Dukane 403-573-02 User Manual
Intelligent Assembly Solutions
HAND PROBE
iQ Series
ULTRASONIC GENERATOR/POWER SUPPLY
Auto
AUTOMATED
PRESS
User’s Manual
Dukane Part No. 403 - 573 - 02
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797
Products are manufactured in ISO
ISO 9001:2008
registered facilities.
-
4900 • FAX (630) 797
www.dukane.com/us
-
4949
iQ Series, Auto User’s Manual
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. While every precaution has been taken
in the preparation of this manual, the manufacturer 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.
Specications subject to change without notice.
This user’s manual documents product features, hardware, and
controls software available at the time this user's manual was
published.
Printed in the United States of America.
Part Number: 403–573–02
This ultrasonic equipment is manufactured under one or more of
the following U.S. Patents:
3,780,926 3,825,481 4,131,505 4,277,710 5,798,599 5,880,580 6,984,921,
7,225,965 7,475,801, and 7,819,158, B2
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Dukane Manual Part No. 403-573-02
Revision History
Revision Revision
Number Summary Date
- 00 Original release. 10/09/2007
- 01 20kHz and 30kHz models added. 08/27/2009
System I/O Connector signals modied.
Amplitude control added.
- 02 I/O Connector Pin 9 signal scale revised. 12/15/2010
Miscellaneous spelling errors corrected.
Fig 5-1 and 5-2 dimensions edited.
Fault conditions modied:
Negative Peak Overload eliminated;
Positive Peak Overload changed to Peak Overload;
Frequency Lock Lost changed to Frequency Overload.
Copyright page modied: Specications subject to change statement added,
and Patent 7,819,158 B2 added.
Updated Dukane ISO certication statement to 2008.
How to Lift Safely information added to Section 2, Health and Safety.
International Protection Rating added to Section 5, Specications.
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Dukane Manual Part No. 403-573-02
Contents
Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . 1
General User Information . . . . . . . . . . . . . . . 3
Generator Overview . . . . . . . . . . . . . . . . . . . 4
Key Generator Features . . . . . . . . . . . . . . . . 4
Thermal Considerations . . . . . . . . . . . . . . . . 5
Section 2- Health and Safety . . . . . . . . . . . . . . . . . . . 7
General Considerations. . . . . . . . . . . . . . . . . 9
Plastics Health Notice . . . . . . . . . . . . . . . . . . 9
Electrical Safety. . . . . . . . . . . . . . . . . . . . . . 10
How to Lift Safely . . . . . . . . . . . . . . . . . . . . 11
Section 3- Installation . . . . . . . . . . . . . . . . . . . . . . . 13
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . .15
Placing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power Grounding . . . . . . . . . . . . . . . . . . . .16
Chassis Grounding Stud . . . . . . . . . . . . . . .16
Connecting Cables . . . . . . . . . . . . . . . . 17-19
MPC Module Installation Guide. . . . . . . 20-25
Section 4 - System Operation . . . . . . . . . . . . . . . . . 27
Standard iQ Auto System Test. . . . . . . . . . . 29
iQ Auto System with MPC Test . . . . . . . . . . 30
Section 5 - Specications . . . . . . . . . . . . . . . . . . . . 33
Section 6 - Automation Interface . . . . . . . . . . . . . . 41
Input/Output Connection Examples. . . . 43-44
E-Stop Circuitry Connection Examples . . . . 46
Section 7 - Contacting Dukane . . . . . . . . . . . . . . . . 47
Dukane Manual Part No. 403-573-02
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Dukane Manual Part No. 403-573-02
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 . . . . . . . . . . . . . . . . . . . . . 4
Key Generator Features . . . . . . . . . . . . . . . . . . . 4
Thermal Considerations . . . . . . . . . . . . . . . . . . . 5
Dukane Manual Part No. 403-573-02
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Dukane Manual Part No. 403-573-02
General User Information
Read This 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
Throughout this manual we use NOTES to provide information that is important for the successful application and understanding of the product. A NOTE block is
shown to the right.
In addition, we use special notices to make you aware
of safety considerations. These are the CAUTION and
WARNING blocks as shown here. They represent increasing levels of important information. These statements help you to identify and avoid hazards and recognize the consequences. One of three different symbols
also accompany the CAUTION and WARNING blocks
to indicate whether the notice pertains to a condition or
practice, an electrical safety issue or an operator protection issue.
Drawings and Tables
The gures and tables are identied by the section number followed by a sequence number. The sequence num-
ber begins with 1 in each section. The gures and tables
are numbered separately. The gures use Arabic sequence
numbers (e.g. –1, –2, –3) while the tables use roman sequence numerals (e.g. –I, –II, –III). As an example, Figure 3–2 would be the second illustration in section three
while Table 3–II would be the second table in section
three.
Section 1 – Introduction
NOTE
Note statements provide additional
information or highlight procedures.
CAUTION
C a u t i o n s t a t e m e n t s
iden t ify co n diti o n s or
practices that could result
in damage to the equipment or other property.
WARNING
Warnin g s tat e m ent s
point out conditions or
practices that could result in personal injury or
loss of life.
Condition
or Practice
Electrical
Hazard
Hearing
Protection
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iQ Series, Auto User’s Manual
Generator Overview
This generator is designed for ultrasonic applications controlled by a Programmable Logic Controller (PLC). Using the available system control inputs and outputs, the
generator can easily be integrated into a wide variety of
automated systems.
The generator design accepts several control input signals,
provides system output signals, has a power status LED
indicator, and an amplitude adjustment control.
An optional Multi-Probe Control (MPC) interface module
allows the generator to power multiple probes selected by
an automated control system.
Line Voltage Regulation automatically maintains
•
constant amplitude regardless of line voltage deviation. The available output power is maintained
with any voltage input within the specied range.
This provides consistent system performance regardless of line voltage uctuations. It also eliminates the need for bulky, external constant–voltage transformers.
Load Regulation provides constant amplitude
•
automatically regardless of power draw. The ultrasonic output amplitude level is held to within
±1% to provide weld process consistency and reduced weld cycle times.
This product’s rugged internal ultrasonic generator circuitry ensures a continuous resonant frequency lock at the
start of each weld. Ultrasonic settings for the drive signal,
phase delay angle, starting frequency and soft–start ramp
parameters can be customized at the factory. (Contact your
local Dukane sales representative for more information.)
Users can modify generator performance to meet a wide
variety of ultrasonic processing requirements if needed.
The generator’s compact size allows multiple units to be
placed into an industrial equipment cabinet, and the generator will operate at the same international line voltage
input specications as the other generators of this product
family. It also includes an RFI line lter that passes strict
CE test specications for global applications.
Key Generator Features
Compact Enclosure Size requires a small footprint for
•
either vertical or horizontal mounting into your equipment cabinet.
Pulse Width Modulation incorporates patented
•
circuitry giving the power supply the ability to
efciently change the output amplitude. This makes
it possible to start large horns with reduced power. It
also provides more power efcient switch-mode generator operation and increased reliability.
Linear Ramp Soft Start circuitry allows the acous-
•
tic stack to ramp up to operating amplitude smoothly,
minimizing the startup surges and abnormal stress to
the stack and generator.
Automatic Tuning tracks the resonant frequency of
•
the acoustic stack (horn, booster, transducer) and ad-
justs the generator output frequency to match it. This
is done for every weld cycle and eliminates the need
to manually tune the generator.
Industrial Line–Power Source means that
•
standard systems will operate worldwide at all
industrial high line voltage levels, whether it is
200VAC @60Hz in Japan, 240VAC @50Hz in
Europe or 208VAC @60Hz in the United States.
There are no internal transformer taps to change
for worldwide operation.
NOTE
120VA C is als o a vaila b l e for t h e se
co un t r i e s : U n it e d S t a t e s o f A me ri c a , C a n a d a , M e x i c o a n d J a p a n .
Amplitude Adjustment Control allows the peak
•
-to-peak excursion of the horn at its workface to
be adjusted between 20% and 100% of the horn’s
nominal amplitude.
Multiple Electronic Overload protec-
•
tion circuits prevent instantaneous component failure in the event of extreme output overload conditions and rated overload
power limit is based on the actual true RMS
power output level.
CE Certication means that the system meets
•
the required European standards to be sold and
used in Europe.
ISO 9001 Certication means that this system
•
has been manufactured to high quality standards
and assures you of manufacturing excellence.
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Dukane Manual Part No. 403-573-02
Section 2 – Health & Safety
55%
60%
65%
75%
100%
50%
Duty Cycle
Standard Generators
Power
(Watts)
Duty Cycle
Generators with Optional Heatsink
Power
(Watts)
55%
60%
65%
75%
100%
100 200 300 400 500 600
50%
100 200 300 400 500 600
Thermal Considerations
The thermal design of this generator is for applications that
require 600 watts or less of power at less than a 50% duty
cycle. For applications that require higher duty cycles, an
optional cooling package is available, Part Number 438-
962. The cooling package includes a heat sink that mounts
to the rear of the generator (Refer to Figure 5-2).
Figure 1-1 shows the thermal capability of the generator
with and without the cooling package. For further
information about the cooling package, contact your local
Dukane sales representative.
NOTE
Add transducer cooling as necessary to keep
front mass temperature to 100°F or less.
Figure 1–1 Thermal and Power Considerations for iQ Auto Generators
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Dukane Manual Part No. 403-573-02
Section 2 – Health & Safety
SECTION 2
Health and Safety
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power Grounding Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How to Lift Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Dukane Manual Part No. 403-573-02
Section 2 – Health & Safety
General Considerations
Please observe these health and safety recommendations for
safe, efcient, 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.
A typical system consists of a generator and/or ultrasonic
process controller, start and stop switches, power controls,
connecting cables, and the probe assembly which includes
the transducer, booster, horn and replaceable horn tip.
Proper Installation - Operate system components only
after they are properly installed and checked.
No Unauthorized Modications - Do not modify your
system in any way unless authorized to do so by the man-
ufacturer. Unauthorized modications may cause injury
to the operator and/or equipment damage. In addition,
unauthorized modications will void the equipment warranty.
Keep the Cover On - Do not remove any equipment cover unless specically directed to do so by the manufacturer. The generator produces hazardous electrical voltages
which could cause injury.
CAUTION
Never operate the generator with the cover off.
This is an unsafe practice and may cause injury.
CAUTION
Parts being joined ultrasonically sometimes vibrate at
audible frequencies. Wear
ear protection to reduce
annoying or uncomfortable sounds. In addition,
sound absorbing materials, enclosures or sound
deectors may be installed
to reduce the noise level.
Grounded Electrical Power - Operate this equipment
only with a properly grounded electrical connection.
(See Page 16 for grounding information.)
Comply with Regulations - You may be required to add
accessories to bring the system into compliance with applicable OSHA regulations for machine guarding and
noise exposure.
Plastics Health Notice
Before using any ultrasonic welding system, be sure you
are familiar with OSHA regulations from the U.S. Department of Labor about the particular type of plastic(s) you
are using.
When plastic materials are being processed, they may emit
fumes and/or gases that could be hazardous. Make sure
you have adequate ventilation whenever these plastics are
processed.
Dukane Manual Part No. 403-573-02
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iQ Series, Auto User’s Manual
L
N
Electrical Safety
Power Grounding Connection
Figure 2-1 illustrates how the AC line is connected.
iQ Auto Power Inlet
Pluggable AC
Line Connector
Figure 2–1 AC Line Connection
CAUTION
If th e re is a n y q ue sti on
abo u t gr o und i ng o f you r
equipment and/or its electrical power source, contact a qualified electrician.
CAUTION
For safe system operation: To
avoid the risk of re, electrical
shock, serious injury or death,
the power line safety ground
must be securely connected
to the center terminal on the
(pluggable) AC line connector.
Terminal
L (Live) Black Lt. Brown
(Ground) Green
N (Neutral) White Lt. Blue
Table 2-I Conventional Wire Color Code
North America Europe
Wire Color
Green w/yellow
stripe
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Dukane Manual Part No. 403-573-02
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. Know your limit and don’t
try to exceed it.
• Ask for help if needed, or if possible, divide the load
to make it lighter.
• Know where you are going to set the item down, and
make sure it and your path are free of obstructions.
Then follow these steps:
Step 1. Stand close to the load with your feet
spread apart about shoulder width, with
one foot slightly in front of the other for
balance.
Step 2. Squat down bending at the knees (not your
waist). Tuck your chin while keeping your
back as vertical as possible.
Section 2 – Health & Safety
CAUTION
Take care in lifting the
equipment. We recommend using a mechanical
lift device to assist.
Step 3. Get a rm grasp of the object before be-
ginning the lift. Begin slowly lifting with
your LEGS by straightening them. Never
twist your body during this step.
Step 4. Once the lift is complete, keep the object
as close to the body as possible. As the
load’s center of gravity moves away from
the body, there is a dramatic increase in
stress to the lumbar region of the back.
Step 5. If you must turn while carrying the load,
turn using your feet-not your torso. To
place the object below the level of your
waist, follow the same procedures in reverse order. Remember, keep your back
as vertical as possible and bend at the
knees.
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