figure 5-2 iQ Explorer TEST, Screen Display Acoustic Stack Test Continued from previous page b. If an overload fault is displayed, a mismatch has occurred between the generator’s ultrasonic output signal and the stack. Refer to the next section, Troubleshooting, 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.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Acoustic Stack Test Continued from previous page 5. Turn the generator off. 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. Turn the generator off, remove the stack from the thruster, and remove the horn from the stack.
Section 5 - System Operational Testing Procedure for Cycling the System 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 fixture in place. c. Performed the Operational Test of the Acoustic Stack as 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.
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Section 6 - Troubleshooting SECTION 6 Troubleshooting Dukane Manual Part No.
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Section 6 - Troubleshooting Troubleshooting Problem Possible Solution Unit power-up sequence stops, and front panel ON/OFF button is flashing 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. • Fast Flashing Red - AC line over/under voltage detected or internal power supply failure.
Page 82 Table 6 - I Press moved sufficiently far down to activate lower limit switch. Servo controller program error. Lower travel limit switch activated. While in Teach mode, time allowed for press to produce moderate/large forces was exceeded. Down Travel Limit Force Duration Exceeded Servo controller hardware error. Checksum Error Command Error Error occurred with servo amplifier.
Table 6 - I Dukane Manual Part No. 403-575-00 Power fault. Check AC line. AC line voltage drops below 190 VAC on 240 VAC systems, and below 95 VAC on 120 VAC systems. Generator correctly locks to the resonant Horn comes in contact with the part nest frequency of the ultrasonic stack, but or anvil. loses the lock at a point later in the weld cycle. Fluctuations in AC power. 1. Improper stack assembly. 2. Defective ultrasound cable. 3. Ramp up time is too short. Check the incoming AC line power.
Page Table 6 - II 84 Possible Solution(s) Power fault. Check AC line. AC line voltage drops below 190 VAC on 240 VAC systems, and below 95 VAC on 120 VAC systems. Generator correctly locks to the resonant Horn comes in contact with the part nest frequency of the ultrasonic stack, but or anvil. loses the lock at a point later in the weld cycle. Overload (frequency) at xxx msecs. Check for coupling between stack and part. Fluctuations in AC power. 1. Improper stack assembly. 2.
Section 6 - Troubleshooting Verifying Feature Operation The iQ ES generator can be configured 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 Transducer • Force Transducer (Load Cell) Each of these features has a corresponding output on the iQ Explorer's Cycle Data page.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Power To verify operation of this feature perform an acoustic stack test. If no power is displayed, contact Dukane. Electronic Pressure Regulator and the Pressure Transducer The electronic pressure regulator and pressure transducer are components of the same system. The electronic pressure regulator accepts commands from the iQ generator and sets the air pressure to the desired user-selected value.
Section 6 - Troubleshooting Effects of I/O and System Errors on Process Flow The welding cycle can be divided into a series of segments: Cycle Start, Downstroke, Trigger, Weld Pressure 1, Weld Pressure 2, and Hold. In each of these segments, operator action, rear panel inputs, and process limits can affect the flow of the process. What follows are examples of how some events can alter the flow of the welding process, and how they can be identified.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual The Cycle Terminates 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 trigger, weld, and hold characteristics are displayed as zeroes.
Section 6 - Troubleshooting Premature Weld Termination Weld Termination Due to End of Weld/Ground Detect An End-of-Weld signal from the thruster limit switches and a Ground Detect signal to the J602 connector cause the Weld portion of the cycle to terminate. A characteristic of this type of weld termination is Hold Time. If the Hold portion of the cycle is executed, then the weld was terminated by an end of weld/ground detect error. Figure 6-5 illustrates this condition.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Weld Termination Due to Secondary Control Secondary controls are additional controls that allow the weld to be controlled by more than one process parameter. In this example, the weld portion of the cycle ends when either the primary control parameter (in this case, Weld by Time for 50 ms) or the secondary control parameter (Weld Energy for 20.0 joules) is reached.
Section 6 - Troubleshooting The iQ Generator Won’t Cycle 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 activation switches; Auto if the system is configured for use with an automated system.
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Section 7 - Maintenance SECTION 7 Maintenance Dukane Manual Part No.
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Section 7 - Maintenance Front and Rear Panels I/O Connector Cleaning The Input/Output connector has a pair of 4-40 threaded jack screws to secure the connector. Make sure the screws are snug, but do not overtighten them. • Do not use any solvents or abrasive cleaners to clean any of the panels. • Do not spray or apply cleaner directly on the generator. • Apply a small amount of cleaner on a soft, clean cloth first. Then, clean the panel with the moistened cloth.
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Section 8 - Options 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 . . . . . . . . . . . . . . . .
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Section 8 - Options 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 generator: Power Inlet Options 120V Systems for North America and Japan 120V systems for North America and Japan have a fixed (non-detachable) power cord. This option is available on generators with power ratings of 1200 watts or less and with operating frequencies of 20kHz, 30kHz, or 40kHz.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual 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 deactivate the AC power to the system.
Section 8 - Options 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 110-4426 Dual pressure is a feature that is exclusive to Dukane press systems.
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Section 9 - Contacting Dukane SECTION 9 Contacting Dukane Dukane Manual Part No.
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Section 9 - Contacting Dukane Contacting 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 over the telephone, so it is best to call from a telephone located near the equipment.
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Section 10 - Specifications SECTION 10 Specifications Generator Outline Drawings . . . . . . . . . . . . . . . . . . 109 Weights, Dimensions, Operating Environment . . . . . 111 AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . 113 Interpreting the Model Number . . . . . . . . . . . . . . . . . 114 Regulatory Agency Compliance . . . . . . . . . . . . . . . . 115 Dukane Manual Part No.
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Dukane Manual Part No. 403-575-00 3.45 [87.53] ALLOW 5" EACH SIDE FOR COOLING 13.23 [335.92] IN mm OPTIONAL FRONT POWER SWITCH 17.16 [435.77] ALLOW 3" IN BACK FOR CABLING. ALLOW 5" EACH SIDE FOR COOLING 12.55 [318.67] 3.81 [96.
Figure 10-2 Page 110 ALLOW 5" BOTH SIDES FOR COOLING. 13.20 [335.37] OPTIONAL FRONT POWER SWITCH 17.16 [435.76] ALLOW 3" IN BACK FOR CABLING. 5.50 [139.78] IN (mm) WEIGHT: 25 LBS 5.19 [131.83] ALLOW 5" BOTH SIDES FOR COOLING. 12.54 [318.61] AC POWER ENTRY OPTIONS CARDCAGE PANELS ULTRASOUND & SYSTEM I/O'S iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Layout - High Profile iQ Generator Dukane Manual Part No.
Dukane Manual Part No. 403-575-00 17.16 [435.8] ALLOW 6"/150mm BEHIND UNIT FOR CABLE CONNECTIONS 5.19 [131.8] 5.50 [139.7] IN mm 14.51 [368.5] 3.15 [80.0] WEIGHT 34 LBS ALLOW 2"/50mm ON SIDES FOR COOLING AIR FLOW 6.29 [159.
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Weights High Profile Low Profile High Power lb kg lb kg lb kg Generator Only 25 11.3 20 9.1 34 15.4 Generator + Packing Materials 30 13.6 25 11.3 39 17.7 Table 9–I iQ Generator Weights Dimensions Dimensions - in (mm) Model 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.
Section 10 - Specifications AC Power Requirements Operating Frequency Generator Model Number Overload Power Ratings (Watts) Input AC Power Requirements Nominal AC Volt @ Maximum RMS Current 15kHz 15HS360-2A-XX-XX 3600 200-240V 50/60 Hz @ 25 Amps 15kHz 15HS480-2A-XX-XX 4800 200-240V 50/60 Hz @ 30 Amps 20kHz 20HS120-1A-XX-XX 1200 100-120V 50/60 Hz @ 15 Amps 20kHz 20HS120-2A-XX-XX 1200 200-240V 50/60 Hz @ 8 Amps 20kHz 20HS180-2A-XX-XX 1800 200-240V 50/60 Hz @ 12 Amps 20kHz 20HS240-2A-
Page 114 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 and energy weld control, with a distance, EPR and force press interface board and an RS-232 and Ethernet communications board. 2 = 200-240 V for 5.25” tall chassis 1800 W and above 2 = 200-240 V for 3.5 tall chassis 1200 W and below 1 = 100-120 V for 5.
Section 10 - Specifications Regulatory Agency Compliance FCC The generator complies with the following Federal Communications Commission regulations. • The limits for FCC measurement procedure MP-5, “Methods of Measurement of Radio Noise Emissions from ISM Equipment”, pursuant to FCC Title 47 Part 18 for Ultrasonic Equipment. CE Marking This mark on your equipment certifies that it meets the requirements of the EU (European Union) concerning interference causing equipment regulations.
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Section 11 - Appendices SECTION 11 Appendices Appendix A, List of Figures . . . . . . . . . . . . . . . . . . . . 119 Appendix B, List of Tables . . . . . . . . . . . . . . . . . . . . 122 Dukane Manual Part No.
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Section 11 - Appendices Appendix A No. Description List of Figures Page 2-1 Example of 220/240 Volt Grounded 3-Prong Receptacle.................................................9 2-2 International 220/240 Volt Grounding ..............................................................................9 3-1 Lockout Device in Open Position, Unlocked..................................................................13 3-2 Bottom Lockout Device in Closed Position, Locked...................................
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Appendix A Continued List of Figures No. Description Page 4-15 iQ Explorer, Start Motion After Force Decreases By......................................................49 4-16 iQ Explorer, Motion Control Mode Speed.......................................................................50 4-17 iQ Explorer, Speed, Motion Type, Profile.......................................................................
Section 11 - Appendices Appendix A No. Continued Description List of Figures Page 6-4 Cycle Terminated Due to Pre-trigger Overtravel............................................................88 6-5 Weld Terminated Due to End of Weld/Ground Detect....................................................89 6-6 Weld Terminated Due to Trigger Lost.............................................................................89 6-7 Weld Segment Terminated by a Secondary Control............................
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Appendix B List of Tables No. Description 2-I iQ Generator Weights...................................................................................................... 10 3-I Rack Mounted Bracket Part Numbers............................................................................. 16 3-II Generator Input Signals (J2)............................................................................................
Index Index Dukane Manual Part No.
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Index Index G A Acoustic Stack 74 AC Power Cord 95 AC Power Requirements 113 Agency Compliance 115 CE Marking 115 FCC 115 IP (International Protection) Rating Air Cylinder Size 63 Amplitude 65 Appendices 117 List of Figures 119 List of Tables 122 115 C Configuration Port Connector 27 Connecting Cables 29 Cycle Data 55, 69 D Digi-Trac 73 Drawings and Tables 3 Dukane 73 Address 105 Contacting 103 E-mail 105 Fax 105 Intelligent Assembly Solutions 105 Phone 105 Website 105 Dynamic Hold Method 52 E Electr
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual P I Continued - Installation Placement 15 Placement in a Seismic Region 16 When to Use Lockout / Tagout Devices 13 Interpreting the Model Number 114 IP (International Protection) Rating 115 iQ Explorer Help System 43 Software connection 56 Support Features Numeric Pad and Keyboard 42 System Tab 76 View Speed Profile 50 iQ Explorer User's Manual 403-579-00 44 iQ HMI 42 L Low Line Voltage Power Supply 4 M Maintenance 93 AC Power Cord 95 Air Ve
Index R Ramp Down Time 65 Ramp Up Time 65 RFI Grounding 28 S Specifications 107 AC Power Requirements 113 Dimensions 112 Interpreting the Model Number 114 Operating Environment 112 Weights 112 Static Hold Method 53 Stopping the Weld Cycle 42 System 77 Cycling 77 System Inputs Connector 19 System Inputs Connector Pinout 20 System Inputs Signal Descriptions 21 System Operational Testing 71 System Outputs Connector 23 System Outputs Signal Descriptions 24 System Power Output 74 System Tab 76 T TEST button 7
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Dukane ISO ISO CERTIFICATION Dukane chose to become ISO 9001:2008 certified 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, manufacturing, delivery and service. This certificate reinforces Dukane's status as a quality vendor of technology and products.
Please refer to our website at: www.dukane.com/us/sales/intsales.htm to locate your local representative. Series Ultrasonic Generator/Power Supply ES User's Manual Part No. 403 - 575 - 00 www.dukane.com/us Printed in the United States of America Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St.
