Intelligent Assembly Solutions Series ULTRASONIC GENERATOR/POWER SUPPLY LS AUTOMATED HAND PROBE PRESS User’s Manual Dukane Part No. 403-574-01 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949 are manufactured in ISO registered facilities. ISO 9001:2008 Products www.dukane.
Copyright © 2010 Notice of Rights: All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical, photocopying, recording, or by any information storage and retrieval system, without written permission from the manufacturer. Notice of Liability: The information contained is this manual is distributed on an “As is” basis, without warranty.
Revision History Revision Number - 00 Revision Summary Date Original release. 01/25/2008 - 01 Add High Power models. 09/21/2010 Update system I/O pin descriptions. Add Trigger by Power. Add iQ LinQTM. Web address revised. Revise Regulatory Agency Compliance statement. Health and Safety - Add safe lifting practices. Installation - Add lockout/tagout information and seismic zone information.
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Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General User Information Read the Manual First Notes, Cautions and Warnings Drawings and Tables Generator Overview Key Generator Features Section 2 - Health and Safety . . . . . . . . . . . . . . . . . . . . . . 5 General Considerations Plastics Health Notice Electrical Safety Lifting the Equipment Section 3 - Installation . . . . . . . . . . . .
Contents Continued Section 6 - Process Control Settings . . . . . . . . . . . . . . . . . 45 User-Provided Process Control Overview Manual Welding Automated Welding Automated Process Control Input Signals Status Output Signals Screen Navigation Basics Programming the Generator - Some Examples Section 7 - System Operational Testing . . . . . . . . . . . . . . . 55 Section 8 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 – Introduction SECTION 1 Introduction General User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Read the Manual First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Drawings and Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Generator Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section 1 – Introduction General User Information Read the Manual First Before operating your ultrasonic generator, read this User’s Manual to become familiar with the equipment. This will ensure correct and safe operation. The manual is organized to allow you to learn how to safely operate this generator. The examples given are chosen for their simplicity to illustrate basic operation concepts. Notes, Cautions and Warnings NOTE Note statements provide additional information or highlight procedures.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Generator Overview This generator is designed for basic ultrasonic applications that use either manually operated hand probes or ultrasonic probes controlled by automation systems. Using the available system control inputs and output status signals, it can easily be controlled by automated machines. The generator design accepts several control input signals, and provides system status output signals.
Section 2 – Health & Safety SECTION 2 Health and Safety General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Plastics Health Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Domestic Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 International Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section 2 – Health & Safety General Considerations Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your equipment. In this manual, the term system refers to a complete group of components associated with the welding of plastic or metal parts, also known as an ultrasonic assembly system.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Electrical Safety Domestic Power Grounding For safety, the power cords used on this product have a three-wire, grounding-type power cord. Figure 2-1 illustrates the appropriate electrical outlet to use with the power cord that is included with systems shipped to North America. CAUTION If you have a two-prong electrical receptacle, we strongly recommend that you replace it with a properly grounded three-prong type.
Section 2 – Health & Safety Lifting the Equipment High Profile Low Profile High Power 3600W High Power 4800 W lb kg lb kg lb kg lb kg Generator Only 25 11.3 20 9.1 32 14.5 34 15.4 Generator + Packing Materials 30 13.6 25 11.3 37 16.7 39 17.7 Table 2–I iQ Generator Weights How to Lift Safely • Before lifting, take a moment to think about what you’re about to do. • Examine the object for sharp corners, slippery spots or other potential hazards.
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Section 3 – Installation SECTION 3 Installation Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 When to Use Lockout/Tagout Devices . . . . . . . . . . . . . . . 13 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Connecting Cables . . . . . . . . . . . . . . . .
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Section 3 – Installation Before Installation As you plan for the installation of your generator, please consider these important subjects as listed below: • When to use lockout / tagout devices • Lifting the generator safely - See Section 2 - Health and Safety, P. 9 When to Use Lockout / Tagout Devices WARNING Electrical safety hazards exist inside the generator chassis. Before making any internal adjustments to the generator, apply a lockout/tagout (LOTO) device to the generator chassis.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Lockout/Tagout Continued from previous page 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. 3. Authorized personnel apply a lockout/ tagout (LOTO) device to the plug end of the generator's electrical cord. Using a typical clam shell type LOTO device: 1) Open the clam shell.
Section 3 – Installation Unpacking Carefully open your shipping container, and make sure it contains the items shown on the shipping documents. Inspect all items, and report any damage immediately. Placement Generator placement and cable routing should permit easy access and not interfere with normal system operation. CAUTION Allow 5 inches for air ventilation at the cooling air inlet and at the exhaust air outlet.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Placing the Generator when Used in an Active Seismic Region If the iQ generator is to be used in an active seismic region, secure the unit by rack-mounting it or by securing the unit to a benchtop. 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. System Type Mount the generator to a 19-inch equipment rack.
Section 3 – Installation Benchtop Mounting If you choose to mount the generator on a benchtop follow these instructions: 1) 2) 3) Install the four (4) optional hold down brackets. See Figure 3-5 below. Secure one side of each L backet to the generator's sheet metal cover. Secure the other side of each l bracket to the bench itself. 18.84 [478.47] 18.04 [458.15] ?.280 HOLE ALLOW 3" IN BACK FOR CABLING. NOTE 1.14 [29.0] 13.20 [335.37] 10.00 [254.0] 12.54 [318.61] ALLOW 5" BOTH SIDES FOR COOLING.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual RFI Grounding In addition to the safety considerations previously mentioned, proper grounding at the generator power cord is essential for the effective suppression of electrical noise or RFI (Radio Frequency Interference). Every ultrasonic generator contains a RFI filter which blocks noise on the AC power line from entering the system control circuitry.
Section 3 – Installation Connecting Cables (Quick Start Guide) Details about the various system connectors and their pin assignments are covered in Section 4. Manually Operated Probe System (Hand Probe) Step 1. Ground the generator chassis using the supplied 14-Gauge wire, and attach it to the grounding stud: A in Figure 3-6. Step 2. Attach the hand probe’s HD–15 system input connector to J2 on the I/O panel: B in Figure 3 -6. Step 3.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual J7 is optional. INPUTS J2 I 0 J7 LINE VOLTAGE: 200-240 Vac 50/60Hz, 10A J4 PE AC POWER INLET GROUNDING STUD OUTPUTS J3 J1 ULTRASOUND OUTPUT Figure 3 - 6 Generator - Rear View (low profile model) Automation Controlled Probe System Step 1. Ground the generator chassis using the supplied 14-Gauge wire, and attach it to the grounding stud:A in Figure 3-6. Step 2. Optional – Ground the probe support.
Section 4 – Standard Connections SECTION 4 Standard Connections Rear Panel Layout Overview . . . . . . . . . . . . . . . . . . . . . . . . 23 AC Power Inlet Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 IEC AC Power Inlet Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Power Switch/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Chassis Grounding Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section 4 – Standard Connections Rear Panel Layout Overview This section provides an overview of the generator rear panel layout, which includes panel areas dedicated to various standard system functions and options that are available. Figure 4 - 1 illustrates the panel layout.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual AC Power Inlet Panel The standard AC power inlet panel is described in this section. IEC AC Power Inlet Connector The IEC AC power inlet connector mounted on the system AC power inlet panel requires a properly configured IEC compliant power cord, which enables worldwide system operation by simply changing the power cord. Low profile systems are equipped with a 10 amp rated IEC inlet connector.
Section 4 – Standard Connections Note that a simple switch closure (relay contact) connected to a control input can not activate the input unless an external power supply is added to power the input. However, if you don’t want to add an additional power supply, you can configure switch closure inputs to operate referenced to chassis ground by adding jumper connections to the System Inputs connector.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Pin Signal Name Cable Color Code Signal Option Requirements 1 +22V BLK 2 Power Ground WHT 3 Remote Setup Selection Bit 0 Input RED MPC Option Required 4 Remote Setup Selection Bit 1 Input GRN MPC Option Required 5 Remote Setup Selection Bit 2 Input ORN MPC Option Required 6 Remote Setup Selection Bit 3 Input BLU MPC Option Required 7 Remote Setup Selection Bit 4 Input WHT/BLK 8 Ultrasound Activation/Cycle Start Inpu
Section 4 – Standard Connections Pin 5 (Remote Setup Selection Bit 2 Input) Pin 10 (Front Panel Control Lock Input) Pin 5 is the Remote Setup Selection Bit 2, which is the third least significant bit used to select different welding setups with an automation control system. This input is also used to select different channels when a Multiple Probe Controller (MPC) Interface option board is installed.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual System Outputs Connector System Outputs Connector Pinout The SYSTEM OUTPUTS connector mounted on the generator I/O panel includes connections for all of the basic system status and monitor output signals, which will typically connect to an automated control system.
Section 4 – Standard Connections Pin 7 (Any Fault Status Output) Pin 7 is a digital active low status output that activates whenever any fault condition is detected that inhibits ultrasound output and normal system operation. This output will be an open circuit when no system fault conditions are detected. Any Fault output remains active until cleared by the System Latch Reset input or by the start of the next weld cycle.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Pin 17 (Amplitude/Power Regulation Status Output) (Contact your sales representative about Power Regulation availability.) This status signal is most useful when the power regulation mode is selected. This Out of Regulation status signal would indicate that due to inadequate pressure against the ultrasonic horn, the power regulation level setting can not be achieved when the amplitude level is set to the maximum level of 100%.
Section 4 – Standard Connections Pin 23 (Suspect Part Status Output) Pin 23 is a digital active low status output that activates, either momentarily or until the start of the next welding cycle, when the welding parameters recorded during the previous welding cycle are outside of the programmed suspect part limits. This output will be an open circuit after a welding cycle when a suspect part has not been detected. Pin 24 (Isolated Common) Pin 24 is electrically isolated from chassis ground.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Ultrasound Output Connector The ultrasound output connector used with all standard generators is a high voltage (5000V) coaxial style SHV-BNC connector. This connector provides superior shielding of electrical noise, compared to other types of connectors. The ultrasound output connector mates with fully shielded coaxial ultrasound cables that are secured with a simple and reliable quarter-turn bayonet style attachment mechanism.
Section 4 – Standard Connections Configuration Port Connector The configuration port connector is a DB-9M (standard Dsubminiature nine circuit, male) typically used for RS-232 serial communications. This serial port (DTE) connects to a serial port (DCE) on a computer via a standard 9-pin serial cable. If the computer does not have a serial port, you may use a USB-to-serial conversion cable.
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Section 5 – Standard System Status and Controls SECTION 5 Standard System Status and Controls Front Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 System Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 System Power Output Level (Bar Graph) . . . . . . . . . . . . . . . . . . . . . 37 System Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 4-line LCD Display . . . . . . . . . . . . . . . . . . . . . . . . .
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Section 5 – Standard System Status and Controls Front Panel Overview This section provides an overview of the front panel’s two main functions: monitoring (with the system displays), and controlling the system (with the user navigation control keys). System Power Output Level Bar Graph Overload Indicator I N FO SYSTEM POWER OUTPUT LEVEL OVER LOAD TE 40 60 80 100 SYSTEM OPERATING MODE ON LINE POWER TEST OFF LINE NC EL ST L # 1 PART COUNT WELD TIME POWER ENERGY 125 0.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Keys - Right of Display Keys - Left of Display I N FO SYSTEM POWER OUTPUT LEVEL OVER LOAD TE 40 60 80 100 SYSTEM OPERATING MODE ON LINE POWER TEST OFF LINE NC EL ST L # 1 PART COUNT WELD TIME POWER ENERGY 125 0.080 S 1050 W 350 J EN Figure 5 - 2 Front Panel Control Detail Control Keys Keys Left of the Display Navigation Keys (4) Weld Method - Time, Energy, Power, - programmed by the user. Time is the default method.
Section 5 – Standard System Status and Controls TEST Hold the TEST key momentarily to activate ultrasound and view system operating parameters. NOTE To activate the TEST mode, the system must be ONLINE. The LCD screen will show the real time settings for Amplitude, Power (does not appear with Time Only generators), and Operating Frequency. This information is useful in troubleshooting.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Start-up Sequence After all connections have been completed, 1. Push the rear panel AC breaker switch to ON. The generator begins its self-diagnostics sequence. SYSTEM POWER OUTPUT LEVEL OVER LOAD 2. POWER TEST flashes (RED) for several seconds. 0 20 40 60 80 100 SYSTEM OPERATING MODE POWER TEST 3. First, the entire System Power Output Level bargraph lights up momentarily (verifying that all bar graph LED segments are functional).
Section 5 – Standard System Status and Controls Stopping the Weld Cycle Normal Conditions The cycle stops when the programmed welding cycle ends. Emergency Conditions Manual System Press OFFLINE to stop the ultrasound signal. This may be done under any condition. Automated System Customer-supplied external controls provide the means to stop the cycle for an automated system. An auxiliary cable connects these external controls to the iQ generator at connector J2.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual System Parameter Settings Overview This section provides the default system settings programmed at the factory. Some of these system parameter settings are dependent on the nominal system operating frequency while other parameters are independent of the frequency. The default settings should work with over 90% of the ultrasonic loads and welding applications that might be encountered.
Section 6 – Process Control Settings System Parameter Adjustment Limits Continued from previous page Setting Ranges for All Frequencies Setting Description User Adjustment Limit Minimum Maximum Amplitude Setting 20% 100% Free Run Frequency *** Default Free Run Default Free Run Frequency minus 500 Hz Frequency plus 500 Hz Ramp-up Time 0.010 second 1.
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Section 6 – Process Control Settings Section 6 Process Control Settings User-Provided Process Control Overview . . . . . . . . . . . . . . . 47 Manual Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Automated Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Automated Process Control Input Signals . . . . . . . . . . . . . . . 47 Status Output Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Screen Navigation Basics . . . . .
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Section 6 – Process Control Settings User- Provided Process Control Overview Automated Process Control Input Signals The generator includes a process control system to control welding process. The basic “B models” can be programmed to weld by time. “E model” generators can weld by time and energy. See Figure 11-5 for model number information. Refer to Section 4 for the available input control signals on the system input connector.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Screen Navigation Basics This section gives you a step-by-step guide to navigating through some of the basic menu structure. 1. Press CANCEL until you see the Main Menu screen as it is shown here. Selection indicator is on OPERATE MODE. 2. Press ENTER to view OPERATE MODE selections. Selection indicator is on PROCESS DATA. 3. Press ENTER. The screen you see is the one that appears just after the generator is first switched ON.
Section 6 – Process Control Settings Programming the Generator - Some Examples On the following pages these programming examples cover how to: • Have a PLC Control the Ultrasound Activation • Weld by Time • Weld by Energy • Adjust Amplitude • Adjust Ramp Up Time (Soft Start) • Adjust Ramp Down Time (Soft Stop) NOTE Once a primary weld method has been selected (Time, Energy, Peak Power), pressing the INFO key takes you to a “Hot Key” screen.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual HOW TO - Weld by Time 1. Press CANCEL until you see the Main Menu screen as it is shown here. Move the selection indicator to PROCESS SETUP. 2. Press ENTER and you will see the screen as shown here. # 1: OPERATE MODE PROCESS SETUP HARDWARE SETUP PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES 3. Select PROCESS CONTROL, and press ENTER.
Section 6 – Process Control Settings HOW TO - Weld by Energy (Available only if generator has energy option.) 1. Press CANCEL until you see the Main Menu screen as it is shown here. Move the selection indicator to PROCESS SETUP. 2. Press ENTER and you will see the screen as shown here. 3. Select PROCESS CONTROL, and press ENTER. With no option boards installed in the generator, you will get a WELD BY choice of iQ SYSTEM or AUTOMATION.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual HOW TO - Adjust Amplitude 1. Press CANCEL until you see the Main Menu screen as it is shown here. Move the selection indicator to PROCESS SETUP. 2. Press ENTER and you will see the screen as shown here. 3. Select PROCESS CONTROL, and press ENTER. With no option boards installed in the generator, you will get a WELD BY choice of iQ SYSTEM or AUTOMATION.
Section 6 – Process Control Settings HOW TO - Adjust Ramp Up/Down Times The Ramp Up feature, also called soft start, applies amplitude at the beginning of the weld cycle to start the stack assembly (transducer, booster, horn) linearly, rather than in two instantaneous surges. The stack is brought up to operating amplitude smoothly, without shock stress. Although the Ramp Up time is factory set, it is variable and can be adjusted to account for starting characteristics of a particular horn.
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Section 7 – System Operational Testing SECTION 7 System Operational Testing System Verification Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Preliminary Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Testing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Probe Operation . . . . . . . . . . . . . . . . . . . . . . .
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Section 7 – System Operational Testing System Verification Tests Preliminary Setup Step 1. Plug in the AC line cord to the correct AC power outlet. See Table 11 -II for the model power requirements. Step 2. Attach a compatible ultrasonic probe to the ultrasound output connector - J1. A I 0 LINE VOLTAGE: 200-240 Vac 50/60Hz, 10A Step 3. Activate the AC Breaker/Switch A to the ON position.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual System Test Any unusually loud noise from the probe stack indicates that it has been improperly assembled. Check the probe stack for correct assembly and proper torque. Step 2. Connect a probe to the generator ultrasonic output. Step 3. Place the probe so that the tip of the horn is not in contact with anything. If you are using a hand probe, you may feel a slight vibration or sensation in your hand. This is normal.
Section 7 – System Operational Testing Probe Operation NOTE 1. If the generator is not online, press the ON/OFFLINE mode key, labeled C in Figure 7-6. The System Operating Mode ONLINE indicator (G in Figure 7-5) will be green. Neither a hand probe or an automation system can trigger the generator to produce an ultrasound output if the generator is OFFLINE. 2. Hand Probe – Apply the probe tip to the components to be ultrasonically joined, and press the hand probe’s activation switch.
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Section 8 – Troubleshooting SECTION 8 Troubleshooting No Ultrasonic Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Operate Input . . . . . . . . . . . . . . . . . . . . .
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Section 8 – Troubleshooting No Ultrasonic Output Probe Make sure that the probe coaxial cable is connected to the generator ultrasonic output connector J1. Basic generator models have the BNC connector on the rear panel. Also, make sure the probe stack was properly assembled. Cables Make sure that both the U/S coaxial and system I/O cables are securely connected.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual System Power Output Level: Red Generator Fault Does Not Reset When the system does not automatically reset, the generator needs servicing. Red - Fault Condition System Power Diagnostic Procedures When the SYSTEM POWER OUTPUT LEVEL turns red (arrow on the right end of the bar graph), there is an overload condition that disables generator operation. See J in Figure 8-2 below.
Section 9-Maintenance Welding Problems Weak Welds Weak welds, or underwelding, is caused by insufficient energy being transmitted to the part. You can increase the weld pressure, increase the weld time or change to a higher gain booster to increase the amplitude to increase the energy delivered to the weld. Excess Flash The energy director may be too large. You can try to reduce the weld pressure and/or weld time. The parts may have too much shear interferences or a nonuniform joint dimension.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Pop-up Status Screens System Status Signal Average Overload Peak Overload Status Text Displayed System Status or Fault Explanation OVERLOAD - AVERAGE AT X.XXX SECONDS POWER ABOVE GENERATOR RATING An Average Overload fault tripped. Output power exceeded rated wattage. Lower the welding pressure or amplitude. Fault will reset when next weld cycle starts. OVERLOAD - PEAK AT X.
Section 9-Maintenance SECTION 9 Maintenance Front and Rear Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Control Keys/Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section 9-Maintenance Front and Rear Panels Air Ventilation Slots Cleaning Keep the ventilation slots free from obstructions. If excessive dust or dirt collects on the slots, wipe or vacuum them clean. Do not use compressed air to clean them as this may force the dirt inside the chassis. • Do not use any solvents or abrasive cleaners on the any of the panels (including the LCD display). • Do not spray any cleaning product directly on the panels.
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Section 10 - Options SECTION 10 Options Power Inlet Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 120V Systems for North American and Japan . . . . . . . . . . . . . 73 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 120V Power Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 AC Power Inlet Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 AC Power Cord . . . . . . . . . . . . . . .
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Section 10 - Options This section of the User’s Manual provides a general overview of some options/upgrades, all of which are subject to availability, for the basic ultrasonic generator: Power Inlet Options 120V Systems for North America and Japan 120V systems for North America and Japan have a fixed (non-detachable) power cord. This option is available on generators with power ratings of 1200 watts or less and with operating frequencies of 20kHz, 30kHz, or 40kHz.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual AC Power Inlet Panel The optional AC power inlet panel is described here. AC Power Cord The AC power cord (A in Figure 10-2) is appropriately rated and permanently mounted to the power inlet panel. Power Switch/Circuit Breaker The power switch/circuit breaker (B in Figure 10-2) has a rocker type actuator switch that will activate or deactivate the AC power to the system.
Section 10 - Options I/O Panel Options A Single Connector System I/O Panel B See B in Figure 10-4 where the I/O panel is set up for the single I/O connector, a HD15F type. The generator label for this connector is, SYSTEM INPUTS/OUTPUTS. Another label identifies the connector as J12. The I/O panel can be customized with multiple types of connectors such as the single HD15F, terminal blocks, etc. Contact your local sales representative for more details.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Option Panel Modules A single optional module can be installed in the iQ generator’s Option Module Panel. See A in Figure 10 - 4 where the option panel is set up for a Remote Control Module. Multi- Probe Control (MPC) Interface Option Part Number - 110- 4251 The iQ generator can be configured with an optional MPC Interface circuit board that powers and controls an external MPC multi- probe control module.
Section 10 - Options MPC I/O Connections Signal names and Pin numbers and the connectors related to the MPC option are shown in the table below. See the pages referred to in the table for more information about the signals.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Cut Outs MPC Interface Installation Guide The MPC interface is designed for assembly systems where one ultrasonic generator is sequenced to as many as 16 ultrasonic probes. The MPC interface is typically supplied as a stand-alone bench-top unit, or as a component that can be mounted in a through-panel configuration. For panel mounted modules: Use Figure 10-6 below to determine the size of the cutout needed for your equipment panel.
Section 10 - Options Connecting Cables Front Connections For stand-alone interfaces and securely installed panel mounted interfaces: Refer to Figure 10 -8 below. Complete these connections. Rear Connections Refer to Figure 10 -7 below, and complete these connections. 1. Earth ground - Connect one end of a user-supplied 14-Gauge ground wire to the ground connection at the rear of the MPC, A in Figure 10 -7.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual MPC Interface Status LEDs System Status E F When the system is powered and ready, the front panel SYSTEM STATUS LED lights up, and becomes GREEN (E in Figure 10 - 9). If this LED is lit with a YELLOW/ORANGE color, a recoverable fault condition has tripped. This indicates that the system is operational, but a fault condition has occurred preventing normal operation.
Section 10 - Options MPC Cycle Illustration The flow chart below illustrates a typical welding cycle when the MPC feature is used. Confirm probes are retracted from weld position. Wait 40 mS to confirm binary code has been received by generator. Load part to be welded. PLC activates generator’s automation start input. PLC monitors all other generator status output features. Have all probes processed a weld? No Move part to the welding position. Generator’s MPC Ready Status Output deactivates.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Remote Amplitude Control Module 100% Part Number - 110- 4183 80% This optional module enables remote control of output amplitude of the iQ system. The control interface is a 4–20mA current loop. The current loop connector and fault indicator are shown below in Figure 10–12. The output can be adjusted from 36% to 100%. The scale factor is a 4% amplitude change for each mA change.
Section 10 - Options Menu Selections With the optional Remote Amplitude Control Module installed, the generator detects the module. As a result there is an additional menu to consider: AMPLITUDE CONTROL AMPLITUDE SETTING RAMP UP / DOWN TIME AMPLITUDE SETTING 90 % SELECT DIGIT CHANGE VALUE AMPLITUDE SETTING AMPLITUDE CONTROL BY iQ SYSTEM AUTOMATION This menu available only with Remote Amplitude Control option. Figure 10-13 Amplitude Control Menu Detail See Figure 10-13 above.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Automation Thruster Control Module the thruster will descend to the down position at a speed that is determined by the pressure regulator setting on the front of the thruster. Part Number - 110- 4206 This optional module enables the iQ system to control a Dukane iQ thruster. The module is illustrated in Figure 10-14. Check your thruster operator’s manual for cable connection information.
Section 10 - Options To enable the thruster, Pins 3 and 9 must be shorted together through a safety circuit (see Table 10-V) during normal operation. During an abort or emergency stop condition, the connection between Pins 3 and 9 must open to disable movement of the thruster. In addition to opening the connection between Pins 3 and 9, Pins 4 and 7 must be shorted together to alert the process controller of the condition. The accessory cable for J5 is Part No. 200-1413-XX.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual 24VDC 24VDC 0VDC 0VDC NPN TO PNP CONVERSION IN 1 OUT 1+ IN 1 COM OUT 1- IN 2 OUT 2+ IN 2 COM OUT 2- IN 3 OUT 3+ IN 3 COM OUT 3- IN 4 OUT 4+ IN 4 COM OUT 4- LOAD LOAD LOAD LOAD 110-4397 24VDC 24VDC 0VDC 0VDC SPECIFICATIONS: INPUTS: MINIMUM VOLTAGE: 5.0 Vdc MAXIMUM VOLTAGE: 30.0 Vdc CURRENT: 1.5mA @ 5.0 Vdc / 9.5mA @ 24.0 Vdc OUTPUTS: MINIMUM VOLTAGE: 5.0 Vdc MAXIMUM VOLTAGE: 30.
Section 10 - Options 24VDC 24VDC 0VDC 0VDC PNP TO NPN CONVERSION IN 1 OUT 1+ IN 1 COM OUT 1- IN 2 OUT 2+ IN 2 COM OUT 2- IN 3 OUT 3+ IN 3 COM OUT 3- IN 4 OUT 4+ IN 4 COM OUT 4- LOAD LOAD LOAD LOAD 110-4397 24VDC 0VDC 24VDC 0VDC SPECIFICATIONS: INPUTS: MINIMUM VOLTAGE: 5.0 Vdc MAXIMUM VOLTAGE: 30.0 Vdc CURRENT: 1.5mA @ 5.0 Vdc / 9.5mA @ 24.0 Vdc OUTPUTS: MINIMUM VOLTAGE: 5.0 Vdc MAXIMUM VOLTAGE: 30.0 Vdc MAXIMUM CURRENT: 50mA VOLTAGE DROP ( + TO - ): 1.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual 24VDC 0VDC 24VDC 0VDC +5V TO +24V PNP CONVERSION +5V +5V +5V OPEN COLLECTOR WITH PULL-UP RESISTOR IN 1 OUT 1+ IN 1 @ 0V = ON IN 1 @ 5V = OFF IN 1 COM OUT 1- IN 2 OUT 2+ LOAD ACTIVE HIGH TTL IN 2 @ 0V = OFF IN 2 @ 5V = ON IN 2 COM OUT 2- IN 3 OUT 3+ LOAD ACTIVE LOW TTL IN 3 @ 0V = ON IN 3 @ 5V = OFF IN 3 COM OUT 3- IN 4 OUT 4+ LOAD OPEN COLLECTOR IN 4 @ 0V = ON IN 4 @ 5V = OFF IN 4 COM OUT 4- LOAD GND 110-4397 SPECIFI
Section 10 - Options TM iQLinQ communication options allow automated systems to monitor and change settings in iQ generators. These options provide machine builders the ability to integrate the generator into an electrical cabinet and to use the machine’s HMI to program or monitor weld settings. All Dukane iQ LS generators include the RS-232 Interface option, which can be used to set amplitude and monitor power. Using this option avoids adding expensive analog cards into PLC racks.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual iQLinQ™ PROFIBUS Communications Module Parameters that can be obtained via PROFIBUS Part Number - 110-4554 1. All parameters that are configured via PROFIBUS The PROFIBUS option module allows the iQ generator to connect to a PROFIBUS network. Since PROFIBUS is multipoint instead of point-to-point, more than one generator can be connected to a single bus cable.
Section 10 - Options iQ LinQTM Ethernet/IPTM Module Parameters that can be obtained via Ethernet/IP Part Number - 110- 4644 1. All parameters that are configured via EtherNet/IP. The EtherNet/IP option module allows the iQ generator to connect to an EtherNet/IP network. The option module is an external DIN-rail mounted device that acts as a bridge between the automation network and an iQ generator’s RS-232 port. See Figure 10-21 below. 2.
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Section 11 - Specifications SECTION 11 Specifications Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Low Profile Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 High Profile Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 High Power (3600W) Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 High Power (4800W) Chassis . . . . . . . . . . . . . . . . . . . . . .
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Dukane Manual Part No. 403-574-01 IN mm 3.45 [87.63] ALLOW 5" EACH SIDE FOR COOLING 9.98 [253.49] OPERATOR DISPLAY 0 60 80 100 OFF LINE LOAD OVER OPERATOR CONTROLS POWER TEST SYSTEM OPERATING MODE 40 SYSTEM POWER OUTPUT LEVEL 20 ON LINE 17.16 [435.86] OPTIONAL FRONT POWER SWITCH ALLOW 3" IN BACK FOR CABLING. ALLOW 5" EACH SIDE FOR COOLING 9.30 [236.22] 3.81 [96.
IN (mm) OPERATOR DISPLAY ALLOW 5" BOTH SIDES FOR COOLING. 9.95 [252.73] ON LINE 60 POWER TEST SYSTEM OPERATING MODE 40 SYSTEM POWER OUTPUT LEVEL 20 OPERATOR CONTROLS 0 80 100 OFF LINE LOAD OVER 17.16 [435.86] OPTIONAL FRONT POWER SWITCH ALLOW 3" IN BACK FOR CABLING. 5.19 [131.83] ALLOW 5" BOTH SIDES FOR COOLING. 9.29 [235.97] 5.50 [139.
Dukane Manual Part No. 403-574-01 IN [mm] ALLOW 5" EACH SIDE FOR COOLING 17.16 [435.8] 5.19 [131.8] 5.50 [139.7] ALLOW 5" EACH SIDE FOR COOLING 12.51 [317.8] 3.15 [80.0] AC POWER ENTRY ALLOW 3" IN BACK FOR CABLING.
Figure 11- 4 High Power (4800W) Chassis Drawing IN [mm] ALLOW 5" EACH SIDE FOR COOLING 17.16 [435.8] 5.19 [131.8] 5.50 [139.7] ALLOW 5" EACH SIDE FOR COOLING 14.51 [368.5] 3.15 [80.0] ALLOW 3" IN BACK FOR CABLING. AC POWER ENTRY ULTRASOUND & SYSTEM I/O'S iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Page 98 Dukane Manual Part No.
Section 11 - Specifications Weight: High Profile Low Profile High Power 3600W High Power 4800 W lb kg lb kg lb kg lb kg Generator Only 25 11.3 20 9.1 32 14.5 34 15.4 Generator + Packing Materials 30 13.6 25 11.3 37 16.7 39 17.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual AC Power Requirements The AC input power requirements depend on the frequency and output power rating of the generator. Table 11-II below, lists both the AC requirements (maximum current drawn before overload) and the AC outlet service rating for each model.
HB Dukane Manual Part No. 403-574-01 2 E- 2 = 200-240V for 5.25” tall chassis 1800W and above 2 = 200-240V for 3.5” tall chassis 1200W and below 1 = 100-120V for 5.25” tall chassis 1200W and below (fixed power cord) This means: A 20kHz generator, rated for 1,200W, horizontal bench, 3.5” tall chassis, operating on a 200-240 VAC line, designed for time and energy weld control, with a remote control board in the options slot.
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual Regulatory Agency Compliance FCC The generator complies with the following Federal Communications Commission regulations. • The limits for FCC measurement procedure MP-5, “Methods of Measurement of Radio Noise Emissions from ISM Equipment”, pursuant to FCC Title 47 Part 18 for Ultrasonic Equipment.
Section 12 - Contacting Dukane SECTION 12 Contacting Dukane Dukane Manual Part No.
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Section 12 - 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 LCD display • Software version (Press INFO. With selection indicators at System Information, press ENTER to get this data.
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Appendices APPENDICES List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Guide to iQ Generator Menu Structure . . . . . . . . . . . . . 111-127 Dukane Manual Part No.
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Appendices List of Figures No. 2-1 2-2 3-1 3-2 3-3 3-4 3-5 3-6 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 5-1 5-2 5-3 5-4 5-5 5-6 7-1 7-2 7-3 7-4 7-5 7-6 8-1 8-2 8-3 10-1 10-2 10-3 10-4 10-5 10-6 10-7 Description Page Example of 220 Volt, Grounded, 3-prong Receptacle......................................................8 International 220/240V Grounding...................................................................................8 Lockout Device in Open Position, Unlocked..................................
iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual List of Figures continued No. 10-8 10-9 10-10 10-11 10-12 10-13 10-14 10-15 10-16 10-17 10-18 10-19 10-20 10-21 11-1 11-2 11-3 11-4 11-5 Description Page MPC Module Front Connectors......................................................................................79 MPC Module Status LEDs..............................................................................................80 MPC Cycle Flow Chart.....................................
Appendices Guide to iQ Generator Menu Structure DUKANE iQ LS SERIES Menus Page Number Time Only Operate 113 Process Setup - Automated Probe 114 Process Setup - Hand Probe 115 Process Setup - MPC Probe 116 Process Setup - Process Limits 117 Process Setup - Utilities 118 Time and Energy Operate 119 Process Setup - Automated Probe 120 Process Setup - Hand Probe 121 Process Setup - MPC Probe 122 Process Setup - Process Limits 123 Process Setup - Utilities 124 OPERAT
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Appendices OPERATE OPERATE MODE PROCESS DATA PROCESS STATISTICS SYSTEM PARAMETERS XXXXX 0.0000 S XXXXX XXXXX XXX% XXXXX XXX% XXXXX XXX% 100% 0W 19,899 Hz “Rxx” = Remote Setup Number and #xx = Local Setup Number # 1 PART COUNT WELD TIME PART COUNT GOOD BAD SUSPECT AMPLITUDE POWER FREE RUN FRQ AMPLITUDE POWER OPERATE FRQ 100% 60 W 20,020 Hz Time Only Menus Page 1 of 15 SYSTEM PARAMETERS screen changes to this screen if TEST button is pressed. 113 Page Dukane Manual Part No.
Page PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Weld Time WELD CONTROL No option boards installed PROCESS SETUP Hold Time HOLD CONTROL iQ SYSTEM DISABLED AFTERBURST CONTROL AUTOMATED PROBE WELD CONTROL BY Afterburst Duration Afterburst Delay ENABLED Automated Probe AMPLITUDE CONTROL See Amplitude Control Menu Probe Delay Time Probe Delay Automated Probe AUTOMATION See Amplitude Control Menu Amplitude Control Page 2 of 15 Time Only Menus iQ Series, Ultrasonic Generator/P
Appendices PROCESS SETUP PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES HAND PROBE WELD CONTROL BY Hand Probe iQ SYSTEM Hand Probe Detected Amplitude Control HAND PROBE Weld Control Weld Time See Amplitude Control Menu HAND PROBE SWITCH See Amplitude Control Menu Time Only Menus Page 3 of 15 115 Page Dukane Manual Part No.
Page PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Weld Time WELD CONTROL PROCESS SETUP MPC PROBE iQ SYSTEM MPC Interface Detected MPC PROBE WELD CONTROL BY MPC Probe AMPLITUDE CONTROL See Amplitude Control Menu Probe Delay Time Probe Delay MPC Probe AUTOMATION See Amplitude Control Menu Amplitude Control Page 4 of 15 Time Only Menus iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual 116 Dukane Manual Part No.
Appendices PROCESS SETUP PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Process Limits PROCESS LIMITS SUSPECT PART BAD PART WELD TIME LIMIT Disable WELD TIME LIMIT Enable Maximum Weld Time Disable Maximum Weld Time Minimum Weld Time Enable Minimum Weld Time Time Only Menus Page 5 of 15 117 Page Dukane Manual Part No.
Page Current Setup Erased YES NO Current Setup ERASE SETUPS PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES All Setups Erased Erasing . . .
Appendices OPERATE OPERATE MODE PROCESS DATA PROCESS STATISTICS SYSTEM PARAMETERS XXX % XXXX W XXXXX Hz XXXXX XXXXX XXX% XXXXX XXX% XXXXX XXX% 0.000 S 0W 0J XXXXX “Rxx” = Remote Setup Number and “#xx” = Local Setup Number R 1 PART COUNT WELD TIME PEAK POWER ENERGY PART COUNT GOOD BAD SUSPECT AMPLITUDE POWER FREE RUN FRQ AMPLITUDE POWER OPERATE FRQ XXX % XXXX W XXXXX Hz Time and Energy Menus Page 7 of 15 SYSTEM PARAMETERS screen changes to this screen if TEST button is pressed .
Page Disabled Energy Secondary Energy Secondary Pk Power Secondary Energy Peak Power Disabled Energy Disabled iQ SYSTEM Hold Time Afterburst Duration Afterburst Delay Enabled See Amplitude Control Menu TRIGGER WATTS AMPLITUDE CONTROL TRIGGER TIMEOUT Probe Delay Time Automated Probe AUTOMATION See Amplitude Control Menu Amplitude Control Page 8 of 15 Time and Energy Menus NOTE: These TRIGGER menus are only available when Trigger by Power is enabled in the Hardware Setup menu.
Appendices Weld Peak Power Weld by Peak Power WELD CONTROL PROCESS SETUP PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Weld by Time Weld Time Max Weld Time Hand Probe Detected AMPLITUDE CONTROL See Amplitude Control Menu Page 9 of 15 Time and Energy Menus HAND PROBE SWITCH NOTE: Trigger by Power is not supported in Hand Probe mode.
Page Disabled Secondary Energy Secondary Pk Power Secondary Energy Energy Disabled Peak Power Secondary Weld Ctrl Energy Disabled Secondary Pk Power Peak Power Secondary Weld Control Secondary Weld Control Weld Energy Max Weld Time Weld Peak Power Weld Time Weld by Energy MPC PROBE TRIGGER WATTS See Amplitude Control Menu TRIGGER TIMEOUT Probe Delay Time MPC Probe AUTOMATION See Amplitude Control Menu Amplitude Control Page 10 of 15 Time and Energy Menus NOTE: These TRIGGER menu
Appendices Enable BAD PART LIMITS WELD TIME WELD PEAK POWER WELD ENERGY PROCESS SETUP PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES ENERGY LIMIT Disable Maximum Energy Minimum Energy PROCESS LIMITS SUSPECT PART BAD PART Minimum Weld Time Maximum Weld Time Enable Process Limits Enable WELD TIME LIMIT Disable PEAK POWER LIMIT Disable Maximum Peak Power Minimum Peak Power Enable SUSPECT PART LIMITS WELD TIME WELD PEAK POWER WELD ENERGY ENERGY LIMIT Disable Maximum Energy Minimum
Page Setup Erased YES NO Erase Current Setup ERASE SETUPS PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES All Setups Erased Erasing . . .
Appendices PROCESS SETUP AMPLITUDE CONTROL AMPLITUDE SETTING RAMP UP / DOWN TIME WARNING MODIFIED SETTINGS MAY EFFECT OPERATION OF UNIT Amplitude Ramp Time Ramp Up Time Ramp Down Time Amplitude Control Page 13 of 15 Time and Energy (and Time Only) Menus AMPLITUDE SETTING 90 % SELECT DIGIT CHANGE VALUE 125 Page Dukane Manual Part No.
Page No *** *** *** Process Data Process Statistics System Parameters SERIAL ACTIVE Weld Time X.
Appendices #1: SETUP NAME OPERATE MODE PROCESS SETUP HARDWARE SETUP SETTINGS MAY AFFECT MODIFYING HARDWARE WARNING: OPERATION OF UNIT I/O PORT SETUP ADVANCED HARDWARE ON OFF FREQ LOCK/HOLD SYSTEM RESTORE FREE RUN FREQUENCY TRIGGER BY POWER PHASE SHIFT Free Run Frequency XXXXX Hz Entry Accepted ADVANCED HARDWARE: SETTINGS Wide 21000-19000 Narrow 20200-19800 Manual Entry Page 15 of 15 Time and Energy Menus Normal 20500-19500 SYSTEM FREQ LIMITS RESTORE DEFAULTS LOCK AND HOLD MODE IS ENAB
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Dukane ISO ISO CERTIFICATION Dukane chose to become ISO 9001:2008 certified in order to demonstrate to our customers our continuing commitment to being a quality vendor. By passing its audit, Dukane can assure you that we have in place a well–defined and systematic approach to quality design, manufacturing, delivery and service. This certificate reinforces Dukane's status as a quality vendor of technology and products.
Please refer to our website at: www.dukane.com/us/sales/intsales.htm to locate your local representative. Series, LS Generators, User's Manual Part No. 403-574-01 www.dukane.com/us Printed in the United States of America Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St.
