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Dukane 403-574-01 - page 1
ISO 9001:2008 Products ar e manufactured in ISO register ed facilities. Intelligent Assembly Solutions www .dukane.com/us Dukane Part No. 403-574-01 Series UL TRASONIC GENER A TOR/ POW ER SUP P L Y LS User ’ s Manual Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (63 ...
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Dukane 403-574-01 - page 2
Page ii Dukane Manual Part No. 403-574-01 Copyright © 2010 Notice of Rights: All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical, photocopying, recording, or by any information storage and retrieva ...
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Dukane 403-574-01 - page 3
Page iii Dukane Manual Part No. 403-574-01 R e vi s io n Hist or y Revision Revision Number Summary Date - 00 Original release. 01/25/2008 - 01 Add High Power models. 09/21/2010 Update system I/O pin descriptions. Add T rigger by Power . Add iQ LinQ TM . W eb address revised. Revise Regulatory Agency Compliance statement. Health and Safe ...
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Dukane 403-574-01 - page 4
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Dukane 403-574-01 - page 5
Page v Dukane Manual Part No. 403-574-01 Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 General User Information Read the Manual First Notes, Cautions and W arnings Drawings and T ables Generator Overview Key Generator Features Section 2 - Health and Safety . . . . . . . . . . . . . . . . . . . . ...
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Dukane 403-574-01 - page 6
Page vi Dukane Manual Part No. 403-574-01 Contents Continued Section 6 - Process Control Settings . . . . . . . . . . . . . . . . . 45 User-Provided Process Control Overview Manual W elding Automated W elding Automated Process Control Input Signals Status Output Signals Screen Navigation Basics Programming the Generator - Some Examples S ...
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Dukane 403-574-01 - page 7
Page 1 Section 1 – Intr oduction Dukane Manual Part No. 403-574-01 SECTION 1 Intr oduction General User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 R e a d t h e M a n u a l F i r s t ..................................... 3 Notes, Cautions and W arnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
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Dukane 403-574-01 - page 8
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Dukane 403-574-01 - page 9
Page 3 Section 1 – Intr oduction Dukane Manual Part No. 403-574-01 General User Information Read the Manual First Before operating your ultrasonic generator , read this User ’ s Manual to become familiar with the equipment. This will ensure correct and safe operation. The manual is organized to allow you to learn how to safely operat ...
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Dukane 403-574-01 - page 10
Page 4 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Generator Overview This generator is designed for basic ultrasonic applications that use either manually operated hand probes or ultrasonic probes controlled by automation systems. Using the avail- able system control i ...
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Dukane 403-574-01 - page 11
Page 5 Section 2 – Health & Safety Dukane Manual Part No. 403-574-01 SECTION 2 Health and Saf ety G e n e r a l C o n s i d e r a t i o n s .............................. 7 P l a s t i c s H e a l t h N o t i c e ................................ 7 E l e c t r i c a l S a f e t y .................................... 8 D o m e s t i ...
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Dukane 403-574-01 - page 12
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Dukane 403-574-01 - page 13
Page 7 Section 2 – Health & Safety Dukane Manual Part No. 403-574-01 General Considerations Ple ase obs erve these hea lth and saf et y rec ommen datio ns for safe , ef ci ent , and inju ry-fr ee op erati on of your equi p - men t. In th is man ua l, t he ter m sy stem r ef ers to a com plete gro up of co mpone nt s as so cia te ...
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Dukane 403-574-01 - page 14
Page 8 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Approved 2 pole, 3 wir e grounding receptacle HUBBELL No. 5652 or equivalent to NEMA 6–15R or 6–20R Figure 2 - 1 Example of 220/240 V olt, Grounded, 3-Prong Receptacle C A UTION If th ere i s any qu ...
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Dukane 403-574-01 - page 15
Page 9 Section 2 – Health & Safety Dukane Manual Part No. 403-574-01 St ep 1. Stand close to the load with your feet spread apart about shoulder width, with one foot slightly in front of the other for balance. Step 2. Squat down bendin g at the knee s (not your waist). Tuc k your chin while keepin g your back as vertical as possibl ...
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Dukane 403-574-01 - page 16
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Dukane 403-574-01 - page 17
Page 1 1 Section 3 – Installation Dukane Manual Part No. 403-574-01 SECTION 3 Installa tion B e f o r e I n s t a l l a t i o n ........................... 1 3 When to Use Lockout/T agout Devices . . . . . . . . . . . . . . . 13 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Placement . . . . . ...
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Dukane 403-574-01 - page 18
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Dukane 403-574-01 - page 19
Page 13 Section 3 – Installation Dukane Manual Part No. 403-574-01 Bef ore Insta ll atio n As yo u pla n for t he in stal latio n of y our g ener ator, please consider these important subjects as listed below: • When to use lockout / tagout devices • Lifting the generator safely - See Section 2 - Health and Safety , P . 9 When to U ...
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Dukane 403-574-01 - page 20
Page 14 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Lockout/T agout Procedur e 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 genera ...
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Dukane 403-574-01 - page 21
Page 15 Section 3 – Installation Dukane Manual Part No. 403-574-01 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 wit ...
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Dukane 403-574-01 - page 22
Page 16 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Placing the Generator when Used in an Active Seismic Region If the iQ gener ato r is to be use d in an acti ve seismic regi on, secure the unit by rack-mounting it or by securing the uni ...
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Dukane 403-574-01 - page 23
Page 17 Section 3 – Installation Dukane Manual Part No. 403-574-01 Benchtop Mounting If you choose to mount the generator on a benchtop follow these instructions: 1) Install the four (4) optional hold down brackets. See Figure 3-5 below . 2) Secure one side of each L backet to the generator's sheet metal cover . 3) Secure the othe ...
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Dukane 403-574-01 - page 24
Page 18 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 RFI Grounding In addition to the safety considerations previously men- tioned, proper grounding at the generator power cord is essential for the effective suppression of electrical noise ...
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Dukane 403-574-01 - page 25
Page 19 Section 3 – Installation Dukane Manual Part No. 403-574-01 C A UTION T he po w e r co rd i s e q u i pp e d w it h a three-prong , gro un d- ed-type plu g for you r safe t y . W h e n e v e r a t w o - s l o t r e - c e p t a c l e i s e n c o u n t e r e d , w e s t r o n g l y r e c o m m e n d t h a t i t i s r e p l a c e d ...
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Dukane 403-574-01 - page 26
Page 21 Page 20 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Figure 3 - 6 Generator - Rear View (low prole model) Automation Controlled Probe System Step 1. Gro und the gene rat or cha ssis usin g the supp lied 14- Gauge wire , and att ...
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Dukane 403-574-01 - page 27
Page 21 Page 20 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 SECTION 4 Standar d Connections Rear Panel Layout Overview . . . . . . . . . . . . . . . . . . . . . . . . 23 A C P o w e r I n l e t P ...
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Dukane 403-574-01 - page 28
Page 23 Page 22 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page 23 Page 22 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua ...
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Dukane 403-574-01 - page 29
Page 23 Page 22 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page 23 Page 22 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka ...
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Dukane 403-574-01 - page 30
Page 25 Page 24 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page 25 Page 24 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua ...
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Dukane 403-574-01 - page 31
Page 25 Page 24 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page 25 Page 24 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka ...
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Dukane 403-574-01 - page 32
Page 27 Page 26 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page 27 Page 26 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua ...
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Dukane 403-574-01 - page 33
Page 27 Page 26 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page 27 Page 26 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka ...
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Dukane 403-574-01 - page 34
Page 29 Page 28 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page 29 Page 28 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua ...
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Dukane 403-574-01 - page 35
Page 29 Page 28 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page 29 Page 28 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka ...
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Dukane 403-574-01 - page 36
Page 31 Page 30 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page 31 Page 30 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua ...
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Dukane 403-574-01 - page 37
Page 31 Page 30 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page 31 Page 30 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka ...
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Dukane 403-574-01 - page 38
Page 33 Page 32 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Dukane Manual Part No. 403-574-01 Page 33 Page 32 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manua ...
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Dukane 403-574-01 - page 39
Page 33 Page 32 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Page 33 Page 32 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Section 4 – Standar d Connections Duka ...
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Dukane 403-574-01 - page 40
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Dukane 403-574-01 - page 41
Page 35 Section 5 – Standar d System Status and Controls Dukane Manual Part No. 403-574-01 SECTION 5 Standar d System Sta tus and Contr ols F r o n t P a n e l O v e r v i e w .............................. 3 7 S y s t e m D i s p l a y s .................................. 3 7 System Power Output Level (Bar Graph) . . . . . . . . . . . ...
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Dukane 403-574-01 - page 42
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Dukane 403-574-01 - page 43
Page 37 Section 5 – Standar d System Status and Controls Dukane Manual Part No. 403-574-01 Front Panel Overview This section provides an overview of the front panel’ s two main functions: monitoring (with the system displays), and controlling the system (with the user navigation control keys). LOAD 80 60 100 OVER 40 0 20 SYSTEM POWER ...
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Dukane 403-574-01 - page 44
Page 38 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Control Keys Keys Left of the Display INFO After the primary weld method has been chosen, you can press the INFO key to go directly to the “Hot Key” screen where frequently used ...
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Dukane 403-574-01 - page 45
Page 39 Section 5 – Standar d System Status and Controls Dukane Manual Part No. 403-574-01 TEST Hold the TEST key momentarily to activate ultrasound and view system operating parameters. The LCD screen will show the real time settings for Amplitude, Power (does not appear with T ime Only generators) , and Operating Frequency . This inf ...
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Dukane 403-574-01 - page 46
Page 40 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Start-up Sequence After all connections have been completed, 1. Push the rear panel AC breaker switch to ON . The generator begins its self-diagnostics sequence. 2. POWER TEST ash ...
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Dukane 403-574-01 - page 47
Page 41 Section 5 – Standar d System Status and Controls Dukane Manual Part No. 403-574-01 S t o p p i n g t h e W e l d C y c l e Normal Conditions The cycle stops when the programmed welding cycle ends. Emergency Conditions Manual System Press OFFLINE to stop the ultrasound signal. This may be done under any condition. Automated Syst ...
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Dukane 403-574-01 - page 48
Page 42 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 System Parameter Settings Overview This section provides the default system settings programmed at the factory . Some of these system parameter settings are dependent on the nominal ...
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Dukane 403-574-01 - page 49
Page 43 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 Continued Setting Description User Adjustment Limit Setting Ranges for All Frequencies Minimum Maximum Amplitude Setting 20% 100% Free Run Frequency *** Default Free Run Frequency minus 500 Hz Default Free Run Frequency plus 500 Hz Ramp-up T ime 0.010 secon ...
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Dukane 403-574-01 - page 50
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Dukane 403-574-01 - page 51
Page 45 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 Section 6 Pr ocess Contr ol Settings User-Provided Process Control Overview . . . . . . . . . . . . . . 47 M a n u a l W e l d i n g .................................. 4 7 A u t o m a t e d W e l d i n g ............................... 4 7 Automated Process ...
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Dukane 403-574-01 - page 52
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Dukane 403-574-01 - page 53
Page 47 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 User- Provided Process Control Overview The generator includes a process control system to control welding process. The basic “B models” can be programmed to weld by time. “E model” generators can weld by time and ener gy . See Figure 1 1-5 for mode ...
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Dukane 403-574-01 - page 54
Page 48 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Sc ree n N avi ga tio n B asi cs This section gives you a step-by-step guide to navigating through some of the basic menu structure. AMPLITUDE 50 % FREE RUN FRQ 20000 Hz OPERA TE MOD ...
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Dukane 403-574-01 - page 55
Page 49 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 1. Press CANCEL until you see the Main Menu screen as it is shown here. Move the selection indicator to PROCESS SETUP . 2. Press ENTER and you will see the screen as shown here. 3. Select PROCESS CONTROL , and press ENTER . W ith no option boards installed ...
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Dukane 403-574-01 - page 56
Page 50 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 HOW TO - W eld by Time 1. Press CANCEL until you see the Main Menu screen as it is shown here. Move the selection indicator to PROCESS SETUP . 2. Press ENTER and you will see the scr ...
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Dukane 403-574-01 - page 57
Page 51 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 HOW TO - W eld by Energy (Available only if generator has energy option.) 1. Press CANCEL until you see the Main Menu screen as it is shown here. Move the selection indicator to PROCESS SETUP . 2. Press ENTER and you will see the screen as shown here. 3. Se ...
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Dukane 403-574-01 - page 58
Page 52 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 HOW TO - Adjust Amplitude 1. Press CANCEL until you see the Main Menu screen as it is shown here. Move the selection indicator to PROCESS SETUP . 2. Press ENTER and you will see the ...
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Dukane 403-574-01 - page 59
Page 53 Section 6 – Pr ocess Control Settings Dukane Manual Part No. 403-574-01 HOW TO - Adjust Ramp Up/Down Times The Ramp Up feature , also called soft start , applies amplitude at the beginning of the weld cycle to start the stack assem bly (transd ucer , booster , hor n) line arly , rather than in two instantaneous surges. The stac ...
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Dukane 403-574-01 - page 60
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Dukane 403-574-01 - page 61
Page 55 Section 7 – System Operational T esting Dukane Manual Part No. 403-574-01 SECTION 7 System Oper a tional T esting System V erication T ests ........................... 5 7 P r e l i m i n a r y S e t u p ....................................... 5 7 T esting the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...
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Dukane 403-574-01 - page 62
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Dukane 403-574-01 - page 63
Page 57 Section 7 – System Operational T esting Dukane Manual Part No. 403-574-01 System V erication T ests Preliminary Setup Step 1. Plug in the AC line cord to the correct AC power outlet. See T able 1 1 -II for the model power requirements. Step 2. Attach a compatible ultrasonic probe to the ultrasound output connector - J1. Step ...
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Dukane 403-574-01 - page 64
Page 58 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 System T est T o test the system’ s ultrasound operation, perform the following steps. Step 1. For this test, the generator must be ONLINE. If the OFFLINE LED is showing yellow ( D ...
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Dukane 403-574-01 - page 65
Page 59 Section 7 – System Operational T esting Dukane Manual Part No. 403-574-01 Probe Operation 1. If the generator is not online, press the ON/OFFLINE mode key , labeled C in Figure 7-6. The System Op- erating Mode ONLINE indicator ( G in Figure 7-5) will be green. 2. Hand Probe – Apply the probe tip to the components to be ultras ...
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Dukane 403-574-01 - page 66
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Dukane 403-574-01 - page 67
Page 61 Section 8 – T r oubleshooting Dukane Manual Part No. 403-574-01 SECTION 8 T r oubleshooting N o U l t r a s o n i c O u t p u t .............................. 6 3 P r o b e ................................................. 6 3 C a b l e s ................................................ 6 3 G e n e r a t o r ................... ...
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Dukane 403-574-01 - page 68
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Dukane 403-574-01 - page 69
Page 63 Section 8 – T r oubleshooting Dukane Manual Part No. 403-574-01 No Ultrasonic Output Probe Make sure that the probe coaxial cable is connected to the generator ultrasonic output connector J1. Basic generator models have the BNC connector on the rear panel. Also, make sure the probe stack was properly assembled. Cables Make sure ...
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Dukane 403-574-01 - page 70
Page 64 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 System Power Output Level: Red Red - Fault Condition When the SYSTEM POWER OUTPUT LEVEL turns red (arrow on the right end of the bar graph), there is an overload condition that disab ...
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Dukane 403-574-01 - page 71
Page 65 Section 9-Maintenance Dukane Manual Part No. 403-574-01 W elding Problems W eak W elds W eak welds, or underwelding, is caused by insufcient energy being transmitted to the part. Y ou can increase the weld pressure, increase the weld time or change to a higher gain booster to increase the amplitude to increase the energy deliv ...
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Dukane 403-574-01 - page 72
Page 66 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Pop-up Status Screens System Status Signal Status T ext Displayed System Status or Fault Explanation Average Overload OVERLOAD - A VERAGE A T X.XXX SECONDS POWER ABOVE GENERA TOR RA ...
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Dukane 403-574-01 - page 73
Page 67 Section 9-Maintenance Dukane Manual Part No. 403-574-01 SECTION 9 Maintenance F r o n t a n d R e a r P a n e l s ............................ 6 9 C l e a n i n g .............................................. 6 9 D i s p l a y ............................................... 6 9 C o n t r o l K e y s / B u t t o n s ............. ...
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Dukane 403-574-01 - page 74
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Dukane 403-574-01 - page 75
Page 69 Section 9-Maintenance Dukane Manual Part No. 403-574-01 Front and Rear Panels Cleaning • Do not use any solvents or abrasive cleaners on the any of the panels (including the LCD display). • Do not spray any cleaning product directly on the pan- els. T o remove dust, rst try gently dusting with a micro - ber cleaning clo ...
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Dukane 403-574-01 - page 76
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Dukane 403-574-01 - page 77
Page 71 Section 10 - Options Dukane Manual Part No. 403-574-01 SECTION 10 Options P o w e r I n l e t O p t i o n s ............................... 7 3 120V Systems for North American and Japan . . . . . . . . . . . . . 73 E l e c t r i c a l S a f e t y .................................. 7 3 1 2 0 V P o w e r G r o u n d ............... ...
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Dukane 403-574-01 - page 78
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Dukane 403-574-01 - page 79
Page 73 Section 10 - Options Dukane Manual Part No. 403-574-01 This section of the User ’ s Manual provides a general overview of some options/upgrades, all of which are sub- ject to availability , for the basic ultrasonic generator: Power Inlet Options 120V Systems for North America and Japan 120V systems for North America and Japan h ...
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Dukane 403-574-01 - page 80
Page 74 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 AC Power Inlet Panel The optional AC power inlet panel is described here. AC Power Cord The AC power cord ( A in Figure 10-2) is appropriately rated and permanently mounted to the po ...
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Dukane 403-574-01 - page 81
Page 75 Section 10 - Options Dukane Manual Part No. 403-574-01 I/O Panel Options Single Connector System I/O Panel See B in Figure 10-4 where the I/O panel is set up for the single I/O connector , a HD15F type. The generator label for this connector is, SYSTEM INPUTS/OUTPUTS . Another label identies the connector as J12. The I/O panel ...
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Dukane 403-574-01 - page 82
Page 76 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Optional MPC Interface Connections Complete Steps 1 - 4 of the basic connections as de- scribed on Pages 19-20. These involve: • Grounding (optional), • Ultrasound Output, • Sy ...
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Dukane 403-574-01 - page 83
Page 77 Section 10 - Options Dukane Manual Part No. 403-574-01 Pin Signal Name Connector 3 Setup Bit 0 Input J2 (Page 20) 4 Setup Bit 1 Input 5 Setup Bit 2 Input 6 Setup Bit 3 Input 18 MPC Ready Out J3 (Page 25) T able 10 - II MPC I/O Connector Signals MPC I/O Connections Signal names and Pin numbers and the connectors re- lated to the M ...
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Dukane 403-574-01 - page 84
Page 78 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 MPC Interface Installation Guide The MPC interface is designed for assembly systems where one ultrasonic generator is sequenced to as many as 16 ultrasonic probes. The MPC interface ...
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Dukane 403-574-01 - page 85
Page 79 Section 10 - Options Dukane Manual Part No. 403-574-01 Connecting Cables For stand-alone interfaces and securely installed panel mounted interfaces: Rear Connections Refer to Figure 10 -7 below , and complete these connections. 1. Earth ground - Connect one end of a user-supplied 14-Gauge ground wire to the ground connection at t ...
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Dukane 403-574-01 - page 86
Page 80 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 MPC Interface Status LEDs System Status When the system is powered and ready , the front panel SYSTEM ST A TUS LED lights up, and becomes GREEN ( E in Figure 10 - 9). If this LED is ...
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Dukane 403-574-01 - page 87
Page 81 Section 10 - Options Dukane Manual Part No. 403-574-01 Confirm probes are retracted from weld position. Load part to be welded. Move part to the welding position. Move probes to the welding position. MPC Ready Status Output active? PLC activates generator ’s binary code inputs to select active probe. W ait 40 mS to confirm bina ...
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Dukane 403-574-01 - page 88
Page 82 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Remote Amplitude Control M o d u l e Part Number - 1 10- 4183 This optional module enables remote control of output amplitude of the iQ system. The control interface is a 4–20mA cu ...
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Dukane 403-574-01 - page 89
Page 83 Section 10 - Options Dukane Manual Part No. 403-574-01 AMPLITUDE CONTROL AMPLITUDE SETTING RAMP UP / DOWN TIME AMPLITUDE SETTING 90 % CHANGE V ALUE SELECT DIGIT AMPLITUDE SETTING AMPLITUDE CONTROL BY iQ SYSTEM AUTOMA TION This menu av ailable only with Remote Amplitude Control option. Figure 10-13 Amplitude Control Menu Detai ...
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Dukane 403-574-01 - page 90
Page 84 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Automation Thruster Control M o d u l e Part Number - 1 10- 4206 This optional module enables the iQ system to control a Dukane iQ thruster . The module is illustrated in Figure 10-1 ...
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Dukane 403-574-01 - page 91
Page 85 Section 10 - Options Dukane Manual Part No. 403-574-01 T o enable the thruster , Pins 3 and 9 must be shorted together through a safety circuit (see T able 10-V) during normal operation. During an abort or emergency stop condition, the connection between Pins 3 and 9 must open to disable movement of the thruster . In addition to ...
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Dukane 403-574-01 - page 92
Page 86 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 NPN T O PNP CONVERSION SPECIFICA TIONS: INPUTS: MINIMUM VOL T AGE: 5.0 Vdc CURRENT : 1.5mA @ 5.0 Vdc / 9.5mA @ 24.0 Vdc MAXIMUM VOL T AGE: 30.0 Vdc MAXIMUM CURRENT : 50mA MAXIMUM VOL ...
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Dukane 403-574-01 - page 93
Page 87 Section 10 - Options Dukane Manual Part No. 403-574-01 PNP TO NPN CONVERSION SPECIFICA TIONS: INPUTS: MINIMUM VOL T AGE: 5.0 Vdc CURRENT : 1.5mA @ 5.0 Vdc / 9.5mA @ 24.0 Vdc MAXIMUM VOL T AGE: 30.0 Vdc MAXIMUM CURRENT : 50mA MAXIMUM VOL T AGE: 30.0 Vdc MINIMUM VOL T AGE: 5.0 Vdc OUTPUTS: VOL T AGE DROP ( + T O - ): 1.0 Vdc MAX NO ...
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Dukane 403-574-01 - page 94
Page 88 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 +5V T O +24V PNP CONVERSION +5V IN 1 @ 0V = ON IN 1 @ 5V = OFF GND IN 2 @ 5V = ON IN 2 @ 0V = OFF IN 3 @ 0V = ON IN 3 @ 5V = OFF ACTIVE HIGH TTL ACTIVE LOW TTL OPEN COLLECTOR WITH PU ...
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Dukane 403-574-01 - page 95
Page 89 Section 10 - Options Dukane Manual Part No. 403-574-01 iQLinQ communication options allow automated systems to monitor and change settings in iQ generators. These options provide machine builders the ability to integrate the generator into an electrical cabinet and to use the machine’ s HMI to program or monitor weld settings. ...
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Dukane 403-574-01 - page 96
Page 90 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 J2 U/S I 0 LINE VOLT AGE: 200-240 Vac 50/60Hz, 15A PE J3 J4 J1 BUS ERROR PROFIBUS J16 i Q Li nQ ™ PR OF IB U S Co mm un ic a t i on s Mo du l e P a rt N um be r - 1 10 -4 55 4 The ...
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Dukane 403-574-01 - page 97
Page 91 Section 10 - Options Dukane Manual Part No. 403-574-01 iQ LinQ TM Ethernet/IP TM Module Part Number - 1 10- 4644 The EtherNet/IP option module allows the iQ generator to connect to an EtherNet/IP network. The option module is an external DIN-rail mounted device that acts as a bridge between the automation network and an iQ genera ...
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Dukane 403-574-01 - page 98
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Dukane 403-574-01 - page 99
Page 93 Section 1 1 - Specications Dukane Manual Part No. 403-574-01 SECTION 11 Specica tions D r a w i n g s ......................................... 9 5 Low Prole Chassis ....................................... 9 5 High Prole Chassis ...................................... 9 6 High Power (3600W) Chassis . . . . . . . . . . ...
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Dukane 403-574-01 - page 100
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Dukane 403-574-01 - page 101
Page 95 Section 1 1 - Specications Dukane Manual Part No. 403-574-01 Figure 1 1-1 Low Prole Chassis Drawing LOAD 80 60 100 OVER 40 0 20 SYSTEM POWER OUTPUT LEVEL SYSTEM OPERATING MODE ON LINE OFF LINE POWER TEST OPERA TOR CONTROLS AC POWER ENTRY UL TRASOUND & SYSTEM I/O'S OPTIONS P ANEL ALLOW 3" IN BACK FOR CABLING. A ...
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Dukane 403-574-01 - page 102
Page 96 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Figure 1 1- 2 High Prole Chassis Drawing SYSTEM OPERATING MODE SYSTEM POWER OUTPUT LEVEL 20 0 40 OVER 100 60 80 LOAD POWER TEST OFF LINE ON LINE AC POWER ENTRY OPERA TOR CONTROLS ...
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Dukane 403-574-01 - page 103
Page 97 Section 1 1 - Specications Dukane Manual Part No. 403-574-01 Figure 1 1- 3 High Power (3600W) Chassis Drawing ALLOW 3" IN BACK FOR CABLING. AC POWER ENTRY UL TRASOUND & SYSTEM I/O'S AC POWER ENTRY 5.19 [131.8] 5.50 [139.7] 17.16 [435.8] ALLOW 5" EACH SIDE FOR COOLING 12.51 [317.8] 3.15 [80.0] IN [mm] ALLOW 5 ...
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Dukane 403-574-01 - page 104
Page 98 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Figure 1 1- 4 High Power (4800W) Chassis Drawing ALLOW 5" EACH SIDE FOR COOLING ALLOW 5" EACH SIDE FOR COOLING ALLOW 3" IN BACK FOR CABLING. AC POWER ENTRY UL TRASOUND ...
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Dukane 403-574-01 - page 105
Page 99 Section 1 1 - Specications Dukane Manual Part No. 403-574-01 Operating Environment Operate the generator within these guidelines: T emperature : 40° F to 10 0°F (+4°C to + 38° C) Air Particulates : Keep the equipment dry Minimize exposure to moisture, dust, dirt, smoke and mold Humidity : 5% to 95% Non–condensing @ +5°C ...
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Dukane 403-574-01 - page 106
Page 100 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 AC Power Requirements The AC input power requirements depend on the frequency and output power rating of the generator . T able 1 1-II below , lists both the AC requirements (maximu ...
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Dukane 403-574-01 - page 107
Page 101 Section 1 1 - Specications Dukane Manual Part No. 403-574-01 Inter preting the Model Number 20 HB 120 - 2 E- R1 P o wer Le vel 480 = 4800 W atts 360 = 3600 W atts 240 = 2400 W atts 180 = 1800 W atts 120 = 1200 W atts 060 = 600 W atts System Process Contr ols A = Advanced Weld Controller (time and energy) AC Line Input 2 = 200 ...
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Dukane 403-574-01 - page 108
Page 102 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 Regulatory Agency Compliance C A UTION DO NO T mak e an y modi- cations to the gene rat or o r a s s o c i at e d c a b le s a s the changes ma y resu lt in viol ati ng one or mo ...
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Dukane 403-574-01 - page 109
Page 103 Section 12 - Contacting Dukane Dukane Manual Part No. 403-574-01 SECTION 12 Contacting Dukane ...
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Dukane 403-574-01 - page 110
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Dukane 403-574-01 - page 111
Page 105 Section 12 - Contacting Dukane Dukane Manual Part No. 403-574-01 Co ntacting Du kane Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • Model number , line voltage and serial number • Fault/error indicators from the LCD display • Software version (P ...
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Dukane 403-574-01 - page 112
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Dukane 403-574-01 - page 113
Page 107 Appendices Dukane Manual Part No. 403-574-01 APPENDICES L i s t o f F i g u r e s .................................... 1 0 9 L i s t o f T a b l e s ..................................... 1 1 0 Guide to iQ Generator Menu Structure. . . . . . . . . . . . . . 1 1 1-127 ...
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Dukane 403-574-01 - page 114
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Dukane 403-574-01 - page 115
Page 109 Appendices Dukane Manual Part No. 403-574-01 List of Figures 2-1 Example of 220 V olt, Grounded, 3-prong Receptacle ..................................................... 8 2-2 International 220/240V Grounding ..................................................................................8 3-1 Lockout Device in Open Position, ...
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Dukane 403-574-01 - page 116
Page 1 10 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 No. Description Page 2-I iQ Generator W eights ....................................................................................................... 9 3-I Rack Mount Bracket Part ...
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Dukane 403-574-01 - page 117
Page 1 1 1 Appendices Dukane Manual Part No. 403-574-01 Menus Page Number Time Only Operate 1 13 Process Setup - Automated Probe 1 14 Process Setup - Hand Probe 1 15 Process Setup - MPC Probe 1 16 Process Setup - Process Limits 1 17 Process Setup - Utilities 1 18 Time and Energy Operate 1 19 Process Setup - Automated Probe 120 Process Se ...
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Dukane 403-574-01 - page 118
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Dukane 403-574-01 - page 119
Page 1 13 Appendices Dukane Manual Part No. 403-574-01 # 1 P ART COUNT XXXXX WELD TIME 0.0000 S OPERA TE T ime Only Menus Page 1 of 15 “Rxx” = Remote Setup Number and #xx = Local Setup Number OPERA TE MODE PROCESS DA T A PROCESS ST A TISTICS SYSTEM P ARAMETERS P ART COUNT XXXXX GOOD XXXXX XXX% BAD SUSPECT XXXXX XXX% XXXXX XXX% AMPLIT ...
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Dukane 403-574-01 - page 120
Page 1 14 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime Only Menus Page 2 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES No option boards installed Automated Probe AUTOMA TED PROBE WELD CONTROL BY AUTOM ...
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Dukane 403-574-01 - page 121
Page 1 15 Appendices Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime Only Menus Page 3 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Hand Probe HAND PROBE WELD CONTROL BY HAND PROBE SWITCH iQ SYSTEM HAND PROBE Weld Control Amplitude Control Weld T ime Hand Probe Detected See Amplitude Control Menu See Amplitude Contr ...
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Dukane 403-574-01 - page 122
Page 1 16 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime Only Menus Page 4 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES MPC Probe MPC PROBE WELD CONTROL BY AUTOMA TION WELD CONTROL MPC Probe AMPLITUDE ...
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Dukane 403-574-01 - page 123
Page 1 17 Appendices Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime Only Menus Page 5 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Process Limits Disable Maximum Weld T ime Minimum Weld T ime PROCESS LIMITS SUSPECT P ART BAD P ART WELD TIME LIMIT Enable Disable Maximum Weld T ime Minimum Weld T ime WELD TIME LIMIT ...
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Dukane 403-574-01 - page 124
Page 1 18 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime Only Menus Page 6 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Utilities UTILITIES SETUP CONTROL SETUP UTILITIES SETUP UTILITIES NAME CURRENT SE ...
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Dukane 403-574-01 - page 125
Page 1 19 Appendices Dukane Manual Part No. 403-574-01 OPERA TE T ime and Energy Menus Page 7 of 15 “Rxx” = Remote Setup Number and “#xx” = Local Setup Number OPERA TE MODE PROCESS DA T A PROCESS ST A TISTICS SYSTEM P ARAMETERS R 1 P ART COUNT WELD TIME PEAK POWER ENERGY 0.000 S 0 W 0 J P ART COUNT XXXXX GOOD XXXXX XXX% BAD SUSPE ...
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Dukane 403-574-01 - page 126
Page 120 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy Menus Page 8 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES No option boards installed Automated Probe AUTOMA TED PROBE WELD CONTROL BY ...
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Dukane 403-574-01 - page 127
Page 121 Appendices Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy Menus Page 9 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Hand Probe HAND PROBE WELD CONTROL BY HAND PROBE SWITCH iQ SYSTEM WELD CONTROL Weld by T ime Weld by Peak Power Weld by Energy Weld T ime Weld Peak Power Weld Energy Max Weld T ime ...
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Dukane 403-574-01 - page 128
Page 122 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy Menus Page 10 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES MPC Probe MPC PROBE WELD CONTROL BY AUTOMA TION iQ SYSTEM WELD CONTROL MPC ...
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Dukane 403-574-01 - page 129
Page 123 Appendices Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy Menus Page 1 1 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Process Limits Disable Maximum Weld T ime Minimum Weld T ime PROCESS LIMITS SUSPECT P ART BAD P ART SUSPECT P ART LIMITS WELD TIME WELD PEAK POWER WELD ENERGY BAD P ART LIMITS WE ...
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Dukane 403-574-01 - page 130
Page 124 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy (and T ime Only) Menus Page 12 of 15 PROCESS SETUP PROCESS CONTROL PROCESS LIMITS UTILITIES Utilities UTILITIES SETUP CONTROL SETUP UTILITIES SETUP UT ...
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Dukane 403-574-01 - page 131
Page 125 Appendices Dukane Manual Part No. 403-574-01 PROCESS SETUP T ime and Energy (and T ime Only) Menus Page 13 of 15 AMPLITUDE CONTROL AMPLITUDE SETTING RAMP UP / DOWN TIME Amplitude Control WARNING MODIFIED SETTINGS MA Y EFFECT OPERA TION OF UNIT Amplitude Ramp T ime Ramp Up T ime Ramp Down Time AMPLITUDE SETTING 90 % CHANGE V ALUE ...
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Dukane 403-574-01 - page 132
Page 126 iQ Series , Ultrasonic Generator/Power Supply LS User ’s Manual Dukane Manual Part No. 403-574-01 I/O PORT SETUP CONFIGURE INPUTS CONFIGURE OUTPUTS RESTORE DEF AUL TS HARDW ARE T ime and Energy Menus Page 14 of 15 #1: SETUP NAME OPERA TE MODE PROCESS SETUP HARDWARE SETUP PORT SE ...
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Dukane 403-574-01 - page 133
Page 127 Appendices Dukane Manual Part No. 403-574-01 ADV ANCED HARDW ARE T ime and Energy Menus Page 15 of 15 #1: SETUP NAME OPERA TE MODE PROCESS SETUP HARDWARE SETUP I/O PORT SETUP ADV ANCED HARDWARE SYSTEM RESTORE TRIGGER BY POWER ADV ANCED HARDWARE: SETTINGS RESTORE DEF AULTS FREQ LOCK/HOLD SYSTEM FREQ LIMITS Wide 21000-19000 Phase ...
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Dukane 403-574-01 - page 134
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Dukane 403-574-01 - page 135
Dukane ISO ISO CER TIFICA TION Duka ne chose to become ISO 9001:20 08 certi- fied in order to demonstrate to our customers our continuing commitment to being a quality ve nd or . By pass ing its audi t, Duka ne can as su re you that we have in place a well–defined and systematic approach to quality design, manu - facturing, deliver y and ser vi ...
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Dukane 403-574-01 - page 136
Part No. 403-574 -01 Dukane Intel ligent Assembl y Solu tions • 2900 Dukan e Driv e • St . Char les, I llinoi s 6017 4 USA • TEL (630) 797-49 00 • F AX (630) 797–4 949 Series, LS Generators, User's Manual Printed in the United States of America www .dukane.com/us Please r ef er to our website a t: www .dukane.com/us/sales/intsales.ht ...
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