Dukane iQ Series User Manual
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Dukane iQ Series User Manual

Dukane iQ Series User Manual

Ultrasonic generator/power supply
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Intelligent Assembly Solutions
Series
ULTRASONIC GENERATOR/POWER SUPPLY
ES
AUTOMATED
HAND PROBE
PRESS
User's Manual
Dukane Part No. 403 
575 
00
–
–
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797– 4900 • FAX (630) 797– 4949
ISO 9001:2008
Dukane products are manufactured
www.dukane.com/us
in ISO registered facilities.

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  • Page 1 Dukane Part No. 403  575  – – Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797– 4900 • FAX (630) 797– 4949 ISO 9001:2008 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. 08/19/2011 Page iii Dukane Manual Part No. 403-575-00...
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  • Page 5: Table Of Contents

    Quick Start - Servo Welder ......44-55 Quick Start - Pneumatic Welder ....56-69 Continued Page v Dukane Manual Part No. 403-575-00...
  • Page 6 Section 8 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Section 9 - Contacting Dukane . . . . . . . . . . . . . . . 103 Section 10 - Specifications .

  • Page 7: Section 1- Introduction

    Press System Overview ....4 Key Features ....4 Page 1 Dukane Manual Part No. 403-575-00...
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  • Page 9: General User Information

    (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 Electrical Operator section three. or Practice Safety Issue Protection (hearing) Page 3 Dukane Manual Part No. 403-575-00...

  • Page 10: Press System Overview

    This been manufactured to high quality standards and provides consistent system performance regardless of assures you of manufacturing excellence. line voltage fluctuations. It also eliminates the need for bulky, external constant–voltage transformers. Page 4 Dukane Manual Part No. 403-575-00...

  • Page 11: Section 2 - Health And Safety

    International Power Grounding ....9 Lifting the Equipment ......10 Page 5 Dukane Manual Part No. 403-575-00...
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  • Page 13: General Considerations

    A typical iQ Series System consists of the iQ generator, a press with thruster, No Unauthorized Modifications - Do not modify your switches, controls, cables, transducer, system in any way unless authorized to do so by Dukane booster, horn, and fixture, and iQ Explorer Corporation. Unauthorized modifications could cause equipment damage and/or injury to the operator.

  • Page 14: Plastics Health Notice

    Inquiries should be made to the U.S. Department of Labor concerning OSHA regulations for a particular plastic prior to processing with Dukane ultrasonic equipment. CAUTION When making cable connec- tions to system equipment...

  • Page 15: Electrical Safety

    100/120 AC systems is permanently Provided Cable attached to the rear of the generator. Units with this Figure 2–2 International 220/240V Grounding power cord are for use in North America or Japan. Page 9 Dukane Manual Part No. 403-575-00...

  • Page 16: Lifting The Equipment

    To place the object below the level of your waist, follow the same procedures in re- verse order. Remember, keep your back as vertical as possible and bend at the knees. Page 10 Dukane Manual Part No. 403-575-00...

  • Page 17: Section 3 - Installation

    Recheck Connections ..... . . 37 Connect AC Power ......37 Page 11 Dukane Manual Part No. 403-575-00...
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  • Page 19: Before Installation

    . Before making The figure to the right shows the lockout device in the any internal adjustments closed, locked position. to the generator, apply a lockout/tagout (LOTO) device to the generator chassis . Continued Page 13 Dukane Manual Part No. 403-575-00...
  • 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. 403-575-00...

  • Page 21: Unpacking

    See Section 10 - Specifications, for generator drawings. gradients and increase component life. 17.16 [435.86] 3.45 3.81 [87.63] [96.8] EXHAUST AIR OUTLET COOLING AIR INLET OPTIONAL [mm] POWER BUTTON Generator Front View (typical) Low Profile Figure 3-3 Continued Page 15 Dukane Manual Part No. 403-575-00...

  • Page 22: Placement In A Seismic Region

    Rack- Mounting Install the four brackets from Dukane's rack-mount kit to the generator. See Table 3-I, and Figure 3- 4 (showing a low profile unit) below.
  • Page 23 12.54 [318.52] ALLOW 5" BOTH SIDES FOR COOLING. OPTIONAL HOLD DOWN BRACKETS 17.16 147-1398 [435.86] 5.19 5.50 [131.83] [139.7] 1.40 [35.6] OPTIONAL HOLD [mm] DOWN BRACKETS Securing iQ Generator to Benchtop Figure 3-5 Page 17 Dukane Manual Part No. 403-575-00...

  • Page 24: Rear Panel Layout Overview

    The press interface board is avail- voltage connection to ultrasonic stack. able in several different configura- Configuration Port Connector (J4) – Digital control tions. See Section 8, Options for port to modify system parameters. more information. Page 18 Dukane Manual Part No. 403-575-00...

  • Page 25: 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 19 Dukane Manual Part No. 403-575-00...

  • Page 26: System Inputs Connector Pinout

    Table 3-II, to assist with custom automation system wir- ing and assembly. Figure 3-8 System I/O Panel (standard panel shown) NOTE Refer to Section 8, Options for information on optional features. Page 20 Dukane Manual Part No. 403-575-00...

  • Page 27: System Inputs Signal Descriptions

    Pin 4 is the Remote Setup Selection Bit 1, which is the second least significant bit used to select different weld- Figure 3-10 HD-15M, Generator Input Cable ing setups with an automation control system. Connector Continued Page 21 Dukane Manual Part No. 403-575-00...
  • Page 28 This pin must be left open whenever a press control board is installed. Connecting this pin to chassis ground will inhibit press operation. Page 22 Dukane Manual Part No. 403-575-00...

  • Page 29: System Outputs Connector

    The system monitor output signals are analog signals used to monitor ultrasonic amplitude setting and ultrasonic output Figure 3–12 DB-25M, Generator Output Cable power levels, referenced to the Monitor Common (Pin 13). Connector Continued Page 23 Dukane Manual Part No. 403-575-00...

  • Page 30: System Outputs Connector Pinout

    It will remain active until the thruster head raises to the top of the stroke. This output will be an open circuit when a trigger condition hasn’t been detected. Continued Page 24 Dukane Manual Part No. 403-575-00...
  • Page 31 Pin 14 (Not Used) Pin 14 is connected to the system chassis ground. Continued Page 25 Dukane Manual Part No. 403-575-00...
  • Page 32 Pin 25 is an open connection. bad part limits. This output will be an open circuit when a bad part has not been detected. Page 26 Dukane Manual Part No. 403-575-00...

  • Page 33: Ultrasound Output Connector

    (black carbon deposits) port features. on either the ultrasound output connector or the ultrasound cable connectors. Figure 3-14 Configuration Port Connector Page 27 Dukane Manual Part No. 403-575-00...

  • Page 34: 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 28 Dukane Manual Part No. 403-575-00...

  • Page 35: Connecting Cables

    Power Cord Power Part Number 200 - 1110 240V, 15A North America 200 - 1541 240V, 10A 200 - 1111 240V, 16A Continental Europe 200 - 1542 240 V, 10A Power Cords Table 3-IV Page 29 Dukane Manual Part No. 403-575-00...
  • Page 36 1) With a pneumatic press/thruster 2) With a remote controller and a servo press/thruster 3) With a servo press/thruster Diagrams and tables that follow show these three configurations and list the cables used respectively. Page 30 Dukane Manual Part No. 403-575-00...
  • Page 37 Section 3 - Installation Connecting Cables Pneumatic Press/Thruster Generator and Pneumatic Press/Thruster - Connections Diagram Continued Figure 3-15 Page 31 Dukane Manual Part No. 403-575-00...
  • Page 38 Series Ultrasonic Generator/Power Supply ES User’s Manual Continued from previous page Pneumatic Press/Thruster Generator and Pneumatic Press/Thruster Cables Table 3-V Continued Page 32 Dukane Manual Part No. 403-575-00...
  • Page 39 Section 3 - Installation Servo Press/Thruster (Version 1) Continued Generator, Remote Controller, and Servo Press/Thruster - Connections Diagram Figure 3-16 Page 33 Dukane Manual Part No. 403-575-00...
  • Page 40 Series Ultrasonic Generator/Power Supply ES User’s Manual Continued from previous page Servo Press/Thruster (Version 1) Generator, Remote Controller, and Servo Press/Thruster Cables Table 3-VI Page 34 Dukane Manual Part No. 403-575-00...
  • Page 41 Section 3 - Installation Servo Press/Thruster (Version 2) Continued Generator and Servo Press/Thruster - Connections Diagram Figure 3-17 Page 35 Dukane Manual Part No. 403-575-00...
  • Page 42 Series Ultrasonic Generator/Power Supply ES User’s Manual Continued from previous page Servo Press/Thruster (Version 2) Generator and Servo Press/Thruster Cables Table 3-VII Page 36 Dukane Manual Part No. 403-575-00...

  • Page 43: Networking

    • Remote Controller • Press/Thruster • Connections to Local Area Network Connect AC Power When all cabling connections have been made, and they have been systematically rechecked, connect AC line power to your system. Page 37 Dukane Manual Part No. 403-575-00...
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  • Page 45: Section 4 - Operation

    Quick Start Servo ....... .44-55 Quick Start Pneumatic ......56-69 Page 39 Dukane Manual Part No. 403-575-00...
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  • Page 47: Overview

    (HMI) or a computer (user supplied), using iQ Explorer. In addition the press, acoustic stack and any tooling are adjusted as necessary. For additional information about the other key Dukane components of the system, see these User Manuals: • iQ Explorer (Part No. 403-579-00), and •...

  • Page 48: Stopping The Weld Cycle

    Two support features incorporated into your iQ Explorer ing process and controlling the system are accomplished software are its virtual numeric pad/keyboard and its help system. using the iQ HMI or your computer and Dukane's iQ Explorer software. Numeric Pad and Keyboard Stopping the Weld...

  • Page 49: Help System

    Use the iQ HMI 2) that item is linked to Help. Windows keyboard, or press Help in the top menu bar, and navigate to the desired topic. Page 43 Dukane Manual Part No. 403-575-00...

  • Page 50: Quick Start - Servo Welder

    File Name box, and select an unused setup. This will ensure that you do not overwrite a pre-existing setup. See Figure 4-6 below. Dukane iQ Explorer - [Welder 1- Setup 4] Hardware Tab iQ Explorer, Start-up, Hardware Tab Figure 4-6 Page 44 Dukane Manual Part No.
  • Page 51 See Figure 4-8. NOTE This Initiate Mode selection as- sumes there is a stand-alone, benchtop system with manual acti- vation switches. Select Manual in Initiate Mode. iQ Explorer, Process Settings > Initiate Mode Figure 4-8 Page 45 Dukane Manual Part No. 403-575-00...
  • Page 52 See Figure 4-10, Initial Trigger Force Settings. 6.000 iQ Explorer, Process Settings > Trigger > Type > Force > Max Trigger Time Figure 4-9 Linear Weld Joint (inches) Suggested Initial Trigger Force Setting Figure 4-10 Page 46 Dukane Manual Part No. 403-575-00...
  • Page 53 If you do not know this 0.20 position where this contact is made, select the Teach button. See Figure 4-12 on the next page. iQ Explorer, Process Settings > Sensing Speed Figure 4-11 Page 47 Dukane Manual Part No. 403-575-00...
  • Page 54 Explorer, Teach Start Sensing Distance Figure 4-12 Servo Step 9 - Select Trigger Method Still on the Process Settings tab, select Normal as the trigger method. Select Trigger Method, Normal iQ Explorer, Select Trigger Method Figure 4-13 Page 48 Dukane Manual Part No. 403-575-00...

  • Page 55: Iq Explorer, Start Motion After Force Decreases By

    Servo Step 11 - Program Start Motion After Force Decreases By: Continuing with the Process Settings tab. . . See Figure 4-15. This patented feature is found only on Dukane's servo press systems. If the feature is selected, the system will stop motion once the desired Trigger Force is achieved.

  • Page 56: Iq Explorer, Speed, Motion Type, Profile

    This can be done by manipulating the Speed Profile until the Power Graph shows a smooth, constant result. See Figure 4-18 at right for a view of a Speed iQ Explorer, View Speed Profile Figure 4-18 Profile. Page 50 Dukane Manual Part No. 403-575-00...

  • Page 57: Iq Explorer, Amplitude Setting

    100%. The range for this fea- ture is between 20% and 100%. Typical amplitude setting is 100%. Range is between 20% and 100% iQ Explorer, Amplitude Setting Figure 4-19 Continue with settings on the next page. Post Weld Page 51 Dukane Manual Part No. 403-575-00...

  • Page 58: Dynamic Hold Method

    This feature can be beneficial in producing superior weld strength and appearance. iQ Explorer, Process Settings> Post Weld > Dynamic Hold Method Figure 4-20 Continued Page 52 Dukane Manual Part No. 403-575-00...

  • Page 59: Static Hold Method

    Servo Step 15 - Test the Acoustic Stack Run a test of the acoustic stack. Please go to Section 5 of this User's Manual, System Op- erational Testing, where the system test procedures are outlined. Page 53 Dukane Manual Part No. 403-575-00...

  • Page 60: Iq Explorer, Process Limits Tab

    Display. Those limits will be displayed on the Cycle Data screen, and this will be important for future diagnostics of the welder setup. Process Limits Tab Figure 4-22 iQ Explorer, Process Limits Tab Page 54 Dukane Manual Part No. 403-575-00...

  • Page 61: Iq Explorer, Cycle Data

    After all the parameters have been programmed, initiate the weld cycle. View the results at the Cycle Data tab to insure all parameters have been achieved. See the example shown below in Figure 4-23. iQ Explorer, Cycle Data Figure 4-23 Page 55 Dukane Manual Part No. 403-575-00...

  • Page 62: Quick Start - Pneumatic Welder

    File Name box, and select an unused setup. This will ensure that you do not overwrite a pre-existing setup. See Figure 4-25 below. Dukane iQ Explorer - [Welder 1 - Setup 4] iQ Explorer Start-up, Hardware Tab Figure 4-25 Page 56...

  • Page 63: Iq Explorer, Process Settings>Initiate Mode

    8 - Secondary Control These boxes organize the weld process into the events that occur during the weld process. Figure 4-26 shows the Welder Type selection. Dukane iQ Explorer - [Welder 1- Setup 4] Select Press NOTE This Initiate Mode selection as-...

  • Page 64: Suggested Initial Trigger Force

    - For a basic setup this value Compensation Point can be programmed at zero. Typically force values above 10 pounds are programmed at zero. Continued See Figure 4-29 on the next page. Page 58 Dukane Manual Part No. 403-575-00...

  • Page 65: Iq Explorer, Process Settings>Trigger Type

    Pneumatic Step 6 - Process Settings>Trigger >Type Figure 4-29 below shows Trigger Type and the other example values discussed on the previous page. Dukane iQ Explorer - [Welder 1- Setup 4] iQ Explorer Process Settings > Trigger >Type Figure 4-29...

  • Page 66: Suggested Initial Weld Time

    2.000 seconds, the system will terminate the weld initial basic setup. process. iQ Explorer Process Settings > Weld Figure 4-31 Suggested Initial Weld Time Linear Weld Joint (inches) Suggested Initial Weld Time Figure 4-32 Page 60 Dukane Manual Part No. 403-575-00...
  • Page 67 Explorer, Process Settings > Post Weld > Hold Method > Hold Time Figure 4-33 Continued Page 61 Dukane Manual Part No. 403-575-00...

  • Page 68: Iq Explorer, Process Settings>Post Weld>Pressure

    Initial Weld Force chart. See Table 4-I and Figure 4-35 iQ Explorer > Process Settings > Post Weld > Pressure Figure 4-34 Linear Weld Joint (inches) Continued Suggested Initial Weld Force Figure 4-35 Page 62 Dukane Manual Part No. 403-575-00...

  • Page 69: Air Cylinder Size

    Verify the size of your air cylinder diameter. Use Table 4-I to determine actual force at a given pressure. Pressure Cylinder Diameter (in) (psi) Pounds of Force Comparison Table 4-I between Dukane Air Cylinders Page 63 Dukane Manual Part No. 403-575-00...

  • Page 70: Upstroke Pressure

    Upstroke pressure has little or no effect on weld results. However, overall cycle time is affected by upstroke travel time. For a basic weld setup, program Upstroke Pressure at 80 psi. See Figure 4-34. Page 64 Dukane Manual Part No. 403-575-00...
  • Page 71 Default settings for Ramp Up Time and See Figure 4-36 below Ramp Down Time are dependent on the frequency of the welding system. Local 0.150 0.000 Figure 4-36 iQ Explorer, Process Settings > Amplitude Page 65 Dukane Manual Part No. 403-575-00...
  • Page 72 Pneumatic Step 13 - Test the Acoustic Stack Run a test of the acoustic stack. Please go to Section 5 of this User's Manual, System Op- erational Testing, where the system test procedures are outlined. Page 66 Dukane Manual Part No. 403-575-00...
  • Page 73 If this is the first time on this tab (for your selected setup), the status for each parameter will be blank. See Figure 4-38 below. Dukane iQ Explorer - [Welder 1- Setup 4] iQ Explorer, Process Limits Tab - I Figure 4-38...
  • Page 74 Figure 4-39 shows a typical basic setup with several parameters selected. Dukane iQ Explorer - [Welder 1- Setup 4] iQ Explorer, Process Limits Tab - II Figure 4-39 Page 68...
  • Page 75 (right and/or left) at the bottom to view the entire set of weld parameters. Parameters Dukane iQ Explorer - [Welder 1- Setup 4] Scroll Bar iQ Explorer, Cycle Data Page Figure 4-40 Page 69 Dukane Manual Part No.
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  • Page 77: Section 5 - System Operational Testing

    Operational Test of the Acoustic Stack ....74 Procedure for Cycling the System ....77 Page 71 Dukane Manual Part No. 403-575-00...
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  • Page 79 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 and phase angle (vibrational charac- teristics) of the stack that is being driven.
  • Page 80 Digi-Trac. All Dukane stack components are manufactured to tolerance specifications within this range. A non-Dukane horn, an improperly assembled stack, or a stack component...
  • Page 81 • If the system passes the tests of these four steps, proceed to the section called Procedure for Cy- cling the System, on the next page. • If one or more of these tests have failed, go to the next step. Continued Page 75 Dukane Manual Part No. 403-575-00...
  • Page 82 The System tab of iQ Explorer has a section for Advanced Hardware. These features are designed for unique horns and applications. See Figure 5-4. NOTE Consult Dukane Corporation before making adjustments For more information about stacks, see this to these settings. article: www.dukane.com/us/SE_stackarticle.
  • Page 83 4. Cycle the system. Activate both opti-touch switches at the same time to start the system, and hold fingers in place until the ultrasound starts. Releasing the fingers before ultrasound starts will abort the cycle. Page 77 Dukane Manual Part No. 403-575-00...
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  • Page 85: Section 6 - Troubleshooting

    Section 6 - Troubleshooting SECTION 6 Troubleshooting Page 79 Dukane Manual Part No. 403-575-00...
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  • Page 87: Troubleshooting

    NOTE If troubleshooting does not provide satisfactory re- sults, please contact Dukane Corporation (see Sec- tion 9 - Contacting Dukane) for servicing. The iQ ES generator and iQ Explorer are serviceable only by Dukane personnel. Unauthorized attempts to service either product will void any warranty.
  • Page 88 Series Ultrasonic Generator/Power Supply ES User’s Manual Error Messages, Servo-related Table 6 - I Page 82 Dukane Manual Part No. 403-575-00...
  • Page 89 Section 6 - Troubleshooting Error Messages, Servo-related (continued) Table 6 - I Page 83 Dukane Manual Part No. 403-575-00...
  • Page 90 Series Ultrasonic Generator/Power Supply ES User’s Manual Error Messages, Pneumatic-related Table 6 - II Page 84 Dukane Manual Part No. 403-575-00...

  • Page 91: Verifying Feature Operation

    - 0.03 inches to - 0.10 inches. This means that only after the head passes the reference mark, will the distance data from the iQ generator be useful as it relates to the phases of the weld cycle. Page 85 Dukane Manual Part No. 403-575-00...

  • Page 92: Electronic Pressure Regulator And The Pressure Transducer

    Ultrasonic Generator/Power Supply ES User’s Manual Power To verify operation of this feature perform an acoustic stack test. If no power is displayed, contact Dukane. Electronic Pressure Regulator and the Pressure Transducer The electronic pressure regulator and pressure transducer are components of the same system.

  • Page 93: Data From An Uninterrupted Cycle

    CYCLE TIME STROKE 0.975 1.7921 0.050 0.0023 28.4 1.000 2.025 1.8090 0.879 1.7927 0.050 0.0020 28.4 1.000 1.929 1.8092 0.877 1.7928 0.050 0.0022 28.4 1.000 1.927 1.8092 Figure 6-1 Data from an Uninterrupted Cycle Page 87 Dukane Manual Part No. 403-575-00...

  • Page 94: Cycle Terminated By I/O During Downstroke

    COUNT TIME DIST PRESSURE 1 PRESSURE 1 PRESSURE 1 TIME CYCLE TIME STROKE 0.887 1.7527 0.887 1.7527 0.831 1.7522 0.831 1.7522 0.827 1.7516 0.827 1.7516 Figure 6-4 Cycle Terminated Due to Pre-trigger Overtravel Page 88 Dukane Manual Part No. 403-575-00...

  • Page 95: Premature Weld Termination

    WELD DIST WELD ENERGY HOLD TOTAL TOTAL COUNT TIME DIST PRESSURE 1 PRESSURE 1 PRESSURE 1 TIME CYCLE TIME STROKE 0.882 1.7928 0.015 0.0006 1.897 1.8094 Figure 6-6 Weld Termination Due to Trigger Lost Page 89 Dukane Manual Part No. 403-575-00...

  • Page 96: Weld Segment Terminated By A Secondary Control

    HOLD TOTAL TOTAL COUNT TIME DIST PRESSURE 1 PRESSURE 1 PRESSURE 1 TIME CYCLE TIME STROKE 0.994 1.7916 0.038 0.0026 >>20.9 1.032 1.7942 Figure 6-8 Weld Segment Terminated by a Bad Part Limit Page 90 Dukane Manual Part No. 403-575-00...

  • Page 97: No Ultrasound

    Verify that a time for the weld cycle is displayed. NOTE • Verify that a value shows in Weld Peak Power, Method 1. If no value displays, there is a problem. For help, go to Contact- , Page 105. ing Dukane Page 91 Dukane Manual Part No. 403-575-00...
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  • Page 99: Section 7 - Maintenance

    Section 7 - Maintenance SECTION 7 Maintenance Page 93 Dukane Manual Part No. 403-575-00...
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  • Page 101: Front And Rear Panels

    Allow 5 inches (127 mm) of clearance outside each ventila- tion slot. The air intake is on the right, and the exhaust is on the left. This is shown in Figure 3–3, Page 15. Page 95 Dukane Manual Part No. 403-575-00...
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  • Page 103: Section 8 - Options

    P7 Servo Board ........101 Page 97 Dukane Manual Part No. 403-575-00...
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  • Page 105: Power Inlet Options

    CAUTION 120V Power Ground  If there is any question about For safety, the power cords used on all Dukane prod- the grounding of your recep- ucts have a three-prong, grounding-type plug. tacle, have it checked by a qualified electrician. Do not cut off the power cord ground- ing prong, or alter the plug in any way.

  • Page 106: Ac Power Inlet Panel

    (RFI) that is common in an industrial environ- ment. The chassis ground stud is in Figure 8-2. Proper system grounding is discussed on Page 9. Page 100 Dukane Manual Part No. 403-575-00...

  • Page 107: Press Interface Board

    P/N 110-4426 in place of the pneumatic cylinder. Instead of controlling Dual pressure is a feature that is exclusive to Dukane press the force, the servo system controls the speed of the horn systems. It increases clamp force to improve the plastic during the weld and hold phases.
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  • Page 109: Section 9 - Contacting Dukane

    Section 9 - Contacting Dukane SECTION 9 Contacting Dukane Page 103 Dukane Manual Part No. 403-575-00...
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  • Page 111 Section 9 - Contacting Dukane Contacting Dukane Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • Model number, line voltage and serial number. • Fault/error indicators from the iQ Explorer. • Software version.
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  • Page 113: Section 10 - Specifications

    Interpreting the Model Number....114 Regulatory Agency Compliance ....115 Page 107 Dukane Manual Part No. 403-575-00...
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  • Page 115: Outline Drawings

    Section 10 - Specifications Figure 10-1 Layout - Low Profile Generator Page 109 Dukane Manual Part No. 403-575-00...
  • Page 116 Series Ultrasonic Generator/Power Supply ES User’s Manual Layout - High Profile Generator Figure 10-2 Page 110 Dukane Manual Part No. 403-575-00...

  • Page 117: Layout - High Power Iq Generator

    Section 10 - Specifications Figure 10-3 Layout - High Power Generator Page 111 Dukane Manual Part No. 403-575-00...

  • Page 118: Weights, Dimensions, Operating Environment

    Nonoperating storage guidelines: -4°F to 158°F (-20°C to +70°C) Temperature: Keep the equipment dry. Air Particulates: Minimize exposure to moisture, dust, dirt, smoke and mold. 5% to 95% Non–condensing @ 0°C to +30°C Humidity: Page 112 Dukane Manual Part No. 403-575-00...

  • Page 119: Ac Power Requirements

    An X used above in the Model Numbers is a “wildcard” character meaning any valid character code combination. Maximum line current requirement is specified at the minimum nominal AC line voltage and the rated power level. Page 113 Dukane Manual Part No. 403-575-00...

  • Page 120: Interpreting The Model Number

    Series Ultrasonic Generator/Power Supply ES User’s Manual Interpreting the Model Number Figure 10-4 Interpreting the Model Number Page 114 Dukane Manual Part No. 403-575-00...

  • Page 121: Regulatory Agency Compliance

    Safety of Machinery - Electrical Equipment of Machines Part 1: General Requirements. IP (International Protection) Rating The iQ generator has an IP rating from the IEC (International Electrotechnical Commission). The rating is IP2X, in compliance with finger-safe industry standards. Page 115 Dukane Manual Part No. 403-575-00...
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  • Page 123: Section 11 - Appendices

    Appendix A, List of Figures....119 Appendix B, List of Tables ....122 Page 117 Dukane Manual Part No. 403-575-00...
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  • Page 125: Appendix A List Of Figures

    4-11 iQ Explorer, Process Settings Tab>Sensing Speed ............47 4-12 iQ Explorer, Teach Start Sensing Distance..............48 4-13 iQ Explorer, Select Trigger Method ................48 4-14 iQ Explorer, Select Welder Method, Parameter, Max Time ...........49 Continued Page 119 Dukane Manual Part No. 403-575-00...
  • Page 126 Explorer, Error Detected, Cycle Stop ................75 iQ Explorer, System Tab, Advanced Hardware..............76 Data from an Uninterrupted Cycle .................87 Cycle Terminated by I/O During Downstroke..............88 Cycle Terminated by High Bad Limit Downstroke............88 Continued Page 120 Dukane Manual Part No. 403-575-00...

  • Page 127: List Of Figures

    120VAC Power Inlet Panel ..................100 10-1 Layout - Low Profile iQ Generator ................109 10-2 Layout - High Profile Generator ...................110 10-3 Layout - High Power iQ Generator ................111 10-4 Interpreting the Model Number ..................114 Page 121 Dukane Manual Part No. 403-575-00...

  • Page 128: Appendix B - List Of Tables

    Generator to Pneumatic Press/Thruster Cables ............32 3-VI Servo Press/Thruster, Version 1 Connections ..............34 3-VII Servo Press/Thruster, Version 2 Connections ..............36 Pounds of Force Comparison Between Dukane Air Cylinders ........63 Error Messages, Servo-related ..................82 6-II Error Messages, Pneumatic-related ................84 iQ Generator Weights ....................112 9-II iQ Generator Dimensions .....................112...

  • Page 129: Index

    Index Index Page 123 Dukane Manual Part No. 403-575-00...
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  • Page 131 AC Power Inlet Panel 19 Chassis Grounding Stud 19 IEC AC Power Inlet Connector 19 FCC 115 Power Switch/Circuit Breaker 19 System I/O Panel 19 System Inputs Connector 19 Recheck Connections 37 Continued Unpacking 15 Page 125 Dukane Manual Part No. 403-575-00...
  • Page 132 P6 - EPR/Load Cell with Distance 101 Select Trigger Method 48 P7 - Servo Board 101 Set Amplitude 51 Static Hold Method 53 Teach Start Sensing Distance 48 Test the Acoustic Stack 53 Trigger 46 View Speed Profile 50 Page 126 Dukane Manual Part No. 403-575-00...
  • Page 133 Test the Acoustic Stack 53, 66 Troubleshooting 79 iQ Generator Won’t Cycle 91 iQ Pneumatic Press Error Messages 84 iQ Servo Press Error Messages 82 No Ultrasound 91 Ultrasound Output Connector 27 Utilities tab 74 Page 127 Dukane Manual Part No. 403-575-00...
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  • Page 135 By passing its audit, Dukane can assure traditional inspection–oriented quality system you that we have in place a well–defined and...
  • Page 136 Part No. 403   - 575  - 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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