Dukane Infinity Series User manual

ULTRASONIC SERVO
PRESS SYSTEMS
USER MANUAL
Infinity™Series
www.dukane.com [email protected]

403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual ii
Copyright © 2023
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
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Noce of Liability:

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

described herein.



Dukane Part Number: 403-618-03
Dukane ultrasonic equipment is manufactured under one or more U.S. Patents.

hps://www.dukane.com/patents/

403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual iii
SECTION 1 - Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Introducon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 - Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
General Consideraons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
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
Thrusters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Dukane HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Unpacking the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Placement on Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Cable Connecons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System Inputs/Outputs Signal Pinouts on the J5 Connector . . . . . . . . . . . . . . . . . . 18
System Inputs/Outputs Signal Descripons on the J5 Connector . . . . . . . . . . . . . . . 19
Contents

403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual iv
SECTION 4 - Tooling Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Tooling Setup for model 43NTX1N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
 . . . . . . . . . . . . . . . . . . . . . . . 22
Installing the Ultrasonic Stack ModuleN. . . . . . . . . . . . . . . . . . . . . 23
Removing the Ultrasonic Stack ModuleN. . . . . . . . . . . . . . . . . . . . 28
N. . . . . . . . . . . . . . . . . . 30
N. . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Tooling Setup for model 43NTX2N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
 . . . . . . . . . . . . . . . . . . . . . . . 32
Installing the Ultrasonic Stack Module . . . . . . . . . . . . . . . . . . . . . 33
Removing the Ultrasonic Stack Module . . . . . . . . . . . . . . . . . . . . 36
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Tooling Setup for model 43NTX3N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
 . . . . . . . . . . . . . . . . . . . . . . . 39
Installing the Ultrasonic Stack Module . . . . . . . . . . . . . . . . . . . . . 40
Removing the Ultrasonic Stack Module . . . . . . . . . . . . . . . . . . . . 43
 . . . . . . . . . . . . . . . . . . 45
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Tooling Setup for model 43NTX4N. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
 . . . . . . . . . . . . . . . . . . . . . . . 47
Installing the Ultrasonic Stack Module . . . . . . . . . . . . . . . . . . . . . 48
Removing the Ultrasonic Stack Module . . . . . . . . . . . . . . . . . . . . 51
 . . . . . . . . . . . . . . . . . . 53
 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Adjusng the Thruster Posion (for X1, X3 and X4) . . . . . . . . . . . . . . . . . . . . . . . 55
Adjusng the Thruster Posion (for X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Aligning the Fixture (for all models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Contents

403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual v
Contents
SECTION 5 - Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Control and Indicators Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Press System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Press Controls and Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Operang Safety Switch Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
E-Stop Switch Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
HMI Connecons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
SECTION 6 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
IQ Explorer 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Geng Started Using IQ Explorer 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
SECTION 7 - Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Thruster Specicaons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Operang Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Model Outline Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Innity™ Generator Number Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Innity™ System Number Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
SECTION 8 - Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Alarm Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
SECTION 9 - Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Six-Month Periodic Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Contacting Dukane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Dukane ISO Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Contacting Dukane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 1

SECTION 1
Introducon


403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 2
Introduction
Press System Overview



General User Information


Figure 1-1 Typical Press System
FIXTURING
COLUMN
BASE
ULTRASONIC STACK
THRUSTER
HMI
GENERATOR

403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 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





403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 4
SECTION 2
Health and Safety

403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 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


disconnect the system electrically

including the generator and press.
WARNING





403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 6
Safe Operation
CAUTION


             

              

that absorb sound may be located to surround the system.
WARNING
 
       

CAUTION





403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 7


Grounded, 3-Prong Receptacle

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.
                


                  



to NEMA 6–15R or 6–20R
Grounding Contacts
Typical Outlet
Provided Cable


403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 8
CAUTION


Grounding for RFI Suppression



              


Operate Switches


STO Safety Modes
The STO funcon is designed to comply with the EN 13849 standard, but it is not cered by an independent test body.













control.
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.

403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 9

Regulatory Agency Compliance
CAUTION
Do NOT make any

the generator or
associated cables
as the changes may



equipment is
manufactured.
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
• 
• 
• 

measurement, Control and Laboratory Use.
IP Rating



UL


UL 61010–1, IEC 61010-1
CAN/CSA


SECTION 3 | INSTALLATION
403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 10
SECTION 3
Installaon

403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 11
SECTION 3 | INSTALLATION
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.

SECTION 3 | INSTALLATION
403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 12
AC Power Requirements

and 3-2.
Generators
TABLE 3-1 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
  15 Amps
  15 Amps
  15 Amps
  15 Amps
  15 Amps
Thrusters

403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 13
SECTION 3 | INSTALLATION
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



Table 3-3
AC Power Requirements
Dukane HMI
AC line voltage - 90-260 VAC
AC line current - 1 Amp
Model Number Description
Weight

lbs kg
  215 98
  162 74
  43 20
  293 133
  202 92
  83 38
  400 182
  317 144
  125 57
  433 197
  351 160
  156 71
NOTE: 
found in table 7-3.

SECTION 3 | INSTALLATION
403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 14






Figure 3-4
Figure 3-5
Figure 3-3
MOUNTING HOLE
LOCATIONS


403-618-03 Infinity™ Series Servo Ultrasonic Press Systems User Manual 15
SECTION 3 | INSTALLATION
Figure 3-6
MOUNTING HOLE
LOCATIONS

Figure 3-7
UNITS: INCHES [MM]
n.50 [12.7]2X
18.6 [472]
ULTRASOUND STACK
CENTER
24.84 [630.9]
13.22 [335.8] .70 [17.8]
8.05 [204.3]
MOUNTING HOLE
LOCATIONS