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Dukane iQ Series manuel d'utilisation

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Table des matières du manuel d’utilisation

  • Page 1

    ISO 9001:2000 Products are manufactured in ISO registered facilities. Intelligent Assembly Solutions www .dukane.com/us Dukane Part No. 403 – 577– 01 iQ Series UL TRASONIC HAND HELD S Y STEMS HP User’ s Manual Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797- 4900 • F AX (630)[...]

  • Page 2

    Page  ii  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Printed in the United States of America. Part Number: 403–577–01 This ultrasonic equipment is manufactured under one or more of the following U.S. Patents: 3,7 80,9 26 3,8 25,4 81 4, 131, 505 4, 277, 710 5, 798 ,599 5,88 0[...]

  • Page 3

    Page  iii Dukane Manual Part No. 403-577-00 R e vis ion His tor y Revision Revision Number Summary Date - 00 Original release. 08/01/2008 - 01 Add 20kHz and 30kHz models. 1 1/12/2009 Update Pop-up Fault Status Screens. Add T rigger by Power feature. Add Options section.[...]

  • Page 4

    Page  iv  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 5

    Page  v Dukane Manual Part No. 403-577-00 Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . 1 Section 2- Health and Safety . . . . . . . . . . . . . . . . . . . 5 Section 3- Installation . . . . . . . . . . . . . . . . . . . . . . . . 9 U n p a c k i n g ............................ 1 1 P l a c i n g .........[...]

  • Page 6

    Page  vi  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 7

    Page  1 Section 1 – Intr oduction Dukane Manual Part No. 403-577-01 SECTION 1 Intr oduction General User Information . . . . . . . . . . . . . . . . . . 3 Read The Manual First . . . . . . . . . . . . . . . . . . . . . . 3 Notes, Cautions and W arnings . . . . . . . . . . . . . . . . . . 3 Drawings and T ables . . . . . . . . . . . . . [...]

  • Page 8

    Page  2  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 9

    Page  3 Section 1 – Intr oduction Dukane Manual Part No. 403-577-01 General User Information Read This Manual First Before operating your ultrasonic system, read this User’ s Manual to become familiar with the equipment. This will ensure correct and safe operation. The manual is orga- nized to allow you to learn how to safely operate [...]

  • Page 10

    Page  4  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 System Overview Y our iQ Series U ltrasonic Hand Held  Syst em  has t wo basic components:   an ultrasonic generator , and a hand probe. Generator The generator is specically designed for ultrasonic appli - cations[...]

  • Page 11

    Page  5 Section 2 – Health & Safety Dukane Manual Part No. 403-577-01 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[...]

  • Page 12

    Page  6        iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 13

    Page  7 Section 2 – Health & Safety Dukane Manual Part No. 403-577-01 General Considerations Ple ase obse rve thes e hea lth and safe ty recom men dat ions for saf e, ef cien t, and inj ury -fre e o per atio n o f y our equ ipm ent. In th is ma nual , the term sy ste m refe rs to a compl ete group of com pon ents assoc iat ed wit[...]

  • Page 14

    Page  8        iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Electrical Safety Domestic Power Grounding For safety , the power cords used on this product have a three-wire, grounding-type power cord. Figures 2-1 and 2- 2 illustrate the appropriate electrical outlet to use w[...]

  • Page 15

    Page  9 Section 3 – Installation Dukane Manual Part No. 403-577-01 SECTION 3 Installa tion Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 P l a c i n g .......................................... 1 1 R F I G r o u n d i n g .................................... 1 1 C o n n n e c t i n g C a b l[...]

  • Page 16

    Page  10                  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 17

    Page  1 1 Section 3 – Installation Dukane Manual Part No. 403-577-01 Unpacking Carefully open your shipping container , and make sure it contains the items shown on the shipping documents. Inspect all items, and report any missing items or damage immediately . Placing Make certain generator placement and cable routing do not interfere w[...]

  • Page 18

    Page  12                  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Connecting Cables - Quick Start Guide Complete the basic connections as shown below: • AC Line Input • HAND PROBE Connector • Grounding Stud • AC Power Cord Connection Step 1. Attach the[...]

  • Page 19

    Page  13 Section 3 – Installation Dukane Manual Part No. 403-577-01 Power Cords 200/240 V olt Systems The IEC AC power inlet connector mounted on the rear panel requires a properly congured IEC compliant power cord. The 200/240 AC power cords supplied with the generators are matched to the ultrasonic output power rating and the conti[...]

  • Page 20

    Page  14                  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Pin Signal Name 0V Output Common 1 End of W eld Alarm 2 Any Fault Alarm 3 Bad Part T able 3-II System OUTPUTS Connector Signals Pin 0V (Output Common) Pin 0V is connected to chassis ground. Pin [...]

  • Page 21

    Page  15 Section 4 – Contr ols and Connections Dukane Manual Part No. 403-577-01 F r o n t P a n e l O v e r v i e w ............................... 1 7 S t a r t - U p S e q u e n c e ................................. 1 9 LCD Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 SECTION 4 Contr ols[...]

  • Page 22

    Page  16                  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 23

    Page  17 Section 4 – Contr ols and Connections Dukane Manual Part No. 403-577-01 Figure 4-1 Front Panel F ro nt P anel Ov er v ie w This section gives an overview of the front panel functions: powering the generator on/off; monitoring the process with the display; and, programming with the control keys. Control Keys The control keys sho[...]

  • Page 24

    Page  18                  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 CAUTION Make sure the stack is prop- erly assembled before it is con nect ed to the sys tem. The horn should never come in dir ect cont act with a metal x - ture or anvil when ultrasound is a[...]

  • Page 25

    Page  19 Section 4 – Contr ols and Connections Dukane Manual Part No. 403-577-01 Star t - up Seq uen ce After all connections have been completed. 1. Push the Power Switch to ON (Figure 4-2). The generator performs a self-diagnostics sequence. 2. The Power -up screen appears briey - Figure 4-3. 3. The next screen is an Operate screen[...]

  • Page 26

    Page  20                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 L CD Dis pla y O v er vie w There are two basic kinds of screen displays: Operate screens, and In Cycle screens. Figure 4-5 Example of an In Cycle Screen IN CYCLE Frequency: 40087 Hz Power: [...]

  • Page 27

    Page  21 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-577-01 SECTION 5 Pr ocess Contr ol Settings Select the W elding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Navigating Through the Modes . . . . . . . . . . . . . . . . . . . . . 24-25 H o l d ........................................... 2 6 A m p[...]

  • Page 28

    Page  22                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 29

    Page  23 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-577-01 P rocess C ontro ller Settings This section of the manual helps the reader become familiar with the operating modes, and illustrates some typical programming steps. There are three welding modes available. These correspond to the three ways in which the welde[...]

  • Page 30

    Page  24                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Navigating Through the Modes When the generator is rst powered up, the default operating mode is Manual, and Manual Weld is shown at the top of the display as shown in Figure 5-1. Navigat[...]

  • Page 31

    Page  25 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-577-01 Navigate to Energy Mode 1. Follow the sequence shown in the gures to the right to navigate from T ime mode to Energy mode. In Time mode (Figure 5-5), press the ENERGY key , and the screen as shown in Figure 5-6 appears. 2. The phrase, Enter Changes Mode , [...]

  • Page 32

    Page  26                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Hold HOLD is used more often with T ime or Energy modes, but it can be used with the Manual mode. It is a period of time that can be set to follow release of the probe’ s trigger switch. D[...]

  • Page 33

    Page  27 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-577-01 System Information, Hardware Settings, Advanced Settings When the INFO key is pressed the display looks like Figure 5-1 1: Using the keys, move the pointer to indicate: System Information, Hardware Settings, or Advanced Settings Press ENTER to make the select[...]

  • Page 34

    Page  28                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 3. Advanced Settings Continued Afte r Adva nced Setting s is sele cted, a warn ing screen is displayed as shown in Figure 5-13. Adjusting these settings may affect the operation of your unit[...]

  • Page 35

    Page  29 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-577-01 Advanced Settings Continued T rigger by Power For an explanation of T rigger by Power and the three settings that are connected with it, please refer to Application Note 506 found on our website at: http://www .dukane.com/us/DL_ApplData.asp When T rigger by P[...]

  • Page 36

    Page  30                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Setup Maintenance Introduction The screens available in Setup Maintenance allow the operator to Load, Store, or Delete generator weld setups. As many as eight (8) setups can be loaded and st[...]

  • Page 37

    Page  31 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-577-01 Setup Maintenance C ontinued Saving the Current Setup T ry using your navigation skills on this example: 1. Follow instructions on Page 24 to set the mode to W eld by T ime. Set the time to 1.520 seconds. See Figure 5-23. 2. Press SETUP and then press the + k[...]

  • Page 38

    Page  32                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 39

    Page  33 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-577-01 SECTION 6 Pr obes and Pr obe Stac ks Ultrasonic Probe Overview ...........................35 Theory of Operation ............................................ 36 Probe Conguration ............................................ 36 Ultrasonic Horn ............[...]

  • Page 40

    Page  34                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 41

    Page  35 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-577-01 Figure 6-1 T ypical Hand Held Probes U/S Cable T ypical Horn Less T ip Models Pistol-style Grip Hanger T rigger T ypical Horn Less T ip U/S Cable T rigger Actuator Hand Grip Compressed Air Fitting Strain Relief Strain Relief Rear View Rear View Compressed Ai[...]

  • Page 42

    Page  36                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Theory of Operation Plastic welding is the most common application of ultrasonic assembly . T o perform ultrasonic plastic welding, the vibrating tip is brought into contact with one of the [...]

  • Page 43

    Page  37 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-577-01 Ultrasonic Horn The horn transfers the ultrasonic mechanical vibrations (originating at the transducer in the probe housing) to the plastic parts through direct physical contact. The horn is precision machined and designed to vibrate at either 20k Hz, 30kHz,[...]

  • Page 44

    Page  38                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Stack Assembly Attaching a Replaceable T ip to a Horn 1. Inspe ct al l ho rn an d ti p su rfac es f or st ress cra cks, chips, or gouges. Any of these irregularities will affe ct oper ation [...]

  • Page 45

    Page  39 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-577-01 At tac hin g the Mo unt in g St ud to a Ho rn or a Bo ost er 1. Inspect the stud for cracks or damaged threads. Replace the stud if it is cracked or otherwise dam- aged. 2. R emove any foreign matter from the threaded stud and the mating hole. 3. T hre ad th[...]

  • Page 46

    Page  40                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Attaching The Horn to a Booster , Booster to a Probe, or Horn to a Probe 1. Inspect all surfaces to be joined for stress cracks, chips, or gouges. Any of these irregularities will af fect op[...]

  • Page 47

    Page  41 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-577-01 6. Thread the components together and tighten to the following torque specications using only the correct size wrenches. Use spanner wrenches on components with spanner wrench holes or an open end wrench on components with wrench ats. See Figure 6–5 [...]

  • Page 48

    Page  42                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 HORN HORN HAND PROBE ASSEMBLY HAND PROBE HOUSING HAND PROBE HOUSING A SSEMBLY D ISASSEMBLY Output End Input End Spanner Wrench Holes Mounting Stud (Insert Into Horn First and Tighten to Torq[...]

  • Page 49

    Page  43 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-577-01 Se par ati ng the Horn from a Booster , Booster from a Probe or Horn from a Probe On all transducers and horns with spanner wrench holes, use only the correct size spanner wrench that came with your system to provide sufcient torque to loosen a joint. See[...]

  • Page 50

    Page  44                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Booster Notes How to T ell the Booster Input End from the Output 1. The depth of the threaded hole on the output end is always deeper than the threaded hole on the input end. 2. On an amplif[...]

  • Page 51

    Section 7 – T r oubleshooting Page  45 Dukane Manual Part No. 403-577-01 SECTION 7 T r oubleshooting N o Ultrasonic Output ..................................... 47 System Power Output Level .........................47 W elding Problems ......................................... 48 Pop-up Fault Status Screens.................. 49-50[...]

  • Page 52

    Page  46                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 53

    Section 7 – T r oubleshooting Page  47 Dukane Manual Part No. 403-577-01 No Ultrasonic Output Probe Make sure that the hand probe cable is connected to the generator connector (HAND PROBE) and secured to the rear panel. Also, make sure the hand probe stack is properly assembled. System Power Output Level Overload When an overload occurs[...]

  • Page 54

    Page  48                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 W elding Problems W eak Welds W eak welds, or underwelding, is caused by insufcient energy being transmitted to the part. Y ou can increase the weld pressure, increase the weld duration ([...]

  • Page 55

    Section 7 – T r oubleshooting Page  49 Dukane Manual Part No. 403-577-01 Generator Fault Status Screens - Manual Mode Status T ext Displayed System Status or Fault Explanation An Average Overload fault tripped. Output power exceeded rated wattage. Lower the welding pressure or amplitude. Fault will reset when next weld cycle starts. A P[...]

  • Page 56

    Page  50                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Process Fault Status Screens - Time and Energy Modes Status T ext Displayed System Status or Fault Explanation Latch On Fault ENABLED Latch On Fault DISABLED Set Weld T ime Not Reach[...]

  • Page 57

    Section 8 – Options Page  51 Dukane Manual Part No. 403-577-01 SECTION 8 Options iQ Hand Probe Buzzer Kit ............................. 53 iQ Hand Probe Foot Switch Kit .....................53[...]

  • Page 58

    Page  52                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 59

    Section 8 – Options Page  53 Dukane Manual Part No. 403-577-01 iQ Hand Probe Options Buzzer Kit (Part No. 438-971) In some noisy environments the built-in buzzer can not easily be heard. This buzzer kit is designed for those conditions, and it suits the customer that prefers not to provide their own buzzer (using the status outputs of t[...]

  • Page 60

    Page  54                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 61

    Section 9 – Specications Page  55 Dukane Manual Part No. 403-577-01 SECTION 9 Specica tions Generator Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Probes Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 W e i g h t s .......................................... 5 9 O p e r a t i[...]

  • Page 62

    Page  56                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 63

    Section 9 – Specications Page  57 Dukane Manual Part No. 403-577-01 Figure 9-1 Generator Outline Drawing 12.41 [315.2] 10.00 [254] 3.95 [100.3] 3.51 [89.2] ALLOW 5" (125 mm) BEHIND UNIT FOR CABLE CONNECTIONS IN [mm][...]

  • Page 64

    Page  58                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 Figure 9-2 Probes Outline Drawings and Dimensions A B C A B C D Standard single connector for iQ generator Soft grip handle Standard cable 9 ft (3 m) Air fitting for cooling .25 in O.D. tubi[...]

  • Page 65

    Section 9 – Specications Page  59 Dukane Manual Part No. 403-577-01 Operatin g En vir onment Operate the equipment within these guidelines: T emperature : 40° F t o 10 0°F (+5 °C t o + 38°C ) Air Particulates : Keep the equipment dry . Minimize exposure to moisture, dust, dirt, smoke and mold. Humidity : 5% to 95% non–condensin[...]

  • Page 66

    Page  60                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 AC Power Requirements Operating Frequency System Model Number Generator Model Number Probe Part Number Overload Power Rating (W atts) Input AC Power Requirements Nominal AC V olt North Ameri[...]

  • Page 67

    Section 9 – Specications Page  61 Dukane Manual Part No. 403-577-01 R egu lato r y A genc y Com pli ance CAUTION DO NOT make any modifications to the generator or associated cables as the changes m a y r e s u l t i n v i o l a t i n g one or more regulations under which this equip- ment is manufactured.  FCC The generator complie[...]

  • Page 68

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    Section 10 – I/O Interface Page  63 Dukane Manual Part No. 403-577-01 SECTION 10 Outputs Interf ace Outputs Connection Example . . . . . . . . . . . . . . . . . . . . . . . . . 65[...]

  • Page 70

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  • Page 71

    Section 10 – I/O Interface Page  65 Dukane Manual Part No. 403-577-01 HAND PROBE OUTPUTS 0V 1 2 3 iQ Hand Probe Generator Rear Panel Detail X 1 X 2 T o OUTPUTS: 1, 2, or 3 Provided by Customer Status Indicator or Audible Alarm (333mA maximum) + _ NOTE 0V (Output Common) is connected to Chassis Ground (Earth). Power Supply 0V + 24 V + 30[...]

  • Page 72

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  • Page 73

    Section 1 1 – Contacting Dukane Page  67 Dukane Manual Part No. 403-577-01 SECTION 11 Contacting Dukane[...]

  • Page 74

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  • Page 75

    Section 1 1 – Contacting Dukane Page  69 Dukane Manual Part No. 403-577-01 Co ntactin g Duk ane 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 [...]

  • Page 76

    Page  70                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-577-01 This page intentionally left blank[...]

  • Page 77

    Page  71 Appendices Dukane Manual Part No. 403-574-01 APPENDICES L i s t o f F i g u r e s ..................................... 7 3 L i s t o f T a b l e s ...................................... 7 4[...]

  • Page 78

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  • Page 79

    Page  73 Appendices Dukane Manual Part No. 403-574-01 List of Figures 2-1 Example of 125 V olt, Grounded, 3-prong Plug and Receptacle ...................................... 8 2-2 Example of 250 V olt, Grounded, 3-prong Plug and Receptacle ...................................... 8 2-3 International 220/240V Grounding .......................[...]

  • Page 80

    Page  74                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-574-01 No. Description Page 3-I Standard IEC AC Power Cord Part Numbers .................................................................13 3-II System OUTPUTS Connector Signals ...................[...]

  • Page 81

    Dukane ISO ISO CER TIFICA TION Duka ne chose to becom e ISO 9001:20 00 cert i- fied in order to demonstrate to our customers our continuing commitment to being a quality ve ndo r . By pass ing its au dit , Duka ne can as sur e you that we have in place a well–defined and systematic approach to quality design, manu- facturing, deliver y and ser [...]

  • Page 82

    Par t No. 403 – 577 – 0 1 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797- 4900 • F AX (630) 797- 4949 iQ Series , Ultrasonic Hand Held Systems 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/sa[...]