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Dukane iQ series User Manual

Dukane iQ series User Manual

Ultrasonic generator/power supply, pneumatic systems
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Series
ULTRASONIC GENERATOR/POWER SUPPLY
Pneumatic Systems
ES
AUTOMATED
HAND PROBE
PRESS
User's Manual
Dukane Part No. 403 
5 84 
0 1
–  
–  
Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797– 4900
Dukane products are manufactured in ISO
www.dukane.com
registered facilities

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Summary of Contents for Dukane iQ series

  • Page 1 HAND PROBE PRESS User's Manual Dukane Part No. 403  5 84  –   –   Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797– 4900 Dukane products are manufactured in ISO www.dukane.com 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 shall not have any liability to any person or entity with respect to any liability, loss, or damage caused or al- leged 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. December 6, 2013 - 01 Clarified wording of Bad Limit June 21, 2019 Page iii Dukane Manual Part No. 403-584-01...
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  • Page 5: Table Of Contents

    Screen Basics........41 Continued Page v Dukane Manual Part No. 403-584-01...
  • Page 6 Section 9 - Options . . . . . . . . . . . . . . . . . . . . . . . . . 117 Section 10 - Contacting Dukane . . . . . . . . . . . . . . 123 Section 11 - Specifications .

  • Page 7: Section 1 - Introduction

    Press System Overview ....4 Key Generator Features ....4 Page 1 Dukane Manual Part No. 403-584-01...
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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- Condition Operator tion three while Table 3–II would be the second table in Electrical section three. or Practice Protection Safety Issue (hearing) Page 3 Dukane Manual Part No. 403-584-01...

  • Page 10: Press System Overview

    The available output power is maintained with An iQ Series Ultrasonic Press System ES consists of any voltage input within the specified range. This these components: the iQ generator, press (with thruster,...

  • Page 11: Section 2 - Health And Safety

    International Power Grounding ....9 Lifting the Equipment ......10 Page 5 Dukane Manual Part No. 403-584-01...
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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, fixture, and iQ Explorer II software. Unauthorized modifications could cause equipment dam- age and/or injury to the operator.

  • Page 14: Plastics Health Notice

    OSHA regulations for a particular plastic prior to processing with Dukane ultrasonic equipment Electrical Safety CAUTION The iQ Series generator provides the operating power When making cable connec- and power returns. Make sure the generator is grounded tions to system equipment properly.

  • Page 15: Domestic Power Grounding

    Units with this Figure 2–2 International 220/240V Grounding 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. 403-584-01...

  • Page 16: Lifting The Equipment

    To place the object below the level of your waist, fol- low the same procedures in reverse order. Remember, keep your back as vertical as possible and bend at the knees. Page 10 Dukane Manual Part No. 403-584-01...

  • Page 17: Section 3 - Installation

    Recheck Connections ..... . . 33 Connect AC Power ......33 Page 11 Dukane Manual Part No. 403-584-01...
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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. 403-584-01...
  • Page 20 2) Open the shell, exposing the electrical cord end. 3) Remove the LOTO device, and set it aside. 2. Plug the generator's electrical cord into its AC power source. 3. Push the generator's AC power switch/breaker to the ON position. Page 14 Dukane Manual Part No. 403-584-01...

  • Page 21: Unpacking

    Generator Front View (Typical High Profile) 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. 403-584-01...

  • Page 22: Rear Panel Layout Overview

    Configuration Port Connector (J4) – Digital control See Section 9, Options for more infor- port to modify system parameters. mation about Data Transfer using the Communications Board and more about the Press Interface Module. Page 16 Dukane Manual Part No. 403-584-01...

  • Page 23: Ac Power Inlet Panel

    (NPN) or sourcing (PNP), depending upon how the isolated common connection is terminated. All inputs sink or source 10mA of current from a 24VDC power supply. Continued Page 17 Dukane Manual Part No. 403-584-01...
  • Page 24 Refer to Section 9, Options for information Table 3-II, to assist with custom automation system wir- on optional features. ing and assembly. Continued Page 18 Dukane Manual Part No. 403-584-01...
  • Page 25 Pin 4 is the Remote Setup Selection Bit 1, which is the Figure 3-8 HD-15M, Generator Input Cable second least significant bit used to select different welding Connector setups with an automation control system. Continued Page 19 Dukane Manual Part No. 403-584-01...
  • Page 26 This pin must be left open whenever a press control board is installed. Connecting this pin to chassis ground will inhibit press operation. Page 20 Dukane Manual Part No. 403-584-01...
  • Page 27 The system monitor output signals are analog signals used to monitor ultrasonic amplitude setting and ultrasonic output Figure 3–10 DB-25M, Generator Output Cable power levels, referenced to the Monitor Common (Pin 13). Connector Continued Page 21 Dukane Manual Part No. 403-584-01...
  • Page 28 Generator faults that will activate the Any Fault output: • Overload (Average, Peak, or Frequency) • Overtemperature Fault • System Power Fault Continued Page 22 Dukane Manual Part No. 403-584-01...
  • 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. 403-584-01...
  • Page 30 This output will be an open circuit after a welding cycle when either a suspect or bad part has been detected. Page 24 Dukane Manual Part No. 403-584-01...

  • Page 31: Rfi Grounding

    Section 3 - Installation RFI Grounding CAUTION iQ Series generator provides the operating power To minimize electrical noise and power returns. Make sure the generator is grounded and eliminate ground cur- properly. rents, ground the chassis as shown. Use a STAR configuration (il- In addition to the safety considerations, proper grounding lustrated below).

  • Page 32: Connector Descriptions

    The user can determine which signals are appropriate NOTE for each welding application. For details on integrating the welder with automation, refer to Application Note AN507 (Automation Interface Guidelines) at www .dukane .com/us > DL_ApplData .asp Continued Page 26 Dukane Manual Part No. 403-584-01...
  • 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

    Power Cord Power Part Number 200 - 1110 240V, 15A North America 200 - 1541 240V, 10A 200 - 1111 240V, 16A Continental Europe 200 - 1542 240V, 10A Table 3-III Power Cords Page 28 Dukane Manual Part No. 403-584-01...

  • Page 35: Cable Connections

    Ultrasound (J1) - Cable 3. This output connects grounded three-lead receptacle. the Ultrasound Output of the iQ Series generator to the transducer, through a coaxial cable. The Have a qualified electrician do the...
  • Page 36 NOTE 3) With a servo press/thruste For information about the iQ ES generator for servo systems, please refer to Dukane The diagram and table that follow show the pneumatic User's Manual, 403-587-00. configuration and list the cables used. Page 30...
  • Page 37 Section 3 - Installation Pneumatic Press/Thruster Continued Figure 3-13 Generator and Pneumatic Press/Thruster - Connections Diagram Page 31 Dukane Manual Part No. 403-584-01...
  • Page 38   S eries Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual Continued from Previous Page Pneumatic Press/Thruster Table 3-IV Generator and Pneumatic Press/Thruster Cables Continued Page 32 Dukane Manual Part No. 403-584-01...

  • Page 39: Networking

    OSHA and ANSI requirements . Compliance with all local building and electrical codes is also required . Dukane does not assume any re- sponsibility or liability for circuitry modifications made by the customer or by any third party manufacturer .
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  • Page 41: Section 4 - Control Panel

    Screen Basics....... 41 Page 35 Dukane Manual Part No. 403-584-01...
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  • Page 43: 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 the System Operating Mode Keys, the 4-1 below are discussed.

  • Page 44: System Operating Mode Keys

    The display has a RED background, and the word, appears in a red box in the lower right corner E-STOP of the display. Operating Mode Indicator Offline (yellow) Figure 4-3 Generator in Offline Condition Page 38 Dukane Manual Part No. 403-584-01...

  • Page 45: Navigation Keys

    If the lower active keys are pressed, they will display the Operate screen (left) or the Main Menu (right). Figure 4-6 Active Soft Keys, Example 2 Page 39 Dukane Manual Part No. 403-584-01...

  • Page 46: System Power Output Level

    Example: With a 1200W generator, at 50% amplitude, if the whole graph is lit, that represents 600W. Lighted Power Indicator While the indicator glows GREEN, it shows that the gen- erator has been powered by the AC current. Page 40 Dukane Manual Part No. 403-584-01...

  • Page 47: Screen Basics

    For the screen on the right, active soft keys are used. (See Figure 4-6.) Display arrows point in direction of more text Figure 4-9 Arrows Indicate More Text Page 41 Dukane Manual Part No. 403-584-01...
  • Page 48 2:3 appears. In this example 2 is the number for the seg- ment, and 3 is the number of the cycle in that segment.) Figure 4-11 Main Menu Detail - Setup Identification See Page 67 for more on Setup. Page 42 Dukane Manual Part No. 403-584-01...

  • Page 49: Section 5 - Operation

    Security ........87 Page 43 Dukane Manual Part No. 403-584-01...
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  • Page 51: 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 components would be: require their own individual adjustments as • iQ generator, those components are integrated into your •...

  • Page 52: Stopping The Weld Cycle

    "End of Weld" or "End of 2. Push the power switch on the generator's rear panel to Cycle." See Page 20 for a description of the OFF position. Automation Cycle Stop Input. Page 46 Dukane Manual Part No. 403-584-01...

  • Page 53: Using The Menus

    1 Figure 5–3 Navigating from the Main Menu (Administrator/Process Engineer Logged In) Page 68 Figure 5–4 Navigating from the Main Menu (Setup Logged In) NOTE Security detail can be found on Pages 87-91. Page 47 Dukane Manual Part No. 403-584-01...

  • Page 54: Process Setup

    Ground Detect Scrub Disable Disabled Distance Weld Distance Secondary Weld Method 1 Weld Position Position Energy Weld Energy Weld Power Peak Power Figure 5–5 Process Setup Menu Diagram (1 of 2) Process Setup, Continued Page 48 Dukane Manual Part No. 403-584-01...
  • Page 55 Disable Wide Advanced Process Settings Normal System Frequency Limits Narrow Manual Ramp Up Time Ramp Down Time Restore Advanced Process Defaults Figure 5-5 Process Setup Menu Diagram (2 of 2) Process Setup, Continued Page 49 Dukane Manual Part No. 403-584-01...
  • Page 56 J2 pin 13. See Pages 19 and 20 for additional See Page 64. information. Apply the auto input signal for a minimum of 50 millisec- Process Setup, Continued onds to ensure that the cycle has been started. Page 50 Dukane Manual Part No. 403-584-01...
  • Page 57 If the maximum trigger time is reached the weld is aborted and the press is returned Process Setup, Trigger Type , Continued to top of stroke. Page 51 Dukane Manual Part No. 403-584-01...
  • Page 58   S eries Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual Process Setup, Trigger Type, Continued from Previous Page Power - Dukane has patented Trigger by Power. 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 59 Program Notes After selecting the appropriate weld mode, the op- erator enters data where the weld mode calls for it. Figure 5-8 illustrates the weld mode submenu structure. Process Setup, Weld Mode, Continued Page 53 Dukane Manual Part No. 403-584-01...
  • Page 60 There may be an incomplete cut however. Scrub time al- lows the cut to be completed by keeping the ultrasound Process Setup, Continued signal on for a maximum of 127 milliseconds. Page 54 Dukane Manual Part No. 403-584-01...
  • Page 61 Pressure will be kept on the part until the speed of the press drops to zero. Like the weld methods, a user specified maximum time prevents infinite holding due to an unreachable distance. Process Setup, Continued Page 55 Dukane Manual Part No. 403-584-01...
  • Page 62 Amplitude refers to the peak-to-peak excursion of the horn at its workface. Amplitude settings are given as a percent of the horn’s nominal amplitude in the range of 20% - 100%. Process Setup, Continued Page 56 Dukane Manual Part No. 403-584-01...

  • Page 63: Pressure Profiling Disabled

    Hold portion of the weld. Upstroke Pressure - This is the pressure for the final Figure 5–12 Pressure Profiling Disabled part of the weld cycle, as the head retracts. Enter the Upstroke Pressure. Process Setup, Pressure, Continued Page 57 Dukane Manual Part No. 403-584-01...

  • Page 64: Pressure Profiling Enabled

    With a 10-step profile, each step equals final part of the weld cycle, as the head retracts. one-tenth of the total distance. In this Enter the Upstroke Pressure. example, each step = 0.001 inch. Page 58 Dukane Manual Part No. 403-584-01...
  • Page 65 - Free Run Frequency and Scan Stack, - Frequency Tracking, - Frequency Lock and Hold, - System Frequency Limits, - Ramp Up, and - Ramp Down. Process Setup, Continued Page 59 Dukane Manual Part No. 403-584-01...
  • Page 66 Figure 5-15 on the following page. This is followed by the ones that apply to a particular part de- brief descriptions of each characteristic. pend on the current iQ setup for that part. Process Limits, Continued Page 60 Dukane Manual Part No. 403-584-01...

  • Page 67: Process Limits Menu Diagram

    (That list includes the Time Single Weld 15, plus eight more charac- teristics shown in shaded boxes in the Date diagram to the left.) Setup Figure 5–15 Process Limits Menu Diagram Process Limits, Continued Page 61 Dukane Manual Part No. 403-584-01...
  • Page 68 Weld Distance (Distance Encoder Systems Only) – This is the distance the press travels while the ultrasound signal is applied to the part under pressure. Process Limits, Continued Page 62 Dukane Manual Part No. 403-584-01...
  • Page 69 Part Limits menu to compliment part cycle data. It 2 weld times. does this to show that a system alarm (www.dukane.com/ us/DL_EasyAlarm.asp) was active during the weld cycle Total Weld Energy - This is the sum of energy drawn from for a particular part.
  • Page 70 • Two beeps are given (if buzzer is set to ON). (See Buzzer, Page 79.) • The iQ ES bad part output is activated. Figure 5–19 Process Limits - Bad Limits • BAD is displayed in the part cycle data. Process Limits, Continued Page 64 Dukane Manual Part No. 403-584-01...
  • Page 71 Show None feature for all of the characteristics. After pressing the Show All soft key, the key designation changes to Show None. Press the key so that none of the process characteristics are displayed. Page 65 Dukane Manual Part No. 403-584-01...

  • Page 72: Process Limits

    Restore Factory Defaults Figure 5–21 Utilities/Hardware Menu Diagram NOTE The list of available Process Utilities and Hardware items depends on Security ac- cess level (See Table 5-I.) and on system configuration. Process Utilities, Continued Page 66 Dukane Manual Part No. 403-584-01...

  • Page 73: Process Utilities

    5-25 appears. Typically, Define Sequence would be chosen. Defining the sequence involves entering the information Figure 5–25 Defining the Sequence suggested by Figure 5-25: Sequence Length, etc. For more on Sequencing, go to Appendix C. Process Utilities, Setup Control Continued Page 67 Dukane Manual Part No. 403-584-01...
  • Page 74 As with System Control, a list of setups is displayed. Highlight a setup from the list and press Choose Setup. iQ 1 Figure 5–28 Select Setup - When Setup Security Access is Active Process Utilities, Continued Page 68 Dukane Manual Part No. 403-584-01...

  • Page 75: Copy Setup 1

    Figure 5–29 Copy Setup - 1 The display will appear as it does in Figure 5-31. Figure 5–30 Copy Setup - 2 iQ 1 Figure 5–31 Copy Setup - 3 Process Utilities, Continued Page 69 Dukane Manual Part No. 403-584-01...

  • Page 76: Erase Setup

    MM/DD/YYYY, DD/MM/YYYY, or YYYY/MM/DD Time This utility is used to set the time, in the 24 hour format. Date Entering the current date will be done in the date format already chosen. Page 70 Dukane Manual Part No. 403-584-01...

  • Page 77: Notes

    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 Figure 5–34 Notes Process Utilities, Continued Page 71 Dukane Manual Part No. 403-584-01...

  • Page 78: Hardware Setup

    Bad - Only bad parts are sent to the output device. Suspect - Only suspect parts are sent to the output device. Bad and Suspect - All bad and suspect parts are sent to the output device. Hardware Setup, Continued Page 72 Dukane Manual Part No. 403-584-01...

  • Page 79: Baud Rate

    At the end of every cycle, the cycle data also gets sent out via the serial port. The user can send (print) this data, each time the Print soft key is pressed. Hardware Setup, Continued Page 73 Dukane Manual Part No. 403-584-01...
  • Page 80 Programmable Status Output 1 (J3 pin 4) J3 represents the generator's output connector, and Pin 4 is programmable. It can be programmed to provide: E-Stop Status or Overtemp Status. The default setting is E-Stop. Hardware Setup, Continued Page 74 Dukane Manual Part No. 403-584-01...

  • Page 81: Restore System I/O Defaults

    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 5-37 for the screen view. Hardware Setup, Continued Page 75 Dukane Manual Part No. 403-584-01...
  • Page 82 See Figure 5-39. This warning our website to download Application Note 512 at http:// reminds the operator that modifying www.dukane.com/us/DL_ApplData.asp settings may damage the generator, or the ultrasonic stack. Hardware Setup, Continued Page 76 Dukane Manual Part No. 403-584-01...
  • Page 83 Free Running Frequency setting. For more information about Frequency Tracking, refer to our Application Note 513 on the Dukane website at: http:// www.dukane.com/us/DL_ApplData.asp • Frequency Lock/Hold - When frequency lock and hold...
  • Page 84 A screen appears with the question, Are you sure you want to Restore Advance Process Defaults? Select YES to restore all of the advanced process set- tings to their factory defaults. Hardware Setup, Continued Page 78 Dukane Manual Part No. 403-584-01...
  • Page 85 Press CANCEL to abort. The “Test at Power Up” feature can also be cancelled by iQ 1 Test activating the “System Latch Reset” input (J2-12). Figure 5–41 Test at Power Up Hardware Setup, Continued Page 79 Dukane Manual Part No. 403-584-01...
  • Page 86 Delay by Time Power Start Amplitude Trigger Power Max Trigger Time Position Trigger Position Max Trigger Time Trigger Delay Disabled Delay Until Auto In Figure 5–42 Trigger Function - Basic and Advanced Hardware Setup, Continued Page 80 Dukane Manual Part No. 403-584-01...
  • Page 87 Figure 5–44 Restore Factory Defaults? Before this is allowed, however, an intermediate screen questioning the action appears. See Figure 5-44. NOTE Performing a Restore Factory Defaults can not be reversed. Page 81 Dukane Manual Part No. 403-584-01...

  • Page 88: Operate Screen

    Pressing the soft key again will continue searching for the next previous part that had an alarm. Direction - Press this soft key to change the direction of the search from previous cycle data parts to next cycle data parts. Page 82 Dukane Manual Part No. 403-584-01...

  • Page 89: Real Time Data

    The possible characteristics are: Pressure, Force, Dis- tance, Power, and Frequency. Characteristics displayed depend on system configuration. Figure 5–48 Real Time Data Page 83 Dukane Manual Part No. 403-584-01...

  • Page 90: Graph

    The events are: Weld End, Hold End Figure 5–52 End Graph at Setup NOTE As the graph is being designed with these setup screens, press ENTER to display the graph. Continued Page 84 Dukane Manual Part No. 403-584-01...
  • Page 91 The figure below shows a completed graph. This particular image resulted after pressing the TEST key. See Figure 5-53 below. Vertical Axis, Blue Vertical Axis, Horizontal Axis, Power Frequency Time Figure 5–53 Example Graph Following Test Page 85 Dukane Manual Part No. 403-584-01...

  • Page 92: Help

    - Sep 20 2012 / 11:04:37 Motherboard app: v3.11.02 - Aug 9 2013 / 11:20:24 boot: v1.04 - Sep 20 2012 / 08:48:10 Model # 20HS2402QP6 Back Serial # 229180 Online iQ 1 Figure 5–55 Help Screen Example Page 86 Dukane Manual Part No. 403-584-01...

  • Page 93: Security

    Figure 5-56 Security Screen - No Passwords Set request. If the generator had been programmed to yield control, then after 30 seconds, the remote user would have control. Continued Page 87 Dukane Manual Part No. 403-584-01...
  • Page 94 Remote User Timeout Deny Control by [Admin] showing that the Administrator has current security access. Login is complete for the Administrator. Done iQ 1 Online Figure 5-60 Security Screen - Administrator Access Enabled Continued Page 88 Dukane Manual Part No. 403-584-01...
  • Page 95 Login Password and Done are choices. Press the soft key next to Login Password to login. Done iQ 1 Online Press Done to exit and return to the main menu. Figure 5-62 Security Screen - Logged Out Continued Page 89 Dukane Manual Part No. 403-584-01...
  • Page 96 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 90 Dukane Manual Part No. 403-584-01...
  • Page 97 1 Figure 5-65 Security Prompt for Process Engineer Forgotten Password? Access Contact Dukane if the password has been forgotten. See Section 10 - Contacting Dukane. Process Eng Access Required Please Log In iQ 1...
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  • Page 99: Section 6 - System Operational Testing

    Cycling the System....... . 98 Page 93 Dukane Manual Part No. 403-584-01...
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  • Page 101 Section 6 - System Operational Testing Overview 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 (vibrational characteristics) of the stack that is being driven.
  • Page 102 1. Check the following: a. Make sure that the correct booster and horn for the application are installed in the thruster. b. Check the iQ Series system components for proper grounding. c. Check the ultrasound cable connections on the generator and thruster for proper seating and security.
  • Page 103 5. Turn the generator OFF. Check the stack for proper as- sembly, damaged components, or dirty mating surfaces. Recheck the ultrasound cable for proper connections. Repeat Steps 1 through 4. If the test still fails, go to the next step. Continued Page 97 Dukane Manual Part No. 403-584-01...
  • Page 104 4. Manually cycle the system. Activate both operate switches at the same time to start the system, and hold fingers in place until the ultra- sound starts. Releasing the fingers before ultrasound starts will abort the cycle. Page 98 Dukane Manual Part No. 403-584-01...

  • Page 105: Section 7 - Set-Up Guidelines And Troubleshooting

    The Power-up Sequence Stops ....107 Alarm Messages......108 Page 99 Dukane Manual Part No. 403-584-01...
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  • Page 107: Set-Up Guidelines

    Section 7 - Set-up Guidelines and Troubleshooting Set-up Guidelines The iQ Series ES generator is shipped from the fac- tory with a few default settings. See the table below for those values. Default Settings - Process Setup (iQ Series Generator ES Pneumatic)

  • Page 108: Charts:trigger Force, Weld Time, Weld Force

    Trigger Setting = 2.6 -3.2 (40 -55 pounds) Weld Time = 0.40 - 0.65 seconds Weld Force = 150 - 240 pounds Initial Trigger Force Linear Weld Joint (inches) Figure 7-1 Suggested Initial Trigger Force Continued Page 102 Dukane Manual Part No. 403-584-01...
  • Page 109 Section 7 - Set-up Guidelines and Troubleshooting Continued from Previous Page Initial Weld Time Suggested Initial Weld Time Linear Weld Joint (inches) Figure 7-2 Suggested Initial Weld Time Continued Page 103 Dukane Manual Part No. 403-584-01...
  • Page 110 Trigger Force. If there is not enough downstroke pressure, it may cause the system to fault at Max Trigger Time. Linear Weld Joint (inches) Figure 7-3 Suggested Initial Weld Force Page 104 Dukane Manual Part No. 403-584-01...

  • Page 111: Air Cylinder Size And Force

    Verify the size of your air cylinder diameter. Use Table 7-II below to determine actual force at a given pressure. Pressure Cylinder Diameter (in) (psi) Table 7- II Pounds of Force Comparison between Dukane Air Cylinders Page 105 Dukane Manual Part No. 403-584-01...

  • Page 112: Troubleshooting

    Review the program. There should be a Weld Time lem. For help, go to Section 10 P1 (and Weld Time P2 if dual pressure is used). Set - Contacting Dukane, Page 123. the weld characteristic to Display using the genera- tor's front panel Process Limits screen.

  • Page 113: The Power-Up Sequence Stops

    Dukane If the power indicator stops flashing and remains RED, (see Section 10 - Contacting Dukane) do not go any further, there is a problem with an internal for servicing. The iQ ES generator is power supply.

  • Page 114: Alarm Messages

    (Q-Series) or iQ Explorer II software. Information on particular alarms may also be obtained on the Dukane '"Easy Alarm" web page: http://www. dukane.com/us/DL_EasyAlarm.asp Continued Page 108 Dukane Manual Part No. 403-584-01...
  • Page 115 Section 7 - Set-up Guidelines and Troubleshooting Continued from Previous Page Continued Table 7-III Alarm Message Screens - Page 1 of 3 Page 109 Dukane Manual Part No. 403-584-01...
  • Page 116   S eries Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual Continued from Previous Page Continued Table 7-III Alarm Message Screens - Page 2 of 3 Page 110 Dukane Manual Part No. 403-584-01...
  • Page 117 Section 7 - Set-up Guidelines and Troubleshooting Continued from Previous Page Continued Table 7-III Alarm Message Screens - Page 3 of 3 Page 111 Dukane Manual Part No. 403-584-01...
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  • Page 119: Section 8 - Maintenance

    Section 8 - Maintenance SECTION 8 Maintenance Page 113 Dukane Manual Part No. 403-584-01...
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  • Page 121 This is shown in Figure 3–3, Page 15. I/O Connector The Input/Output connector has a pair of 4-40 threaded jack screws to secure the connector. Make sure the screws are snug, but do not overtighten them. Page 115 Dukane Manual Part No. 403-584-01...
  • Page 122   S eries Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual This page intentionally left blank Page 116 Dukane Manual Part No. 403-584-01...

  • Page 123: Section 9 - Options

    P5 Dual Pressure with Distance ......122 P6 EPR/Load Cell with Distance ......122 Page 117 Dukane Manual Part No. 403-584-01...
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  • Page 125: Power Inlet Options

    Pages 8 and 9 for information about Elec- 240V Systems trical Safety including grounding. Generators with power ratings above 2400 Watts also have fixed power cords. See Table 11-II in Section 11, Specifications. Page 119 Dukane Manual Part No. 403-584-01...

  • Page 126: Data Transfer

    Figure 9-1 shows an example of this output format, and Table 9-I on the next page gives the Part Data Index num- bers and descriptions. Page 120 Dukane Manual Part No. 403-584-01...
  • Page 127 Dukane's DPC Total Stroke generator protocol as closely as possible. Time Format: HH:MM:SS Date -> Formats: DD/MM/YYYY, MM/DD/YYYY, YYYY/MM/DD Setup Number Error Code -> "U Number" without the 'U' Table 9-I Part Data Indexes Page 121 Dukane Manual Part No. 403-584-01...

  • Page 128: Press Interface Module

    Each option is described in general terms: P4 - Dual Pressure Only P/N 110-4426 Dual pressure is a feature that is exclusive to Dukane press systems. It increases clamp force to improve the plastic melt and flow during the weld portion of a cycle and as-...

  • Page 129: Section 10 - Contacting Dukane

    Section 10  -   C ontacting Dukane SECTION 10 Contacting Dukane Page 123 Dukane Manual Part No. 403-584-01...
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  • Page 131 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 and serial number. • Alarm indicators from the generator or displayed by iQ Explorer II.
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  • Page 133: Section 11 - Specifications

    Interpreting the Model Number....135 Regulatory Agency Compliance ....136 Page 127 Dukane Manual Part No. 403-584-01...
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  • Page 135: Outline Drawings

    Section 11 - Specifications Figure 11-1 Layout - Low Profile Generator Page 129 Dukane Manual Part No. 403-584-01...
  • Page 136   S eries Ultrasonic Generator/Power Supply, Pneumatic Systems, ES User’s Manual Figure 11-2 Layout - High Power Generator Page 130 Dukane Manual Part No. 403-584-01...
  • Page 137 Section 11 - Specifications Figure 11-3 Layout - High Profile Generator Page 131 Dukane Manual Part No. 403-584-01...

  • Page 138: Weights, Dimensions, Operating Environment

    Storage guidelines for deactivated equipment: Temperature: -4°F to 158°F (-20°C to +70°C) Air Particulates: Keep the equipment dry. Minimize exposure to moisture, dust, dirt, smoke and mold. Humidity: 5% to 95% Non–condensing @ 0°C to +30°C Page 132 Dukane Manual Part No. 403-584-01...

  • Page 139: Ac Power Requirements

    Section 11 - Specifications Page 133 Dukane Manual Part No. 403-584-01...

  • Page 140: Ultrasonic Pressure

    Operator's Position - dB Ultrasonic Pressure 1 m from the Equipment- dB iQ Generator Ultrasonic Pressure Table 11–IV NOTE All measurements taken with Data Physics Dynamic 4-Channel Signal Analyzer with calibrated 377C01 Microphone and 426B02 Preamplifier. Page 134 Dukane Manual Part No. 403-584-01...

  • Page 141: Interpreting The Model Number

    Section 11 - Specifications Interpreting the Model Number Figure 11-4 Interpreting the Model Number Page 135 Dukane Manual Part No. 403-584-01...

  • Page 142: Regulatory Agency Compliance

    Commission). or associated cables as The rating is IP2X, in compliance with finger-safe the changes may result industry standards. in violating one or more regulations under which this equipment is manufactured. Page 136 Dukane Manual Part No. 403-584-01...

  • Page 143: Section 12 - Appendices

    Appendix C - Sequencing Notes ....144 Appendix D - Menu Structure Diagrams..147 Page 137 Dukane Manual Part No. 403-584-01...
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  • Page 145: Appendix A List Of Figures

    Front Panel's Lighted Power Indicator ................45 Main Menu Screen ......................45 Navigating from the Main Menu (Administrator /Process Engineer Logged In) ....47 Navigating from the Main Menu (Setup Logged In) ............47 Process Setup Menu Diagram ................48-49 Continued Page 139 Dukane Manual Part No. 403-584-01...
  • Page 146 Erase Setup ........................70 5-33 Part Count Settings .......................70 5-34 Notes ..........................71 5-35 Serial Port Selections ....................72 5-36 System Status I/O Selections ..................74 5-37 Restore System I/O Defaults ..................75 5-38 Additional Hardware Settings Diagram .................76 Continued Page 140 Dukane Manual Part No. 403-584-01...
  • Page 147 Security Screen - Logged Out ..................89 5-63 Security Screen - Logged Out ..................90 5-64 Security Screen - Setup is Logged In ................90 5-65 Security Prompt for Process Engineer Access ..............91 5-66 Security Prompt for Setup Access .................91 Continued Page 141 Dukane Manual Part No. 403-584-01...
  • Page 148 11-4 Interpreting the Model Number ..................135 What is a Sequence? ....................144 Insertion Sequence Example ..................145 Sequence Definition ....................146 Process Setup Menu Diagram ................147-148 Process Limits Menu Diagram ..................149 Utilities/Hardware Menu Diagram ................150 Page 142 Dukane Manual Part No. 403-584-01...

  • Page 149: Appendix B List Of Tables

    Generator and Pneumatic Press/Thruster Cables ............. 32 Security Access to Main Menu Item ................87 Default Settings - Process Setup ..................101 7-II Pounds of Force Comparison Between Dukane Air Cylinders ........105 7-III Alarm Messages, Pneumatic-related ................109 Part Data Indexes ......................121 11-I iQ Generator Weights ....................132...

  • Page 150: Appendix C - Sequencing Notes

    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 144 Dukane Manual Part No. 403-584-01...
  • Page 151 Setup 02 Cycle 2 Setup 02 Cycle 1 Setup 02 Setup 02 Cycle 4 Cycle 3 Start Point Stop Point Setup 01, Cycle 1 Setup 01, Cycle 2 Figure C-2 Insertion Sequence Example Continued Page 145 Dukane Manual Part No. 403-584-01...
  • Page 152 • 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 146 Dukane Manual Part No. 403-584-01...

  • Page 153: Appendix D - Menu Structure Diagrams

    Ground Detect Scrub Disable Disabled Weld Distance Distance Secondary Weld Method 1 Weld Position Position Weld Energy Energy Weld Power Peak Power Process Setup, Continued Figure D-1 Process Setup Menu Diagram (1 of 2) Page 147 Dukane Manual Part No. 403-584-01...
  • Page 154 Frequency Lock and Hold Disable Wide Advanced Process Settings Normal System Frequency Limits Narrow Manual Ramp Up Time Ramp Down Time Restore Advanced Process Defaults Figure D-1 Process Setup Menu Diagram (2 of 2) Page 148 Dukane Manual Part No. 403-584-01...
  • Page 155 (That list includes the Time Single Weld 15 characteristics, plus eight more characteristics shown in shaded Date boxes in the diagram to the left.) Setup Figure D-2 Process Limits Menu Diagram Page 149 Dukane Manual Part No. 403-584-01...
  • Page 156 Network Settings Restore Factory Defaults Figure D-3 Utilities/Hardware Menu Diagram NOTE The list of available Process Utilities and Hardware items depends on Security ac- cess level (See Table 5-I.) and on system configuration. Page 150 Dukane Manual Part No. 403-584-01...

  • Page 157: Index

    Index Index Page 151 Dukane Manual Part No. 403-584-01...
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  • Page 159 Frequency Lock/Hold 77 Frequency Tracking 77 Chassis Grounding Stud 17 Connect AC Power 33 General User Information 3 Connecting Cables 29 Drawings and Tables 3 Recheck Connections 33 Notes, Cautions and Warnings 3 Connector Continued Page 153 Dukane Manual Part No. 403-584-01...
  • Page 160 Plastics Health Notice 8 Layout - Low Profile iQ Generator 129 Recommendations 7 Lifting the Equipment 10 Help 86 List of Figures 139 How to Lift Safely 10 List of Tables 143 Lockout /Tagout Devices 13 Page 154 Dukane Manual Part No. 403-584-01...
  • Page 161 Show All 65 Power Inlet Options 119 Show None 65 Press Interface Board 122 Suspect Limits 65 P4 - Dual Pressure Only 122 Time 63 P5 - Dual Pressure with Distance 122 Continued Page 155 Dukane Manual Part No. 403-584-01...
  • Page 162 Output Duration 75 Scan Stack 76 Programmable Status Output 1 (J3 pin 4) 74 Screen Basics 41 Programmable Status Output 2 (J3 pin 5) 75 Scrub 54 Restore System I/O Defaults 75 Security 87 Page 156 Dukane Manual Part No. 403-584-01...
  • Page 163 Method 53 Dual 53 Single 53 Mode 53 Peak Power 62 Pressure 57 Time 62 Total Cycle Time 63 Total Weld Distance 63 Total Weld Time 63 Trigger Force 102 Welder Name 67 Page 157 Dukane Manual Part No. 403-584-01...
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  • Page 165 By passing its audit, Dukane can as- based on partnership for continuous improve- sure you that we have in place a well–defined ment. This concept is key in that Dukane no and systematic approach to quality design, longer focuses on inspection, but on indi- manufacturing, delivery and service.
  • Page 166 Ultrasonic Generator/Power Supply, Pneumatic Systems, www.dukane.com ES User's Manual Part No. 403   - 584  - 01 Printed in the United States of America Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-  4 900...

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