Dukane ES User Manual

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Page 1

Intelligent Assembly Solutions

Series

ULTRASONIC GENERATOR/POWER SUPPLY

Servo Systems

AUTOMATED HAND PROBE PRESS

User's Manual

Dukane Part No. 403 – 587– 00

Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797– 4900 • FAX (630) 797– 4949

Dukane products are manufactured

ISO 9001

in ISO registered facilities.

www.dukane.com/us

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

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 Dukane Corporation.

Notice of Liability: 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.

Specications 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.

Dukane Part Number: 403-587-00

Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents: (* = Inactive)

3,780,926 * 4,131,505* 4,277,710* 5,798,599 5,880,580 6,984,921 7,225,965 7,475,801, 7,819,158 and, 8,052,816

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Dukane Manual Part No. 403-587-00

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Revision History

Revision Revision Number Summary Date

- 00 Original release. November 20, 2013

Dukane Manual Part No. 403-587-00

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Dukane Manual Part No. 403-587-00

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Contents

Section 1- Introduction .......................1

General User Information .............................3

Press System Overview ..............................4

Key Generator Features..............................4

Section 2 - Health and Safety ..................5

General Considerations ..............................7

Plastics Health Notice................................8

Electrical Safety ....................................8

Lifting the Equipment ...............................10

Section 3 - Installation ....................... 11

Before Installation..................................13

Unpacking........................................15

Placement........................................15

Rear Panel Layout Overview .........................16

AC Power Inlet Panel .................................17

System I/O Panel.....................................17

RFI Grounding ....................................25

Connector Descriptions .............................26

Power Cords......................................28

Cable Connections .................................29

Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Recheck Connections...............................36

Connect AC Power.................................36

Section 4 - Control Panel.....................37

Overview.........................................39

System Operating Mode Keys ........................40

Navigation Keys ...................................41

System Power Output Level ..........................42

Screen Basics.....................................43

Dukane Manual Part No. 403-587-00

Continued

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Continued from Previous Page

Section 5 - Operation ........................45

Overview.........................................47

Generator Start-up Sequence ........................47

Stopping the Weld Cycle ............................48

Using the Menus...................................49

Set-up Guidelines..................................93

Section 6 - Optional Control ..................95

Other Control Functions.............................97

Stopping the Weld Cycle ............................97

Software Support Features ..........................97

Quick Start Using iQ Explorer II.....................99

Contents

Unique Features .................................111

Section 7 - System Operational Testing........113

Section 8 - Maintenance.....................121

Section 9 - Options.........................125

Section 10 - Contacting Dukane ..............131

Section 11 - Specications ..................135

Generator Outline Drawings.........................137

Weights, Dimensions, Operating Environment ..........140

AC Power Requirements ...........................141

Ultrasonic Pressure ...............................142

Interpreting the Model Number ......................143

Regulatory Agency Compliance......................144

Section 12 - Appendices....................145

Appendix A - List of Figures .........................147

Appendix B - List of Tables..........................152

Page vi

Appendix C - Sequencing Notes .....................153

Appendix D - Alarm Messages.......................156

Appendix E - Menu Structure Diagrams................161

Index .................................. 165

Dukane Manual Part No. 403-587-00

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Section 1 - Introduction

SECTION 1

Introduction

General User Information . . . . . . . . . . . . . . 3

Press System Overview . . . . . . . . . . . . . . . 4

Key Generator Features . . . . . . . . . . . . . . . 4

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General User Information

Read this Manual First

Before operating your ultrasonic system, 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 equipment. The examples given are chosen for their simplicity to illustrate basic operation concepts.

This manual provides information to set up, operate, and interface this generator/power supply as an integral part of

Dukane’s iQ Series ES press system. Particular models are listed in Section 11 - Specications

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 a operator protection issue.

Drawings and Tables

The gures and tables are identied by the section number followed by a sequence number. The sequence num-

ber begins with one 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

Caution statements identify conditions or

practices that could result in damage to the equipment or other property.

WARNING

Warning statements point out conditions or practices that could result in personal injury or loss of life.

Condition or Practice

Electrical Safety Issue

Operator Protection (hearing)

Dukane Manual Part No. 403-587-00

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Press System Overview

An iQ Series Ultrasonic Press System ES consists of these components: the iQ generator, press (with thruster, switches, controls, cables, transducer, booster, horn, and xture) and iQ Explorer II software. The software allows the operator to control the system either remotely or at the press location.

The iQ Series ES generator has rugged internal ultrasonic circuitry and ensures a continuous resonant frequency lock at the start of each weld.

The generator’s compact size allows multiple units to be placed into an industrial equipment cabinet. This generator will operate at the same international line voltage input specications as the other generators of this product family (unless the 120V option is installed). It also includes an

RFI line lter that passes FCC, CE, UL, and CSA testing

for global applications.

Key Generator Features

• The Generator Interface has a 5" LCD color display and soft keys that enhance the intuitive menu navigation.

• Digital Control of all power supply functions, includ- ing digital frequency synthesis, and parameters allows for unique congurations and allows for future upgrades.

• Process Parameters such as frequency, amplitude and power are all updated at a 0.5 ms rate.

• Pulse Width Modulation incorporates patented circuitry giving the power supply the ability to

efciently change and maintain the output amplitude.

This makes it possible to start large horns with reduced

power. It also provides more power-efcient switch-

mode generator operation and increased reliability.

• Linear Ramp Up/Down circuitry allows the acoustic stack to be brought to operating amplitude smoothly, minimizing start-up surges and undue stress to stack and generator. This circuitry also allows decreases to amplitude as the weld cycle ends. The stack is brought down from its maximum operating amplitude smoothly, reducing shock stress.

• Digi-Trac Tuning tracks the resonant frequency of the acoustic stack (horn, booster, and 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.

• Line Voltage Regulation automatically maintains constant amplitude regardless of line voltage devia-

tion. The available output power is maintained

with any voltage input within the specied 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 ultrasound 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.

• Wide Line Voltage Operation means that stan- dard systems will operate worldwide within their standard AC voltage ranges.

• Flow Through Cooling Tunnel with a matched high–performance heat sink and thermostatically controlled fan reduces thermal gradients and increases component life.

• AC Power Inrush protection reduces electri- cal stress on the internal components by protecting them from AC power startup transient current surges.

• Multiple Electronic Overload protection circuits prevent instantaneous component failure in the event of extreme output overload conditions. The overload power limit is based on the actual true RMS power output level.

• Process Limits include: distance, weld peak force, position, weld energy, and peak power. These programmable limits provide the means to adapt to a wide variety of welding applications.

• Rear Panel Expansion Slot is available to allow for custom congurations for OEM and cost effec-

tive solutions.

• RS-232 Serial Conguration Port is used for eld software upgrades, troubleshooting and ad-

vanced hardware setup with optional PC-based

congurator.

• CECertication means that the system meets the required European standards to be sold and used in Europe (high line voltage models only).

• ISO9001Certication means that this system has been manufactured to high quality standards and assures you of manufacturing excellence.

• TUV Certication - TÜV Rheinland certies

Dukane products comply with applicable UL (Underwriters Laboratories) and CSA (Canadian Standards Association) requirements.

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Dukane Manual Part No. 403-587-00

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Section 2 - Health and Safety

SECTION 2

Health and Safety

General Considerations . . . . . . . . . . . . . . . . 7

Plastics Health Notice . . . . . . . . . . . . . . . . . 8

Electrical Safety ..............................8

Domestic Power Grounding ...................... 9

International Power Grounding .................... 9

Lifting the Equipment .........................10

Dukane Manual Part No. 403-587-00

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Dukane Manual Part No. 403-587-00

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Section 2 - Health and Safety

General Considerations

Please observe these health and safety recommendations for safe, efcient, and injury-free operation of your

equipment.

Proper Installation - Operate system components only after they are properly installed.

NoUnauthorizedModications- Do not modify your system in any way unless authorized to do so by Dukane

Corporation. Unauthorized modications could cause equipment damage and/or injury to the operator. In addition, unauthorized modications will void equipment

warranty.

Keep the Cover On - Do not remove any equipment cover unless directed to do so by Dukane Corporation. The generator produces hazardous electrical voltages which

could cause injury.

Grounded Electrical Power - Operate this equipment only with a grounded electrical connection.

See Electrical Safety for grounding instructions, Page 9.

Comply with Regulations - You may be required to add accessories to bring the system into compliance with applicable regulations (OSHA in the USA) for machine guarding and noise exposure.

Use Eye Protection - Wear ANSI approved safety impact goggles.

Acoustic Stack Hazard - When an acoustic stack (transducer, booster, horn and tip) is energized by the ultrasound signal, it presents a potential hazard. Stay clear of an energized stack.

NOTE

These recommendations apply to the welding system. System in this manual refers to a complete group of components associated with the welding of parts, also known as an ultrasonic assembly system. A typical iQ Series System consists of the iQ generator, a press with thruster, switches, controls, cables, transducer, booster, horn, and xture, and iQ Explorer II software.

WARNING

Any xture manufactured by

a third party must comply with all OSHA and ANSI re-

quirements. All xtures must

be guarded as necessary.

Dukane Corporation does not

assume any responsibility or liability for xtures manufactured by the customer or any third

party manufacturer.

WARNING

Never operate the generator with the cover off. This is an unsafe practice and may cause injury.

System E-STOP (abort) Switch - Install a system E- STOP (abort) switch at each operator station when ultra-

sonic plastic assembly equipment is used with automatic material handling equipment in an automated system.

Foot Switch - Do not use a foot switch. Using a foot switch in place of the optical touch nger switches (operate switches) violates OSHA regulations. Do not install a foot switch.

Dukane Manual Part No. 403-587-00

CAUTION

At some time you may be asked

to remove equipment covers by the Dukane Service Dept.

personnel. Before doing so, disconnect the unit electrically from the incoming line AC power. If the unit is a press/ thruster, lock the Air Lockout Valve, located on the rear panel, in its closed position.

Continued

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Continued from Previous Page

General Considerations

System Electrical Cabling - Electrical power must be off when connecting or disconnecting electrical cables.

Do Not Wear Loose Clothing or Jewelry - They can become caught in moving parts.

Stay Alert - Watch what you are doing at all times. Use common sense. Do not operate the press when you are

tired or distracted from the job at hand.

Do Not Operate the Equipment - Your judgement or reexes could be impaired while taking prescription medi-

cations. If so, do not operate the equipment. Be familiar with warning labels and recommended activity restrictions that accompany your prescription medications. If you have any doubt, do not operate the equipment.

Plastics Health Notice

Certain plastic materials, when being processed, may emit fumes and/or gases that may be hazardous to the operator’s health. Proper ventilation of the work station should be provided where such materials are processed. 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

Parts being joined ultrasonically will at times vibrate at audible frequencies. Wear ear protectors to reduce annoying

or uncomfortable sounds. In addition, ultrasound bafes, sound enclosures, or materials that absorb sound may be located to surround the system. Ultrasound pressure level could exceed 110dB. See Ultrasonic Pressure, Table 11-IV, Page 142.

WARNING

Keep head, hands, limbs and body at least six

inches (152 mm) away

from an operating press/

thruster. A vibrating, descending horn can cause burns and/or crushing

injuries.

Electrical Safety

The iQ Series generator provides the operating power and power returns. Make sure the generator is grounded properly.

In addition to the safety considerations, proper grounding is essential for the effective suppression of RFI (Radio Frequency Interference). Every generator contains a RFI

lter which blocks noise on the AC power line from entering the generator control circuitry. This lter also prevents

ultrasonic RFI from being fed back into the AC power line.

If you experience problems with RFI from the press, run an additional grounding wire from the press base grounding stud to the nearest grounded metal pipe or equivalent earth ground by means of a ground clamp. Use at least 14 AWG wire for the connection to the press base.

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CAUTION

When making cable connections to system equipment or disconnecting cables

from system equipment, make sure electrical power to the system is turned off, and AC power cords are removed from their receptacles. After the cables have been securely connected and the connections and cable routing checked a nal time, the power may be restored.

Continued

Dukane Manual Part No. 403-587-00

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Continued from Previous Page

Section 2 - Health and Safety

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.

Approved 2 pole, 3 wire grounding receptacle HUBBELL No. 5652 or equivalent to NEMA 6–15R or 6–20R

Figure 2–1 Example of 220/240 Volt,

Grounded, 3-Prong Receptacle

International Power Grounding

The power cable normally provided for international use is compatible with the power outlet used in many Continental European countries (Refer to Figure 2–2.) However, if your application requires another type of power cord, check with your equipment supplier, and follow local regulations concerning proper wiring and grounding.

CAUTION

If you have a two-prong electrical receptacle, we strongly recommend that you replace

it with a properly grounded three-prong type. Have a qualied electrician replace it following the National Electric Code and any local codes and ordinances that apply.

See Figures 2–1 and 2–2.

CAUTION

If there is any question about the grounding of your receptacle, have it checked by a

qualied electrician. Do not cut off the power cord grounding prong, or alter the plug in any way. If an extension cord is needed, use a three-wire cord that is in good condition. The cord should have an adequate power rating to do the job safely. It must be plugged into a grounded receptacle. Do not use a two-wire extension cord with this product.

Grounding Contacts

Typical Outlet

Provided Cable

Figure 2–2 International 220/240V Grounding

Dukane Manual Part No. 403-587-00

100/120 Volt AC Systems (North America or

Japan)

The power cord (including strain relief) supplied with the 100/120VAC systems is permanently attached to the rear of the generator. Units with this power cord are for use in North America or Japan.

240V Systems

High power generators with power ratings above 2400W also use permanently attached power cords.

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Lifting the Equipment

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:

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.

2. Squat down bending at the knees (not your waist). Tuck your chin while keeping your back as vertical as possible.

3. Get a rm grasp of the object before beginning the lift. Begin slowly lifting with your LEGS by straightening them. Never twist your body during this step.

For equipment weights see Page 140, Table 11-I in Section 11, Specications.

Take care when lifting the equipment. We recommend using a mechanical lift device

to assist.

NOTE

CAUTION

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.

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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Dukane Manual Part No. 403-587-00

Page 17

Section 3 - Installation

SECTION 3

Installation

Before Installation...........................13

When to Use Lockout/Tagout Devices ............... 13

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Rear Panel Layout Overview .................. 16

AC Power Inlet Panel ......................... 17

System I/O Panel............................. 17

RFI Grounding ............................ 25

Connector Descriptions ...................... 26

Power Cords...............................28

Cable Connections ......................... 29

Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Recheck Connections . . . . . . . . . . . . . . . . . . . . . . . 36

Connect AC Power .......................... 36

Dukane Manual Part No. 403-587-00

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Dukane Manual Part No. 403-587-00

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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, Page 10.

When to Use Lockout / Tagout Devices

Section 3 - Installation

Figure 3-1 Lockout Device In Open Position, Unlocked

The typical kind of LOTO device for this generator is a clam shell type device (with lockout capability). The LOTO device is placed over the plug end of the generator electrical cord. This effectively prevents access to the energy isolation point. See the example

of one such device in the gure above.

The gure to the right shows the lockout device in the

closed, locked position.

Figure 3-2 Bottom Lockout Device In Closed Position, Locked

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.

Continued

Dukane Manual Part No. 403-587-00

Page 13

Page 20

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Continued from Previous Page

Lockout/Tagout

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.

2) Place the electrical cord plug end inside the shell.

3) Close the shell.

4) Secure the shell with its lock, and lock it.

4. Wait a minimum of ve minutes for the generator

to discharge its electrical energy.

5. After taking these steps, make the necessary

adjustments to the generator.

Assuming the generator is being put back into service.

Procedure to use AFTER making any internal adjustments to the generator:

1. Authorized personnel remove the lockout/tagout

device from the plug end of the generator's electrical cord. Using a typical clam shell type LOTO device:

1) Unlock the protective shell.

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.

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Dukane Manual Part No. 403-587-00

Page 21

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.

Allow at least 5 inches [13 cm] of space on both ends of the generator chassis for air circulation. Allow space between 3-6 inches, [8-15 cm] - at the rear of the chassis for cable clearance. (The amount of space depends on the chassis type and what rear panel connections there are.)

See Section 11 - Specications, for generator drawings.

Section 3 - Installation

CAUTION

Allow 5 inches for air ventila-

tion at the cooling air inlet and at the exhaust air outlet. The fan draws in fresh air to cool

the internal components, reduce thermal gradients and increase component life.

If excessive dust accumulates in the slots, wipe or vacuum them clean. Do not use compressed air as this may force the dust inside the chassis.

5.19

[131.83]

Exhaust Air Outlet

IN [mm]

Figure 3-3 Generator Front View (Typical High Prole)

17.16

[435.86]

Cooling Air Inlet

NOTE

Active Seismic Region Placement - If the generator will be put in an active seismic region, please refer to Application Note 511 at, http://www.dukane.com/us/

DL_ApplData.asp

Dukane Manual Part No. 403-587-00

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

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 3-4 illustrates a typical panel layout.

DUKANE CORP.

ST. CHARLES IL. 60174

UL: 1012:2010 CSA: C22.2 61010-1-12 IEC: 61010-2012

DISCONNECT LINE POWER

BEFORE REMOVING COVER

MADE IN U.S.A.

-WARNING-

POWER LINE OUTLET MUST BE GROUNDED

U.S. PATENTS 7,475,801

7,819,158 AND 7,225,965

J6 BASE/ABORT

J9 ETHERNET

LINE VOLTAGE: 200-240 Vac

50/60Hz, 10A

Figure 3-4 Generator Rear Panel

AC Power Inlet Panel

A IEC Power Inlet Connector – Attaches to an IEC style

power cord.

B Power Switch – Circuit Breaker – Used to switch sys-

tem power ON and OFF.

C Chassis Grounding Stud – Chassis connection for a

protective earth ground.

The System I/O Panel

J5 THRUSTER

J11 ENCODER

J10 RS-232

SYSTEM INPUTS

SYSTEM OUTPUTS

CONFIGURATION

ULTRASOUND J1

Options Module Panel

H Communications Board (See NOTE below.)

Shown in the example above are these ports:

J9 - Ethernet J10 - Serial RS-232

K Press Interface Module (See NOTE below.)

Shown in the example above are these ports:

J6 - Base/Abort

D System Input Connector (J2) – Connections for sys-

tem control input signals.

E System Output Connector (J3) – Connections for sys-

tem status output signals.

F Ultrasound Output Connector (J1) – Coaxial high volt-

age connection to ultrasonic stack.

G Conguration Port Connector (J4) – Digital control

port to modify system parameters.

Page 16

J5 - Thruster J11 - Encoder

NOTE

The press interface board is available in several different congurations. See Section 9, Options for more infor- mation about Data Transfer using the Communications Board and more about the Press Interface Module.

Dukane Manual Part No. 403-587-00

Page 23

Section 3 - Installation

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 congured IEC

compliant power cord, which enables worldwide system operation by simply changing the power cord.

Low prole systems are equipped with a 10 amp rated IEC inlet connector. The high prole systems include a 16/20

amp rated IEC inlet connector. 120VAC and 3600/4800W systems include a non-detachable power cord.

An appropriately rated power cord must be securely attached to the welding system’s IEC inlet connector. If the

correct power cord conguration is not included with the

system for the local AC power outlet at your location, an appropriate IEC power cord should be available from a local electrical parts supplier. Note that the system undervoltage lockout will inhibit system operation if a North

American power cord congured for 120V is connected to

the system. A minimum of 180V is required for the system to operate.

Fixed AC Power Cords

For some models an appropriately rated AC power cord is permanently mounted to the power inlet panel.

Power Switch/Circuit Breaker

The power switch/circuit breaker has a rocker type actuator switch that will activate or deactivate the AC power to the system. The power ON position is marked with the internationally recognized I symbol, the power OFF position is marked with the 0 symbol. This power switch also integrates an appropriately sized over-current protection circuit breaker function in the generator.

If an over-current condition trips the circuit breaker, it will automatically switch to the OFF position. If the overload current that caused the circuit breaker to trip is due to a transient condition, the circuit breaker can be reset by switching the actuator back to the ON position. If when resetting the circuit breaker after it has tripped, it immediately trips again, there is likely an internal system malfunction, and the generator will require service.

Do not repeatedly try to reset the circuit breaker. If it trips, this will only cause more damage to the generator.

Chassis Grounding Stud

The chassis grounding stud is used to attach a protective earth ground to the generator. This will aid in the suppression of electrical interference or radio frequency interference (RFI) that is common in a industrial envi-

ronment. The chassis ground stud is C in Figure 3-5. Proper system grounding is discussed on Page 9.

DUKANE CORP.

ST. CHARLES IL. 60174

LINE VOLTAGE: 200-240 Vac

50/60Hz, 10A

MADE IN U.S.A.

UL: 1012:2010 CSA: C22.2 61010-1-12 IEC: 61010-2012

-WARNING-

POWER LINE OUTLET MUST BE GROUNDED

DISCONNECT LINE POWER

BEFORE REMOVING COVER

U.S. PATENTS 7,475,801

7,819,158 AND 7,225,965

Figure 3-5 IEC AC Power Inlet Connector

System I/O Panel

The standard system I/O panel is described in this section. See Figure 3-6 on the next page.

System Inputs Connector

The SYSTEM INPUTS connector mounted on the system I/O panel includes connections for all of the basic system control input signals, that will typically come from an automated control system. The cable attached to this connector includes all of the available system control signals, which will be controlled by an output card or output port on the automation controller.

The user can determine which signals to use for each particular welding application, but there must be at least one connection to this connector in order to activate the ultrasound output. All of the input signals on this connector are electrically isolated (signals are NOT referenced to chassis ground) and activated when a 24VDC voltage source is connected to the signal input pin, referenced to the isolated common pin. The electrically isolated input signals can be driven from an automation controller output that is either sinking (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

Dukane Manual Part No. 403-587-00

Page 17

Page 24

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Continued from Previous Page

Note that a simple switch closure (relay contact) connected to a control input can not activate the input without adding an external power supply to power the input.

Adding jumper connections to pins available on the System Inputs connector, can congure switch closure inputs

to operate referenced to generator chassis ground (nonisolated), without adding a separate power supply, if desired.

Refer to Application Note AN507 (Automation Interface Guidelines) at http://www.dukane.com/us/DL_ApplDa- ta.asp for wiring diagrams of example applications.

System Inputs Connector Pinout

The SYSTEM INPUTS connector is a HD-15F (high density D-subminiature 15 circuit female) connector. Connector pin numbers for this connector are shown in Figure 3-7. The male connector on the cable is a mirror image of the panel-mounted connector and is shown in Figure 3-8. Table 3-I lists the signal names and descriptions, with more detailed descriptions that follow. The wire color coding for the system input cable is listed in Table 3-II, to assist with custom automation system wiring and assembly.

Figure 3-6 System I/O Panel (Standard Panel Shown)

NOTE

Refer to Section 9, Options for information on optional features.

Continued

Page 18

Dukane Manual Part No. 403-587-00

Page 25

1 2 3 4 5

11 12 13 14 15

Section 3 - Installation

Continued from Previous Page

Pin Signal Name Cable Color Code Signal Option Requirements

1 +22VDC Power Supply BLK

2 +22VDC Power Ground WHT

3 Remote Setup Selection Bit 0 Input RED

4 Remote Setup Selection Bit 1 Input GRN

5 Remote Setup Selection Bit 2 Input ORN

6 Remote Setup Selection Bit 3 Input BLU

7 Remote Setup Selection Bit 4 Input WHT/BLK

8 Ultrasound Activation/Cycle Start Input RED/BLK

9 Not Used GRN/BLK Not Used

10 Front Panel Control Lock Input ORN/BLK Not Used

11 Press Inhibit for Hand Probes BLU/BLK Hand Probe

12 System Latch Reset Input BLK/WHT

13 Isolated Common RED/WHT

14 Not Used GRN/WHT

15 Automation Cycle Stop Input BLU/WHT

Table 3-I Generator Input Signals (J2)

System Inputs Signal Descriptions

Pin 1 (+22VDC Power Supply)

This pin can supply +22VDC at up to 250mA to power the user’s automation controls.

Pin 2 (+22VDC Power Ground)

Pin 2 is the +22VDC return and is tied to the system chassis ground.

Pin 3 (Remote Setup Selection Bit 0 Input)

Pin 3 is the Remote Setup Selection Bit 0, which is the

least signicant bit used to select different welding setups

with an automation control system.

Pin 4 (Remote Setup Selection Bit 1 Input)

Pin 4 is the Remote Setup Selection Bit 1, which is the

second least signicant bit used to select different welding

setups with an automation control system.

5 4 3 2 1

15 14 13 12 11

Figure 3-7 HD-15F, Generator Input Connector

Figure 3-8 HD-15M, Generator Input Cable

Connector

Dukane Manual Part No. 403-587-00

Continued

Page 19

Page 26

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Continued from Previous Page

Pin 5 (Remote Setup Selection Bit 2 Input)

Pin 5 is the Remote Setup Selection Bit 2, which is the

third least signicant bit used to select different welding

setups with an automation control system.

Pin 6 (Remote Setup Selection Bit 3 Input)

Pin 6 is the Remote Setup Selection Bit 3, which is the second most signicant bit used to select different welding setups with an automation control system.

Pin 7 (Remote Setup Selection Bit 4 Input)

Pin 7 is the Remote Setup Selection Bit 4, which is the

most signicant bit used to select different welding setups

with an automation control system.

Pin 8 (Ultrasound Activation/ Cycle Start Input)

Pin 8 is used to activate the generator ultrasound output. Activation of this control input will switch the ultrasound output ON, and deactivating this signal will switch ultrasound OFF. This input signal will also function as a cycle start input, where the ultrasound activation and timing are completely under the control of the process controller. Depending on the welding process controller setup, this input signal could be activated momentarily to start a welding cycle.

Pin 9 (Not Used) Pin 10 (Not Used) Pin 11 (Press Inhibit for Hand Probes)

Pin 11 is used to disconnect power applied to a press or thruster, if a hand probe is connected to the system input connector, for safety considerations. The hand probe activation switch could unexpectedly start a welding cycle that activates a press or thruster to the down position. The hand probe cable connector is wired to apply chassis ground to this pin, when it is attached to the system, which activates a press inhibit relay that disconnects power from the pneumatic press valves. This pin must be left open whenever a press control board is installed. Connecting this pin to chassis ground will inhibit press operation.

Pin 12 (System Latch Reset Input)

Pin 12 is used to reset the Any Fault or System Overload status outputs (See Status Output descriptions). If a fault occurs during a weld cycle, these outputs will normally remain active until the next weld cycle is initiated. Activating this input will reset the status output faults and may simplify automation programming.

NOTE

Refer to Latch on Bad Part, on Page 51 for more information.

Pin 13 (Isolated Common)

Pin 13 is electrically isolated from chassis ground. Using isolated sourcing (PNP) output drivers, this common line would be connected to isolated ground potential. Using isolated sinking (NPN) output drivers, this common line would be connected to the isolated positive supply voltage

output.

Pin 14 (Not Used)

Pin 14 is an open connection.

Pin 15 (Automation Cycle Stop Input)

Pin 15 is an input control signal that when enabled, can be used by the automation control system as a redundant signal to shut the ultrasound output off. This signal could

also be recongured through menu selections to function

as an automation end-of-weld control signal input.

Page 20

Dukane Manual Part No. 403-587-00

Page 27

Section 3 - Installation

Pin Signal Name Cable Color Code Signal Option Requirements

1 +22VDC Power Supply BLK

2 Spare Output WHT

3 +22VDC Power Ground RED

4 Programmable Status Output 1 GRN

5 Programmable Status Output 2 ORN

6 Ultrasound Active Status Output BLU

7 Any Fault Status Output WHT/BLK

8 Press Trigger Status Output RED/BLK

9 System Overload Status Output GRN/BLK

10 System Online Status Output ORN/BLK

11 Press Top of Stroke Status Output BLU/BLK

12 Current Loop OK Status Output BLK/WHT Not Used

13 Analog Monitor Signal Common RED/WHT

14 Not Used GRN/WHT

15 Power Signal Monitor Output BLU/WHT

16 Amplitude Monitor Output BLK/RED

17 Programmable Status Output 3 WHT/RED

18 MPC Ready Status Output ORN/RED Not Used

19 System Power OK Status Output BLU/RED

20 Bad Part Status Output RED/GRN

21 Good Part Status Output ORN/GRN

22 System Ready Status Output BLK/WHT/RED

23 Suspect Part Status Output WHT/BLK/RED

24 Isolated Common RED/BLK/WHT

25 Not Used GRN/BLK/WHT

Table 3-II System Output Connector Signals (J3)

System Outputs Connector

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. The cable attached to this connector includes all of the available system output signals, which will be read or monitored by a digital input card or analog inputs on the user-supplied automation controller. The user can determine which signals are appropriate for each welding application.

The system monitor output signals are analog signals used to monitor ultrasonic amplitude setting and ultrasonic output power levels, referenced to the Monitor Common (Pin 13).

13 11 9 7 5 3 1

25 23 21 19 17 15

Figure 3–9 DB-25F, Generator Output Connector (J3)

1 3 5 7 9 11 13

15 17 19

21 23 25

Figure 3–10 DB-25M, Generator Output Cable Connector

Continued

Dukane Manual Part No. 403-587-00

Page 21

Page 28

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Continued from Previous Page

This is at system chassis ground potential (non-isolated). All of the digital output status signals on this connector, are isolated (signals are not referenced to generator chassis ground). When a status output signal is activated, it will sink current (500mA Max. sourced by a 24VDC supply) to isolated common. In automation terms, the outputs are NPN (sinking) and would drive a PNP (sourcing) input that is referenced to the Isolated Common pin.

The digital status output signals can only sink current to isolated common. They cannot be changed to a sourcing (PNP) type output. If sourcing status outputs are required, there is an optional isolated NPN to PNP conversion module that is DIN rail mountable. The module converts the standard isolated sinking (NPN) status output signals to isolated sourcing (PNP) status output signals. Consult your local sales representative for information about the conversion module.

System Outputs Connector Pinout

The SYSTEM OUTPUTS connector is a DB-25F (standard D-subminiature 25 circuit female) connector. Connector pin numbers for this connector are shown in Figure 3-9. The male connector on the cable is a mirror image of the panel mounted connector and is shown in Figure 3-10. Table 3-II lists the signal names. Detailed descriptions are listed in System Outputs Signal Descriptions that follow. To assist with custom automation system wiring and assembly, the wire color coding for the system outputs cable is listed in Table 3-II.

System Outputs Signal Descriptions

Pin 1 (+22VDC Power Supply)

This pin can supply +22VDC at up to 250mA to power the user’s automation controls.

Pin 2 (Not Used)

Pin 2 is an open connection.

Pin 3 (+22VDC Power Ground)

Pin 3 is the +22VDC return and is tied to the system chassis ground.

Pin 4 (Programmable Status Output 1)

Pin 4 is a digital active low status output that can be reassigned to other system status signals. The output can be assigned to E-STOP, Over Temperature or Servo Error. [The Pin 4 default output: Servo Error.]

Pin 5 (Programmable Status Output 2)

Pin 5 is a digital active low status output that can be reassigned to other system status signals. The output can be assigned to Hold, In Cycle, In Cycle with No Afterburst, or Servo Home.

[The Pin 5 default output: Servo Home.]

Pin 6 (Ultrasound Active Status Output)

Pin 6 is a digital active low status output that activates when the system is delivering ultrasonic power to the load attached to the ultrasound output connector. This output will be an open circuit when the ultrasound output is off.

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. Generator faults that will activate the Any Fault output:

• Overload (Average, Peak, or Frequency)

• Overtemperature Fault

• System Power Fault

Page 22

Continued

Dukane Manual Part No. 403-587-00

Page 29

Continued from Previous Page

Section 3 - Installation

Pin 8 (Press Trigger Status Output)

Pin 8 is a digital active low status output that activates

when the specied trigger type has occurred. 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.

Pin 9 (System Overload Status Output)

Pin 9 is a digital active low status output that activates whenever any overload condition is tripped. Activation of the overload status output signal could be caused by an average overload, a positive peak overload or a negative peak overload condition. After the overload status output activates, it will remain active until the next ultrasound activation cycle begins and this output will automatically reset. This output will be an open circuit when no overload conditions have been detected.

Pin 10 (System On-Line Status Output)

Pin 10 is a digital active low status output that activates when the system is in the ON LINE operating mode, which enables the activation of the ultrasonic output. This output will be an open circuit if the system is switched to the OFF LINE operating mode, which will prevent the start of a welding cycle or activation of the ultrasound output. Note that an automation controlled process can not weld any parts, if the system is, accidentally or otherwise, switched to the OFF LINE operating mode.

Pin 11 (Press Top of Stroke Status Output)

Pin 14 (Not Used)

Pin 14 is connected to the system chassis ground.

Pin 15 (Power Signal Monitor Output)

Pin 15 is an analog output signal used to monitor the power output from the welding system. The scaling on this output signal is as shown below: 15kHz, 20kHz, 30kHz and 40kHz systems 1 Watt = 0.001 VDC (1mV per Watt) 50kHz and higher systems 1 Watt = 0.010 VDC (10mV per Watt) Examples: 20kHz system measures 0.525 VDC on Power Monitor Output = 525 Watts 50kHz system measures 0.525 VDC on Power Monitor Output = 52.5 Watts

Pin 16 (Amplitude Monitor Output)

Pin 16 is an analog output signal used to monitor the system amplitude setting. The scaling on this output signal is 100% amplitude = 10.0 VDC, or 0.1 VDC per 1% amplitude. This monitor signal output would typically be used when a remote control option board is installed

in the system. The automation control system will adjust

the system’s amplitude setting remotely, using a 4-20mA current loop attached to the input of the remote control board. Using this monitor output, the control system can verify that the amplitude is set to the expected programmed amplitude level.

Pin 11 is a digital active low status output that activates when the press/thruster head is in the top of stroke position. This output will be an open circuit when the press/ thruster head is not at the top of stroke position.

Pin 12 (Not Used) Pin 13 (Analog Monitor Signal Common)

Pin 13 is the signal common (ground) connection for all of the analog monitor signals (on Pins 15 and 16). This signal common pin is connected to system chassis ground and is not isolated from the generator chassis. This is an analog signal ground connection. Do not connect anything to this ground connection, except the wiring to the inputs of the analog instrumentation devices used to measure the monitor output signals.

Dukane Manual Part No. 403-587-00

Continued

Page 23

Page 30

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Continued from Previous Page

Pin 17 (Programmable Status Output 3)

Pin 17 is a digital active low status output that activates when the system is regulating the amplitude level correctly. This output becomes an open circuit when the system falls out of regulation. When that happens, it can-

not adjust the system output to the output level that was

programmed as the regulation set point. This signal will be activated at the end of the ramp-up time until the beginning of the ramp-down time. This status signal will be active for the time the ultrasound is at the programmed amplitude setting. The output can be assigned to Amplitude Regulation

Status, Servo Error Status, Home Servo Status or Teaching Status. [Pin 17 default output: Amplitude Regulation Status.]

Pin 18 (Not Used) Pin 19 (System Power OK Status Output)

Pin 19 is a digital active low status output that activates when no fault conditions are detected by any of the power fault detection circuits included in the system. This output will be an open circuit when any power related fault is detected in the system.

Pin 20 (Bad Part Status Output)

Pin 20 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 bad part limits. This output will be an open circuit when a bad part has not been detected.

Pin 21 (Good Part Status Output)

This status output signal will activate only when the system is ready to activate ultrasound or begin a weld cycle. Pin 22 is a digital active low status output that activates when a weld processing cycle is completed and the welding process control system is ready to start the next welding cycle. This output will be an open circuit when the welding process controller determines that the next welding cycle cannot be started. This includes system faults or off line active, but not a process fault like Overload.

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. This common line should be connected to negative output at a user-provided isolated 24VDC power supply. The isolated NPN status output signals can drive PNP inputs.

Pin 25 (Not Used)

Pin 25 is an open connection.

Pin 21 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 do not exceed the programmed suspect or bad part limits. This output will be an open circuit after a welding cycle when either a suspect or bad part has been detected.

Pin 22 (System Ready Status Output)

Page 24

Dukane Manual Part No. 403-587-00

Page 31

Earth Ground

#14 Gauge

Stranded or

Solid Wire

Fixed Probe Mount

or 2nd Chassis Grounding Stud

3rd Chassis Grounding Stud

Chassis Grounding Stud

Recommended protective earth ground connection wire color: green or green with yellow stripe.

Section 3 - Installation

RFI Grounding

The iQ Series generator provides the operating power

and power returns. Make sure the generator is grounded properly.

In addition to the safety considerations, proper grounding is essential for the effective suppression of RFI (Radio Frequency Interference). Every generator contains a

RFI lter which blocks noise on the AC power line from entering the generator control circuitry. This lter also

prevents ultrasonic RFI from being fed back into the AC power line.

CAUTION

To minimize electrical noise and eliminate ground currents, ground the chassis

as shown. Use a STAR conguration (illustrated below). Do not DAISY CHAIN the grounds.

Dukane Manual Part No. 403-587-00

Page 25

Page 32

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Connector Descriptions

iQ Generator Connectors

J1 - 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.

J2 - System Inputs Connector

The SYSTEM INPUTS connector includes connections for all of the basic system control input signals that will typically come from an automated control system. The cable attached to this connector includes all of the available system control signals, which will be controlled by an output card or output port on the automation controller.

The user can determine which signals to use for each particular welding application, but there must be at least one connection to this connector in order to activate the ultrasound output.

J3 - System Outputs Connector

The SYSTEM OUTPUTS connector includes connections for all of the basic system status and monitor output signals, which will typically connect to an automated control system. The cable attached to this connector includes all of the available system output signals, which will be read or monitored by a digital input card or analog inputs on the user-supplied automation controller.

Figure 3-11 Ultrasound Output Connector

very high AC voltage (1200VAC). At high power levels this can exceed 2 amperes of current and must be securely terminated via the ultrasound cable for safe operation. Use original equipment ultrasound cables for safe and reliable system operation. Improperly assembled ultrasound cables can result in high voltage arcing and will destroy the ultrasound connectors.

Do not use your generator if there is any evidence of arcing (black carbon deposits) on either the ultrasound output connector or the ultrasound cable connectors.

CAUTION

The ultrasonic output from this connector (that drives the attached ultrasonic load) is a

The user can determine which signals are appropriate for each welding application.

Page 26

NOTE

For details on integrating the welder with automation, refer to Application Note AN507 (Automation Interface Guidelines)

at www.dukane.com/us > Downloads > Application Notes.

Continued

Dukane Manual Part No. 403-587-00

Page 33

Continued from Previous Page

J4 - Conguration Port Connector

The conguration port connector is a DB-9M (standard D-subminiature 9 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.

Section 3 - Installation

This port is used for eld updates to the generator rmware, without removing the enclosure cover.

This port can also be used with a software application running on a Windows PC to modify the factory

default system settings and hardware congurations.

Contact your local sales representative for software availability information and access to documentation

that will allow you to make use of the conguration

port features.

J6 - Base/Abort

The Base/Abort connector accepts the operate and emergency stop signals from the optical operate switches and abort switch on the base. If you are using custom automation, you may have separate operate and abort switches, but these still connect to this connector on the generator.

J9 - Ethernet

This port is used for Ethernet communication between the generator and HMI running iQ Explorer II software.

Figure 3-12 Conguration Port Connector

J10 - RS-232

This port is primarily used for welder diagnostic functions accessible via serial communication to a PC. Guidance will be provided by Dukane if the need to use the capability arises.

J11 - Encoder

This connector accepts signals from the distance encoder on the press.

J5 – Thruster

This connector is used to interface various control signals between the press and generator.

Dukane Manual Part No. 403-587-00

Page 27

Page 34

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Power Cords

The AC line cords supplied with the standard generators are matched to the ultrasonic output power rating and the

continent of specied use. See Table 3-III.

ceptacle is encountered, we strongly recommend that it is replaced with a properly grounded three-lead recep-

tacle.

Have a qualified electrician do the replacement in accordance with the National Electrical Code and local codes and ordinances. DO NOT cut off the power cord grounding prong or alter the plug in any way.

CAUTION

The power cord is equipped with a three-prong, grounded-type plug for your safety. Whenever a two-slot re-

Continent of Use Power Cord

Part Number

200 - 1110 240V, 15A

North America

200 - 1541 240V, 10A

200 - 1111 240V, 16A

Continental Europe

200 - 1542 240V, 10A

Table 3-III Power Cords

Power

Page 28

Dukane Manual Part No. 403-587-00

Page 35

Cable Connections

The iQ Servo Presses are congured in one of two ways, depending on the model. Each has unique cabling require-

ments.

Section 3 - Installation

Version 1- Remote Controller

Conguration

(Press Models: 43S215, 43S245-AX)

Typical Components:

• iQ Generator

• iQ Servo Press

• Remote Controller (contains servo electronics)

• HMI Interface (optional on some systems)

• Customer Automation Equipment

Connect the Cables

Use the following references as guides to making the connections: For press model 43S215, use Figure 3-13 and Table 3-IV. For press models 43S245-AX, use Figure 3-13 and Table 3-V.

1. Make the basic cable connections 1 through 9, and

13-16.

2. Make any optional connections.

3. Connect any customer-supplied equipment such as

automation. Use cables 17 and 18 for automation.

4. Connect customer-supplied electricity using cables

10, 11, and 12.

Connect the power cords last, but do not turn on the power yet.

CAUTION

Before connecting or

disconnecting cables:

Put power switches for

the iQ generator, press, remote controller, and any usersupplied automation equipment in the OFF position. Turn off electrical power. Remove AC power cords from their receptacles.

NOTE

Some connectors have a pair of threaded jack screws to secure the connector. Make sure the screws are snug, but do not overtighten them.

CAUTION

DO NOT operate the

generator unless the

ultrasound coaxial ca-

ble is connected and

the transducer is installed in the thruster. Otherwise, an overload condition could occur, with possible damage to the generator.

5. Recheck all connections. When they are secure, you are ready to connect electrical power.

6. Finally, connect electrical power. See Section 11, Specications for AC power requirements.

Dukane Manual Part No. 403-587-00

Continued

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Page 36

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Continued from Previous Page

Servo Press/Thruster (Version 1)

Automation Equipment

SYSTEM INPUTS

SYSTEM OUTPUTS

ULTRASOUND

CONFIGURATION

MUST BE GROUNDED.

DISCONNECT LINE POWER

BEFORE REMOVING COVER.

1 2 3 4

J11 ENCODER

J10 RS-232

J5 THRUSTER

ETHERNET

J6 BASE/ABORT

DUKANE CORP

U.S. PATENT 5,880,580

OTHER PATENTS PENDING

ST. CHARLES IL 60174

MADE IN U.S.A.

200-240 Vac

50/60Hz, 15A

LINE VOLTAGE:

K C

T U

R E

205

O O V

E SE

N I R E D

204 J

NC E

O O

I/ I/

R R

O E

T T

206

E RU

N H

E T

N O

100

ST.

KAN U D

Vac

Hz,

I L R E W O P : G N

I N R A W

201 J

202 J

WW.DUKA NE.COM W

R. E V O C G N

I V O M E R E R O F E B R E W O P E N

I L T C

NE N O C IS D

-WARNING-

POWER LINE OUTLET

Earth

Ground

Figure 3-13 iQ Generator, Remote Controller, and Servo Press/Thruster Connections (Version 1)

Page 30

Dukane Manual Part No. 403-587-00

Continued

Page 37

HMI

Section 3 - Installation

Continued from Previous Page

Servo Press/Thruster (Version 1)

Remote

Controller

Connections

Generator Base Thruster

Length

(meters)

J205 -

SERVO

FEEDBACK

2.4 - - - AC INPUT -

2.4 - - - - AC INPUT

2.4 AC INPUT - - - -

Part Number

One of the following:

200-1110 (240 VAC, 15A, US)

200-1111 (240 VAC, 16A, Europe)

200-1612 (240 VAC, 15A, India)

One of the following:

200-1541 (240 VAC, 10A, US)

200-1542 (240 VAC, 10A, Europe)

200-1624 (240 VAC, 10A, India)

200-1576 (120 VAC)

(Power cord is integral to

generator,)

1 200-1655-XXM XX - - SERVO POWER J100 -

2 200-1647-XXM XX - - THRUSTER I/O J206 -

3 200-1648-XXM XX - - ENCODER J204 -

4 200-1649-XXM XX - -

5 200-1289-XXM XX J1 - ULTRASOUND - -

6 200-1556-XXM XX J5 - - J202 -

7 200-1613-XXM XX J11 - - J201 -

8 200-1545-XXM XX J6 J35 - - -

No.

Cable

9 200-1553-XXM XX J9 - - - ETHERNET

13 200-1557 5 - - PE - -

14 200-1557 5 - GRND - - -

15 200-1557 5 - - - PE -

16 200-1557 5 PE - - - -

17 200-1380-XXM XX J2 - - - -

18 200-1381-XXM XX J3 - - - -

Table 3-IV iQ Generator, Remote Controller, and Servo Press/Thruster Cables for Press Model 43S215

Dukane Manual Part No. 403-587-00

Continued

Page 31

Page 38

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Continued from Previous Page

Servo Press/Thruster (Version 1)

HMI

Remote

Controller

Connections

Generator Base Thruster

Length

(meters)

J205 -

SERVO

FEEDBACK

2.4 - - - AC INPUT -

2.4 - - - - AC INPUT

2.4 AC INPUT - - - -

Part Number

One of the following:

200-1541 (240 VAC, 10A, US)

200-1542 (240 VAC, 10A, Europe)

200-1624 (240 VAC, 10A, India)

200-1576 (120 VAC)

One of the following:

200-1541 (240 VAC, 10A, US)

200-1542 (240 VAC, 10A, Europe)

200-1624 (240 VAC, 10A, India)

200-1576 (120 VAC)

One of the following:

200-1110 (240 VAC, 15A, US)

200-1111 (240 VAC, 16A, Europe)

200-1612 (240 VAC, 15A, India)

200-1541 (240 VAC, 10A, US)

200-1542 (240 VAC, 10A, Europe)

200-1624 (240 VAC, 10A, India)

(for 120 VAC models, power cord

is integral to generator)

1 200-1646-XXM XX - - SERVO POWER J100 -

2 200-1647-XXM XX - - THRUSTER I/O J206 -

3 200-1648-XXM XX - - ENCODER J204 -

4 200-1649-XXM XX - -

5 200-479-XXM XX J1 - ULTRASOUND - -

6 200-1556-XXM XX J5 - - J202 -

7 200-1613-XXM XX J11 - - J201 -

8 200-1545-XXM XX J6 J35 - - -

No.

Cable

9 200-1553-XXM XX J9 - - - ETHERNET

13 200-1557 5 - - PE - -

14 200-1557 5 - GRND - - -

15 200-1557 5 - - - PE -

16 200-1557 5 PE - - - -

Table 3-V iQ Generator, Remote Controller, and Servo Press/Thruster Cables for Press Models 43S245-AX

Page 32

Dukane Manual Part No. 403-587-00

17 200-1380-XXM XX J2 - - - -

18 200-1381-XXM XX J3 - - - -

Page 39

Cable Connections Continued

Version 2 - Integrated Conguration

(Press Models: 43S220, 43S340)

Section 3 - Installation

Typical Components:

• iQ Generator

• iQ Servo Press with Integrated Servo Electronics

• HMI Interface (optional on some models)

• Customer Automation Equipment

Connect the Cables

Use Figure 3-14 and Table 3-VI as guides to making the connections.

1. Make the basic cable connections 2 through 6, and

9-11.

2. Make any optional connections.

3. Connect any customer-supplied equipment such as

automation. Use cables 12 and 13 for automation.

4. Connect customer-supplied electricity using cables 1,

7, and 8.

Read and follow the NOTE about cable layout to the right.

CAUTION

Before connecting or dis-

connecting cables: Put

power switches for the iQ

generator, press and any user-supplied automation equipment in the OFF position. Turn off electrical power. Remove AC power cords from their receptacles.

NOTE

Arrange the cable layout so that cable 1 is physically separated from other cables connected to the thruster (see Figure 3-14). Do not bundle cables 1, 7, or 8 with any other cables.

Connect the power cords last, but do not turn on the power yet.

5. Recheck all connections. When they are secure, you are ready to connect electrical power.

6. Finally, connect electrical power. See Section 11, Specications for AC power requirements.

CAUTION

DO NOT operate the

generator unless the ultrasound coaxial cable is

connected and the transducer is installed in the thruster. Otherwise, an overload condition could occur, with possible damage to the generator.

Continued

Dukane Manual Part No. 403-587-00

Page 33

Page 40

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Continued from Previous Page

Servo Press/Thruster (Version 2)

Earth

Ground

13 12

Automation Equipment

ULTRASOUND

-WARNING-

POWER LINE OUTLET

MUST BE GROUNDED.

DISCONNECT LINE POWER

BEFORE REMOVING COVER.

SYSTEM INPUTS

200-240 Vac

LINE VOLTAGE:

50/60Hz, 15A

SYSTEM OUTPUTS

J11 ENCODER

J5 THRUSTER

J6 BASE/ABORT

CONFIGURATION

J10 RS-232

DUKANE CORP

U.S. PATENT 5,880,580

ST. CHARLES IL 60174

MADE IN U.S.A.

ETHERNET

OTHER PATENTS PENDING

NOTE:

Separate

cables 1, 7

and 8 from

other cables.

DO NOT

bundle these

with other

cables.

Figure 3-14 iQ Generator and Servo Press/Thruster Connections (Version 2)

Page 34

Continued

Dukane Manual Part No. 403-587-00

Page 41

Connections

Section 3 - Installation

Continued from Previous Page

Servo Press/Thruster (Version 2)

Generator Base Thruster HMI

Length

(meters)

Part Number

2.4 - - AC INPUT -

2.4 - - - AC INPUT

2.4 AC INPUT - - -

One of the following:

200-1541 (240 VAC, 10A, US)

200-1542 (240 VAC, 10A, Europe)

200-1624 (240 VAC, 10A, India)

No.

Cable

200-1576 (120 VAC)

2 200-1556-XXM XX J5 - THRUSTER I/O -

3 200-1613-XXM XX J11 - ENCODER -

4 200-479-XXM XX J1 - ULTRASOUND -

One of the following:

200-1541 (240 VAC, 10A, US)

200-1542 (240 VAC, 10A, Europe)

5 200-1545-XXM XX J6 J35 - -

6 200-1553-XXM XX J9 - - ETHERNET

200-1624 (240 VAC, 10A, India)

200-1576 (120 VAC)

One of the following:

200-1110 (240 VAC, 15A, US)

200-1111 (240 VAC, 16A, Europe)

200-1612 (240 VAC, 15A, India)

200-1541 (240 VAC, 10A, US)

200-1542 (240 VAC, 10A, Europe)

200-1624 (240 VAC, 10A, India)

(for 120 VAC, 3600 W, or 4800 W models, power cord is

integral to generator)

9 200-1557 5 - - PE -

10 200-1557 5 - GRND - -

Table 3-VI iQ Generator and Servo Press/Thruster Cables (Version 2)

Dukane Manual Part No. 403-587-00

11 200-1557 5 PE - - -

12 200-1380-XXM XX J2 - - -

13 200-1381-XXM XX J3 - - -

Page 35

Page 42

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Networking

Where several welders are connected, please refer to the iQ Explorer II User's Manual, 403-585-00. Refer to the Section on networking. Among other things, there is information about connection through:

• a stand-alone network, and

• a local area network.

Recheck Connections

Recheck all cabling connections for the:

• iQ ES Generator

• 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.

WARNING

Any modications to the

Activation Switch (also known as the Operate

Switch) circuit must comply with all OSHA and ANSI requirements. Compliance with all

local building and electrical codes

is also required.

Dukane Corporation does not as-

sume any responsibility or liability for circuitry modications made by the customer or by any third party

manufacturer.

WARNING

Any modifications to the Emergency Stop Switch (also

known as the E-STOP or Abort

Switch) circuit must comply

with all OSHA and ANSI requirements.

Compliance with all local building and

electrical codes is also required.

Page 36

Dukane Corporation does not assume

any responsibility or liability for circuitry modications made by the customer or by any third party manufacturer.

Dukane Manual Part No. 403-587-00

Page 43

Section 4 - Control Panel

SECTION 4

Control Panel

Overview...................................39

System Operating Mode Keys ..................40

Navigation Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

System Power Output Level....................42

Screen Basics...............................43

Dukane Manual Part No. 403-587-00

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

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Page 38

Dukane Manual Part No. 403-587-00

Page 45

Overview

This section introduces the iQ Series ultrasonic generator

Section 4 - Control Panel

ES control panel and color display with this information:

• FunctionsofthepanelcomponentsshowninFigure

4-1belowarediscussed.

• Somescreenbasicsareintroduced:

— Making selections,

  —Interpretingonscreenarrows,

— Using the virtual keyboard feature, and

  —Takingalookatsetupidentication.

Color Display

Soft Keys (8)

System

Operating Mode Keys (3)

NOTE

Do not touch the display. Touch only

the System Operating Mode Keys, the Navigation Keys and the Soft Keys to the left and right of the display.

Cleaning - If the display is dirty, clean it by rst putting a mild cleaning solution on a clean, soft cloth. Then, gently wipe the cloth over the screen.

Navigation Keys (4)

Lighted Power Indicator

CANCEL Key

Figure 4-1 iQ Generator Display and Control Keys

Dukane Manual Part No. 403-587-00

ENTER Key

Page 39

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

System Operating Mode Keys

ON LINE - After AC power has been activated and the

generator is operating normally, ON LINE is the normal operating mode. The generator can produce ultrasound signals in this mode. The display has a WHITE background and the word,

Online appears in a GREEN box in the display's lower

right corner.

TEST - After AC power has been activated and the gen-

erator is operating normally, in the ON LINE mode, the TEST key can be pushed.

This activates a momentary ultrasound pulse allowing the operator to test system function. The display 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.

OFFLINE - After AC power has been activated and the

generator is operating normally, the OFFLINE key may

be pressed to put the generator into the ofine mode. In

this mode the generator can not generate an ultrasound signal.

The display has a YELLOW background, and the word,

Ofine appears in a yellow box in the lower right corner

of the display. See Figure 4-3 to the right.

Operating Mode Indicator Online (green); Ofine (yellow); or E-STOP (red)

Figure 4-2 Display Detail, Operating Mode Indicator

If a transducer is not connected to the ultrasound output con-

nector, the system should be set to the OFFLINE mode. Do not activate the ultrasound output without a transducer connected. Make sure that the stack is properly assembled before it is connected to the system. The horn should never come in direct contact with a metal xture or anvil with ultrasound activated.

CAUTION

The display has a RED background, and the word,

E-STOP appears in a red box in the lower right corner

of the display.

Page 40

Operating Mode Indicator Ofine (yellow)

Figure 4-3 Generator in Ofine Condition

Dukane Manual Part No. 403-587-00

Page 47

Section 4 - Control Panel

Navigation Keys

Moving the Cursor - Press the left and right navi-

gation keys to move the display’s cursor left or right respectively. Press the up and down navigation keys to move up one level in the menu, or to move back one level. Also, use the keys to change the value of a selected digit.

Enable/Disable - The navigation keys have another

function. Any of the four keys can be pressed to either enable or disable a particular menu item. See Figure 4-4.

ENTER Key

Press ENTER to conrm and store a selection in memory. Example: After entering a time value, press ENTER.

CANCEL Key

Press the CANCEL key to return to the previous screen or cursor position. Think of it as a “back” key. Selection is not stored in memory.

Navigation Key (4)

Press one of the navigation keys to Enable the func-

tion.

Press again, to Disable the function once more.

Figure 4-4 Navigation Keys (4), with Enter and Cancel

Active Key

Soft Keys Bordering the Display (8)

Use the eight keys that border the display to make selections from the choices shown on the display.

Not all keys will be active on any given screen.

Example 1: For the display shown on the right, three of the eight soft keys are active:

Administrator Password, Erase, and Done.

Example 2: At times the soft keys act like navigation keys to help move from screen to screen. In the example shown to the right, the two keys nearest the arrow (on either side of the display) will respond to an operator's touch. The arrows indicate more information is available - either left

or right. In the example shown in the gure to the right,

pressing the active soft key(s) will display more real time data. If the lower active keys are pressed, they will display the Operate screen (left) or the Main Menu (right).

Figure 4-5 Active Soft Keys, Example 1

Active Key

Figure 4-6 Active Soft Keys, Example 2

Dukane Manual Part No. 403-587-00

Page 41

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

System Power Output Level

(Bar Graph)

A bar graph displays the percentage of ultrasonic power being drawn by the load. The display uses LED’s that show:

GREEN - normal operation.

YELLOW - warning of potential overload.

RED - warning that an overload condition exists.

Peak Detect Feature

To indicate the maximum peak power achieved during a weld cycle, the LED in the bar graph corresponding to the peak level remains on (for about one second) after the weld cycle has been completed.

Flash on Overload at 90%

The OVERLOAD indicator begins to ash (RED) when the generator produces 90% of the overload power rating. This feature alerts the operator to an impending overload fault condition.

Bar Graph Power Scaling

Power scaling is related to amplitude. At 100% amplitude the whole graph is lit, and the generator is operating at 100% power. At 50% amplitude the entire graph is lit, and the generator is operating at 50% power. If the amplitude setting is lowered, the graph rescales automatically according to the revised amplitude. Example: With a 1200W generator, at 50% amplitude, if the whole graph is lit, that represents 600W.

Bar Graph

Figure 4-7 System Power Output Level, Bar Graph and Overload Indicator

CAUTION

If the System Output Power Level red overload indicator is lit, that means there is an overload fault. If this hap-

pens, verify that the ultrasonic stack

is not damaged.

Lighted Power Indicator

While the indicator glows steady GREEN, it indicates that the generator has been powered by the AC current.

Page 42

Dukane Manual Part No. 403-587-00

Page 49

Screen Basics

Making Selections

Figure 4-8 shows there are several ways that an item has been selected:

• A word or phrase is bounded by a black border.

• A black box surrounds the selected item.

• A line of text is highlighted.

• The cursor shows what digit is selected.

Section 4 - Control Panel

Word bounded by black border

Black box surrounds selected item

Figure 4-8 Making Selections

Interpreting On Screen Arrows

Arrows pointing up, down, left and right give visual cues that more text is available in the direction the arrow points. Two examples are shown in Figure 4-9 below. For the screen on the left, the up or down navigation keys are used to move the display. For the screen on the right, active soft keys are used to move the display left or right.

Line of highlighted text

Cursor showing selected digit

(See Active Soft Keys, Figure 4-6.)

Figure 4-9 Arrows Indicate More Text

Dukane Manual Part No. 403-587-00

Display arrows point in the direction of more text.

Page 43

Page 50

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Virtual Keyboard

A virtual keyboard pops up when there is a need to make an entry for the Security and Hardware screens.

In the example shown below the operator is prompted to choose a Setup Name.

Figure 4-10 Virtual Keyboard

Setup Identication

Setupidenticationcanbeseeninthelowerrightcorner ofthescreen.

TheexampleshowninFigure4-11illustratesthatsetup controlisbyautomation(Auto)andthatSetup#1programhasbeenselectedforthegenerator.

Setup can also be controlled by iQSystem(iQ) or by se- quencing(Apairofnumbersthatresemblearatiosuchas 2:3appears.Inthisexample2isthenumberforthesegment,and3isthenumberofthecycleinthatsegment.)

See Page 69 for more on Setup.

Page 44

Figure 4-11 Main Menu Detail - Setup Identication

Dukane Manual Part No. 403-587-00

Page 51

Section 5 - Operation

SECTION 5

Operation

Overview...................................47

Generator Start-up Sequence ..................47

Stopping the Weld Cycle ......................48

Using the Menus.............................49

Process Setup................................ 50

Process Limits................................ 62

Utilities/Hardware ............................. 68

Operate Screen............................... 84

Current Setup ................................ 84

Graph ...................................... 85

Help........................................ 87

Security ..................................... 88

Set-up Guidelines............................93

Dukane Manual Part No. 403-587-00

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

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Page 46

Dukane Manual Part No. 403-587-00

Page 53

Section 5 - Operation

Overview

The iQ Series generator, model ES, is typically part of a

system. Major system major components would be:

• iQ generator,

• iQ Explorer II (software),

• User Interface (HMI),

or computer (user supplied), and

• iQ Press System.

Press, acoustic stack, and tooling will require their own individual adjustments as those components are integrated into your particular system.

Helpful information on a wide variety of assembly equipment, processes and

With this type of system, the user controls nearly all aspects of the welding process and has several choices of how best to accomplish this: Control can be done through the color front panel of the iQ ES generator. System control can also be done with the User Interface

(HMI) or a computer (user supplied), using iQ Explorer II.

techniques can be found at the Dukane

website:

http://www.dukane.com/us/PPL_upa.htm

See Downloads for these User Manuals:

• iQ Explorer II (Part No. 403-585-00),

 •iQ Press System ES (Part No. 403-569-00), and  •iQ Press System Servo ES (Part No. 403-578-00).

Generator Start-up Sequence

NOTE

1. Press the rear panel AC breaker switch to ON.

2. The front panel lighted power indicator ashes during

the start up sequence, then turns a steady GREEN (See Figure 5-1) when the generator is activated.

Lighted Power Indicator

Figure 5–1 Front Panel's Lighted Power Indicator

3. After the generator is activated, the LCD displays an image that identies the Dukane iQ Series type. The sequence ends when the Main Menu screen is displayed as shown in Figure 5-2.

(ON)

(OFF)

Dukane Manual Part No. 403-587-00

Figure 5–2 Main Menu Screen

Page 47

Page 54

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Stopping the Weld Cycle

Normal Conditions

The cycle stops when the programmed welding cycle ends or when the rear panel's Cycle Stop input is activated.

NOTE

Emergency Conditions

Push the power switch on the generator's rear panel to the OFF position. The front panel lighted power indicator goes out showing that power has been turned off.

Manual System

Do either of these things:

1. Press OFFLINE to stop the ultrasound signal. This may be done under any condition, OR

2. Push the power switch on the generator's rear panel to the OFF position.

Automated System External Controls:

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. Activating the System Input called "Automation Cycle Stop" will stop the weld process or the complete cycle depending on if it's congured for "End of Weld" or "End of Cycle." See Page 20 for a description of Automation Cycle Stop Input.

Page 48

Dukane Manual Part No. 403-587-00

Page 55

Using the Menus

Navigation through the menus typically begins at the Main Menu. This menu can take two forms as shown below. If either the Administrator or Process Eng (Process Engineer) has logged in, the screen looks like that shown in Figure 5-3. If Setup has logged in, the screen looks like that shown in Figure 5-4.

The screens look identical with one exception:

The Administrator/Process Engineer screen has Utilities/ Hardware while the Setup screen has Select Setup. Go to the pages referenced for more detail about each sub-menu.

Section 5 - Operation

NOTE

Screen Prompts - Whenever a message pops up on the screen, please follow its instructions or take note of a condition, and take appropriate action.

Pages 50-61

Pages 62-67

Pages 68-83

Page 85

Figure 5–3 Navigating from the Main Menu (Administrator/Process Engineer Logged In)

Page 84

Pages 86-87

Page 87

Pages 88-92

Page 70

Figure 5–4 Navigating from the Main Menu (Setup Logged In)

Security detail can be found on Pages 88-92.

Dukane Manual Part No. 403-587-00

NOTE

Page 49

Page 56

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Process Setup

Travel Limit

Initiate Mode

Trigger Type

** See NOTE.

Primary Weld Method

Secondary Weld Method

Weld Prole

Dynamic Hold Method

Auto

Manual

Force

Power

Position

Latch on Bad Part

Force at Trigger Max Trigger Time

Trigger Power

Trigger Position

Distance

Position

Energy

Peak Power

Disabled

Position

Energy

Peak Power

Constant

Segmented

Enable

Disable

Weld Distance Max Weld Time

Weld Position

Weld Energy

Weld Power

Enable

Disable

Enable

Disable

Until Force Reached

Distance

Enable

Disable

Max Trigger Time

Teach Trigger Position

Constant Weld Speed Enable Melt Detect

Speed

Sensing Start Position

Start Amplitude

Max Trigger Time

Max Weld Time

Distance Increment

Dynamic Hold Speed

Hold Distance

Main Menu

Sensing Speed

Sensing Start Position

Trigger by Force and Trigger by Position have Pre-trigger and Trigger Delay Trigger features not shown here but described on Page 82.

After Force Drops By

Enable Melt Detect

Dynamic Hold Speed

Sensing Speed

NOTE

After Force Drops By

Max Hold TimeDynamic Hold Peak Force

Max Hold Time

Static Hold Method

Afterburst

Time

Disable

Enable

Disable

Hold Time

Afterburst Delay Time

Weld Amplitude

Top of Stroke Position

Acceleration

Advanced Servo Settings

Deceleration

Travel Limit

Weld Motion Control

Free Run Frequency

Scan Stack

Frequency Tracking

Frequency Lock and Hold

Advanced Process Settings

System Frequency Limits

Ramp Up Time

Ramp Down Time

Restore Advanced Process Defaults

Figure 5–5 Process Setup Menu Diagram

Afterburst Duration Afterburst Amplitude

Teach Top of Stroke

Teach Travel Limit

Speed

Force

Enable

Disable

Wide

Normal

Narrow

Manual

Yes

Enable

Disable

NOTE

Options for Secondary Weld Method choices are dependent on the Primary Weld Method choices that have been made.

NOTE

Available weld choices depend on Security access level (See Table 4-II.) system conguration, and primary weld method.

Continued

Page 50

Dukane Manual Part No. 403-587-00

Page 57

Continued from Previous Page

Process Setup

The rst submenu of Process Setup to consider is:

Section 5 - Operation

Travel Limit

This setting sets the position limit the servo press is permitted to travel. Its purpose is to prevent

contact between the horn and xture. This position is

monitored continuously throughout the weld.

See additional information on Page 55.

Initiate Mode

Initiate Mode controls the way a cycle is started, using either of two modes, Manual or Auto.

Manual

The cycle is started by depressing both operate switches on the press base (Operate Switch 1 and Operate Switch

2) within 0.35 seconds of each other.

Depress the operate switches continuously until the trigger switch on the press has activated or until the

ultrasonic signal is applied.

Latch on Bad Part

When this feature is active (It is available only with the Manual Initiate mode.), the cycle stops when a bad part is detected, and SYSTEM LOCKED, Bad Part Limit Exceeded, LATCHED appears on the iQ display. The operator must deal with the LATCHED message before

a new cycle will start. The next cycle will not activate until the latch is cleared.

There are two ways the latch can be cleared:

•RemovetheLATCHED Message from the Display

1. Go to the Main Menu.

2. Go to Utilities, and then to Part Count Settings.

3. Enable Clear Bad Part. (See Figure 5-7 to the right.)

When these three steps are completed, the operator can press the ENTER key to clear the latch, or

•ActivatetheSystemLatchResetInput

The System Latch Reset Input signal (Pin 12 of J2, the System Inputs connector) can be activated.

Travel Limit

Weld Position

Select Parameter

Figure 5-6 Teaching Travel Limit

Enabled

Figure 5-7 Enable Clear Bad Part

Travel Limit

Move to Saved Pos

Back

iQ 5

NOTE

What is a “bad part”? Bad part limits dene what is considered to be a bad part.

If the UPPER limit of a selected characteristic is reached during its phase of the weld cycle, the weld process is stopped, and the part is identied as a bad part.

If the LOWER limit of a selected parameter is not reached by the end of its phase of the weld cycle, the assembly process is stopped, and the part is identied as a bad part.

See Pages 66-67.

Online

See Page 20 for information about Pin 12 of the System Inputs (J2) connector. The pin can be used for latch reset.

Dukane Manual Part No. 403-587-00

Process Setup, Continued

Page 51

Page 58

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Process Setup, Continued from Previous Page

Auto (Initiate Mode)

The AUTO mode requires a voltage signal applied to J2 pin 8. The applied voltage level, either ground or +22VDC, must be the opposite of the voltage level applied to J2 pin 13. See Pages 19 and 20 for additional information. Apply the auto input signal for a minimum of 50 millisec-

Pre-trigger and Trigger Delay information can be found on Page 82.

onds to ensure that the cycle has been started.

Trigger Type

Trigger Type is the next Process Setup submenu.

NOTE

“Trigger” denes the type of event that turns on the ultrasound signal. This event can be:

• a force level from the force load cell,

• a power level reached by the generator, or

• a position reached by the thruster.

Typescanbe:

Trigger Type

•Force

•Power

•Position

Force

Power

Position

Figure 5-8 Trigger Type Submenu Diagram

Force at Trigger Max Trigger Time

Trigger Power

Trigger Position

Max Trigger Time

NOTE

Available trigger types depend on system conguration, and primary weld method.

Sensing Start Position

Start Amplitude

Sensing Speed

Sensing Start Position

Sensing Speed

CAUTION

Use extreme caution when using the Momentary trigger type. Opening the trigger

switch will NOT terminate the weld cycle. Guard the horn/xture “pinch point” to prevent hands, or ngers from being crushed by the vibrating horn.

Page 52

Program Notes

Afterselectingtheappropriatetriggertype,theoperatorentersdatawherethetriggertypecallsforit. Forinstance,alltriggertypescallforaMax Trigger Timetobeentered.

SeeFigure5-8,TriggerTypeSubmenuDiagram.

Process Setup, Continued

Dukane Manual Part No. 403-587-00

Page 59

Process Setup, Continued from Previous Page

Position

The factory default setting for Trigger Type is Position.

After the system has completed the initiate mode, the press head travels down at the Sense Speed until it has reached the trigger position.

After the trigger position is reached, it then changes to the programmed welding speed.

Section 5 - Operation

The gure to the right shows the Process Setting menu

appearance when Position is the trigger type.

Set the trigger position. This is the place on the distance encoder where the ultrasound signal will be activated.

A secondary parameter Max Trigger Time needs to be pro- grammed as well. If the weld is not accomplished within the set time, the weld will be terminated.

Power

Dukane has patented its Trigger by Power feature. Go to Dukane's blog: http://usblog.dukane.com/2010/01/ trigger-by-power-feature-aids-weld_27.html for more information about this feature.

During the downstroke, the ultrasound signal is immediately turned on with the Start Amplitude setting. When the power level reaches the trigger value, the weld amplitude is applied. Choose this trigger type when the operator wants the ultrasound signal to start as the horn touches the part to be welded. If the maximum trigger time is reached, the weld is aborted and the press is returned to top of stroke.

Figure 5-9 Trigger Type - Position

TheguretotherightshowsthatwithPower as the triggertype,veotherparametersneedtobeset:

Trigger Power, Max Trigger Time, Start Amplitude, Sensing Start Position, and Sensing Speed.

Dukane Manual Part No. 403-587-00

100

Figure 5-10 Trigger Type - Power

NOTE

MAX TRIGGER TIME is a secondary characteristic of Position, Power and Force. The time forces the weld portion of the cycle to stop even if the specied control parameter

is not met.

Process Setup, Continued

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Process Setup, Continued from Previous Page

Force

TheguretotherightshowsthatwithForce as the trig- ger type, Trigger Force, Max Trigger Time, Sensing

Start Position, and Sensing Speed need to be programmed.

Sensing Start Position

A feature of the servo press teaches a Sensing Start Position. This position can be programmed once the Sensing Start Position (Figure 5-11) soft key is pressed. That will be a choice when either force or power is the trigger type.

The gure to the right illustrates the display that appears

Sensing Start Position Soft Key

after the soft key is pressed. In this case, because the

Figure 5-11 Trigger Type - Force

servo is outside its limits, the operator is prompted to hold the operate switches so that the servo thruster can move. Once it is moved, the Sensing Start Position can be set.

It is critical to program the Sensing Start Posi-

Sensing Start Position is the actual position in the machine travel where the system begins to sense for the trigger force to be achieved. As the horn approaches the Sensing Start Position, the servo changes to the Sensing Speed setting.

tion so that the horn is never in contact with the part at this position, taking into account the height variability of unwelded parts. Failure to do so may result in equipment damage.

NOTE

Sensing Speed

Press the Sensing Speed softkey.Figure5-13shows thatthespeedwillbesetinthehighlightedarea.Usethe navigationkeystoselectdigits.Whennished,press ENTER.

SensingSpeedisthespeed(inchesormillimetersper

second) at which the horn travels between the Start Sens-

ing Position and just before achieving the trigger point.

A typical starting value of Sensing Speed is 0.040 in/s (1.0 mm/s). Sensing Speed can be set higher for shorter cycle times, or lower for greater trigger force detection accuracy.

Move to Saved Pos

Select Parameter

Figure 5-12 Teaching Sensing Start Position

iQ 5

Online

Page 54

Figure 5-13 Setting Sensing Speed

Process Setup, Continued

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Process Setup, Continued from Previous Page

Teach a Position

There are various programmable positions in a servo press setup. Access to this process is made available through screens such as shown in Figure 5-11 on the previous page.

Moving the Thruster - Tomovetheservopress/

thrusterduringtheteachingprocesstheuserwillusethe opticalswitcheslocatedonthebase.Whenthegenerator isplacedintoateachingmode,theswitcheswillnot triggeraweld.

Speed - There are three speeds available in the teach

window.Thelowspeedisextremelyslowandismeant fornetuningtheposition.Thehighspeedsettingis quitefastandmeanttogettheservopressfromtopof stroketothepartquickly.However,youwillndthatthe mediumspeedsatisesmostneeds.

Direction - The direction to jog the servo press up or

downcanbechangedaswell.

Section 5 - Operation

Duringtheteachingprocess,theuserwillgetfeedbackon forceandcurrentpositionfromtheon-screendisplay.

Move to Saved Position - If a previous position has

been set, the user can press the Move to Saved Position

buttonandusetheswitchestomovetheservoatthehigh speedtothepreviousposition.Fineradjustmentscanbe madefromthereifdesired.

Select Parameter-Chooseaparameterfromthelist

ofthreechoices:

 •TopofStrokePosition,

 •SensingStartPosition,or

 •TravelLimit.

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Process Setup, Continued from Previous Page

Primary Weld Method

Primary Weld Method is the next Process Setup submenu.

Theweldmethoddeneswhentheultrasoundsignalis terminatedafterithasbeentriggered.

Select from four choices:

Distance - The system welds until the press travels

the user-specied distance from the trigger point. A user-specied maximum time prevents innite

welding due to an unreachable distance.

Primary Weld Method

Distance

Position

Energy

Peak Power

Figure 5-14 Primary Weld Method Submenu Diagram

Weld Distance Max Weld Time

Weld Position

Weld Energy

Weld Power

Max Weld Time

Position - The system welds until the press

travels to the position measured from the reference mark (zero position) of the distance encoder. A user

specied maximum time prevents innite welding due

to an unreachable position.

Energy - The system welds until the generator

delivers a specied level of energy to the transducer

while the horn is in contact with the part. A user-

specied maximum time prevents innite welding due

to an unreachable energy level.

Energy, measured in joules, has a range of 0 to

100000.0, and has a 0.1 joule resolution.

Peak Power - The system welds until the generator

delivers a specied level of power to the transducer. A user-specied maximum time prevents innite

welding due to an unreachable power level. Peak Power, measured in Watts, has a 0.1 Watt resolution. Peak Power range is dependent on the generator's maximum output power rating.

Secondary Weld Method

Secondary Weld Method is the next item to consider

in the Process Setup menu.

The secondary weld method denes an alternative

control to terminate the ultrasound signal after it has been triggered. The feature may be disabled or there are three weld methods from which to choose: Position, Energy, and Peak Power.

NOTE

Downstroke Distance = Distance the horn

travels until the ultrasound trigger point is reached. Weld Distance = Distance the horn moves during the application of ultrasound to create the weld. Hold Distance = Distance the horn moves during the hold or “cooling” portion of the weld cycle. End Position = Downstroke Distance + Weld Distance.

NOTE

Options for Secondary Weld Method choices are dependent on the Primary Weld Method choices that have been made.

Disabled

Secondary Weld Method

Figure 5-15 Secondary Weld Method Submenu Diagram

Position

Energy

Peak Power

Page 56

Process Setup, Continued

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Process Setup, Continued from Previous Page

Weld Prole

Weld Prole is the next Process Setup submenu.

Section 5 - Operation

This setting determines whether a constant force or speed is applied during the weld process or whether a

10-segment prole of forces or speeds is applied.

Constant Speed or Force - The constant speed

or force specied by the user is applied to the servo

for the duration of the weld. Figure 5-17 to the right shows that Constant Weld

Speed needs to be set when choosing Constant.

Segmented Speed or Force - The speed

or force prole entails a set of 10 parameters that

determine what speed or force is applied during the

specied segment of the weld process.

See Figure 5-18 and Figure 5-19 to the right.

Distance Increment - When the weld method

is energy or peak power, a user-specied distance

increment is required to determine the length of each

of the prole segments to track when to transition from one prole segment to the next.

Weld Prole

Constant

Segmented

Figure 5–16 Weld Prole Submenu Diagram

Figure 5–17 Weld Prole Constant

Enable

Disable

Enable

Disable

Constant Weld Speed

Enable Melt Detect

Speed

Enable Melt Detect

Distance Increment

After Force Drops By

Enable Melt Detect - Enabling Melt Detect

allows for greater control of the part's collapse speed

prole. When enabled, another parameter must be

addressed: After Force Drops By.

After Force Drops By - The melt detect portion

of the weld is linked to the force applied by the press, but only after the initial force drops by a given percentage. It is this percentage that is entered for this parameter (in the range of 0% to 50%).

Figure 5–18 Weld Prole Segmented

Figure 5–19 Setting Speeds for the Segments

Process Setup, Continued

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Process Setup, Continued from Previous Page

Dynamic Hold Method

The hold process related to the servo press is split into two parts. The dynamic hold is executed before the static hold. The hold process can include one or both of these methods and both may be disabled.

The dynamic hold method occurs after the weld method

has completed. The dynamic hold method continues the

movement of the horn until a user-specied distance occurs or until a user-specied force is achieved. Holding allows

the material to solidify (under pressure) before the press head retracts. Hold method choices are:

• Until Force Reached,

• Distance,

• Disabled Until Force Reached - This setting keeps a user-dened

speed on the part until the force of the press reaches the

specied peak force following the weld process. A user specied maximum time prevents an innite hold. This

option is only available when using speed motion control.

A user specied maximum time prevents innite holding

due to an unreachable distance.

Dynamic Hold Method

Until Force Reached

Enable

Distance

Disable

Figure 5–20 Dynamic Hold Method Submenu Diagram

Dynamic Hold Speed

Dynamic Hold Peak Force

Max Hold Time

Hold Distance

Dynamic Hold Speed

Max Hold Time

Distance - This setting determines the distance the press

travels following the weld process. Depending on the mo-

tion control mode, the user dened force or speed will be applied to the part. A user specied maximum time prevents

innite holding due to an unreachable distance.

Hold Distance - The distance the press head travels following the weld process.

Dynamic Hold Speed - The speed at which the press

head travels until the user specied distance is met.

Max Hold Time - The maximum amount of time the press will apply pressure to the part during the hold process.

Disabled - This setting disables dynamic hold and its options.

Figure 5–21 Dynamic Hold Method - Until Force is Reached

Figure 5–22 Dynamic Hold Method - Distance

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Process Setup, Continued

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Process Setup, Continued from Previous Page

Static Hold Method

The hold process related to the servo press is split into two parts. The static hold is accomplished after the dynamic hold. The hold process can include one or both of these methods and both may be disabled.

Static Hold Method

Time

Disable

Section 5 - Operation

Hold Time

Static Hold determines the amount of time the press position is held following the dynamic hold process (if enabled) or the weld process (if dynamic hold is disabled).

Disabled

Choose Disabled when no static hold method is needed.

Time

Thissettingdeterminestheamountoftimethepress positionisheldfollowingthedynamicholdprocess (ifenabled)ortheweldprocess(ifdynamicholdis disabled).SeetheFigure5-24totherightshowing the Static Hold Methoddisplay.

Figure 5–23 Static Hold Method Submenu Diagram

Figure 5–24 Static Hold Method Display

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Process Setup, Continued from Previous Page

Afterburst

The next submenu in Process Setup deals with Afterburst. In some applications the part being welded may stick to the horn as the head of the press retracts. Afterburst dislodges the part by sending a short burst of ultrasound on the upstroke.

Afterburst is dened by three values: the delay time, the

duration of the afterburst, and by the amplitude.

Afterburst

Enabled

Disabled

Afterburst Delay Time

Afterburst Duration

Afterburst Amplitude

Delay is the time from the start of the upstroke until the start of the afterburst.

Duration is how long the afterburst ultrasound signal is on. Amplitude denes the amplitude of the afterburst ultra-

sound signal. The afterburst feature can be turned off by choosing Dis-

abled, or it can be turned on by choosing Enabled.

When enabled, the delay and duration times and the ampli-

tude are then entered. See the gure to the right.

Weld Amplitude

Weld Amplitude is the next parameter to select. This refers to the peak-to-peak excursion of the horn at its workface.

Amplitude settings are given as a percent of the horn’s nominal amplitude in the range of 20% - 100%.

Figure 5–25 Afterburst Submenu Diagram

Figure 5–26 Afterburst Display

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Process Setup, Continued

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Process Setup, Continued from Previous Page

Advanced Servo Settings

The servo press makes available some advanced settings and operations. See Figure 5-27 for the Advanced Servo Settings submenu diagram.

Figure 5-28 shows the color front panel screen on which values are entered for the four variables:

Top of Stroke Position - The thruster returns to

this position after each weld cycle.

Acceleration - The acceleration used to achieve the

velocity required of the servomotor when the speed is in transition to a higher velocity.

Deceleration - The deceleration used to achieve

the velocity required of the servomotor when the speed is in transition to a lower velocity.

Section 5 - Operation

Advanced Servo Settings

Top of Stroke Position

Acceleration

Deceleration

Travel Limit

Weld Motion Control

Figure 5–27 Advanced Servo Settings Submenu Diagram

Teach Top of Stroke

Teach Travel Limit

Speed

Force

Travel Limit - This setting sets the position limit

the servo press is permitted to travel. Its purpose is

to prevent contact between the horn and xture. This

position is monitored continuously throughout the weld. The maximum Travel Limit is based on the maximum stroke distance of the press.

Weld Motion Control - This is the last of the Advanced

Servo Settings.

This setting determines whether force or speed is controlled by the servo during the weld process. Figure 5-29 at the right illustrates these choices.

Advanced Process Settings

Advanced Process Settings are enabled through the Utilities/Hardware menu. Please see Pages 78-83 for information on enabling these settings and for brief descriptions of each setting.

Figure 5–28 Advanced Servo Settings Display

CAUTION

DO NOT make any adjustments to Acceleration or

Deceleration unless you have first contacted qualified Dukane personnel for guidance in making any necessary adjust-

ments.

Weld Motion Control

Figure 5–29 Weld Motion Control Submenu Diagram

Speed

NOTE

Speed mode is highly recommended as it is the only mode for which all press hardware can be calibrated and validated. The Force mode is provided only for the purposes of experimentation and is not intended for production.

Force

Dukane Manual Part No. 403-587-00

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Process Limits

Overview

As the weld cycle progresses, time, distance, power, and energy data are kept for each portion of the cycle. These measurements, also called process characteristics, form a process record for each part. Records’ analysis can establish parts limits which then can be used to determine if the current process is “in control”. The iQ generator can report the process characteristics as Bad or Suspect. The characteristics can also be displayed or printed without evaluation.

Limits are set using either statistical methods or physical system constraints. Statistical methods can be applied to pre-production parts that were evaluated for physical characteristics of quality (e.g., strength, appearance). Results of this evaluation are correlated to the process characteristics. Limits for the characteristics related to part quality are calculated. Other limits are determined by the system itself. For instance, Total Cycle Time limits may be established to end the cycle before an index table moves. Downstroke Distance may be set to detect a misload or incomplete assembly.

Available Process Characteristics

The list of available process characteristics is shown in

Figure 5 - 30 on the following page. This is followed by

brief descriptions of each characteristic.

NOTE

Of the available process characteristics, the ones that apply to a particular part depend on the current iQ setup for that part.

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Process Limits, Continued

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Process Limits, Continued from Previous Page

Section 5 - Operation

Process Limits

Downstroke Time

Position at Trigger

Trigger Delay Time **

Trigger Delay Distance **

Force at Trigger

Weld Time

Weld Distance

Weld Energy

Weld Peak Power

Weld End Position

Weld Peak Force

Hold Time

Hold Distance

Total Cycle Time

Total Stroke Distance

Alarm Status

Time

Date

Setup

** Limits available when Trigger Delay is enabled.

Suspect Limits

Bad Limits

Display Only

OFF

Low Limits

Low Limits High Limits

High Limits

The list of available process character-

Disabled

istics depends on Security access level (See Table 4-II.) system conguration,

Display

Force Bad

Force Suspect

Display

OFF

and on the chosen weld mode.

Main Menu

NOTE

Figure 5–30 Process Limits Menu Diagram

Dukane Manual Part No. 403-587-00

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Process Limits, Continued from Previous Page

Process Characteristics Dened

Downstroke Time – This is the time from the start of the welding cycle to the trigger point.

Position at Trigger – This is the position relative to the home position of the mounted distance encoder at the trigger point of a weld.

Force at Trigger – This is the force applied to the part

sampled at the instant of the trigger point.

Weld Time – This is the length of time the ultrasound is applied to the part.

Weld Distance – This is the distance the press travels while the ultrasound signal is applied to the part.

Weld Energy – This is the amount of energy drawn from the generator while the ultrasound signal is applied to the part.

Weld Peak Power – This is the highest instantaneous power delivered to the transducer.

Weld End Position – This is the position relative to the home position of the mounted distance encoder at the

instant of the end of the weld.

Weld Peak Force – This is the highest instantaneous force that is measured during the weld method.

Hold Time – Thisisthetimethehornmaintains

pressure on the part after the ultrasound signal has

stopped.

Hold Distance - This is the distance the press travels while maintaining pressure during the hold process, after the ultrasound signal has stopped.

Total Cycle Time – This is the period from the start of the weld cycle to the end of the weld cycle. The start

of the cycle is dened as the point the auto input signal

begins or when manual operate switches are activated.

The end of the cycle is dened as the point the head

retracts from the part.

Total Stroke Distance – This is the position relative to the home position of the mounted distance encoder at the end of the hold process.

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Process Limits, Continued

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Process Limits, Continued from Previous Page

Alarm Status – This feature is included with the Part Lim- its menu to compliment part cycle data. It does this to show that a system alarm (www.dukane.com/us/DL_EasyAlarm. asp) was active during the weld cycle for a particular part.

There are four options with Alarm Status – one that disables the feature, and three other options that allow for the part record to show that an alarm was active.

Options:

1) Disabled – Alarm Status is off. If an alarm occurs, no signal will be generated for the welded part record.

2) and 3) Force Bad, or Force Suspect – The ultrasonic generator will provide a signal when a system alarm activates. The operator chooses whether to categorize the part under this circumstance as Suspect or as Bad. Whatever designation is given to the part, it will be carried on to become an item in the part record.

Figure 5-31 on the right shows with the red square symbol, that Force Bad has been chosen as the option for Alarm Status.

Section 5 - Operation

Figure 5–31 Process Limits - Alarm Status

4) Display – Whenever a system alarm happens, the ultrasonic generator indicates this on the display's Operate screen. A square green indicator appears alongside the term Alarm Status. This is a visual cue to the operator. The part record will not have this information.

Time – This is the current time of day according to the iQ generator timer.

Date – This is the current date according to the iQ genera- tor timer.

Setup – This is the number of the current setup.

Dukane Manual Part No. 403-587-00

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Process Limits, Continued from Previous Page

Data from Process Characteristics

Data from each weld cycle can be monitored through the available process characteristics.

Programming choices for each characteristic are:

— No Display,

— Display Only,

— Bad Limits, and

— Suspect Limits.

No Display

Figure 5-32 shows that Position is the selected process characteristic, and no choices have been made for that characteristic. Weld characteristic is not displayed.

Figure 5–32 Process Limits - No Display

Display Only

Figure 5-33 shows Display Only was chosen for the Weld Time process characteristic.

That process characteristic is displayed during normal operation on the Operate screen.

Bad Limits

This is also known as Bad Part Limits.

Figure 5-34 shows that Peak Power is the selected characteristic. Bad Limits are ON, and Low Limits and High Limits need to be set.

The Bad part limits are used to establish boundaries that de-

ne unacceptable results for parts that are being processed.

If a bad limit is either not met or is exceed, the weld cycle

is ended immediately, and the operator is notied in these

ways:

• Two beeps are given (if buzzer is set to ON).

(See Buzzer, Page 80.)

• The iQ ES bad part output is activated.

• BAD is displayed in the part cycle data.

Figure 5–33 Process Limits - Display Only

Figure 5–34 Process Limits - Bad Limits

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Process Limits, Continued from Previous Page

Suspect Limits

This is also known as Suspect Part Limits.

Suspect part limits detect out-of-limit conditions without ending the weld cycle. These limits are used when process characteristics are grouped within a "gray area" between good and bad. Parts can be sorted as good, bad, and suspect. Suspect parts can be inspected manually. Suspect limits can also be used as a form of pre-control in applications where statistical process control methods are being used.

When a suspect part limit has not been met or that it was

exceeded, the operator is notied in these ways:

• One beep is given (if buzzer is set to ON).

(See Buzzer, Page 80 .)

• The iQ ES suspect part output is activated.

• SUSPECT is displayed in the part cycle data.

Section 5 - Operation

In Figure 5-34 the selected characteristic is Peak

Power.

Both Suspect Limits and Bad Limits are ON for which both Low Limits and High Limits need to be entered.

Part Cycle Data

The weld characteristics chosen to be displayed can be seen in real time using the Operate Screen.

See OPERATE SCREEN on Page 84.

Show All

Notice that Figure 5-35 indicates there is an active soft key for the selection: Show All.

Press the Show All key to display all the process characteristics.

Change your mind?

If you change your mind and decide not to display all of the characteristics, press the Show None soft key, to turn off the display feature for all of the characteristics.

Figure 5–35 Process Limits - Suspect Limits

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Utilities/Hardware

Process Utilities

Welder Name

Setup Control

Copy Setup

Erase Setup

Part Count Settings

Notes

Language

Base Units

Date Format

Time

Date

Setup Name

Horn

Booster

Fixture

Manual P1

Manual P2 / Hold

Dynamic Trigger

Down Speed / Flow Control

Mechanical Stop

HSC Setting

HSC Start Position

Pre-trigger / EOW Flags

Main Menu

Hardware Setup

Serial Port

Output Format

LF After CR

Output Mode

Baud Rate

Serial Limit Indicators

Serial Headers

System Status I/O

Auto Start Input

Auto Stop Input Enabled

J3 pin 4

J3 pin 5

Figure 5–36 Utilities/Hardware Menu Diagram

J3 pin 17

Output Duration

Restore System I/O Defaults

Adv Process Settings

Buzzer

Text Keyboard

Test at Power Up

Adv Trigger Settings

Network Settings

Servo Diagnostics

Restore Factory Defaults

NOTE

The list of available Process Utilities and Hardware items depends on Security access level (See Table 4-II.) and on system conguration.

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Process Utilities, Continued

Dukane Manual Part No. 403-587-00

Page 75

Process Utilities

Overview

Process Utilities provides setup management and part tracking tools. Notes are included to allow unique names to be given to many setup components.

Setups and their components can be identied. This information can be used to recall setup conditions.

Figure 5-37 shows that, with the exception of Notes, there are 10 utilities to consider. Review the brief descriptions of these utilities below:

Welder Name

Use the virtual keyboard to give the welder its own iden-

tication.

Section 5 - Operation

Figure 5–37 Setup Control

Setup Control

Setup Control denes where control for setup originates:

with the iQ System, with Automation, or with Sequenc- ing.

Select a Method of Control - When the soft key

Change Method is pressed, an image like the one shown in Figure 5-38 appears.

Choose from three methods that dene where control for a

particular setup originates:

iQ System - Control originates through the iQ generator and its program.

Sequencing - Control originates through the sequence denition as programmed through the iQ generator. See more on Sequencing in Appendix C.

Automation - Control originates from an external source connected to the generator's System Input J2-8. The ultrasonics output remains activated only when the external

source applies a signal to J2-8.

Figure 5–38 Setup Control - Select a Method

Figure 5–39 Setup Control - Sequencing Chosen

If Sequencing is selected, then the screen shown in Figure

5-38 appears. Typically, Dene Sequence would be chosen.

Dening the sequence involves entering the information

suggested by Figure 5-40: Sequence Length, etc.

For more on Sequencing, go to Appendix C.

Dukane Manual Part No. 403-587-00

Figure 5–40 Dening the Sequence

Process Utilities Continued

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Process Utilities, Continued from Previous Page

Choose a Setup

Choosingasetupdependsontwofactors:

SetupControl,andSecurityAccess

Setup Control - Using Setup Control through the Process Utilities menu, the three types of control deal with setup selection in these ways:

- iQ System - Press the Select Setupsoftkey. (SeeFigure5-37.)

Figure 5–41 Setup Control - Automation Selected

- Sequencing - Press the Edit Setupsoftkey.

(SeeFigure5-39.)

- Automation - Press the Edit Setupsoftkey.

(SeeFigure5-41.)

After pressing the Select Setup or Edit Setup key, a Choose Setup screen like the one in Figure 5-42 to the

right is displayed.

Then, highlight a setup from the setup number list.

Next, press the Choose Setup soft key to conrm the choice.

Security Access - If Security access has been established, then menu access can be limited depending on what Security access level is active.

If the Setup Security is active, then the main screen would look like it does in Figure 5-43 to the right.

To choose a setup in this case, press the Select Setup soft key.

As with System Control, a list of setups is displayed. Highlight a setup from the list and press Choose Setup.

Figure 5–42 Setup Control - Choose Setup

NOTE

Read the Security material starting on Page 88 for more information.

Page 70

Figure 5–43 Select Setup - When Setup Security Access is Active

Process Utilities, Continued

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Process Utilities, Continued from Previous Page

Copy Setup

Thisfeatureallowsparametersfromonesetuptobe copied toanothersetup.InFigure5-44totheright, Copy SetupisselectedfromtheProcessUtilitieslist.

Press the Copy Setupsoftkey,andthedisplayshown inFigure5-45appears.

Choosesetups:Copy From, and Copy To.

Then press the soft key, Press Here to Copy.

Section 5 - Operation

ThedisplaywillappearasitdoesinFigure5-46.

Figure 5–44 Copy Setup - 1

Figure 5–45 Copy Setup - 2

Dukane Manual Part No. 403-587-00

Figure 5–46 Copy Setup - 3

Process Utilities, Continued

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Process Utilities, Continued from Previous Page

Erase Setup

Setupparameterscanbeerasedforthecurrentsetup,or forallsetups.Ascreenwillposethequestion,"Are you

sure you want to erase all setups?"AnswerYes or Notoproceedwiththeeraseprocess.

See Figure 5-47 to the right.

Part Count Settings

This utility permits part count modication through its

three submenus:

Reset Part Count - Selecting this sets the part count to zero (0). Therefore the next cycle completed would create part number one (1).

Preset Part Count - Enter a number that starts the part counter.

Count Bad Parts - Enable this to increment the part count if a bad part occurs.

Clear Bad Part - Enable this to allow the operator to clear a Bad Part Limit Exceeded message displayed on the front panel. Allowing the operator to clear the bad part message will also reset the bad part latch.

Figure 5–47 Erase Setup

See Figure 5-48 to the right.

Language

The language displayed by the front panel is made through this utility.

Base Units

Select either Imperial or Metric units with this utility.

Date Format

The date utility allows for three ways to display the date:

• Month/Day/Year - MM/DD/YYYY

• Day/Month/Year - DD/MM/YYYY

• Year/Month/Day - YYYY/MM/DD

Time

This utility is used to set the current time.

Date

Entering the current date will be done in the date format already chosen.

Figure 5–48 Part Count Settings

Process Utilities, Continued

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Process Utilities, Continued from Previous Page

Notes

It is important to document information about your process. With the dozen components that make up Notes for one setup, a customized record can be invaluable. See Figure 5-49 below.

This utility makes it easy to name, or identify each of the parameters using the virtual keyboard.

The Erase Name option also makes it easy to quickly remove a name.

One benet to all of this is that future setup time will be

much shorter when trying to create the same or similar setup.

Section 5 - Operation

NOTE

Although most of the Notes are related to pneumatic systems, all of them are text based. So they could include any type of setup information.

Notes

Figure 5–49 Notes

Setup Name

Horn

Booster

Fixture

Manual P1

Manual P2 / Hold

Dynamic Trigger

Down Speed / Flow Control

Mechanical Stop

HSC Setting

HSC Start Position

Pre-trigger / EOW Flags

HSC = Hydraulic Speed Control

EOW = End of Weld

Dukane Manual Part No. 403-587-00

Process Utilities, Continued

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Hardware Setup

Hardware Setup and its submenus can be used before start-up, or during normal operation.

Typically Process Utilities have been set before Hard-

ware Setup is completed. Time, Date, Base Units, Setup Control, and the other utilities have usually already been established before Hardware Setup is programmed.

Serial Port

The rst group of hardware settings deals with the serial port on the generator. These selections congure the iQ

generator's RS-232 port to transfer cycle data to a separate computer. At the end of every cycle, the cycle data gets

sent out via the serial port. See Figure 5-50.

Output Format

Hardware Setup

Serial Port

Use the Output Format function to choose one of three keyboard characters as the delimiter:

Comma - Ta b - Semicolon

Most database and spreadsheet programs are able to read or save data in a delimited format. See Page 128 for more detailed information about the serial data format.

LF after CR

Each line of output ends with a carriage return (CR). Some devices automatically insert a line feed (LF) to advance the paper, while others do not. Enabling the LF After CR function makes it possible to insert a line feed at the end of an output string.

Output Mode

Use Output Mode to determine the type of data that will

appear in the part record. Selections are dened below:

All - All parts are sent to the output device immediately after the weld cycle.

None - No parts are sent to the output device.

Output Format

LF After CR

Output Mode

Baud Rate

Serial Limit Indicators

Serial Headers

Figure 5–50 Serial Port Selections

Good - Only good parts are sent to the output device.

Bad - Only bad parts are sent to the output device.

Suspect - Only suspect parts are sent to the output

device.

Bad and Suspect - All bad and suspect parts are sent to the output device.

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Hardware Setup, Continued from Previous Page

Baud Rate

Baud rate is the serial port output speed in bits per second.

Choose a baud rate appropriate for your output device.

Serial Limit Indicators

Limit indicators are characters that appear in front of displayed or printed part data indicating whether the data has reached or exceeded an upper or lower limit.

The greater than sign (>) means that an upper limit Suspect value has been exceeded.

Two greater than signs (>>) mean that an upper limit Bad value has been exceeded.

The less than sign (<) means that a lower limit Suspect value has not been reached.

Two less than signs (<<) mean that a lower limit Bad value has been exceeded.

Section 5 - Operation

NOTE

Baud rate settings on both the sending unit (iQ generator) and the receiving unit (computer) must be the same for communication between the devices to work properly.

Select Disable if the limit indicator might confuse a program that is running an SPC or data collection application.

Select Enable to allow use of the limit indicators.

Serial Headers

The user can send (print) serial header data each time the Print soft key is pressed. The serial header data sent is

based on the "displayed" Process Limits, as dened in the

Process Limits screen.

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Page 82

Serial Port

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Hardware Setup, Continued from Previous Page

System Status I/O

The next group of hardware settings (following the Serial Port settings) deals with the generator's System Status I/O. These six selections enable customizing of some of the iQ generator's input and output signals. Figure 5-51 shows these functions.

Auto Start Input

Use the Auto Start Input function to choose one of two types of input that can originate the Auto Start signal:

Hardware Setup

System Status I/O

Auto Start Input

Auto Stop Input Enabled

Solid State, or Mechanical

Choosing Solid State will have no timing delay after the activation of the Auto Input signal. This setting is typically used when a PLC controller is used to activate the Auto Input.

Choosing Mechanical will have a congurable timing delay after the activation of the Auto Input signal. This setting is typically used when a relay is used to activate the Auto Input.

Choosing Mechanical presents another choice. That is

Switch Debounce Time which is congurable to 5ms,

10ms or 25ms.

Auto Stop Input Enabled

This function can be disabled or enabled. The default setting is Enabled and set to End of Cycle.

When Auto Stop Input is enabled, the operator is prompt- ed to choose the event that causes the auto stop:

Choose either, End of Weld, or End of Cycle.

J3 pin 4

J3 pin 5

J3 pin 17

Output Duration

Restore System I/O Defaults

Figure 5–51 System Status I/O Selections

• End of Weld - When Auto Stop is set to End of

Weld, the auto stop input signal terminates the weld but

not the complete weld cycle. If hold is enabled, it begins at the trigger of this signal.

• End of Cycle - When Auto Stop is set to End

of Cycle, the auto stop input signal terminates the

complete weld cycle (hold is not executed, even if enabled).

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Hardware Setup, Continued from Previous Page

J3 pin 4

J3 represents the generator's output connector, and Pin 4 is programmable. The default setting is Servo Alarm.

It can be programmed to provide:

E-Stop Status, Overtemp Status, or Servo Alarm.

J3 pin 5

J3 represents the generator's output connector, and Pin 5 is programmable. The default setting is Home Servo.

It can be programmed to provide:

Hold Status, Incycle Status, Incycle no Afterburst, or Home Servo.

J3 pin 17

Section 5 - Operation

J3 represents the generator's output connector, and Pin 17 is programmable. The default setting is Amplitude Regulation.

It can be programmed to provide:

Amplitude Regulation, Teaching, or Servo Alarm.

Output Duration

Use the Output Duration function to decide on how long the output signal should be:

Maintained, or 100ms Pulse

The default setting is Maintained.

Restore System I/O Defaults

Choose this function to restore the original system input/ output defaults.

Once Restore is chosen, a secondary screen is displayed asking the operator to verify the choice:

Are you sure you want to Restore I/O Defaults?

Figure 5–52 Restore System I/O Defaults

See Figure 5-52 for the screen view.

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Hardware Setup

Serial Port

System Status I/O

iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Hardware Setup, Continued from Previous Page

Additional Hardware Settings

The next group of hardware settings (following the Serial Port settings and the System Status I/O settings) deals with various functions. These eight selections provide further customizing of the iQ generator. Figure 5-53 diagrams these selections.

Advanced Process Settings

Enabling Advanced Process Settings allows the opera-

tor to adjust a few of the higher level settings through the

Process Settings menus.

Adv Process Settings

Buzzer

To enable Advanced Process settings:

1. From the main menu select the Utilities/Hard-

ware soft key. In the Process Utilities screen

select the Hardware Setup soft key.

2. In the Hardware Settings screen scroll to Adv.

Process Settings which is located near the

bottom of the list, press the Enable soft key, and then the YES soft key in the next screen. Advanced process settings are now enabled.

Care should be taken when changing these settings because the system could be damaged in some way.

Before changes are allowed, a warning screen displays an alert. See Figure 5-54.

Descriptions of each of the settings are shown below.

• Free Run Frequency

Free run is the frequency at which the generator drives the ultrasound output pulses until a valid feedback signal is detected. Typically this value should be below the operating frequency of the stack.

• Frequency Tracking

Text Keyboard

Test at Power Up

Adv Trigger Settings

Network Settings

Servo Diagnostics

Restore Factory Defaults

Figure 5–53 Additional Hardware Settings Diagram

Figure 5–54 Advanced Process Settings Warning

When Enabled, at the end of each cycle the operating frequency is applied to the Free Running Frequency setting. It's based on a 16 point average. Therefore, after 16 cycles, the actual operating frequency will be the Free Running Frequency setting. If the generator has not been cycled for a minimum of 5 minutes, the generator will request that the stack be scanned in order to verify the optimum Free Running Frequency setting.

For more information about Frequency Tracking, refer to our Application Note 513 on the Dukane website at:

http://www.dukane.com/us/DL_ApplData.asp

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Hardware Setup, Continued from Previous Page

• Frequency Lock/Hold

When frequency lock and hold is disabled, the frequency

of the stack is tracked by changing the frequency of the ultrasound driving pulses to match the actual operating frequency of the stack.

When enabled the frequency of the feedback is tracked until lock is achieved. Then it is ignored and the

ultrasound output remains at a xed frequency until the

end of the weld. For more information about Frequency Lock/Hold, refer

to our Application Note 505 on the Dukane website at:

http://www.dukane.com/us/DL_ApplData.asp

• System Frequency Limits

Wide - In wide mode the upper and lower frequency limits are set to the maximum and minimum allowed frequencies for the generator. These values are dependent on the system frequency of the generator.

Normal - In Normalmode the upper and lowerfrequencylimitsequalthefreerunfrequency±500Hz.

Narrow- In Narrowmode the upper and lower frequencylimitsequalthefreerunfrequency±200Hz.

Manual-InManualmodetheusersetstheupperand lowerfrequencylimits.Tobevalid,thesettings must bewithinthemaximumand minimum values for the generator and atleast 25Hz greater than the"upper" freerunfrequencyand25Hzlessthan"lower"freerun frequency.

Section 5 - Operation

NOTE

Why System Frequency Limits Modes

Might be Chosen

Wide - This mode is primarily used for testing "bare" transducers (no booster or horn attached).

Normal - This mode is the one most often used covering a wide variety of horns.

Narrow - This mode is used when the acoustic stack has known unwanted frequencies that are close to the main operating frequency.

Manual - This mode allows for a frequency range to include only frequencies that are wanted, and excluding unwanted frequencies.

• Scan Stack

With Advanced Process Settings enabled, to scan a stack return to the Main Menu.

1. Select the Process Setup soft key to display the Process Setup screen. Scroll to Adv. Process

Settings in the list and select the Adv. Process Settings soft key.

2. Scroll to Free Run Frequency in the displayed list and press the Scan Stack soft key.

A WARNING appears as shown in Figure 5-55 to

the right.

Dukane Manual Part No. 403-587-00

Figure 5–55 Scan Stack Warning

NOTE

For more detail on the Scan Stack feature please refer to our website to download Application Note 512 at http://www.du-

kane.com/us/DL_ApplData.asp

Hardware Setup, Continued

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Hardware Setup, Continued from Previous Page

3. Press ENTER to continue. The scan takes place with Amplitude, Power and

Frequency values are shown. Figure 5-56 illustrates the screen view after a successful scan.

• Ramp Up Time

Although the Ramp Up time is factory set, it is variable and can be adjusted to account for starting characteristics of a particular stack.

The Ramp Up setting depends on the generator load at the start of a cycle.

The Ramp Up time increases the amplitude linearly, in the programmed time period at the start of the weld, from zero to the programmed amplitude level. The stack is brought up to the operating amplitude smoothly, without shock stress.

• Ramp Down Time Although the Ramp Down time is factory set, it is vari-

able and can be adjusted to account for characteristics

of a particular stack. Ramp Down Time decreases the amplitude linearly to

zero in the programmed time period following the end of the weld, when ultrasound is shutting off. The stack is brought down from its weld amplitude,

reducing shock stress.

Figure 5–56 Scan Stack Results

Ramp Down Time extends the service life of complex acoustic stacks by minimizing stresses encountered during the process of shutting off the ultrasound. It is especially recommended for very large horns, or when the ultrasound is shut off in air.

NOTE

Ramp Down Time

• Restore Advance Process Defaults

Activate this feature, and it will restore all of the advanced process settings to their factory defaults.

Buzzer

Use the Buzzer function to turn the internal generator buzzer on or off.

Disabled - The buzzer will not sound.

Enabled - The buzzer can signal two different events. When the buzzer in enabled, it beeps once when a suspect part occurs, and it beeps twice when a bad part occurs.

The default buzzer setting is Disabled.

See Figure 5-57.

• Buzzer Top of Stroke - When enabled, buzzer sounds when top of stroke is reached.

• Buzzer at Trigger - When enabled, buzzer sounds when the trigger point is reached.

Hardware Setup, Continued

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Hardware Setup, Continued from Previous Page

Text Keyboard

The virtual keyboard is enabled by default, and it pops up when required. When disabled, the virtual keyboard will not appear.

Test at Power Up

Each time the generator is powered On, the operator will be prompted to execute a TEST of the ultrasonics stack. The TEST can also be cancelled. The feature can be disabled from the Hardware Settings screen. Test at Power Up is Enabled by default. See Figure 5-58.

The “Test at Power Up” feature can also be cancelled by activating the “System Latch Reset” input (J2-12).

Advanced Trigger Settings

When Advanced Trigger Settings are enabled, basic trigger settings are enhanced.

For example, in the Process Setup menu, when Force is the Trigger Type, Pre-trigger is an advanced trigger function and is added to rene the Force selection. See Figure 5-59 on the next page where basic and advanced trigger functions are illustrated.

Network Settings

The Network Settings screen as seen in Figure 5-59 has

ve elements:

1. DHCP - These initials stand for Dynamic Host Con-

guration Protocol. The protocol was established for

assigning dynamic IP addresses to devices on a network.

Figure 5–57 Buzzer Enabled

Test at Power Up is enabled. Please clear area around the

stack and press Test button for 1 second before welding

parts.

Press CANCEL to abort.

Figure 5–58 Test at Power Up

Section 5 - Operation

iQ 1

Test

DHCP should be enabled if connecting multiple generators when using an Ethernet router or switch.

DHCP can be enabled or disabled depending on customer requirements.

2. IP Address - This Internet Protocol address is a num-

ber unique to a piece of equipment acting as an identier

when the equipment is connected to a network. An IP

address is specied when a static IP is required.

3. Network Mask - Automatically assigned by the DHCP server.

4. Gateway Address - Automatically assigned by the DHCP server.

5. Network Link - This shows the status of the connection to a network:

Linked - This displays the speed of the network connection.

Not Linked - Down

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Hardware Setup, Continued from Previous Page

Servo Diagnostics

Reserved for use by Dukane personnel, these diagnostics monitor servo inputs, test status, performance and cycles.

KeytoTriggerFunction:

Basic Trigger Function Advanced Trigger Function

Trigger Type

Force

Power

Position

Force at Trigger Max Trigger Time

Pre-trigger

Trigger Delay Not a choice if Pre-trigger is Enabled

Disabled

Delay by Distance

Trigger Power

Max Trigger Time

Start Amplitude

Sensing Start Position

Sensing Speed

Max Trigger Time

Trigger Delay

Disabled

Enabled

Trigger Position

Pre-trigger Amplitude

Pre-trigger Position

Trigger Delay Distance

Sensing Start Position

Max Trigger Delay Time

Teach Trigger Position

Sensing Speed

Figure 5–59 Trigger Function - Basic and Advanced

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Hardware Setup, Continued from Previous Page

Restore Factory Defaults

Choose Restore Factory Defaults when restoring the generator software to the factory default settings.

Section 5 - Operation

Before this is allowed, however, an intermediate screen questioning the action appears. See Figure 5-61.

Important:

Performing a Restore Factory Defaults can not be reversed.

Network Link Down

Figure 5–60 Network Settings

NOTE

If the user is directly connecting to a laptop or PC, the PC's IP address should be set to 169.254.0.x (x must be 2-255). The (x_ in the computer's IP address can not be the same x as in the generator's IP address.

NOTE

Network Settings are maintained even after a Restore Factory Defaults.

Are you sure you want to Restore Factory Defaults?

Figure 5–61 Restore Factory Defaults?

Main Menu

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Operate Screen

The Operate screen displays weld cycle data in real time.

Figure 5-62 shows the main Operate screen.

Process characteristics listed below the setup name are the ones chosen (as process limits) to be displayed or programmed.

Part # in the upper left corner of the Operate screen records the running total of processed parts.

When a minimum of 10 parts have been processed, press the soft key next to the total number of parts box. The next screen Search Part History appears, and allows searches by Part Number, Time, Date, Previous Bad, Previous Suspect, and Previous Alarm.

Part Number History

Search by Part # - Press this soft key to search for a

specic part number in the cycle data.

Total Parts Processed

Figure 5–62 Main Operate Screen

Process Characteristic

Setup Name

Pressing the Part # soft key displays a search screen after a minimum of 10 parts are in the cycle data.

Search by Time - Press this soft key to search for a part

know to have been welded at a specic time in the cycle

data.

Search by Date - Press this soft key to search for a

specic part welded on a specic date in the cycle data.

Previous Bad - Press this soft key to search for a previously welded bad part in the cycle data. Pressing the soft key again will continue searching for the next previously welded bad part.

Previous Suspect - Press this soft key to search for a previously welded suspect part in the cycle data. Pressing the soft key again will continue searching for the next previously welded suspect part.

Previous Alarm - Press this soft key to search for a previously part that had an alarm in the cycle data. Pressing the soft key again will continue searching for the next previous part that had an alarm.

Figure 5–63 Part Number Screen

Direction - Press this soft key to change the direction of

the search from previous cycle data parts to next cycle data parts.

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Current Setup

While viewing the Operate screen, (or from the Main Menu), press the soft key next to Current Setup, and a

view similar to the one shown in Figure 5-64 will appear.

This is usually a multiple page (display) list of the main parameters that were set for the current setup.

Process Limits

Press the soft key next to Process Limits, and the process limits list, similar to the one shown in Figure 5-65 is dis-

played. Adjustments to the list of process characteristics

can be made easily.

Press Back when nished making adjustments to the list of process characteristics, and once again the main Operate screen will be shown.

Section 5 - Operation

Figure 5–64 Current Setup

Figure 5–65 A Process Limits List

Real Time Data

See Figure 5-66.

Press the soft key next to Real Time Data, and the display changes to show press characteristics for the current setup and weld cycle.

The possible characteristics are: Force, Distance, Power, Frequency, and Speed.

Characteristicsdisplayeddependonsystemconguration.

Figure 5–66 Real Time Data

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Graph

The generator is factory programmed to provide graphs with amplitude and power as the vertical axes. Figure 5-67 shows the beginning graph screen.

Graph Setup

Figure 5-68 shows the graph setup screen used when selecting parameters for the two vertical axes of the graph. (The horizontal axis represents time.)

Select from these parameters:

Amplitude, Power, Frequency, Energy, Distance,

Speed, Force

1. Red Axis - Press one active soft key representing

the parameter for the vertical (red) axis. This axis is on the left side of the graph.

Figure 5–67 Graph Screen

2. Blue Axis - Press one active soft key representing the parameter for the vertical (blue) axis. This axis is on the right side of the graph.

Figure 5-69 shows the graph setup screen used to choose a starting point for the graph.

3. Choose one of the active soft keys representing the event that starts the graphing procedure.

The events are:

Cycle Start, Trigger, or Weld Start.

Figure 5-70 shows the graph setup screen used to select the end point for the graph.

4. Chose one of the active soft keys representing one of two events that after they have nished, the graph- ing procedure will come to an end. The events are:

Weld End, Hold End

Figure 5–68 Graph Axis Setup Screen

Figure 5–69 Start Graph at Setup

Page 86

Figure 5–70 End Graph at Setup

NOTE

When in the graph setup screen, press ENTER to return to the graph screen.

Continued

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Graph, Continued from Previous Page

Completed Graph

The gure below shows a completed graph.

This particular image resulted after pressing the TEST key.

Section 5 - Operation

Red Vertical Axis,

Power

Figure 5–71 Example Graph Following Test

Help

From the main screen, (Figure 5-72 to the right) press the soft key next to Help.

Horizontal Axis,

Time

Blue Vertical Axis,

Frequency

This will produce a screen that gives information about your generator, including model and serial numbers.

An example of this screen is seen in Figure 5-73.

NOTE

Color Front Panel v1.11.02 will also display the network IP Address in the bottom left corner of the HELP screen.

Dukane Manual Part No. 403-587-00

Figure 5–72 Locating Help on the Main Menu

Figure 5–73 Help Screen Example

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Security

The Security menu choices control access to the programming menus by using individual logins for three levels: Administrator, Process Engineer, and Setup.

The table below shows what access each security level has. In addition the Operator column shows the access a generator operator would have when the three levels of control are in use.

Main Menu Item

Graph Screen

Operate Screen

Process Setup

Process Limits

Process Utilities

Hardware Setup

Current Setup

••

= Select Setup is available.

Persons needing an individual login.

Administrator

Process

Engineer

O O O O

O O X X

O O O •• X

O X X X

O O O X

O=AccessX=NoAccess

NOTE

Operator - Usually the operator does not need to use the Security feature. Typically an operator only monitors the weld cycle using the Operate and Graph screens.

Operator

Setup

Table 5 - I Security Access to Main Menu Item

Remote User Timeout

The purpose of this option of the Security menu is to yield (allow) or deny access to the programming features of the iQ generator under certain conditions.

This feature is most useful when a remote user (using iQ Explorer II software) and a user at the generator might both want to control the generator. A request for control (by either user) shows on the generator display and on the remote computer display. (See Figure 5-85, Page 92.)

If no response is given (by either user) to this request within 30 seconds, then in whatever state the generator had been left (Deny Control or Yield Control) before the request for control, that is the state in which the generator will continue to operate.

Example: A remote user requests control of the generator, and no one is at the generator to respond to the request. If the generator had been programmed to yield control, then after 30 seconds, the remote user would have control.

NOTE

The default setting for Remote User Timeout is Deny Control.

Access (to program the generator), is assigned to the Administrator as a default setting if no passwords have been set.

Figure 5-74 Security Screen - No Passwords Set

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Security, Continued from Previous Page

Using Security

Enabling Passwords for the First Time

1. Press the Security soft key. The Security Screen appears as shown in Figure 5-74. The word None means no passwords have been enabled or set.

In the example that follows, three passwords will be set: First, for the Administrator, then for the Process Engi-

neer, and nally, for the Setup password.

Section 5 - Operation

2. Select, Administrator Password None in the list. (The selected phrase is highlighted in green.)

The soft keys Administrator Password, and Done are now displayed. See Figure 5-75.

3. Press the Administrator Password soft key, and the alphanumeric virtual keyboard is displayed. This is shown in Figure 5-76.

Enter a password of up to 15 characters.

Press Apply Changes when nished.

The next screen to appear looks like Figure 5-77.

Because the screen message says, Security Enabled:

Currently Logged Out, the Administrator must enter the Login Password to activate access to security features.

Figure 5-75 Security Screen - Administrator Password

Selected

Figure 5-76 Virtual Keyboard

Once the Administrator password has been entered, the screen appears as shown in Figure 5-78.

Note the change in the Security Screen from what is seen in Figure 5-75. The Administrator Password has been Enabled. Also Administrator Access is followed by [Admin] showing that the Administrator has current security access.

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Figure 5-77 Security Screen - Currently Logged Out

Figure 5-78 Security Screen - Administrator Access

Enabled

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iQ Series Ultrasonic Generator/Power Supply, Servo Systems, ES User’s Manual

Security, Continued from Previous Page

At this point the Administrator typically has four options:

• Logout - Press the soft key next to Logout, and

the Administrator will be logged out. None of the security levels will be active.

• Done - Press the soft key next to Done to exit

and return to the main menu.

• Erase - Select Administrator Password En-

abled in the list. Press the Erase soft key, and the password will be erased or,

• Continue enabling passwords.

If the Login Password soft key is pressed,

For additional passwords, complete Steps 4 and 5.

and a wrong password is entered, a screen prompt indicates an incorrect

Also, please read the NOTE to the right.

password has been entered. The next screen shows that the person has been logged out. Restart the login process to activate the security features.

NOTE

4. After enabling the Administrator password, the next

level to activate is usually Process Engineer.

Select, Process Eng Password None in the list.

Next, Select Process Eng Password with the upper left soft key, and the alphanumeric virtual keyboard is displayed. Enter a password of up to 15 characters.

Press Done when nished.

5. After setting the Administrator password and the Pro-

cess Engineer Password, select the line: Setup Password None. Set a password for Setup repeating the methods already explained.

Figure 5-79 shows the Security Screen when all three passwords have been enabled.

Press the Logout key. Figure 5-80 shows that the Administrator has logged out.

Press the soft key next to Login Password to login.

Press Done to exit and return to the main menu.

Figure 5-79 Security Screen - Passwords Enabled

Figure 5-80 Security Screen - Logged Out

Security Screen

Security Enabled: Currently Logged Out

06/24/2013 13:30

Done

iQ 1

Online

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Security, Continued from Previous Page

Section 5 - Operation

After Passwords are Enabled

Once passwords have been enabled as described on the previous page, generator menu access is controlled.

For each person assigned a password, please use the four steps detailed below for the login/logout procedure.

1. Press the soft key for Security. The Security Screen appears as shown in Figure 5-81.

The previous user has logged out.

2. Any of the three passwords (Setup, Process Eng, or Admin) that were already enabled can be entered.

In this case, the Setup password will be entered, and the screen then will resemble what is shown in Figure 5-82.

NOTE

When using the Security feature, only one person can be logged in at a time. Each login session must end with a logout.

Figure 5-81 Security Screen - Logged Out

Security Screen

Security Enabled: Currently Logged Out

06/24/2013 13:30

iQ 1

Done

Online

The Security Screen indicates that Setup Eng controls access to the generator.

3. Press Done to continue working with the available menus.

Available menus for Setup Eng are: Select Setup, Operate Screen, Graph, Help, and Security.

4. When nished working with the generator, press Security to get to the Security Screen again. Then press the soft key next to Logout to quit.

5. Finally, press Done so that the main menu screen is displayed when the session is complete.

Figure 5-82 Security Screen - Setup is Logged In

NOTE

Refer to Table 5-I for a guide to the levels of access that are possible when using the Security function.

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Security, Continued from Previous Page

Other Security Prompts

With login passwords in use, the levels of access to the generator are established.

Security prompts - like the samples seen in Figures 5-83 and 5-84 to the right - are displayed when access to menu features has been limited.

Remote User Request for Control

Setup Access

Required

Please Log In

Figure 5-83 Security Prompt for Process Engineer

Access

Process Eng Access

Required

Please Log In

Figure 5-84 Security Prompt for Setup Access

The screen shown in Figure 5-85 to the right displays when a remote user wants to control the generator.

Access can be granted by pressing the Yield Control soft key.

Deny access by pressing the Deny Control soft key.

Forgotten Password?

Contact Dukane if the password has been forgotten.

See Section 10 - Contacting Dukane.

Figure 5-85 Remote User Seeking Control

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Section 5 - Operation

Set-up Guidelines

The iQ SeriesESgeneratorisshippedwiththedefaultsettingsshowninthetablebelow.

Default Servo Settings

Frequency 15kHz 20kHz 30kHz 40kHz 50kHz

Initiate Mode Manual Manual Manual Manual Manual

Top of Stroke 0.0000 0.0000 0.0000 0.0000 0.0000

Weld Amplitude 90% 90% 90% 90% 90%

Advanced Settings Disabled Disabled Disabled Disabled Disabled

Trigger Type Force Force Force Force Force

Trigger Force (lbs) 75 50 25 15 5

Max. Trigger Time 5.000 5.000 5.000 5.000 5.000

Sensing Speed 0.0500 0.0400 0.0400 0.0300 0.0200

Weld Primary Method Distance Distance Distance Distance Distance

Weld Distance 0.0150 0. 0100 0.0075 0.0050 0.0050

Max. Weld Time 2.000 2.000 2.000 2.000 2.000

Weld Secondary Method Disabled Disabled Disabled Disabled Disabled

Weld Prole Constant Constant Constant Constant Constant

Weld Prole Speed 0.0500 0.0400 0.0300 0.0200 0.0200

Melt Detect Enabled Enabled Enabled Enabled Enabled

Force Drop % 5% 5% 5% 5% 2%

Dynamic Hold Method Disabled Disabled Disabled Disabled Disabled

Static Hold Method Time Time Time Time Time

Static Hold Time 1.000 0.700 0.500 0.300 0.300

Afterburst Disabled Disabled Disabled Disabled Disabled

Travel Limit Based on

Press Stroke

Based on

Press Stroke

Based on

Press Stroke

Based on

Press Stroke

Based on

Press Stroke

Table 5-II Default Settings - Process Setup

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Changing Default Settings

From the Main Menu, go to Process Setup. Each of the items shown in the table above is listed as a Process Setup submenu item and can be customized for your process. Refer to Pages 50-61 for more information about working with the Process Setup menu.

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