Dukane ULTRASONIC GENERATOR/POWER SUPPLY LS 403-574-01 User Manual

ISO 9001:2008Products are manufactured in ISO registered facilities.Intelligent Assembly Solutionswww.dukane.com/usDukane Part No. 403-574-01 SeriesUL

Page  4 iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Generator OverviewThis generator is designed for

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Page  95Section 11 - SpecicationsDukane Manual Part No. 403-574-01Figure 11-1 Low Prole Chassis DrawingLOAD8060 100OVER400 20SYSTEM POWER OUTPUT LEV

Page  96                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Figure 11- 2 High Prole Chas

Page  97Section 11 - SpecicationsDukane Manual Part No. 403-574-01Figure 11- 3 High Power (3600W) Chassis DrawingALLOW 3" IN BACK FOR CABLING.AC

Page  98                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Figure 11- 4 High Power (4800

Page  99Section 11 - SpecicationsDukane Manual Part No. 403-574-01Operating EnvironmentOperate the generator within these guidelines:Temperature: 40

Page  100                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01AC Power RequirementsThe AC

Page  101Section 11 - SpecicationsDukane Manual Part No. 403-574-01Interpreting the Model Number20 HB 120 - 2 E- R1Power

Page  102                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Regulatory AgencyCompliance

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

Page  5Section 2 – Health & Safety Dukane Manual Part No. 403-574-01SECTION 2Health and SafetyGeneral Considerations . . . . . . . . . . . . . . .

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Page  105Section 12 - Contacting DukaneDukane Manual Part No. 403-574-01Contacting DukaneIdentify EquipmentWhen contacting Dukane about a service–rela

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Page  107AppendicesDukane Manual Part No. 403-574-01APPENDICESList of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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Page  109AppendicesDukane Manual Part No. 403-574-01List of Figures2-1 Example of 220 Volt, Grounded, 3-prong Receptacle ...

Page  110                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01No. Description Page2-I i

Page  111AppendicesDukane Manual Part No. 403-574-01Menus Page NumberTime Only Operate 113 Process Setup - Automated Probe

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Page  113AppendicesDukane Manual Part No. 403-574-01# 1 PART COUNT XXXXXWELD TIME 0.0000 S OPERATE Time Only Menus Pag

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Page  114                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01PROCESS SETUP Time Only Me

Page  115AppendicesDukane Manual Part No. 403-574-01PROCESS SETUP Time Only Menus Page 3 of 15 PROCESS SETUPPROCESS CONTROLPROCESS LI

Page  116                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01PROCESS SETUP Time Only Me

Page  117AppendicesDukane Manual Part No. 403-574-01PROCESS SETUP Time Only Menus Page 5 of 15 PROCESS SETUPPROCESS CONTROLPROCESS LI

Page  118                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01PROCESS SETUP Time Only Me

Page  119AppendicesDukane Manual Part No. 403-574-01OPERATE Time and Energy Menus Page 7 of 15 “Rxx” = Remote Setup Number and “#xx” = Local Setup

Page  120                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01PROCESS SETUP Time and Ene

Page  121AppendicesDukane Manual Part No. 403-574-01PROCESS SETUP Time and Energy Menus Page 9 of 15 PROCESS SETUPPROCESS CONTROLPROCES

Page  122                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01PROCESS SETUP Time and Ene

Page  123AppendicesDukane Manual Part No. 403-574-01PROCESS SETUP Time and Energy Menus Page 11 of 15 PROCESS SETUPPROCESS CONTROLPROCE

Page  7Section 2 – Health & Safety Dukane Manual Part No. 403-574-01General ConsiderationsPlease observe these health and safety recommendations f

Page  124                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01PROCESS SETUP Time and En

Page  125AppendicesDukane Manual Part No. 403-574-01PROCESS SETUP Time and Energy (and Time Only) Menus Page 13 of 15 AMPLITUDE CONTROLAMP

Page  126                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01 I/O PORT SETUPCONF

Page  127AppendicesDukane Manual Part No. 403-574-01ADVANCED HARDWARETime and Energy Menus Page 15 of 15 #1: SETUP NAMEOPERATE MODEPROCESS SETUPHAR

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Dukane ISOISO CERTIFICATIONDukane chose to become ISO 9001:2008 certi-fied in order to demonstrate to our customers our continuing commitment to being

Part No. 403-574-01Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–49

Page  8         iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Approved 2 pole, 3 wire grounding recept

Page  9Section 2 – Health & Safety Dukane Manual Part No. 403-574-01Step 1. Stand close to the load with your feet spread apart about s

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Page  11Section 3 – InstallationDukane Manual Part No. 403-574-01SECTION 3InstallationBefore Installation. . . . . . . . . . . . . . . . . . . . . . .

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Page  13Section 3 – InstallationDukane Manual Part No. 403-574-01Before InstallationAs you plan for the installation of your generator, please

Page  iiDukane Manual Part No. 403-574-01Copyright © 2010Notice of Rights:All rights reserved. No part of this manual including the interior design,

Page  14                 iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Lockout/Tagout Procedure t

Page  15Section 3 – InstallationDukane Manual Part No. 403-574-01UnpackingCarefully open your shipping container, and make sure it contains the ite

Page  16                 iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Placing the Generator when Used

Page  17Section 3 – InstallationDukane Manual Part No. 403-574-01Benchtop Mounting If you choose to mount the generator on a benchtop follow these ins

Page  18                 iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01RFI GroundingIn addition to the

Page  19Section 3 – InstallationDukane Manual Part No. 403-574-01CAUTIONThe power cord is equipped with a three-prong, ground-ed-type plug for your sa

Page  21Page  20                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsFigure 3 - 6 Generator

Page  21Page  20                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsDukane Manual Part No.

Page  23Page  22                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsDukane Manual Part No.

Page  23Page  22                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsPage  23Page  22     

Page  iiiDukane Manual Part No. 403-574-01Revision HistoryRevision RevisionNumber Summary Date - 00 Original release. 01/25/2008 - 01

Page  25Page  24                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsDukane Manual Part No.

Page  25Page  24                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsPage  25Page  24     

Page  27Page  26                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsDukane Manual Part No.

Page  27Page  26                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsPage  27Page  26     

Page  29Page  28                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsDukane Manual Part No.

Page  29Page  28                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsPage  29Page  28     

Page  31Page  30                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsDukane Manual Part No.

Page  31Page  30                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsPage  31Page  30     

Page  33Page  32                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsDukane Manual Part No.

Page  33Page  32                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualSection 4 – Standard ConnectionsPage  33Page  32     

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Page  35Section 5 – Standard System Status and ControlsDukane Manual Part No. 403-574-01SECTION 5Standard System Status and ControlsFront Panel Overvi

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Page  37Section 5 – Standard System Status and ControlsDukane Manual Part No. 403-574-01Front Panel OverviewThis section provides an overview of the f

Page  38                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Control KeysKeys Left of the

Page  39Section 5 – Standard System Status and ControlsDukane Manual Part No. 403-574-01TESTHold the TEST key momentarily to activate ultrasoun

Page  40                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Start-up SequenceAfter all co

Page  41Section 5 – Standard System Status and ControlsDukane Manual Part No. 403-574-01Stopping the Weld CycleNormal ConditionsThe cycle stops when t

Page  42                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01System Parameter Settings Ove

Page  43Section 6 – Process Control SettingsDukane Manual Part No. 403-574-01ContinuedSetting DescriptionUser Adjustment LimitSetting Ranges for All F

Page  vDukane Manual Part No. 403-574-01ContentsSection 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General User Infor

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

Page  45Section 6 – Process Control SettingsDukane Manual Part No. 403-574-01Section 6Process Control SettingsUser-Provided Process Control Overview .

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

Page  47Section 6 – Process Control SettingsDukane Manual Part No. 403-574-01User- Provided Process Control OverviewThe generator includes a proce

Page  48                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Screen Navigation BasicsThis

Page  49Section 6 – Process Control SettingsDukane Manual Part No. 403-574-011. Press CANCEL until you see the Main Menu screen as it is shown here.

Page  50                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01HOW TO - Weld by Time1. Pres

Page  51Section 6 – Process Control SettingsDukane Manual Part No. 403-574-01HOW TO - Weld by Energy (Available only if generator has energy option.)1

Page  52                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01HOW TO - Adjust Amplitude 1.

Page  53Section 6 – Process Control SettingsDukane Manual Part No. 403-574-01HOW TO - Adjust Ramp Up/Down Times The Ramp Up feature, also called sof

Page  viDukane Manual Part No. 403-574-01Contents ContinuedSection 6 - Process Control Settings . . . . . . . . . . . . . . . . . 45User-Provided Proc

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Page  55Section 7 – System Operational TestingDukane Manual Part No. 403-574-01SECTION 7System Operational TestingSystem Verication Tests . . . . . .

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Page  57Section 7 – System Operational TestingDukane Manual Part No. 403-574-01System Verication TestsPreliminary SetupStep 1. Plug in the AC lin

Page  58                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01System TestTo test the sys

Page  59Section 7 – System Operational TestingDukane Manual Part No. 403-574-01Probe Operation1. If the generator is not online, press the ON/OFFLINE

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

Page  61Section 8 – TroubleshootingDukane Manual Part No. 403-574-01SECTION 8TroubleshootingNo Ultrasonic Output . . . . . . . . . . . . . . . . . .

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

Page  63Section 8 – TroubleshootingDukane Manual Part No. 403-574-01No Ultrasonic OutputProbeMake sure that the probe coaxial cable is connected to th

Page  1Section 1 – IntroductionDukane Manual Part No. 403-574-01SECTION 1IntroductionGeneral User Information . . . . . . . . . . . . . . . . . . .

Page  64                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01System Power Output Level: Re

Page  65Section 9-MaintenanceDukane Manual Part No. 403-574-01Welding ProblemsWeak WeldsWeak welds, or underwelding, is caused by insufcient energy b

Page  66                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Pop-up Status ScreensSystem S

Page  67Section 9-MaintenanceDukane Manual Part No. 403-574-01SECTION 9MaintenanceFront and Rear Panels . . . . . . . . . . . . . . . . . . . . . .

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

Page  69Section 9-MaintenanceDukane Manual Part No. 403-574-01Front and Rear PanelsCleaning• Do not use any solvents or abrasive cleaners on the any

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Page  71Section 10 - OptionsDukane Manual Part No. 403-574-01SECTION 10OptionsPower Inlet Options . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Page  73Section 10 - OptionsDukane Manual Part No. 403-574-01This section of the User’s Manual provides a general overview of some options/upgrades, a

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Page  74                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01AC Power Inlet Panel The opti

Page  75Section 10 - OptionsDukane Manual Part No. 403-574-01I/O Panel Options Single Connector System I/O Panel See B in Figure 10-4 where the I/O pa

Page  76                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Optional MPC Interface Connec

Page  77Section 10 - OptionsDukane Manual Part No. 403-574-01Pin Signal Name Connector3 Setup Bit 0 InputJ2 (Page 20)4 Setup Bit 1 Input5 Setup Bit 2

Page  78                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01MPC Interface Installation Gu

Page  79Section 10 - OptionsDukane Manual Part No. 403-574-01Connecting CablesFor stand-alone interfaces and securely installed panel mounted in

Page  80                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01MPC Interface Status LEDsSyst

Page  81Section 10 - OptionsDukane Manual Part No. 403-574-01Confirm probes are retracted from weld position.Load part to be welded.Move part to the w

Page  82                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Remote Amplitude Control Modu

Page  83Section 10 - OptionsDukane Manual Part No. 403-574-01 AMPLITUDE CONTROLAMPLITUDE SETTINGRAMP UP / DOWN TIME AMPLITUDE SETTING

Page  3Section 1 – IntroductionDukane Manual Part No. 403-574-01General User InformationRead the Manual FirstBefore operating your ultrasonic gene

Page  84                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01Automation Thruster Control M

Page  85Section 10 - OptionsDukane Manual Part No. 403-574-01To enable the thruster, Pins 3 and 9 must be shorted together through a safety

Page  86                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01NPN TO PNP CONVERSIONSPECIFIC

Page  87Section 10 - OptionsDukane Manual Part No. 403-574-01PNP TO NPN CONVERSIONSPECIFICATIONS:INPUTS:MINIMUM VOLTAGE: 5.0 VdcCURRENT: 1.5mA @ 5.0

Page  88                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01+5V TO +24V PNP CONVERSION+5V

Page  89Section 10 - OptionsDukane Manual Part No. 403-574-01iQLinQ communication options allow automated systems to monitor and change settings

Page  90                   iQ Series, Ultrasonic Generator/Power Supply LS User’s ManualDukane Manual Part No. 403-574-01J2U/SI0LINE VOLTAGE:200-240 V

Page  91Section 10 - OptionsDukane Manual Part No. 403-574-01iQ LinQTM Ethernet/IPTM ModulePart Number - 110- 4644The EtherNet/IP option module allows

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

Page  93Section 11 - SpecicationsDukane Manual Part No. 403-574-01SECTION 11SpecicationsDrawings. . . . . . . . . . . . . . . . . . . . . . . . . .