Dukane Infinity Series User manual

SERVO ULTRASONIC
PRESS SYSTEMS
QUICK START GUIDE
Infinity™ Series
www.dukane.com [email protected]

Copyright © 2021
Dukane
2900 Dukane Drive
St. Charles, IL 60174 USA
Noce of Rights:
All rights reserved. No part of this manual including the interior design, cover design and icons may be


Noce of Liability:




described herein.



Dukane Part Number: 403-618-00
Dukane ultrasonic equipment is manufactured under one or more U.S. Patents.



SECTION 1 - Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Introducon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 - Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Consideraons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Ultrasonic Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Electrical Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Grounding for RFI Suppression. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
STO Safety Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 3 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Before Installaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
 . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
AC Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Generators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Presses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dukane HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Unpacking the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Placement on Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cable Connecons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Contents

SECTION 4 - Tooling Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Aaching the Fixture on the Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installing the Ultrasonic Stack Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Removing the Ultrasonic Stack Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Removing the Module Block from the Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Adjusng the Thruster Posion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Aligning the Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
SECTION 5 - Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Control and Indicators Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Press System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Press Controls and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Operang Safety Switch Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
E-Stop Switch Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
HMI Connecons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SECTION 6 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
IQ Explorer 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Geng Started Using IQ Explorer 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
SECTION 7 - Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Press Specicaons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Operang Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Model Outline Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Innity™ System Number Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
SECTION 8 - Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
SECTION 9 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Six-Month Periodic Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Contacting Dukane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Dukane ISO Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Contents


SECTION 1
Introducon

Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 2

Introduction
Press System Overview



General User Information


Figure 1-1 Typical Press System
FIXTURING
COLUMN
BASE
ULTRASONIC STACK
THRUSTER
HMI
GENERATOR


Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 3
Drawings and Tables


Notes, Cautions and Warnings
   



Condion
or Pracce
Electrical
Hazard
Hearing
Protecon
NOTE


CAUTION


result in damage to the equipment
or other property.
WARNING




Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 4

SECTION 2
Health and Safety


Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 5
Health and Safety
General Considerations
Safe Operation
Please observe these health and safety recommendaons

Proper Installaon
installed.
No Unauthorized Modicaons - Do not modify your system in any
         


Keep the Cover On - Do not remove any equipment covers unless directed


Grounded Electrical Power

See Electrical Safety
Comply with Regulaons


Use Eye Protecon
Acousc Stack Hazard 


System Abort Switch

handling equipment in an automated system.
Foot Switch

System Electrical Cabling

NOTE


guide refers to a complete group


ultrasonic assembly system.
WARNING



be guarded as necessary. Dukane
does not assume any responsibility

by the customer or any third party
manufacturer.
CAUTION

to remove equipment covers by

Group personnel. Before doing so,
disconnect the system electrically

including the generator and press.
WARNING




Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 6

Ultrasonic Pressure
CAUTION

    
    
annoying or uncomfortable sounds.
    
enclosures, or materials that absorb
sound may be located to surround
the system. Ultrasound pressure level

CAUTION

    
system equipment, make sure electrical

      
     
    


     
    
     
    
   
or materials that absorb sound may be
located to surround the system.
WARNING
Keep head, hands, limbs and body at
  
   




Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 7
Figure 2-1
Grounded, 3-Prong Receptacle
Figure 2-2
Electrical Safety
    

• 
• 
• Dukane HMI
        
grounding and RFI suppression grounding.
North American Power Grounding




International Power Grounding
       
        
        



CAUTION
           
   
Electric Code and any local codes and ordinances that apply.
                


                  


Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 8

Grounding for RFI Suppression






Operate Switches


STO Safety Modes

on the press.
1. 

2. 

NOTE

Chassis Grounding Stud

or 2nd Chassis
Grounding Stud
#14 Gauge
Stranded or

3rd Chassis
Grounding Stud



Earth Ground
CAUTION
   
and eliminate ground currents,

   
   



Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 9
FCC
         

• 

CE Marking



• 

EN 55011
 
EN61000–4–2
EN61000–4–3
EN61000–4–4
EN61000–4–5
EN61000–4–6
EN61000–4–8
EN61000–4–11
• 
•           

• 

IP Rating




UL

UL 61010–1, IEC 61010-1
CAN/CSA

Regulatory Agency Compliance
CAUTION
Do NOT make any

the generator or
associated cables
as the changes may



equipment is
manufactured.

Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 10
SECTION 3 | INSTALLATION
SECTION 3
Installaon

SECTION 3 | INSTALLATION
Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 11
Before Installation
         
generator and press, please consider these important

• 
• 
• 
• Placement
When to Use Lockout / Tagout Devices



Figure 3-1
Figure 3-2
WARNING

generator, press, and remote controller units .


device to each component.

Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 12
SECTION 3 | INSTALLATION
AC Power Requirements

and 3-2.
Generators
TABLE 3-I NOTES:
1. 
2. 
3. 

Table 3-1
Table 3-2
Operating
Frequency
Generator Model
Number
Overload
Power
Ratings
(Watts)
Input AC Power Requirements
Nominal AC Volt at Maximum
RMS Current
North America/
Japan AC Outlet
Rating
Output
Voltage
(Nominal)
Output
Current
(Max)
  3600  20A or 30A 1100 3.6
  5000  30A 1100 5.0
  3600   1100 3.6
  5000   1100 5.0
  1200  15A 1300 1.0
  1800  15A 1300 1.5
  2600  15A 1300 2.2
  3600  20A or 30A 1300 3.0
  5000  30A 1100 5.0
  3600   1300 3.0
  5000   1100 5.0
 25HS120-UP-C0-S-N0 1200  15A 1000 1.3
 25HS200-2P-C0-S-N0 2000  15A 1000 2.2
 30HS120-UP-C0-S-N0 1200  15A 850 1.6
 30HS180-2P-C0-S-N0 1800  15A 850 2.3
 35HS120-UP-C0-S-N0 1200  15A 850 1.6
 40HS120-UP-C0-S-N0 1200  15A 750 1.8
 50HS060-UP-C0-S-N0 600  15A 850 0.8
Model Number Input AC Power Requirements Nominal AC Voltage
@ Maximum RMS Current
North America/ Japan
AC Outlet Rating
43NSLA  15 Amps
43NSME  15 Amps
Presses
Dukane HMI

AC line current - 1 Amp

SECTION 3 | INSTALLATION
Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 13
Unpacking the System
The system has been assembled and packaged at the factory for shipment. Depending on the system, components may be





1. 
2. Remove the packing material, and temporarily set aside any other system components, leaving the press on the pallet.
3. 
Placement on Workbench




Model Description
Weight

lbs kg
43NTLA on 43NSLA TM 433 197
43NTME on 43NSME TM 400 182
43NTLA TM 156 71
43NTME TM 125 57
Table 3-3

Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 14
SECTION 3 | INSTALLATION




indicated in Fig. 3-5.
Figure 3-4
Figure 3-5
Figure 3-3

SECTION 3 | INSTALLATION
Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 15
Cable Connecons

• Ultrasonic Generator
• Press
• HMI

1. 
2. 
3. 
4. 
CAUTION
           


DO NOT
            
possible damage to the generator.

Infinity™ Series Servo Ultrasonic Press Systems QUICK START GUIDE 16
SECTION 3 | INSTALLATION
Figure 3-6
Table 3-5
Cable Number Cable Description Standard Length (Meters)
1 Ultrasound 2
2 Press Interface 2
3 Press Grounding 5
4 Generator Grounding 5
5 3
6 2
7 2.5
8 2.5
9 3