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Intelligent Assembly Solutions
Series
ULTRASONIC GENERATOR/POWER SUPPLY
LS
AUTOMATED HAND PROBE PRESS
User’s Manual
Dukane Part No. 403-574-01
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949
Products are manufactured in ISO
ISO 9001:2008 registered facilities.
www.dukane.com/us
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Copyright © 2010 Notice of Rights: All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical, photocopying, recording, or by any information storage and retrieval system, without written permission from the manufacturer. Notice of Liability: The information contained is this manual is distributed on an “As is” basis, with- out warranty. While every precautio
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Revision History 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 Trigger by Power. Add iQ LinQTM. Web address revised. Revise Regulatory Agency Compliance statement. Health and Safety - Add safe lifting practices. Installation - Add lockout/tagout information and seismic zone information. Page 25 - Edited to clarify need for external power suppl
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This page intentionally left blank Page iv Dukane Manual Part No. 403-574-01
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Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . .1 . . . . . . . . General User Information Read the Manual First Notes, Cautions and Warnings Drawings and Tables Generator Overview Key Generator Features Section 2 - Health and Safety . . . . . . . . . . . . . . . .5 . . . . . . General Considerations Plastics Health Notice Electrical Safety Lifting the Equipment Section 3 - Installation . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . Before Installa
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Contents Continued Section 6 - Process Control Settings . . . . . . . . . . . . 45 . . . . . User-Provided Process Control Overview Manual Welding Automated Welding Automated Process Control Input Signals Status Output Signals Screen Navigation Basics Programming the Generator - Some Examples Section 7 - System Operational Testing . . . . . . . . . . 55 . . . . . Section 8 - Troubleshooting . . . . . . . . . . . . . . . . 61 . . . . . . . . No Ultrasonic Output System Power Output Level: Red S
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Section 1 – Introduction SECTION 1 Introduction General User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Read the Manual First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Drawings and Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Generator Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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iQ Series, Ultrasonic Generator/Power Supply LSUser ’sManual This page intentionally left blank Page Dukane Manual Part No. 403-574-01
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Section 1 – Introduction General User Information Read the Manual First Before operating your ultrasonic generator, read this User’s Manual to become familiar with the equipment. This will ensure correct and safe operation. The manual is organized to allow you to learn how to safely operate NOTE this generator. The examples given are chosen for their Note statements provide additional simplicity to illustrate basic operation concepts. information or highlight procedures. Notes, Cautions a
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iQ Series, Ultrasonic Generator/Power Supply LS User’sManual voltage fluctuations. It also eliminates the need Generator Overview for bulky, external constant–voltage transform- This generator is designed for basic ultrasonic applications ers. that use either manually operated hand probes or ultrasonic • Load Regulation provides constant ultrasound probes controlled by automation systems. Using the avail- amplitude automatically regardless of power able system control inputs and output s
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Section 2 – Health & Safety SECTION 2 Health and Safety General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Domestic Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 International Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Lifti
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iQ Series, Ultrasonic Generator/Power SupplyLS User ’sManual This page intentionally left blank Page Dukane Manual Part No. 403-574-01
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Section 2 – Health & Safety General Considerations Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your equip- ment. In this manual, the term system refers to a complete WARNING group of components associated with the welding of plas- Never operate the gen- tic or metal parts, also known as an ultrasonic assembly erator with the cover system. A typical system consists of a generator and/or ul- off. This is an unsafe trasonic process
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iQ Series, Ultrasonic Generator/Power Supply LSUser ’sManual Electrical Safety CAUTION If you have a two-prong elec- Domestic Power Grounding trical receptacle, we strongly For safety, the power cords used on this product have a recommend that you replace three-wire, grounding-type power cord. Figure 2-1 il- it with a properly grounded lustrates the appropriate electrical outlet to use with the three-prong type. Have a power cord that is included with systems shipped to North qualif
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Section 2 – Health & Safety Lifting the Equipment High Profile Low Profile High Power 3600W High Power 4800 W lb kg lb kg lb kg lb kg Generator 25 11.3 20 9.1 32 14.5 34 15.4 Only Generator + Packing 30 13.6 25 11.3 37 16.7 39 17.7 Materials Table 2–I iQ Generator Weights How to Lift Safely • Before lifting, take a moment to think about what you’re about to do. • Examine the object for sharp corners, slippery spots or other potential hazards. Know your limit and don’t try to exceed it. •
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iQ Series, UltrasonicGenerator/Power Supply LS User ’sManual This page intentionally left blank Page 10 Dukane Manual Part No.403-574-01
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Section 3 – Installation SECTION 3 Installation Before Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 13 When to Use Lockout/Tagout Devices. . . . . . . . . . . . . . . 13 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Connecting Cables . . . . . . . . . . . .
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Section 3 – Installation Before Installation As you plan for the installation of your generator, please consider these important subjects as listed below: • When to use lockout / tagout devices • Lifting the generator safely - See Section 2 - Health and Safety, P. 9 When to Use Lockout / Tagout Devices WARNING Electrical safety hazards exist inside the generator chassis. Before making any internal adjustments to the generator, apply a lockout/tagout (LOTO) device to the generator cha
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iQ Series, UltrasonicGenerator/Power Supply LS User ’s Manual Lockout/Tagout Continued from previous page Procedure to use BEFORE making any internal adjustments to the generator: 1. Push the generator's AC power switch/ breaker to the OFF position. 2. Unplug the generator's electrical cord from its source. 3. Authorized personnel apply a lockout/ tagout (LOTO) device to the plug end of the generator's electrical cord. Using a typical clam shell type LOTO device: 1) Open the clam
