Page 1 User's Manual Dukane Part No. 403 – – Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797– 4900 • FAX (630) 797– 4949 ISO 9001 Dukane products are manufactured www.dukane.com/us in ISO registered facilities.
Page 2 The information contained in this manual is distributed on an “As is” basis, without warranty. While every precaution has been taken in the preparation of this manual, Dukane Corporation shall not have any liability to any person or entity with respect to any liability, loss, or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual, or by the hardware products described herein.
Page 3: Revision History
Revision History Revision Revision Number Summary Date - 00 Original release. November 20, 2013 Page iii Dukane Manual Part No. 403-587-00...
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Page 5 Screen Basics........43 Continued Page v Dukane Manual Part No. 403-587-00...
Page 6 Section 9 - Options . . . . . . . . . . . . . . . . . . . . . . . . . 125 Section 10 - Contacting Dukane . . . . . . . . . . . . . . 131 Section 11 - Specifications .
Page 7: Section 1- Introduction
Press System Overview ....4 Key Generator Features ....4 Page 1 Dukane Manual Part No. 403-587-00...
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Page 9: General User Information
Roman sequence numerals (e.g. –I, –II, –III). As an ex- ample, Figure 3–2 would be the second illustration in sec- tion three while Table 3–II would be the second table in Condition Operator Electrical section three. or Practice Protection Safety Issue (hearing) Page 3 Dukane Manual Part No. 403-587-00...
Page 10: Press System Overview
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Press System Overview tion. The available output power is maintained with any voltage input within the specified range. An iQ Series Ultrasonic Press System ES consists of This provides consistent system performance re- these components: the iQ generator, press (with thruster, gardless of line voltage fluctuations.
Page 11: Section 2 - Health And Safety
International Power Grounding ....9 Lifting the Equipment ......10 Page 5 Dukane Manual Part No. 403-587-00...
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Page 13: General Considerations
No Unauthorized Modifications - Do not modify your es, controls, cables, transducer, booster, system in any way unless authorized to do so by Dukane horn, and fixture, and iQ Explorer II software Corporation. Unauthorized modifications could cause equipment damage and/or injury to the operator.
Page 14: Plastics Health Notice
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page General Considerations System Electrical Cabling - Electrical power must be CAUTION off when connecting or disconnecting electrical cables. Parts being joined ultrasoni- Do Not Wear Loose Clothing or Jewelry - They can cally will at times vibrate at become caught in moving parts.
Page 15: Electrical Safety
Units with this International 220/240V Grounding Figure 2–2 power cord are for use in North America or Japan. 240V Systems High power generators with power ratings above 2400W also use permanently attached power cords. Page 9 Dukane Manual Part No. 403-587-00...
Page 16: Lifting The Equipment
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Lifting the Equipment How to Lift Safely • Before lifting, take a moment to think about what you’re about to do. NOTE • Examine the object for sharp corners, slippery spots For equipment weights see Page 140, or other potential hazards.
Page 17: Section 3 - Installation
Recheck Connections ..... . . 36 Connect AC Power ......36 Page 11 Dukane Manual Part No. 403-587-00...
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Page 19: Before Installation
. closed, locked position. Before making any internal ad- justments to the generator, apply a lockout/tagout (LOTO) device to the generator chassis . Continued Page 13 Dukane Manual Part No. 403-587-00...
Page 20 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page 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 generator's electrical cord from its source.
Page 21: Unpacking
Generator Front View (Typical High Profile) Figure 3-3 NOTE Active Seismic Region Placement - If the generator will be put in an active seismic region, please refer to Application Note 511 at, http://www .dukane .com/us/ DL_ApplData .asp Page 15 Dukane Manual Part No. 403-587-00...
Page 22: Rear Panel Layout Overview
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Rear Panel Layout Overview This section provides an overview of the generator rear panel layout, which includes panel areas dedicated to var- ious standard system functions and options that are avail- able.
Page 23: Ac Power Inlet Panel
All inputs sink or source 10mA of current Do not repeatedly try to reset the circuit breaker. If it trips, from a 24VDC power supply. this will only cause more damage to the generator. Continued Page 17 Dukane Manual Part No. 403-587-00...
Page 24: System Inputs Connector Pinout
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page Note that a simple switch closure (relay contact) con- nected to a control input can not activate the input with- out adding an external power supply to power the input.
Page 25: System Inputs Signal Descriptions
Pin 4 is the Remote Setup Selection Bit 1, which is the HD-15M, Generator Input Cable Figure 3-8 second least significant bit used to select different welding Connector setups with an automation control system. Continued Page 19 Dukane Manual Part No. 403-587-00...
Page 26 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page Pin 12 (System Latch Reset Input) Pin 5 (Remote Setup Selection Bit 2 Input) Pin 12 is used to reset the Any Fault or System Overload...
Page 27: System Outputs Connector
The system monitor output signals are analog signals used to monitor ultrasonic amplitude setting and ultrasonic output DB-25M, Generator Output Cable Figure 3–10 power levels, referenced to the Monitor Common (Pin 13). Connector Continued Page 21 Dukane Manual Part No. 403-587-00...
Page 28: System Outputs Signal Descriptions
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page This is at system chassis ground potential (non-isolated). System Outputs Signal Descriptions All of the digital output status signals on this connector, Pin 1 (+22VDC Power Supply)
Page 29 This is an analog signal ground connection. Do not connect anything to this ground connection, except the wiring to the inputs of the analog instrumentation devices used to measure the monitor output signals. Continued Page 23 Dukane Manual Part No. 403-587-00...
Page 30 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page This status output signal will activate only when the system Pin 17 (Programmable Status Output 3) is ready to activate ultrasound or begin a weld cycle. Pin...
Page 31: Rfi Grounding
3rd Chassis earth ground by means of a ground clamp. Use at least 14 Grounding Earth Stud AWG wire for the connection to the press base. Ground Page 25 Dukane Manual Part No. 403-587-00...
Page 32: Connector Descriptions
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Connector Descriptions iQ Generator Connectors J1 - Ultrasound Output Connector The ultrasound output connector used with all stan- dard generators is a high voltage (5000V) coaxial style SHV-BNC connector. This connector provides supe- rior shielding of electrical noise, compared to other types of connectors.
Page 33 J10 - RS-232 This port is primarily used for welder diagnostic functions accessible via serial communication to a PC. Guidance will be provided by Dukane if the need to use the capability arises. J11 - Encoder This connector accepts signals from the distance encoder on the press.
Page 34: Power Cords
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Power Cords CAUTION The AC line cords supplied with the standard generators The power cord is equipped are matched to the ultrasonic output power rating and the with a three-prong, ground- continent of specified use.
Page 35: Cable Connections
Connect the power cords last, but do not turn on the power yet. 5. Recheck all connections. When they are secure, you are ready to connect electrical power. 6. Finally, connect electrical power. See Section 11, Specifications for AC power requirements. Continued Page 29 Dukane Manual Part No. 403-587-00...
Page 36 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page Servo Press/Thruster (Version 1) Generator, Remote Controller, and Servo Press/Thruster Connections (Version 1) Figure 3-13 Continued Page 30 Dukane Manual Part No. 403-587-00...
Page 37 Section 3 - Installation Continued from Previous Page Servo Press/Thruster (Version 1) Generator, Remote Controller, and Servo Press/Thruster Cables for Press Model 43S215 Table 3-IV Continued Page 31 Dukane Manual Part No. 403-587-00...
Page 38 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page Servo Press/Thruster (Version 1) Generator, Remote Controller, and Servo Press/Thruster Cables for Press Models 43S245-AX Table 3-V Page 32 Dukane Manual Part No. 403-587-00...
Page 39 DO NOT operate the generator unless the ul- trasound coaxial cable is connected and the trans- ducer is installed in the thruster. Otherwise, an overload condition could occur, with possible damage to the generator. Continued Page 33 Dukane Manual Part No. 403-587-00...
Page 40 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page Servo Press/Thruster (Version 2) Continued Generator and Servo Press/Thruster Connections (Version 2) Figure 3-14 Page 34 Dukane Manual Part No. 403-587-00...
Page 41 Section 3 - Installation Continued from Previous Page Servo Press/Thruster (Version 2) iQ Generator and Servo Press/Thruster Cables (Version 2) Table 3-VI Page 35 Dukane Manual Part No. 403-587-00...
Page 42: Networking
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Networking Where several welders are connected, please refer to the WARNING iQ Explorer II User's Manual, 403-585-00. Refer to the Any modifications to the Section on networking. Activation Switch (also...
Page 43: Section 4 - Control Panel
Screen Basics....... 43 Page 37 Dukane Manual Part No. 403-587-00...
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Page 45: Overview
Section 4 - Control Panel Overview This section introduces the iQ Series ultrasonic generator ES control panel and color display with this information: NOTE • Functions of the panel components shown in Figure Do not touch the display. Touch only 4-1 below are discussed. the System Operating Mode Keys, the Navigation Keys and the Soft Keys to • Some screen basics are introduced:...
Page 46: System Operating Mode Keys
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual System Operating Mode Keys After AC power has been activated and the ON LINE - generator is operating normally, ON LINE is the normal operating mode. The generator can produce ultrasound signals in this mode.
Page 47: Navigation Keys
If the lower active keys are pressed, they will display the Operate screen (left) or the Main Menu (right). Active Soft Keys, Example 2 Figure 4-6 Page 41 Dukane Manual Part No. 403-587-00...
Page 48: System Power Output Level
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual System Power Output Level (Bar Graph) A bar graph displays the percentage of ultrasonic power being drawn by the load. The display uses LED’s that show: GREEN - normal operation.
Page 49: Screen Basics
For the screen on the right, active soft keys are used to move the display left or right. Display arrows point in the direction of more text. (See Active Soft Keys, Figure 4-6.) Arrows Indicate More Text Figure 4-9 Page 43 Dukane Manual Part No. 403-587-00...
Page 50 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Virtual Keyboard A virtual keyboard pops up when there is a need to make an entry for the Security and Hardware screens. In the example shown below the operator is prompted to...
Page 51: Section 5 - Operation
Security ........88 Set-up Guidelines ......93 Page 45 Dukane Manual Part No. 403-587-00...
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Page 53: Overview
Section 5 - Operation Overview NOTE The iQ Series generator, model ES, is typically part of a Press, acoustic stack, and tooling will system. Major system major components would be: require their own individual adjustments as • iQ generator, those components are integrated into your •...
Page 54: Stopping The Weld Cycle
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Stopping the Weld Cycle Normal Conditions The cycle stops when the programmed welding cycle ends or when the rear panel's Cycle Stop input is activated. NOTE Emergency Conditions Automated System External Controls:...
Page 55: Using The Menus
Page 85 Navigating from the Main Menu (Administrator/Process Engineer Logged In) Figure 5–3 Page 70 Navigating from the Main Menu (Setup Logged In) Figure 5–4 NOTE Security detail can be found on Pages 88-92. Page 49 Dukane Manual Part No. 403-587-00...
Page 56 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Main Menu Process Setup Travel Limit Auto Enable Initiate Mode Latch on Bad Part Manual Disable Force Force at Trigger Max Trigger Time Sensing Speed Sensing Start Position Trigger Power...
Page 57 System Inputs connector) can be activated. See Pages 66-67. See Page 20 for information about Pin 12 of the System Inputs (J2) connector. The pin can be used for latch reset. Process Setup, Continued Page 51 Dukane Manual Part No. 403-587-00...
Page 58 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Process Setup, Continued from Previous Page Auto (Initiate Mode) The AUTO mode requires a voltage signal applied to J2 pin 8. The applied voltage level, either ground or NOTE +22VDC, must be the opposite of the voltage level applied to J2 pin 13.
Page 59 Max Trigger Time grammed as well. If the weld is not accomplished within the set time, the weld will be terminated. Power Dukane has patented its Trigger by Power feature. Go to Dukane's blog: http://usblog.dukane.com/2010/01/ trigger-by-power-feature-aids-weld_27.html for more information about this feature.
Page 60 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Process Setup, Continued from Previous Page Force The figure to the right shows that with Force as the trig- ger type, Trigger Force, Max Trigger Time, Sensing Start Position, and Sensing Speed need to be pro- grammed. Sensing Start Position A feature of the servo press teaches a Sensing Start Posi- tion.
Page 61 - If a previous position has Move to Saved Position been set, the user can press the Move to Saved Position button and use the switches to move the servo at the high speed to the previous position. Finer adjustments can be made from there if desired. - Choose a parameter from the list Select Parameter of three choices: • Top of Stroke Position, • Sensing Start Position, or • Travel Limit. Process Setup, Continued Page 55 Dukane Manual Part No. 403-587-00...
Page 62 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Process Setup, Continued from Previous Page Primary Weld Method Primary Weld Method is the next Process Setup submenu. Primary Weld Method The weld method defines when the ultrasound signal is Distance Weld Distance Max Weld Time terminated after it has been triggered Weld Position...
Page 63 Figure 5–18 Weld Profile Segmented percentage. It is this percentage that is entered for this parameter (in the range of 0% to 50%). Figure 5–19 Setting Speeds for the Segments Process Setup, Continued Page 57 Dukane Manual Part No. 403-587-00...
Page 64 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Process Setup, Continued from Previous Page Dynamic Hold Method The hold process related to the servo press is split into two Dynamic Hold Method Dynamic Hold Speed parts. The dynamic hold is executed before the static hold.
Page 65 (if dynamic hold is disabled). Disabled Choose Disabled when no static hold method is needed. Time This setting determines the amount of time the press position is held following the dynamic hold process (if enabled) or the weld process (if dynamic hold is disabled). See the Figure 5-24 to the right showing Figure 5–24 Static Hold Method Display display. Static Hold Method Process Setup, Continued Page 59 Dukane Manual Part No. 403-587-00...
Page 66 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Process Setup, Continued from Previous Page Afterburst The next submenu in Process Setup deals with Afterburst. In some applications the part being welded may stick to Afterburst Delay Time the horn as the head of the press retracts. Afterburst dis-...
Page 67 The Force mode is provided only for the purposes of experimentation and is not intended for production. Process Setup, Continued Page 61 Dukane Manual Part No. 403-587-00...
Page 68 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Process Limits Overview As the weld cycle progresses, time, distance, power, and energy data are kept for each portion of the cycle. These measurements, also called process characteristics, form a process record for each part. Records’ analysis can es- tablish parts limits which then can be used to determine if the current process is “in control”.
Page 69 (See Table 4-II.) system configuration, Total Cycle Time Force Bad and on the chosen weld mode. Total Stroke Distance Force Suspect Alarm Status Display Time Date Display Setup Figure 5–30 Process Limits Menu Diagram Process Limits, Continued Page 63 Dukane Manual Part No. 403-587-00...
Page 70 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Process Limits, Continued from Previous Page Process Characteristics Defined Downstroke Time – This is the time from the start of the welding cycle to the trigger point. Position at Trigger – This is the position relative to the home position of the mounted distance encoder at the trigger point of a weld.
Page 71 Alarm Status – This feature is included with the Part Lim- its menu to compliment part cycle data. It does this to show that a system alarm (www.dukane.com/us/DL_EasyAlarm. asp) was active during the weld cycle for a particular part. There are four options with Alarm Status – one that disables the feature, and three other options that allow for the part record to show that an alarm was active.
Page 72 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Process Limits, Continued from Previous Page Data from Process Characteristics Data from each weld cycle can be monitored through the available process characteristics. Programming choices for each characteristic are: — No Display, —...
Page 73 • One beep is given (if buzzer is set to ON). (See Buzzer, Page 80 .) • The iQ ES suspect part output is activated. • SUSPECT is displayed in the part cycle data. In Figure 5-34 the selected characteristic is Peak Power.
Page 74 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Main Menu Utilities/Hardware Process Utilities Hardware Setup Serial Port Welder Name Setup Name Setup Control Output Format Horn Copy Setup Booster LF After CR Erase Setup Fixture Output Mode Manual P1...
Page 75 5-38 appears. Typically, Define Sequence would be chosen. Defining the Sequence Figure 5–40 Defining the sequence involves entering the information suggested by Figure 5-40: Sequence Length, etc. For more on Sequencing, go to Appendix C. Process Utilities Continued Page 69 Dukane Manual Part No. 403-587-00...
Page 76 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Process Utilities, Continued from Previous Page Choose a Setup Choosing a setup depends on two factors: Setup Control, and Security Access Setup Control - Using Setup Control through the Process Utilities menu, the three types of control deal with setup...
Page 77 Choose setups: Copy From, and Copy To. Then press the soft key, Press Here to Copy. The display will appear as it does in Figure 5-46. Copy Setup - 1 Figure 5–44 Copy Setup - 2 Figure 5–45 Copy Setup - 3 Figure 5–46 Process Utilities, Continued Page 71 Dukane Manual Part No. 403-587-00...
Page 78 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Process Utilities, Continued from Previous Page Erase Setup Setup parameters can be erased for the current setup, or for all setups. A screen will pose the question, "Are you sure you want to erase all setups?" Answer Yes or No to proceed with the erase process. See Figure 5-47 to the right. Part Count Settings This utility permits part count modification through its...
Page 79 Down Speed / F low Control Mechanical Stop HSC Setting HSC = Hydraulic Speed Control HSC Start Position Pre-trigger / E OW Flags EOW = End of Weld Notes Figure 5–49 Process Utilities, Continued Page 73 Dukane Manual Part No. 403-587-00...
Page 80: Hardware Setup
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Hardware Setup Hardware Setup and its submenus can be used before start-up, or during normal operation. Typically Process Utilities have been set before Hard- ware Setup is completed. Time, Date, Base Units, Setup Control, and the other utilities have usually already been established before Hardware Setup is programmed.
Page 81: Baud Rate
The user can send (print) serial header data each time the Print soft key is pressed. The serial header data sent is based on the "displayed" Process Limits, as defined in the Process Limits screen. Hardware Setup, Continued Page 75 Dukane Manual Part No. 403-587-00...
Page 82 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Hardware Setup, Continued from Previous Page System Status I/O The next group of hardware settings (following the Serial Port settings) deals with the generator's System Status I/O. Hardware Setup These six selections enable customizing of some of the iQ generator's input and output signals.
Page 83 Once Restore is chosen, a secondary screen is displayed asking the operator to verify the choice: Are you sure you want to Restore I/O Defaults? See Figure 5-52 for the screen view. Hardware Setup, Continued Page 77 Dukane Manual Part No. 403-587-00...
Page 84 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Hardware Setup, Continued from Previous Page Additional Hardware Settings The next group of hardware settings (following the Serial Hardware Setup Port settings and the System Status I/O settings) deals with various functions.
Page 85 Why System Frequency Limits Modes Might be Chosen For more information about Frequency Lock/Hold, refer to our Application Note 505 on the Dukane website at: Wide - This mode is primarily used for http://www.dukane.com/us/DL_ApplData.asp testing "bare" transducers (no booster or horn attached).
Page 86 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Hardware Setup, Continued from Previous Page 3. Press to continue. ENTER The scan takes place with Amplitude, Power and Frequency values are shown. Figure 5-56 illus- trates the screen view after a successful scan.
Page 87 5. Network Link - This shows the status of the connec- tion to a network: Linked - This displays the speed of the network con- nection. Hardware Setup, Continued Not Linked - Down Page 81 Dukane Manual Part No. 403-587-00...
Page 88 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Hardware Setup, Continued from Previous Page Servo Diagnostics Reserved for use by Dukane personnel, these diagnostics monitor servo inputs, test status, performance and cycles. Key to Trigger Function: Basic Trigger Function Advanced Trigger Function...
Page 89 IP address. NOTE Network Settings are maintained even after a Restore Factory Defaults. Are you sure you want to Restore Factory Defaults? Main Menu Restore Factory Defaults? Figure 5–61 Page 83 Dukane Manual Part No. 403-587-00...
Page 90 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Process Total Parts Characteristic Processed Setup Name Operate Screen The Operate screen displays weld cycle data in real time. Figure 5-62 shows the main Operate screen. Process characteristics listed below the setup name are the ones chosen (as process limits) to be displayed or programmed.
Page 91 Press the soft key next to Real Time Data, and the display changes to show press characteristics for the current setup and weld cycle. The possible characteristics are: Force, Distance, Power, Frequency, and Speed. Characteristics displayed depend on system configuration. Real Time Data Figure 5–66 Page 85 Dukane Manual Part No. 403-587-00...
Page 92 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Graph The generator is factory programmed to provide graphs with amplitude and power as the vertical axes. Figure 5-67 shows the beginning graph screen. Graph Setup Figure 5-68 shows the graph setup screen used when se- lecting parameters for the two vertical axes of the graph.
Page 93 Locating Help on the Main Menu Figure 5–72 NOTE Color Front Panel v1.11.02 will also display the network IP Address in the bottom left corner of the HELP screen. Help Screen Example Figure 5–73 Page 87 Dukane Manual Part No. 403-587-00...
Page 94 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Security NOTE The Security menu choices control access to the program- Operator - Usually the operator does ming menus by using individual logins for three levels: not need to use the Security feature.
Page 95 Figure 5-75. The Administrator Password has been Enabled. Also Administrator Access is followed by [Admin] showing that the Administrator has current security access. Login is complete for the Administrator. Figure 5-78 Security Screen - Administrator Access Enabled Continued Page 89 Dukane Manual Part No. 403-587-00...
Page 96 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Security, Continued from Previous Page At this point the Administrator typically has four options: • - Press the soft key next to Logout, and Logout the Administrator will be logged out. None of the security levels will be active.
Page 97 Logout to quit. when using the Security function. 5. Finally, press Done so that the main menu screen is displayed when the session is complete. Continued Page 91 Dukane Manual Part No. 403-587-00...
Page 98 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Security, Continued from Previous Page Other Security Prompts With login passwords in use, the levels of access to the generator are established. Setup Access Security prompts - like the samples seen in Figures...
Page 99: Set-Up Guidelines
Disabled Disabled Disabled Afterburst Based on Based on Based on Based on Based on Travel Limit Press Stroke Press Stroke Press Stroke Press Stroke Press Stroke Table 5-II Default Settings - Process Setup Page 93 Dukane Manual Part No. 403-587-00...
Page 100 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Changing Default Settings From the , go to Each Main Menu Process Setup. of the items shown in the table above is listed as a Process Setup submenu item and can be customized for your process.
Page 101: Section 6 - Optional Control
Unique Features ........111 Page 95 Dukane Manual Part No. 403-587-00...
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Page 103: Other Control Functions
• the iQ Ultrasonic Generator/Power Supply ES, board and its help system. with color display, or Numeric Pad and Keyboard • the iQ HMI (or a computer) and Dukane's iQ Explorer II software. NOTE iQ Explorer II provides a touch screen...
Page 104: Help System
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Help Icon Help System The help system is a reference tool to assist in understand- ing key terms of the ultrasonic welding process. The iQ Explorer II help function can be accessed using the top menu bar, or by pressing the F1 key as explained below.
Page 105 Figure 6-4 iQ Explorer II, Start-up Step 2 - Select Unused Setup After moving to the Hardware tab, click on the Setup File Name box, and select an unused setup. This will ensure that you do not overwrite a pre-existing setup. Hardware Tab See Figure 6-5. Figure 6-5 iQ Explorer II, Start-up, Hardware Tab Page 99 Dukane Manual Part No. 403-587-00...
Page 106 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Step 3 - Navigate to the Process Settings Tab See Figure 6-6. Process Settings Tab Select Manual in Initiate Mode. iQ Explorer II, Process Settings Tab and Initiate Mode Figure 6-6 Step 4 - Set Cycle Initiation Mode See Figure 6-6.
Page 107 See Figure 6-8, Initial Trigger/Force Settings. iQ Explorer II , Process Settings > Trigger > Type, Force, Max Trigger Time Figure 6-7 Linear Weld Joint (inches) Suggested Initial Trigger/Force Setting Figure 6-8 Page 101 Dukane Manual Part No. 403-587-00...
Page 108 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Step 6 - Program Sensing Speed On the Process Settings tab, find Sensing Speed. This is the speed (inches or millimeters per second) at which the horn will move during the approach just before reaching the trigger position. A typical starting value for Sensing Speed is 0.040 in/s (1.0 mm/s). Sensing Speed can be set higher for shorter cycle times, or lower for greater trigger force detection accuracy.
Page 109 Once you are at the desired position, press Set to pro- to the size of the press. gram that distance. Select Exit, and follow instructions to home the machine. iQ Explorer II, Teach Sensing Start Position Figure 6-11 Page 103 Dukane Manual Part No. 403-587-00...
Page 110 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Step 9 - Program Weld Characteristics Primary Method NOTE On the Process Settings tab, find Weld > Primary Method, and select Collapse Distance. Programming these weld parameters is similar to programming the Du- Collapse Distance - This is the distance the welder ad- kane DPC IV Plus or other pneumatic vances once the programmed trigger force is reached. Usu-...
Page 111 - the result is the average speed. iQ Explorer II, Process Settings > Weld > Weld Motion Control, Weld Profile, Speed Figure 6-15 Page 105 Dukane Manual Part No. 403-587-00...
Page 112 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Advanced Users - NOTE Advanced users can optimize the weld speed us- View Speed Profile ing a Profile to produce superior weld strength and Selecting brings View Speed Profile excellent cosmetic appearance. See Figure 6-16, up a screen like one shown below.
Page 113 Time parameter is used to terminate the machine cycle if the dynamic hold distance is not reached within the allowable time window. See Figure 6-19. iQ Explorer II, Process Settings> Post Weld > Dynamic Hold Method Figure 6-19 Continued Page 107 Dukane Manual Part No. 403-587-00...
Page 114 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page Hold Static Hold Method After the completion of dynamic hold, if enabled, the press motion stops for a specified amount of time to allow for molten plastic to solidify. This phase is called static hold.
Page 115 Figure 6-21 iQ Explorer II, Process Limits Tab Show All - Sets all of the process limits to be Displayed. Show No Limits - Sets all of the process limits to not display any limits. Page 109 Dukane Manual Part No. 403-587-00...
Page 116 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Step 16 - Run Weld Cycle After all the parameters have been programmed, initiate the weld cycle. Step 17 - View Weld Results View the results at the Cycle Data tab to insure all parameters have been achieved.
Page 117: Unique Features
One instance of the use of this feature is as follows. A file is created for the setup of Part #1 and another file for the setup of Part #2. After running a batch of parts Page 111 Dukane Manual Part No. 403-587-00...
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Page 119: Section 7 - System Operational Testing
Cycling the System....... .119 Page 113 Dukane Manual Part No. 403-587-00...
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Page 121 An iQ Series generator must be operating and connected to the press/thruster in order to test the system. For efficient operation of a Dukane ultrasonic assembly system, the ultrasound signal from the generator must match the frequency of the stack that is being driven. Each stack has unique frequency characteristics dependent on the combination of stack components.
Page 122 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Operational Test of the Acoustic Stack The following test procedure is suggested before starting the generator, to verify that the vibrational characteristics of the stack fall within the range of the Digi-Trac. All Dukane stack components are manufactured to tolerance specifications within this range.
Page 123 Cycling the System, on Page 119. • If one or more of these tests have failed, go to the next step. Q Explorer II, Alarm Detected - Cycle Stopped Figure 7-3 Continued Page 117 Dukane Manual Part No. 403-587-00...
Page 124 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page Acoustic Stack Test If any failure indications are present with the horn 5. Turn the generator OFF. Check the stack for proper removed, check the booster and the transducer for the...
Page 125 4. Manually cycle the system. Activate both operate switches at the same time to start the system, and hold fingers in place until the ultrasound starts. Releasing the fingers before ultra- sound starts will abort the cycle. Page 119 Dukane Manual Part No. 403-587-00...
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Page 127: Section 8 - Maintenance
Section 8 - Maintenance SECTION 8 Maintenance Page 121 Dukane Manual Part No. 403-587-00...
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Page 129: Front And Rear Panels
AC Power Cord The AC power cord should be kept in good condition and free from any cuts. The AC plug should be straight with no bent prongs. Page 123 Dukane Manual Part No. 403-587-00...
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Page 131: Section 9 - Options
Part Data Indexes ........129 Page 125 Dukane Manual Part No. 403-587-00...
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Page 133: Power Inlet Options
Pages 8 and 9 for information about Elec- trical Safety including grounding. 240V Systems Generators with power ratings above 2400 Watts also have fixed power cords. See Table 11-II in Section 11, Specifications. Page 127 Dukane Manual Part No. 403-587-00...
Page 134 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Data Transfer Board and port locations are shown in Figure 3-4. P a r t N umb e r = 4 1 7 Ethernet Port, J9 0 0 0 1 J9 is the generator's Ethernet port. A cable connects J9 Downstroke Time = 0.101 second...
Page 135 Dukane's DPC Time Format: HH:MM:SS generator protocol as Date -> Formats: DD/MM/YYYY, MM/DD/YYYY, YYYY/MM/DD closely as possible. Setup Number Error Code -> "U Number" without the 'U' Part Data Indexes Table 9-I Page 129 Dukane Manual Part No. 403-587-00...
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Page 137: Section 10 - Contacting Dukane
Section 10 - C ontacting Dukane SECTION 10 Contacting Dukane Page 131 Dukane Manual Part No. 403-587-00...
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Page 139 Section 10 - C ontacting 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. • Alarm indicators from the generator or displayed by iQ Explorer II.
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Page 141: Section 11 - Specifications
Interpreting the Model Number....143 Regulatory Agency Compliance ....144 Page 135 Dukane Manual Part No. 403-587-00...
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Page 143 Section 11 - Specifications Figure 11-1 Layout - Low Profile Generator Page 137 Dukane Manual Part No. 403-587-00...
Page 144 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Layout - High Profile Generator Figure 11-2 Page 138 Dukane Manual Part No. 403-587-00...
Page 145 Section 11 - Specifications Figure 11-3 Layout - High Power Generator Page 139 Dukane Manual Part No. 403-587-00...
Page 146: Operating Environment
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Weights High Profile Low Profile High Power Generator 11.34 9.07 15.42 Only Generator 13.61 11.34 17.69 + Packing Materials Table 11–I iQ Generator Weights Dimensions Dimensions - in (mm) Model...
Page 147 Section 11 - Specifications Page 141 Dukane Manual Part No. 403-587-00...
Page 148: Ultrasonic Pressure
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Ultrasonic Pressure Ultrasonic Pressure Generator Models - kHz 360 degrees Useful Beam Ultrasonic Pressure Operator's Position - dB Ultrasonic Pressure 1 m from the Equipment- dB iQ Generator Ultrasonic Pressure Table 11–IV...
Page 149: Interpreting The Model Number
Section 11 - Specifications Interpreting the Model Number Figure 11-4 Interpreting the Model Number Page 143 Dukane Manual Part No. 403-587-00...
Page 150: Regulatory Agency Compliance
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Regulatory Agency Compliance The generator complies with the following Federal Com- The iQ generator complies with these standards: munications Commission regulations. Underwriters Laboratories: • The limits for FCC measurement procedure MP-5, UL 1012: 2010 “Methods of Measurement of Radio Noise Emissions from ISM Equipment”, pursuant to FCC Title 47 Part UL 61010-1:2012, and 18 for Ultrasonic Equipment.
Page 151: Section 12 - Appendices
Appendix D, Alarm Messages ....156 Appendix E, Menu Structure Diagrams ..161 Page 145 Dukane Manual Part No. 403-587-00...
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Page 153 Front Panel's Lighted Power Indicator ................47 Main Menu Screen ......................47 Navigating from the Main Menu (Administrator /Process Engineer Logged In) ....49 Navigating from the Main Menu (Setup Logged In) ............49 Process Setup Menu Diagram ..................50 Continued Page 147 Dukane Manual Part No. 403-587-00...
Page 154 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Appendix A List of Figures Continued from Previous Page Description Page Teaching Travel Limit .....................51 Enable Clear Bad Part ....................51 Trigger Type Submenu Diagram ...................52 Trigger Type - Position ....................53 5-10 Trigger Type - Power .....................53...
Page 155 End Graph at Setup .......................86 5-71 Example Graph Following Test ..................87 5-72 Locating Help on the Main Menu ...................87 5-73 Help Screen Example ....................87 5-74 Security Screen - No Passwords Set ................88 Continued Page 149 Dukane Manual Part No. 403-587-00...
Page 156 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual List of Figures Appendix A Continued from Previous Page Description Page 5-75 Password Screen - Administrator Password Selected ..........89 5-76 Virtual Keyboard ......................89 5-77 Security Screen - Currently Logged Out ...............89 5-78 Security Screen - Administrator Access Enabled ............89...
Page 157 Layout - High Power iQ Generator ................139 11-4 Interpreting the Model Number ..................143 What is a Sequence? ....................153 Insertion Sequence Example ..................154 Sequence Definition ....................155 Process Setup Menu Diagram ..................161 Process Limits Menu Diagram ..................162 Utilities/Hardware Menu Diagram ................163 Page 151 Dukane Manual Part No. 403-587-00...
Page 158: Ac Power Requirements
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Appendix B List of Tables Description Page Generator Input Signals (J2) ................... 19 3-II System Output Communication Signals (J3) ..............21 3-III Power Cords ........................28 3-IV iQ Generator, Remote Controller, and Servo Press/Thruster Cables (43S215) ..... 31 iQ Generator, Remote Controller, and Servo Press/Thruster Cables (43S245-AX) ..
Page 159 The figure shows that a sequence is a process having from 1 to 8 seg- ments and each of those segments has from 1 to 255 cycles. Sequence Figure C-1 What is a Sequence? Continued Page 153 Dukane Manual Part No. 403-587-00...
Page 160 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page Appendix C Sequencing Notes In this example, a sequence to be used in an insert ap- plication has two segments. The first part of the sequence is known as Setup 01 which will process four #1 inserts.
Page 161 • Process Cycles for a Given Segment - Choose 1-255 Sequence Length Current Cycle Cycle or Sequence (1-8 Segments) (1-8) Current Segment (1-8) Process Cycles for a Given Segment (1-255) Figure C-3 Sequence Definition Page 155 Dukane Manual Part No. 403-587-00...
Page 162: Appendix D - Alarm Messages
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Appendix D Alarm Messages Servo Press Alarm Messages The following table lists alarms that may appear on the servo press systems containing a generator with a color front panel display (Q-Series) or iQ Explorer II software.
Page 163 Section 12 - Appendices Appendix D Alarm Messages Continued Servo Press Alarm Message Screens - Page 1 of 4 Table D- I Page 157 Dukane Manual Part No. 403-587-00...
Page 164 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued from Previous Page Appendix D Alarm Messages Continued Servo Press Alarm Message Screens - Page 2 of 4 Table D-I Page 158 Dukane Manual Part No. 403-587-00...
Page 165 Section 12 - Appendices Appendix D Continued from Previous Page Alarm Messages Continued Table D- I Servo Press Alarm Message Screens - Page 3 of 4 Page 159 Dukane Manual Part No. 403-587-00...
Page 166: Alarm Messages
Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Appendix D Continued from Previous Page Alarm Messages Servo Press Alarm Message Screens - Page 4 of 4 Table D-I Page 160 Dukane Manual Part No. 403-587-00...
Page 167 Advanced Process Settings Table 4-II.) system configura- Normal System Frequency Limits tion, and primary weld method. Narrow Manual Ramp Up Time Ramp Down Time Restore Advanced Process Defaults Process Setup Menu Diagram Figure E-1 Page 161 Dukane Manual Part No. 403-587-00...
Page 168 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Appendix E Menu Structure Diagrams Main Menu Process Limits Downstroke Time Position at Trigger Trigger Delay Time ** ** Limits available when Trigger Delay is enabled. Trigger Delay Distance **...
Page 169 Servo Diagnostics Restore Factory Defaults Utilities/Hardware Menu Diagram Figure E-3 NOTE The list of available Process Utilities and Hardware items depends on Security ac- cess level (See Table 4-II.) and on sys- tem configuration. Page 163 Dukane Manual Part No. 403-587-00...
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Page 171: Index
Index Index Page 165 Dukane Manual Part No. 403-587-00...
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Page 173 Buzzer 80 Electrical Safety 9 100/120 Volt Systems 9 Domestic Power Grounding 9 International Power Grounding 9 Cable Connections 29 Enabling Passwords First Time 89 Integrated Configuration 33 Erase Setup 72 Ethernet Port, J9 128 Remote Controller Configuration 29 CE Certification 4 Continued Page 167 Dukane Manual Part No. 403-587-00...
Page 174 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Domestic Power Grounding 9 International Power Grounding 9 FCC 144 General Considerations 7 Features 111 How to Lift Safely 10 Duplicating Process on Multiple Machines 111 Lifting the Equipment 10...
Page 175 Multiple Electronic Overload 4 Output Format 74 Output Mode 74 Networking 36 Part Count Settings 72 Network Settings 81 Notes 73 Part Data Indexes 129 Notes, Cautions and Warnings 3 Part Number History 84 Numeric Pad and Keyboard 97 Position at Trigger 64 Power Cords 28 Power Inlet Options 127 Press System Overview 4 Primary Weld Method 56 Page 169 Dukane Manual Part No. 403-587-00...
Page 176 Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual Continued Ramp Down Time 80 Process Characteristics Defined 64 Ramp Up Time 80 Process Limits 4,62 Real Time Data 85 Data from Process Characteristics 66 Rear Panel Expansion Slot 4 Bad Limits 66 Rear Panel Layout Overview 16 Suspect Limits 67 Recheck Connections 36 Process Characteristics Defined 64...
Page 177 Weld Peak Force 64 Time 72 Weld Peak Power 64 Top of Stroke Position 61 Weld Profile 57 Total Cycle Time 64 Weld Time 64 Total Stroke Distance 64 Wide Line Voltage Operation 4 Travel Limit 51,61 Trigger Advanced Trigger Settings 81 Trigger Type 52 Troubleshooting Alarm Messages 156 TUV Certification 4 Page 171 Dukane Manual Part No. 403-587-00...
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Page 179 By passing its audit, Dukane can assure based on partnership for continuous improve- you that we have in place a well–defined and ment. This concept is key in that Dukane no systematic approach to quality design, manu- longer focuses on inspection, but on individual facturing, delivery and service.
Page 180 Part No. 403 - 587 - 00 Printed in the United States of America Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4 900 • FAX (630) 797- 4949...

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