Dukane 403-574-01 - Manuals

Page 3 - Revision History; Revision; iQ LinQ

Page iii Dukane Manual Part No. 403-574-01 Revision History 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 Trigger by Power. Add iQ LinQ TM . Web address revised. Revise Regulatory Agency Complia...

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

Page 5 - Contents; Continued on next page

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

Page 6 - Continued; Section 11 - Specifications; iQ

Page vi Dukane Manual Part No. 403-574-01 Contents Continued Section 6 - Process Control Settings . . . . . . . . . . . . . . . . . 45 User-Provided Process Control OverviewManual WeldingAutomated WeldingAutomated Process Control Input SignalsStatus Output SignalsScreen Navigation Basics Programmin...

Page 7 - SECTION 1; Introduction

Page 1 Section 1 – Introduction Dukane Manual Part No. 403-574-01 SECTION 1 Introduction General User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Read the Manual First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Notes, Cautions and Warnings . ....

Page 8 - iQ Series

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

Page 9 - General User Information; Read the Manual First; The figures and tables are identified by the section num; CAUTION; WARNING; NOTE

Page 3 Section 1 – Introduction 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 y...

Page 10 - Generator Overview; CE Certification

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 ava...

Page 11 - SECTION 2; Health and Safety

Page 5 Section 2 – Health & Safety Dukane Manual Part No. 403-574-01 SECTION 2 Health and Safety General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical Safety . . . ....

Page 13 - General Considerations; system; Proper Installation -; dition, unauthorized modifications will void the equip; Keep the Cover On -; cover unless specifically directed to do so by the manu; Grounded Electrical Power -; Plastics Health Notice; deflectors may be installed

Page 7 Section 2 – Health & Safety Dukane Manual Part No. 403-574-01 General Considerations Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your equip - ment. In this manual, the term system refers to a complete group of components associ...

Page 14 - qualified electrician. Do not; qualified electrician replace it; See; Electrical Safety; Domestic Power Grounding

Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 Approved 2 pole, 3 wire grounding receptacle HUBBELL No. 5652 or equivalent to NEMA 6–15R or 6–20R Figure 2 - 1 Example of 220/240 Volt, Grounded, 3-Prong Receptacle CAUTION If there is a...

Page 15 - Step 3. Get a firm grasp of the object before be; Lifting the Equipment; How to Lift Safely; • Examine the object for sharp corners, slippery spots

Page Section 2 – Health & Safety Dukane Manual Part No. 403-574-01 Step 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). Tuck your chin while keeping y...

Page 17 - SECTION 3; Installation

Page 11 Section 3 – Installation Dukane Manual Part No. 403-574-01 SECTION 3 Installation Before Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 13 When to Use Lockout/Tagout Devices . . . . . . . . . . . . . . . 13 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 19 - Before Installation; please consider these important subjects as listed; When to Use Lockout /; of one such device in the figure above.

Page 13 Section 3 – Installation Dukane Manual Part No. 403-574-01 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 Saf...

Page 20 - Wait a minimum of five minutes for the

Page 14 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 Lockout/Tagout 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 gener...

Page 21 - Unpacking; Specifications, Section 11; to c o ol t he inter nal c omp o -

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 perm...

Page 22 - If the

Page 1 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 generator is to be used in an active seismic region, secure the unit by rack-mounting it or by securing the ...

Page 23 - Benchtop Mounting; If you choose to mount the generator on a benchtop follow

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 ...

Page 24 - RFI Grounding; ic generator contains a RFI filter which blocks noise on; a STAR configuration (il

Page 1 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 electrica...

Page 25 - Connecting Cables; Section 4; Manually Operated Probe System; Step 1. Ground the generator chassis using the supplied; Power Cords; Refer to

Page 1 Section 3 – Installation Dukane Manual Part No. 403-574-01 CAUTION The power cord is equipped with a three-prong, ground-ed-type plug for your safety. Whenever a t wo -slot re -ceptacle is encountered, we st rongly rec ommend t h a t i t i s r e p l a c e d w i t h a p r o p e r l y g r o u ...

Page 27 - SECTION 4; Standard Connections; Configuration Port Connector

Page 1 Page 0 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Dukane Manual Part No. 403-574-01 SECTION 4 Standard Connections Rear Panel Layout Overview . . . . . . . . . . . . . . . . . . . . . . . . 23 AC Power Inlet Panel . . ....

Page 29 - Rear Panel Layout Overview; AC Power Inlet Panel; Configuration Port Connector – Digital control port; Options Module Panel; Options

Page 3 Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Page 3 Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Dukane Manual Part No. 403-574-01 Rear P...

Page 30 - AC power inlet panel requires a properly configured IEC; Power Switch/Circuit Breaker; Chassis Grounding Stud; Section 3

Page 5 Page 4 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Dukane Manual Part No. 403-574-01 Page 5 Page 4 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections AC P...

Page 31 - System Inputs Connector Pinout; The; . The male connector on the cable is a mirror image; Application Note AN502

Page 5 Page 4 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Page 5 Page 4 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Dukane Manual Part No. 403-574-01 webs...

Page 32 - System Inputs Signal Descriptions; Pin 3 (Remote Setup Selection Bit 0 Input); Pin 3 is the Remote Setup Selection Bit 0, which is the; Pin 4 (Remote Setup Selection Bit 1 Input); Pin 4 is the Remote Setup Selection Bit 1, which is the

Page 7 Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Dukane Manual Part No. 403-574-01 Page 7 Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections System...

Page 33 - Pin 5 (Remote Setup Selection Bit 2 Input); Pin 5 is the Remote Setup Selection Bit 2, which is the

Page 7 Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Page 7 Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Dukane Manual Part No. 403-574-01 Pin 5 ...

Page 34 - System Outputs Connector; connector mounted on the; System Outputs Connector Pinout; connector is a DB-25F; System Outputs Signal Descriptions; Pin 2 is an open connection.

Page Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Dukane Manual Part No. 403-574-01 Page Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections System Out...

Page 35 - Example

Page Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Page Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Dukane Manual Part No. 403-574-01 Pin 7 (Any...

Page 36 - Contact your sales representative about; cannot adjust the system output to the output level that; on the front of the MPC; system faults or offline active, but not a process fault

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

Page 37 - Pin 25 is an open connection.

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

Page 39 - settings and hardware configurations. Contact your local

Page 33 Page 3 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Page 33 Page 3 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Section 4 – Standard Connections Dukane Manual Part No. 403-574-01 Fi...

Page 41 - SECTION 5; Standard System Status

Page 35 Section 5 – Standard System Status and Controls Dukane Manual Part No. 403-574-01 SECTION 5 Standard System Status and Controls Front Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 System Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Page 43 - Front Panel Overview; System Displays; Peak Detect Feature; indicator begins to flash (RED) when; Bar Graph Power Scaling; System Operating Mode; POWER TEST

Page 37 Section 5 – Standard 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 8...

Page 44 - Control Keys; Keys Left of the Display; INFO; direct contact with a metal fixture

Page 3 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 use...

Page 45 - TEST; IMPORTANT; Control Keys Right of the Display; Navigation Keys; Press ENTER to confirm and store a selection in memory.; CANCEL

Page 3 Section 5 – Standard 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 Time Only generators) ,...

Page 46 - The LCD display identifies the Dukane

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...

Page 47 - Stopping the Weld Cycle; Normal Conditions; Press; Automated System; cycle if configured as “End of Weld”.

Page 41 Section 5 – Standard System Status and Controls Dukane Manual Part No. 403-574-01 Stopping the Weld Cycle Normal Conditions The cycle stops when the programmed welding cycle ends. Emergency ConditionsManual System Press OFFLINE to stop the ultrasound signal. This may be done under any condi...

Page 48 - System Parameter Settings; not be possible with the standard system settings.; Default System Parameter Settings; Default Frequency Dependent Settings

Page 4 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 nom...

Page 49 - System Parameter Adjustment Limits; Continued from previous page

Page 43 Section 6 – Process 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 ...

Page 51 - Section 6; Process Control Settings

Page 45 Section 6 – Process Control Settings Dukane Manual Part No. 403-574-01 Section 6 Process Control Settings User-Provided Process Control Overview . . . . . . . . . . . . . . 47 Manual Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Automated Welding . . . . . ....

Page 53 - to the parts to be ultrasonically joined. Then the operator

Page 47 Section 6 – Process 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 energy...

Page 54 - Screen Navigation Basics; pears just after the generator is first switched

Page 4 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 Screen Navigation Basics 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 OPERATE MODEPRO...

Page 55 - until you see the Main Menu screen as; HOW TO - Have a PLC Control the Ultrasound Activation; Programming the Generator - Some Examples; On the following pages these programming examples cover how to:; • Have a PLC Control the Ultrasound Activation

Page 4 Section 6 – Process 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...

Page 56 - HOW TO - Weld by Time

Page 50 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 HOW TO - Weld 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 t...

Page 57 - HOW TO - Weld by Energy

Page 51 Section 6 – Process Control Settings Dukane Manual Part No. 403-574-01 HOW TO - Weld 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...

Page 58 - HOW TO - Adjust Amplitude; Adjust the amplitude. This is a value with a minimum

Page 5 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 se...

Page 59 - Ramp Up feature; linearly; soft stop

Page 53 Section 6 – Process 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 assembly (transducer, booster, horn) linearly , rather than in two...

Page 61 - SECTION 7; System Verification Tests

Page 55 Section 7 – System Operational Testing Dukane Manual Part No. 403-574-01 SECTION 7 System Operational Testing System Verification Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Preliminary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57...

Page 63 - Preliminary Setup; tem Operating Mode display should flash red; activate and the first segment of the

Page 57 Section 7 – System Operational Testing Dukane Manual Part No. 403-574-01 System Verification Tests Preliminary Setup Step 1. Plug in the AC line cord to the correct AC power outlet. See Table 11 -II for the model power requirements. Step 2. Attach a compatible ultrasonic probe to the ultras...

Page 64 - Step 2. Connect a probe to the generator ultrasonic out-

Page 5 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 System Test To 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 ( ...

Page 65 - Probe Operation; erating Mode; Stopping the Ultrasound; System with a User-supplied; This applies only if Auto Stop

Page 5 Section 7 – System Operational Testing 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 t...

Page 67 - SECTION 8

Page 1 Section 8 – Troubleshooting Dukane Manual Part No. 403-574-01 SECTION 8 Troubleshooting No Ultrasonic Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Cables . . . ....

Page 69 - No Ultrasonic Output; Probe; Generator; triggered if it is offline. (If the generator is; Operate Input; Also refer to Table 4-

Page 3 Section 8 – Troubleshooting 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 p...

Page 70 - System Power Output Level:; System Power Diagnostic; flashes RED at a fast rate of about four flashes per; Power Status indicator doesn’t flash, but is ON continu

Page 4 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...

Page 71 - Welding Problems; Weak Welds; Weak welds, or underwelding, is caused by insufficient; Excess Flash; Variations in plastic due to filler materials and moisture

Page 5 Section 9-Maintenance Dukane Manual Part No. 403-574-01 Welding Problems Weak Welds Weak welds, or underwelding, is caused by insufficient energy being transmitted to the part. You can increase the weld pressure, increase the weld time or change to a higher gain booster to increase the ampli...

Page 72 - Pop-up Status Screens

Page 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 Text Displayed System Status or Fault Explanation Average Overload OVERLOAD - AVERAGE AT X.XXX SECONDS POWER ABOVE GENERATOR RA...

Page 73 - SECTION 9

Page 7 Section 9-Maintenance Dukane Manual Part No. 403-574-01 SECTION 9 Maintenance Front and Rear Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Display . . . . . . . . . . ....

Page 75 - Front and Rear Panels; To remove dust, first try gently dusting with a microfi; Screen Cleaning Solutions; bottle from which it can be used, or; Chassis; The cover is preformed to fit over the chassis and has; do not overtighten them.

Page 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. To remove dust, first try gently dusting wit...

Page 77 - iQLinQ

Page 71 Section 10 - Options Dukane Manual Part No. 403-574-01 SECTION 10 Options Power Inlet Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 120V Systems for North American and Japan . . . . . . . . . . . . . 73 Electrical Safety . . . . . . . . . . . . . . . . . . . . . ....

Page 79 - Power Inlet Options; 20V systems for North America and Japan have a fixed; fied electrician replace it fol

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 sy...

Page 80 - The optional AC power inlet panel is described here.; AC Power Cord; The AC power cord (; grounding is discussed in

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...

Page 81 - Single Connector System I/O Panel

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 identifi...

Page 82 - Optional MPC Interface Connections; System Control Inputs/Status Outputs, and; Option Panel Modules; A single optional module can be installed in the; fies cable length. This will vary depending

Page 7 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, • Sys...

Page 83 - MPC Probe Control

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) Table 10 - II MPC I/O Connector Signals MPC I/O Connections Signal names and Pin number...

Page 84 - MPC Interface Installation Guide; Cut Outs; For panel mounted modules:

Page 7 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 inter...

Page 85 - Earth ground - Connect one end of a user-supplied; Front Connections; PROBE 1

Page 7 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 gro...

Page 86 - System Status; When the system is powered and ready, the front panel; lights up, and becomes; is lit with a YELLOW/ORANGE color, a; lights up RED, a hardware fault has been; Probe Selection Status; PROBE SELECTION STATUS; in; lights up GREEN indicating it is the; ultrasonic power is activated.

Page 0 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 STATUS LED lights up, and becomes GREEN ( E in Figure 10 - 9). If this LED ...

Page 87 - MPC Cycle Illustration; The flow chart below illustrates a typical welding

Page 1 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 activ...

Page 88 - Remote Amplitude Control; Current Loop Fault; Future Availability

Page iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 Remote Amplitude Control Module Part Number - 110- 4183 This optional module enables remote control of output amplitude of the iQ system. The control interface is a 4–20mA curre...

Page 89 - IQ SYSTEM; Menu Selections

Page 3 Section 10 - Options Dukane Manual Part No. 403-574-01 AMPLITUDE CONTROLAMPLITUDE SETTINGRAMP UP / DOWN TIME AMPLITUDE SETTING 90 % CHANGE VALUE SELECT DIGIT AMPLITUDE SETTING AMPLITUDE CONTROL BY iQ SYSTEMAUTOMATION This menu available only with Remote Amplitude Control option. Figure 10-13...

Page 90 - Automation Thruster Control; This optional module enables the

Page 4 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 Automation Thruster Control Module Part Number - 110- 4206 This optional module enables the iQ system to control a Dukane iQ thruster. The module is illustrated in Figure 10-14...

Page 91 - Isolated I/O Conversion; Examples; NPN to PNP

Page 5 Section 10 - Options Dukane Manual Part No. 403-574-01 To enable the thruster, Pins 3 and 9 must be shorted together through a safety circuit (see Table 10-V) during normal operation. During an abort or emergency stop condition, the connection between Pins 3 and 9 must open to disable moveme...

Page 95 - RS-232 Interface Option; Configure advanced hardware settings including Phase,; All control parameters that are configured via RS-; Configure advanced hardware settings including Phase,; All control parameters that are configured via RS-

Page 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 ...

Page 96 - PROFIBUS Communications Module; Control Parameters available via PROFIBUS; All parameters that are configured via PROFIBUS

Page 0 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 J2 U/S I 0 LINE VOLTAGE:200-240 Vac50/60Hz, 15A PE J3 J4 J1 BUS ERROR PROFIBUS J16 iQ LinQ ™ PROFIBUS Communications Module Part Number - 110-4554 The PROFIBUS option module al...

Page 97 - Control Parameters available via EtherNet/IP; All parameters that are configured via

Page 1 Section 10 - Options Dukane Manual Part No. 403-574-01 iQ LinQ TM Ethernet/IP TM Module Part Number - 110- 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 t...

Page 99 - Specifications; Low Profile Chassis

Page 3 Section 11 - Specifications Dukane Manual Part No. 403-574-01 SECTION 11 Specifications Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Low Profile Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 High Profi...

Page 105 - Operating Environment; Operate the generator within these guidelines:; Weight

Page Section 11 - Specifications Dukane Manual Part No. 403-574-01 Operating Environment Operate the generator within these guidelines: Temperature : 40°F to 100°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...

Page 107 - Inter; ow

Page 101 Section 11 - Specifications Dukane Manual Part No. 403-574-01 Inter pr eting the Model Number 20 HB 120 - 2 E- R1 P ow er 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 Pr ocess Contr ols A = Advanced W eld Controlle...

Page 108 - Regulatory Agency; DO NOT make any modi-; Rating; FCC; “Methods of Measurement of Radio Noise Emissions; CE Marking; This mark on your equipment certifies that it meets the

Page 10 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 Regulatory Agency Compliance CAUTION DO NOT make any modi- fications to the generator or associated cables as the changes may result in violating one or more reg-ulations unde...

Page 109 - Contacting Dukane

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

Page 111 - Identify Equipment; • Fault/error indicators from the LCD display; tors at; to get this; Intelligent Assembly; Mailing Address; Dukane Ultrasonics; Main; Website

Page 105 Section 12 - Contacting Dukane Dukane Manual Part No. 403-574-01 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 LCD ...

Page 113 - APPENDICES; Guide to

Page 107 Appendices Dukane Manual Part No. 403-574-01 APPENDICES List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Guide to iQ Generator Menu Structure. . . . . . . ...

Page 115 - List of Figures; Description

Page 10 Appendices Dukane Manual Part No. 403-574-01 List of Figures 2-1 Example of 220 Volt, Grounded, 3-prong Receptacle .....................................................8 2-2 International 220/240V Grounding ..................................................................................8 ...

Page 116 - List of Tables; Low Profile Chassis Drawing; continued

Page 110 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 No. Description Page 2-I iQ Generator Weights ....................................................................................................... 9 3-I Rack Mount Bracket...

Page 117 - Menus; Guide to iQ Generator Menu Structure

Page 111 Appendices Dukane Manual Part No. 403-574-01 Menus Page Number Time Only Operate 113 Process Setup - Automated Probe 114 Process Setup - Hand Probe 115 Process Setup - MPC Probe 116 Process Setup - Process Limits 117 Process Setup - Utilities 118 Time and Energy Operate 119 Process Setup -...

Page 119 - im

Page 113 Appendices Dukane Manual Part No. 403-574-01 # 1 P ART COUNT X XXXX WELD TIME 0 .0000 S O P E R A T E T im e O n ly M e n u s P a g e 1 o f 1 5 “Rxx” = Remote Setup Number and #xx = Local Setup Number O PERA TE MODE PROCESS DA TA PROCESS S TA TISTICS SYSTEM P ARAMETERS PART COUNT X XXXX GO...

Page 120 - to

Page 114 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 P R O C E S S S E T U P T im e O n ly M e n u s P a g e 2 o f 1 5 P ROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES No option boards installed A u to m a te d P ro b e ...

Page 123 - TU; Tim

Page 117 Appendices Dukane Manual Part No. 403-574-01 P R O C E S S S E TU P Tim e O nly M en us P ag e 5 o f 1 5 P ROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES P ro c e s s L im its Disable Maximum W eld T ime Minimum W eld T ime P ROCESS LIMITS SUSPECT P ART BAD P ART WELD TIME LIMIT Ena...

Page 124 - ti

Page 11 iQ Series , Ultrasonic Generator/Power Supply LS User’s Manual Dukane Manual Part No. 403-574-01 P R O C E S S S E T U P T im e O n ly M e n u s P a g e 6 o f 1 5 P ROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES U ti li ti e s U TILITIES SETUP CONTROL SETUP UTILITI...

Page 131 - lit

Page 15 Appendices Dukane Manual Part No. 403-574-01 P R O C E S S S E T U P T im e a n d E n e rg y (a n d T im e O n ly ) M e n u s P a g e 1 3 o f 1 5 AMPLITUDE CONTROL AMPLITUDE SETTING RAMP UP / DOWN TIME A m p lit u d e C o n tr o l W ARNING M ODIFIED SETTINGS M AY EFFECT O PERA TION OF UNIT ...

Page 135 - Dukane ISO; ISO CERTIFICATION; System Infrastructure.; C E R T I F I E D

Dukane ISO ISO CERTIFICATION 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-...

Page 136 - Please refer to our website at:

Part No. 403-574-01 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949 Series, LS Generators, User's Manual Printed in the United States of America www.dukane.com/us Please refer to our website at: www .dukane .com/us...