Dukane Ultrasonic Generator 403-575-00 User Manual

Intelligent Assembly Solutionswww.dukane.com/usISO 9001:2008Dukane products are manufactured in ISO registered facilities.Dukane Intelligent Assembly

Press System OverviewAn iQ Series Ultrasonic Press System ES consists of these components: the iQ generator, press (with thruster, switches, control

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Front and Rear PanelsCleaning• Do not use any solvents or abrasive cleaners to clean any of the panels.• Do not spray or apply cleaner direc

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

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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 ultras

AC Power Inlet Panel The optional AC power inlet panel is described here.AC Power CordThe AC power cord (A in Figure 8-2) is appropriately rated and p

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 show

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SECTION 9Contacting DukanePage 103Dukane Manual Part No. 403-575-00Section 9 - Contacting Dukane

SECTION 2Health and SafetyGeneral Considerations . . . . . . . . . . . . . . . . 7Plastics Health Notice . . . . . . . . . . . . . . . . . 8Electrica

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Contacting DukaneIdentify EquipmentWhen contacting Dukane about a service–related problem, be prepared to give the following information: • Model nu

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SECTION 10SpecicationsGenerator Outline Drawings...109Weights, Dimensions, Operating Environment...111AC Power Requirements ...

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Figure 10-1 Layout - Low Prole iQ Generator AC POWERENTRYULTRASOUND &SYSTEM I/O'SOPTIONS CARDCAGEPANELSALLOW 3" IN BACK FOR CABLING.A

Figure 10-2 Layout - High Prole iQ GeneratorALLOW 5" BOTHSIDESFOR COOLING.IN(mm)ALLOW 3" IN BACK FOR CABLING.5.50 [139.78]ALLOW 5" BO

Figure 10-3 Layout - High Power iQ GeneratorWEIGHT 34 LBSULTRASOUND& I/O CONNECTIONSOPTIONAL I/O CONNECTION SLOTSAC POWER INLET CORD6.29 [159.8]5

Operating EnvironmentOperate the equipment within these guidelines:Temperature: 40°F to 100°F (+5°C to +38°C)Air Particulates: Keep the equipment d

AC Power RequirementsNOTES: An X used above in the Model Numbers is a “wildcard” character meaning any valid character code combination. Maximum li

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Interpreting the Model NumberInterpreting the Model Number20 HS 120 - 2 A - P6 - C2 Power Level480 = 4800 Watts360

Regulatory Agency Compliance CAUTIONDO NOT make any modi-cations to the generator or associated cables as the changes may result in violating one or

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SECTION 11AppendicesAppendix A, List of Figures...119Appendix B, List of Tables ...122Page 117Dukane Manual Part No.

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Page 119Dukane Manual Part No. 403-575-00Section 11 - AppendicesList of FiguresNo. Description PageAppendix AContinued2-1 Example of 220/240 Volt G

Page 120 iQ Series Ultrasonic Generator/Power Supply ES User’s ManualDukane Manual Part No. 403-575-00List of FiguresNo. Description PageAppendix AC

Page 121Dukane Manual Part No. 403-575-00Section 11 - AppendicesList of FiguresNo. Description PageAppendix AContinued6-4 Cycle Terminated Due to P

Page 122 iQ Series Ultrasonic Generator/Power Supply ES User’s ManualDukane Manual Part No. 403-575-00Appendix BList of TablesNo. Description Page2-

IndexPage 123Dukane Manual Part No. 403-575-00 Index

Proper Installation - Operate system components only after they are properly installed.NoUnauthorizedModications- Do not modify your system in any

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IndexAAcoustic Stack 74AC Power Cord 95AC Power Requirements 113Agency Compliance 115CE Marking 115FCC 115IP (International Protection) Rating 1

Placement 15Placement in a Seismic Region 16When to Use Lockout /Tagout Devices 13Interpreting the Model Number 114IP (International Protection) Ra

RRamp Down Time 65Ramp Up Time 65RFI Grounding 28SSpecications 107AC Power Requirements 113Dimensions 112Interpreting the Model Number 114Opera

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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

Please refer to our website at:www.dukane.com/us/sales/intsales.htmto locate your local representative.Part No. 403  - 575 - 00Dukane Intelligent Asse

Pre-trigger Switch Adjustment - The pre-trigger switch option starts the horn vibrating before contacting the part to be welded. To ensure safe ope

Approved 2 pole, 3 wire grounding receptacle HUBBELL No. 5652 or equivalent to NEMA 6–15R or 6–20RFigure 2–1 Example of 220/240 Volt, Grounded, 3-

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. S

SECTION 3InstallationBefore Installation... 13When to Use Lockout/Tagout Devices... 13Unpacking . . . . . . . . .

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Before InstallationAs you plan for the installation of your generator, please consider these important subjects as listed below:• When to use l

Printed in the United States of America.Dukane Part Number: 403-575-00Dukane ultrasonic equipment is manufactured under one or more of the following U

Lockout/Tagout Procedure to use BEFORE making any internal adjustments to the generator:1. Push the generator's AC power switch/breaker to t

Figure 3-3 Generator Front View (typical) Low ProleUnpackingCarefully open your shipping container, and make sure it contains the items shown on the

Placement in a Seismic RegionIf the iQ generator is to be used in an active seismic region, secure the unit by rack-mounting it or by securing the uni

Benchtop Mounting If you choose to mount the generator on a benchtop follow these instructions:1) Install the four (4) optional hold down brackets. S

This section provides an overview of the generator rear panel layout, which includes panel areas dedicated to var-ious standard system functions and o

AC Power Inlet Panel The standard AC power inlet panel is described in this sec-tion. IEC AC Power Inlet ConnectorThe IEC AC power inlet connector mou

Refer to Application Note AN507 (Automation Interface Guidelines) at http://www.dukane.com/us/DL_ApplDa-ta.asp for wiring diagrams of example applicat

System Inputs Signal DescriptionsPin 1 (+22V)This pin can supply +22VDC at up to 250mA to power the user’s automation controls.Pin 2 (Power Gnd)Pin 2

.Pin 5 (Remote Setup Selection Bit 2 Input)Pin 5 is the Remote Setup Selection Bit 2, which is the third least signicant bit used to select differen

Pin Signal Name Cable Color Code Signal Option Requirements1 +22V BLK2 Spare Output WHT3 +22V Power Ground RED4 Programmable Status Output 1 GRN5 Pro

Revision HistoryRevision RevisionNumber Summary Date- 00 Original release. 08/19/2011Page iiiDukane Manual Part No. 403-575-00

This is at system chassis ground potential (non-isolated). All of the digital output status signals on this connector, are isolated (signals are not r

Pin 9 (System Overload Status Output)Pin 9 is a digital active low status output that activates whenever any overload condition is tripped. Activation

Pin 17 (Amplitude/Power Regulation Status Output) (Contact your sales representative about Power Regulation availability.) This status signal is most

Ultrasound Output ConnectorThe ultrasound output connector used with all standard generators is a high voltage (5000V) coaxial style SHV-BNC connector

RFI GroundingThe iQ Series generator provides the operating power and power returns. Make sure the generator is grounded properly.In addition to th

Connecting CablesStep 1. Ground the generator chassis with the supplied 14-Gauge wire, and attach it to the grounding stud. See Figure 3-7.Step 2. U

Three CongurationsThe iQ generator, ES models are congured in three basic ways: 1) With a pneumatic press/thruster 2) With a remote controller a

Figure 3-15 iQ Generator and Pneumatic Press/Thruster - Connections DiagramConnecting CablesPneumatic Press/ThrusterContinuedPage 31Dukane Manual Par

Cable No.Part NumberLengthConnectionsGeneratorBaseThrusterHMI1 200-1556-XXMXX J5-OPERATIONAL CONTROL-2 200-1613-XXMXXJ11- ENCODER-3200-479-XXMXXJ1-ULT

Continued Servo Press/Thruster (Version 1)Figure 3-16 iQ Generator, Remote Controller, and Servo Press/Thruster - Connections DiagramJ4J1CONFIGURATIO

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Table 3-VI iQ Generator, Remote Controller, and Servo Press/Thruster Cables Servo Press/Thruster (Version 1)Cable No.Part NumberLength(meters)Connect

Figure 3-17 iQ Generator and Servo Press/Thruster - Connections DiagramServo Press/Thruster (Version 2)Continued J4J1CONFIGURATIONULTRASOUNDSYSTEM O

Table 3-VII iQ Generator and Servo Press/Thruster CablesServo Press/Thruster (Version 2)Cable No.Part Number LengthConnectionsGenerator Base Thruster

NetworkingWhere several welders are connected, please refer to the iQ Explorer User's Manual, 403-579-00, Section 5 - Multiple Welder C

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SECTION 4OperationOverview... 41Start-up... 41Stopping the Weld Cycle ...

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OverviewThe iQ Series generator, model ES, is usually part of a system.Main components of the system are: • iQ generator, • iQ Explorer (software),

Other ControlFunctionsOther control functions - such as monitoring the weld-ing process and controlling the system are accomplished using the iQ HMI o

Help SystemThe help system is a reference tool to assist in understand-ing key terms of the ultrasonic welding process.The iQ Explorer help function

ContentsSection 1- Introduction ...1 General User Information ...3 Press System Overview ...

Quick Start - Servo WelderServo Step 1 - Read Section 3,Installation of the iQ Explorer User's Manual 403-579-00. Insure that proper connection

See Figure 4-7. Figure 4-7 iQ Explorer, Process SettingsProcess Settings TabServo Step 4 - Process Settings > Initiate Mode > ManualSee Figure

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 insur

On the Process Settings tab, nd Sensing Speed. This is the speed (inches per second) at which actua-tion will move during the approach just before r

After pressing Teach, you will see a window similar to the one shown in Figure 4-12.Place an unwelded part into the xture. Press both opti-touch act

On the Process Settings tab, select Weld > Method, Parameter, and Max Time.Collapse Distance - The distance the welder advances once programme

Continuing with the Process Settings tab. . . This is the speed of the thruster during the weld cycle (after Trigger Sensing Speed and Motion Force De

Servo Step 13 - Set AmplitudeContinuing with the Process Settings tab. . . A typical initial amplitude setting is 100%. The range for this fea-ture is

Servo Step 14 - Post Weld SettingsContinuing with the Process Settings tab. . .The post weld phase of the process is often overlooked, however it is i

Hold Static Hold MethodIf Time has been enabled in the Static Hold Method, the actuator motion will stop at the end of the weld cycle for the prog

Contents ContinuedSection 5 - System Operational Testing...71Section 6 - Troubleshooting ...79Section 7 - Maintenance...

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 th

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 al

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 familiariz

Navigate to the Process Settings tab. All welder setup related control parameters are programmed on this tab. The Process Settings page is organized i

Pneumatic Step 5 - Process Settings>TriggerTrigger Type - Select Force as the Trigger Type.Program a force value.For this example we used values ty

Pneumatic Step 6 - Process Settings>Trigger >TypeContinued from previous pageFigure 4-29 iQ Explorer, Process Settings > Trigger >TypeFig

Pneumatic Step 7 - Process Settings> WeldFigure 4-31 iQ Explorer, Process Settings > WeldMode - Select Single Method.Method 1 - Select Collapse

Pneumatic Step 8 - Post Weld SettingsFigure 4-33 iQ Explorer, Process Settings > Post Weld > Hold Method > Hold TimeSelect Time.Program in a

Pneumatic Step 9 - Process Settings > Pressure Figure 4-34 iQ Explorer > Process Settings > Post Weld > PressureFor systems equipped with

Air Cylinder SizeVerify 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

SECTION 1IntroductionGeneral User Information . . . . . . . . . . . . . . 3Press System Overview . . . . . . . . . . . . . . . 4Key Features . . .

Pneumatic Step 10 - Process Settings > PressureContinued from Page 62Hold Pressure - This pressure determines the amount of force applied during Ho

Pneumatic Step 11 - Process Settings >AmplitudeFigure 4-36 iQ Explorer, Process Settings > AmplitudeAmplitude - This refers to the peak-to-peak

Pneumatic Step 12 - Process Settings >Secondary ControlSecondary controls provide additional ways to end the weld portion of a cycle together with

Navigate to the Process Limits tab.If this is the rst time on this tab (for your selected setup), the status for each parameter will be blank.See Fig

Figure 4-39 iQ Explorer, Process Limits Tab - IIUsing the drop down menu for each limit that is im-portant to your application, select Display. That

Pneumatic Step 15 - Cycle DataNavigate to the Cycle Data tab.Begin a weld cycle using the cycle activation switches.• Inspect the weld results of you

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SECTION 5System Operational TestingOverview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Operational Test of the

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OverviewAn iQ Series generator must be operating and connected to the press/thruster in order to test the system. For efcient operation of a Dukane u

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Operational Test of the Acoustic StackThe following test procedure is suggested before starting the generator, to verify that the vibrational characte

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 sect

5. Turn the generator off. Check the stack for proper assembly, damaged components, or dirty mating surfaces. Recheck the ultrasound cable for proper

Procedure for Cycling the System1. Check that you have correctly performed the following:a. Installed the stack in the thruster and have closed the

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

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ProblemPossible SolutionTroubleshootingUnit power-up sequence stops, and front panel ON/OFF button is ashing RED rapidly.Operation of the front panel

Error Message Description Cause(s) Possible Solution(s)Part detected before reach-ing start sensing distance.Force in excess of 50 lb (220 N) was dete

Error Message Description Cause(s) Possible Solution(s)Position Error Allowable servo position following error was exceeded.1. Force required to maint

General User InformationRead This Manual FirstBefore operating your ultrasonic system, read this User’s Manual to become familiar with the equipment.

Table 6 - II Error Messages, Pneumatic-relatediQ Pneumatic Press Error MessagesError Message Description Cause(s) Possible Solution(s)Overload (avera

Verifying Feature OperationThe iQ ES generator can be congured with several features that provide interfaces from the control board to encoders and t

PowerTo verify operation of this feature perform an acoustic stack test. If no power is displayed, contact Dukane.

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 t

The Cycle Terminates During DownstrokeThe system is in downstroke when the cycle has been successfully started and the head travels towards the part.

Premature Weld TerminationWeld Termination Due to End of Weld/Ground DetectAn End-of-Weld signal from the thruster limit switches and a Ground Detect

PART DOWNSTROKE DOWNSTROKE WELD TIME WELD DIST WELD ENERGY HOLD TOTAL TOTALCOUNT TIME DIST PRESSURE 1 PRESSURE 1 PRESSURE 1 TIME CYCLE

The iQ Generator Won’t CycleJust before a weld cycle starts, the iQ generator waits for an initiating signal. If an initiating signal is applied and t

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