Dukane 403-575-00 - Manual

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

SECTION 2 Health and Safety General Considerations . . . . . . . . . . . . . . . . 7Plastics Health Notice . . . . . . . . . . . . . . . . . 8Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Domestic Power Grounding . . . . . . . . . . . . . . . . . . . . . . 9Internat...

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. In ad-...

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 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 Electr...

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 any question about the grounding of your recep- tacle, have it checked by a qualified electrician. Do not cut off th...

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 your back as vertical as possible. Step 3. Get a firm grasp of the object...

SECTION 3 Installation Before Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 13 When to Use Lockout/Tagout Devices . . . . . . . . . . . . . . . 13 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Placement . . . . . . . . . . . . . . . . . . . . . . . ....

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 The typical kind...

Figure 3-3 Generator Front View (typical) Low Profile 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...

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 lo...

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 ben...

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 sty...

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 configured IEC compliant power cord, which enables worldwide system operation by simply ...

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...

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...

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 Trigger Status Output RED/BLK 9 Syst...

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 isola...

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 f...

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 ...

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 Ul- trasound Output of the iQ Series generator to the transducer, through a coaxial cable. The electrical w...

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 respe...

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 CONFIGUR A TION U LTRASOUND SYSTEM OUTPUTS SYSTEM INPUTS J2 J3 PE LINE VO LT AGE: 200-240 Vac 50/6...

Networking Where several welders are connected, please refer to the iQ Explorer User's Manual , 403-579-00, Section 5 - Multiple Welder Connections. After some introductory material, there is information about: • Simple Stand-alone Configuration • Unique IP Address, and • Connection to Local Area Ne...

SECTION 4 Operation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Stopping the Weld Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 iQ Explorer...

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 aspe...

Other Control Functions 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. Stopping the Weld Cycle Normal Conditions The cycle stops when the programmed welding cycle ends ...

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. Top Menu Bar Help is one of the top menu bar items as shown in F...

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.It is important that you understand and familiarize your- self with the...

See Figure 4-7. Figure 4-7 iQ Explorer, Process Settings Process Settings Tab 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...

Select Force as the type of trigger. Then program the desired pounds of force. Next, program Max Trigger Time . 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 Figu...

On the Process Settings tab, find 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...

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 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 Curren...

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 dis- tance is the height of the energy director, or shear joint of the part being welded. Max Time - A secondary...

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 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...

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 Typical amplitude setting is 100%. Range is between 20% and 100% . Continue with P...

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 strengt...

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. Th...

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 Tab Page ...

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 Page 55 Dukane Manual Part No. 403-57...

Quick Start - 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 t...

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 organiz...

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 ...

Pneumatic Step 7 - Process Settings> Weld 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. Usually the distance is the height of the ...

Pneumatic Step 8 - Post Weld Settings Figure 4-33 iQ Explorer, Process Settings > Post Weld > Hold Method > Hold Time 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 ...

Air Cylinder Size Verify the size of your air cylinder diameter. Use Table 4-I to determine actual force at a given pressure. Table 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 ...

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 str...

Pneumatic Step 11 - 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%. Sel...

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 accom- plished either by the primary control or by one or more se...

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. Figure 4-38 iQ Explorer, Process Limits Tab - I Pneumatic Step 14 - Process Limits Tab Continued Page 67 Dukane Manual Part No. 403-...

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 ...

SECTION 5 System Operational Testing Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Operational Test of the Acoustic Stack . . . . . . . . . . . . . . . . 74Procedure for Cycling the System . . . . . . . . . . . . . . . . . . . . 77 Page 71 Dukane Manual Par...

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 ran...

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, 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. ...

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

Problem Possible Solution Troubleshooting 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 ...

Table 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 pressu...

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 Tr...

Power To 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 generator and sets the air p...

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...

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 trig- ger, weld, and hold characteristics are displayed as zeroes. Figure 6-2 shows results of a cy...

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 character- istic of this type of weld termination is Hold Time. If ...

PART DOWNSTROKE DOWNSTROKE WELD TIME WELD DIST WELD ENERGY HOLD TOTAL TOTAL COUNT TIME DIST PRESSURE 1 PRESSURE 1 PRESSURE 1 TIME CYCLE TIME STROKE 13 0.994 1.7916 0.038 0.0026 >>20.9 0 1.032 1.7942 Figure 6-8 Weld Segment Terminated by a Bad Part Limit Weld Termination Due to Secondary Contro...

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 approp...

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

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 first. Then, clean the panel with the moistened cloth. Power Button The butt...

SECTION 8 Options Power Inlet Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 120V Systems for North American and Japan . . . . . . . . . . . . . 99 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 120V Power Ground . . . . . . . . . ....

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 fixed (non-detachable) ...

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 ac...

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 Duka...

SECTION 9 Contacting Dukane Page 103 Dukane Manual Part No. 403-575-00 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 res...

Operating Environment Operate the equipment within these guidelines: Temperature : 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: ...

Interpreting the Model Number Inter pr eting the Model Number 20 HS 120 - 2 A - P6 - C2 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 090 = 900 W atts 060 = 600 W atts System Pr ocess Contr ols A = Blank front panel A C Line Input 2 = 200-24...

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 regulations under which this equipment is manufactured. FCC The generator complies with the following Federal Com- munications Commission regu...

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

Page 119 Dukane Manual Part No. 403-575-00 Section 11 - Appendices List of Figures No. Description Page Appendix A Continued 2-1 Example of 220/240 Volt Grounded 3-Prong Receptacle ................................................9 2-2 International 220/240 Volt Grounding ...............................

Page 122 iQ Series Ultrasonic Generator/Power Supply ES User’s Manual Dukane Manual Part No. 403-575-00 Appendix B List of Tables No. Description Page 2-I iQ Generator Weights ..................................................................................................... 10 3-I Rack Mounted Br...

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 Explo...

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-...