Dukane 403-575-00

Revision History

Revision Revision

Number Summary Date

- 00 Original release. 08/19/2011

Page iii

Dukane Manual Part No. 403-575-00

Contents

Main Intelligent Assembly Solutions ISO 9001:2008 www.dukane.com/us Series ULTRASONIC GENERATOR/POWER SUPPLY ES User's Manual Page Page Page Contents Section 1- Introduction .......................1 Section 2 - Health and Safety ..................5 Section 3 - Installation .......................11 Section 4 - Operation ........................39 Contents Page Page General User Information Read This Manual First Notes, Cautions and Warnings Drawings and Tables Press System Overview Key Generator Features SECTION 2 Health and Safety Page General Considerations General Considerations Plastics Health Notice Electrical Safety Domestic Power Grounding International Power Grounding Lifting the Equipment Take care when lifting the equipment. We recommend using a mechanical lift device to assist. How to Lift Safely SECTION 3 Installation Page Before Installation When to Use Lockout / Tagout Devices Page Unpacking Placement Placement in a Seismic Region Page 16 Figure 3-4 Rack Mounting iQ Generator Rack- Mounting OPTIONAL RACK MOUNT BRACKETS 147-4720 Benchtop Mounting Section 3 - Installation Figure 3-5 Securing iQ Generator to Benchtop OPTIONAL HOLD DOWN BRACKETS OPTIONAL HOLD DOWN BRACKETS 147-1398 Rear Panel Layout Overview A B D E F G K H AC Power Inlet Panel IEC AC Power Inlet Connector Power Switch/Circuit Breaker System I/O Panel System Inputs Connector System Inputs Connector Pinout Refer to Section 8, Options for information on optional features. System Inputs Signal Descriptions Pin 1 (+22V) Pin 2 (Power Gnd) Pin 3 (Remote Setup Selection Bit 0 Input) Pin 4 (Remote Setup Selection Bit 1 Input) Pin 5 (Remote Setup Selection Bit 2 Input) Pin 6 (Remote Setup Selection Bit 3 Input) Pin 7 (Remote Setup Selection Bit 4 Input) Pin 8 (Ultrasound Activation/ Cycle Start Input) Pin 9 (Not Used) Pin 10 (Not Used) Pin 11 (Press Inhibit for Hand Probes) System Outputs Connector System Outputs Connector Pinout System Outputs Signal Descriptions Pin 1 (+22V Power Supply) Pin 2 (Not Used) Pin 3 (+22V Power Ground) Pin 9 (System Overload Status Output) Pin 10 (System On-Line Status Output) Pin 11 (Press Top of Stroke Status Output) Pin 12 (Not Used) Pin 13 (Analog Monitor Signal Common) Pin 14 (Not Used) Pin 17 (Amplitude/Power Regulation Status Output) (Contact your sales representative about Pin 18 (Not Used) Pin 19 (System Power OK Status Output) Pin 20 (Bad Part Status Output) Pin 21 (Good Part Status Output) Pin 22 (System Ready Status Output) Ultrasound Output Connector Conguration Port Connector RFI Grounding Connecting Cables Power Cords Three Congurations Connecting Cables Pneumatic Press/Thruster Table 3-V iQ Generator and Pneumatic Press/Thruster Cables Page 32 Continued Section 3 - Installation Servo Press/Thruster (Version 1) 1 2 3 4 15 11 Figure 3-16 iQ Generator, Remote Controller, and Servo Press/Thruster - Connections Diagram Servo Press/Thruster (Version 1) Dukane Manual Part No. 403-575-00 Page 34 Servo Press/Thruster (Version 2) Table 3-VII iQ Generator and Servo Press/Thruster Cables Servo Press/Thruster (Version 2) Page 36 Networking Recheck Connections Connect AC Power Page SECTION 4 Operation Page Overv iew Start-up Other Control Functions Stopping the Weld Cycle Normal Conditions Emergency Conditions iQ Explorer Support Features Help System Top Menu Bar Using the F1 Key Quick Start - Servo Step 1 - Read Section 3, Installation Servo Step 2 - Hardware Tab Pneumatic Welder Quick Start See Pages 56-69 Servo Step 4 - Process Settings > Initiate Mode > Manual Servo Step 3 - Navigate to the Process Settings Tab Servo Step 5 - Process Settings > Trigger > Type Linear Weld Joint (inches) Servo Step 6 - Program Sensing Speed Servo Step 7 - Program Sensing Start Distance Select Trigger Servo Step 9 - Select Trigger Method Servo Step 8 - Teach Start Sensing Distance Servo Step 10 - Program Weld Characteristics Servo Step 11 - Program Start Motion After Force Decreases By: Servo Advanced Users - NOTE Servo Step 13 - Set Amplitude Servo Hold Dynamic Hold Method Hold Static Hold Method Servo Step 16 - Navigate to the Process Limits Tab Servo Quick Start - Pneumatic Step 1 - Read Section 4 See Pages 44- 55 Servo Welder Quick Start Pneumatic Welder Pneumatic Step 4 - Process Settings>Initiate Mode> Manual Pneumatic Step 3 - Process Settings Pneumatic Step 5 - Process Settings>Trigger Trigger Type - Select Force as the Trigger Type. Linear Weld Joint (inches) Max Trigger Time - Program a Max Trigger Time Compensation Point Pneumatic Step 6 - Process Settings>Trigger >Type Pneumatic Step 7 - Process Settings> Weld Pneumatic Step 8 - Post Weld Settings Process Settings > Post Weld > Hold Method Pneumatic Step 9 - Process Settings > Pressure Figure 4-34 iQ Explorer > Process Settings > Post Weld > Pressure Page 62 Linear Weld Joint (inches) Figure 4-35 Suggested Initial Weld Force Air Cylinder Size Pneumatic Step 10 - Process Settings > Pressure Continued from Page 62 Hold Pressure Upstroke Pressure Pneumatic Step 11 - Process Settings >Amplitude Pneumatic Step 12 - Process Settings >Secondary Control Pneumatic Step 13 - Test the Acoustic Stack Pneumatic Step 14 - Process Limits Tab Pneumatic Step 14 - Process Limits Tab Continued from previous page Pneumatic Step 15 - Cycle Data Page Page Page Overv iew Operational Test of the Acoustic Stack Page Acoustic Stack Test For more information about stacks, see this article: www.dukane.com/us/SE_stackarticle. Procedure for Cycling the System Page Page Page Troubleshooting iQ Servo Press Error Messages Page 1 of 2 Table 6 - I Error Messages, Servo-related Page 82 Up Travel Limit Lower travel limit switch activated Press moved sufciently far up to Section 6 - Troubleshooting activate upper limit switch. iQ Servo Press Error Messages Page 2 of 2 Table 6 - I Error Messages, Servo-related (continued) Page 83 iQ Pneumatic Press Error Messages Table 6 - II Error Messages, Pneumatic-related Page 84 Verifying Feature Operation Distance Power Force Transducer (Load Cell) Electronic Pressure Regulator and the Pressure Transducer An Uninterrupted Cycle Effects of I/O and System Errors on Process Flow The Cycle Terminates During Downstroke Premature Weld Termination Weld Termination Due to End of Weld/Ground Detect Weld Termination Due to Trigger Lost Weld Termination Due to Secondary Control Weld Termination Due to a Bad Limit The iQ Generator Wont Cycle No Ultrasound Page Page Page Front and Rear Panels Cleaning Power Button Chassis Page SECTION 8 Options Page Power Inlet Options 120V Systems for North America and Japan Electrical Safety AC Power Inlet Panel AC Power Cord A Power Switch/Circuit Breaker Chassis Ground Stud Press Interface Board Board location is shown in Figure 3-6. Each option is described in general terms: Page Page Page Contacting Dukane Identify Equipment Intelligent Assembly Solutions Page Page Page Figure 10-1 Layout - Low Prole iQ Generator mm IN Page 109 Figure 10-2 Layout - High Prole iQ Generator IN (mm) Page 110 Figure 10-3 Layout - High Power iQ Generator IN mm Page 111 Operating Environment Operate the equipment within these guidelines: Nonoperating storage guidelines: Dimensions . AC Power Requirements Table 10- III AC Power Requirements NOTES: Page 113 Interpreting the Model Number Options Slot Board Power Level Nominal U/S Frequency Interpreting the Model Number 20 HS 120 - 2 A - P6 - C2 Regulatory Agency Compliance FCC CE Marking IP (International Protection) Rating Page Page Page Appendix A Page Appendix A Appendix B List of Tables Page Page Index A C D E L M N O I Continued - Installation P R S T U Page Dukane ISO ISO CERTIFICATION CERTIFIED ISO 9001:2008