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Table of contents for the manual
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Page 1
ISO 9001:2008 Products are manufactured in ISO registered facilities. Intelligent Assembly Solutions www .dukane.com/us Dukane Part No. 403 – 583– 00 iQ Series UL TRASONIC PO WER SUP P L Y AL User’ s Manual Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • F AX (630) 79[...]
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Page ii iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Printed in the United States of America. Part Number: 403–583–00 This ultrasonic equipment is manufactured under one or more of the following U.S. Patents: 3,7 80,9 26 3, 825, 481 4 ,131 ,505 4,27 7,71 0 5,7 98,5 99 5, 880 ,[...]
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Page iii Dukane Manual Part No. 403-583-00 R e vis ion His tor y Revision Revision Number Summary Date - 00 Original release. 1 1/02/2010[...]
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Page v Dukane Manual Part No. 403-583-00 Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . 1 Section 2- Health and Safety . . . . . . . . . . . . . . . . . . . 5 Section 3- Installation . . . . . . . . . . . . . . . . . . . . . . . 1 1 Before Installation . . . . . . . . . . . . . . . . . . . . . . 13 U n p a[...]
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Page 1 Section 1 – Intr oduction Dukane Manual Part No. 403-583-00 SECTION 1 Intr oduction General User Information . . . . . . . . . . . . . . . . . . 3 Read the Manual First . . . . . . . . . . . . . . . . . . . . . . 3 Notes, Cautions and W arnings . . . . . . . . . . . . . . . . . . 3 Drawings and T ables . . . . . . . . . . . . . [...]
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Page 3 Section 1 – Intr oduction Dukane Manual Part No. 403-583-00 General User Information Read the 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 t[...]
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Page 4 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 System Overview Y our iQ Series Ultrasonic Power Supply A L, an ultra- sonic generator , provides a versatile stand-alone worksta- tion. This product’ s rugged internal circuitry ensures a continu- ous resonant frequ[...]
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Page 5 Section 2 – Health and Safety Dukane Manual Part No. 403-583-00 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 L i f t i n g t [...]
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Page 7 Section 2 – Health and Safety Dukane Manual Part No. 403-583-00 General Considerations Ple ase obse rve thes e hea lth and safe ty recom men dat ion s for saf e, ef cie nt, and in jur y-f ree ope rat ion of you r e qui pme nt. In thi s manu al, the ter m syst em refe rs to a compl ete gro up of com pon ent s assoc iat ed wit [...]
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Page 8 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 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 with[...]
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Page 9 Section 3 – Installation Dukane Manual Part No. 403-583-00 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. Squa t down bend ing at the knees (not your waist). T uck your chin while keeping your back as vertical as possible. Step [...]
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Page 1 1 Section 3 – Installation Dukane Manual Part No. 403-583-00 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1[...]
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Page 13 Section 3 – Installation Dukane Manual Part No. 403-583-00 Bef ore Ins t al latio n As y ou p lan for the ins tall atio n of yo ur g ener ato r , please consider these important subjects as listed below: • When to use lockout / tagout devices • Lifting the generator safely - See Section 2, Health and Safety , Page 9 When to[...]
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Page 14 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 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 generator's[...]
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Page 15 Section 3 – Installation Dukane Manual Part No. 403-583-00 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 . Placement Make certain generator placement and cable routing do not interfere [...]
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Page 16 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Connecting Cables - Quick Start Guide Complete the basic connections as shown below: • AC Line Input • I/O (Input/Output) Connector • Grounding Stud • AC Power Cord Connection Step 1. Conn[...]
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Page 17 Section 3 – Installation Dukane Manual Part No. 403-583-00 Power Cords 200/240 V olt Systems The IEC AC power inlet connector mounted on the rear panel requires a properly congured 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[...]
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Page 18 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Pin Color Description 1 BLK Enable Out 2 WHT Enable In 3 RED System Overload Status Output 4 GRN Ultrasound Active Status Output 5 ORN Any Fault Status Output 6 BLU System Power Status Output 7 WH[...]
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Page 19 Section 4 – Contr ols and Connections Dukane Manual Part No. 403-583-00 Pin 7 (Status Output Common) Pin 7 is connected to chassis ground. The non-isolated NPN status output signals can drive isolated PNP inputs on the automation control system. Pin 8 (System Ready Status Output) This status output signal will activate only whe[...]
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Page 21 Section 4 – Contr ols and Connections Dukane Manual Part No. 403-583-00 F r o n t P a n e l O v e r v i e w ............................... 2 3 Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 LCD Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 SECTION 4 Cont[...]
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Page 23 Section 4 – Contr ols and Connections Dukane Manual Part No. 403-583-00 40100 Figure 4-1 Front Panel F ro nt P ane l Ov er vie 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 ke[...]
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Page 24 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 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 wit h a meta l x - ture or anvil when ultrasound is[...]
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Page 25 Section 4 – Contr ols and Connections Dukane Manual Part No. 403-583-00 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. T wo Power-up screens appear briey - Figure 4-3, and Figure 4-3A. 3. The next screen is [...]
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Page 26 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 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: [...]
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Page 27 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-583-00 SECTION 5 Pr ocess Contr ol Settings Select the W elding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 N a v i g a t i n g t h e M o d e s ............................... 3 0 H o l d ........................................... 3 2 A m p l i [...]
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Page 29 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-583-00 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[...]
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Page 30 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Navigating the Modes When the generator is rst powered up, the default operating mode is Automation, and Automation W eld is shown at the top of the display as shown in Figure 5-1. Naviga[...]
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Page 31 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-583-00 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 T ime mode (Figure 5-5), press the ENERGY key , and the screen as shown in Figure 5-6 appears. 2. The phrase, Enter Changes Mode ,[...]
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Page 32 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Hold HOLD is used more often with T ime or Ener gy modes, but it can be used with the Automation mode. HOLD does not allow the automation program to begin a new cycle until HOLD is nished[...]
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Page 33 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-583-00 System Information, 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 , or Advanced Settings Press ENTER to make the selection. 1. System Information Manufactur[...]
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Page 34 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Continued Ramp Up Time This parameter increases the amplitude linearly in the programmed time period at the start of the weld from zero to the programmed amplitude level. This brings the pro[...]
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Page 35 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-583-00 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 stored for your convenience. Navigating 1. When the SETUP key is presse[...]
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Page 36 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Setup Maintenance C ontinued Changing the Current Setup T ry using your navigation skills on this example: 1. Follow instructions on Page 24 to set the mode to Weld by Time . Set the time to[...]
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Page 37 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 SECTION 6 Pr obes and Pr obe Stac ks Ultrasonic Probe Overview ...........................39 Theory of Operation ............................................ 40 Probe Conguration ............................................ 40 Ultrasonic Horn ............[...]
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Page 39 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 U lt ras on ic P robe Ov er vie w Operating Notes Compressed Air Fitting - In continuous duty operation, it is important to keep the probe cool with compressed air . Use the probe’ s air tting to connect the air source to the probe. See Section 8, Speci[...]
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Page 40 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 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 [...]
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Page 41 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 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[...]
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Page 42 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Stack Assembly Attaching a Replaceable T ip to a Horn 1. Insp ect all ho rn an d t ip sur fac es fo r s tre ss cra cks , chips, or gouges. Any of these irregularities will affe ct oper atio [...]
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Page 43 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 At tac hin g the Mou nt ing 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. Rem ove any foreign matter from the thread ed stud and the mating hole. 3. Th rea d th[...]
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Page 44 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 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 affect ope[...]
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Page 45 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 6. Thread the components together and tighten to the following torque specications 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 6–4 [...]
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Page 46 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 HORN HORN PROBE ASSEMBL Y PROBE HOUSING PROBE HOUSING A SSEMBL Y D ISASSEMBL Y Output End Input End Spanner Wrench Holes Mounting Stud (Insert Into Horn First and T ighten to T orque Specs) [...]
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Page 47 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 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 sufcient torque to loosen a joint. See[...]
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Page 48 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 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[...]
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Section 7 – T r oubleshooting Page 49 Dukane Manual Part No. 403-583-00 SECTION 7 T r oubleshooting No Ultrasonic Output ..................................... 51 System Power Output Level .........................51 W elding Problems ......................................... 52 Pop-up Fault Status Screens........................53[...]
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Section 7 – T r oubleshooting Page 51 Dukane Manual Part No. 403-583-00 No Ultrasonic Output Probe Make sure that the probe cable is connected to the generator connector (PROBE) and secured to the rear panel. Also, make sure the probe stack is properly assembled. System Power Output Level Overload When an overload occurs, it will autom[...]
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Page 52 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 W elding Problems W eak Welds 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 duration ([...]
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Section 7 – T r oubleshooting Page 53 Dukane Manual Part No. 403-583-00 Generator Fault Status Screens - Automation 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.[...]
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Section 8 – Specications Page 55 Dukane Manual Part No. 403-583-00 SECTION 8 Specica tions Generator Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 W e i g h t s .......................................... 5 8 O p e r a t i n g E n v i r o n m e n t .............................. 5 8 A C P o w e r R e q u[...]
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Section 8 – Specications Page 57 Dukane Manual Part No. 403-583-00 Figure 8-1 Generator Outline Drawing 12.41 [315.2] 10.00 [254] 3.95 [100.3] 3.51 [89.2] ALLOW 5" (127 mm) BEHIND UNIT FOR CABLE CONNECTIONS IN [mm][...]
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Page 58 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Operatin g En vir onment Operate the equipment within these guidelines: T emperature : 40 °F to 100° F ( +5°C to +38 °C) Air Particulates : Keep the equipment dry . Minimize exposure to [...]
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Section 8 – Specications Page 59 Dukane Manual Part No. 403-583-00 AC Power Requirements Operating Frequency Generator Model Number Overload Power Rating (W atts) Input AC Power Requirements Nominal AC V olt North America/ Japan AC Outlet Rating 20kHz 20ALP060-1E 600 100-120 V AC, 50/60 Hz @ 9.0 Amps 15.0 Amps 20kHz 20ALP060-2E 200-[...]
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Page 60 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 R egu lat or y Age nc y Com pli ance FCC The generator complies with the following Federal Communications Commission regulations. • The limits for FCC measurement procedure MP-5, “Method[...]
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Section 9 – Contacting Dukane Page 61 Dukane Manual Part No. 403-583-00 SECTION 9 Contacting Dukane[...]
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Section 9 – Contacting Dukane Page 63 Dukane Manual Part No. 403-583-00 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 ([...]
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Page 65 Appendices Dukane Manual Part No. 403-583-00 APPENDICES Appendix A - E-Stop Circuitry Examples . . . . . . . . . . . . . . . . 67 Appendix B - List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Appendix C - List of T ables . . . . . . . . . . . . . . . . . . . . . . . . . . . 69[...]
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Page 67 Appendices Dukane Manual Part No. 403-583-00 Figure A-1 E-Stop Circuitry iQ Auto Enable Out Enable In Dedicated E-Stop Switch Wiring Diagram System I/O Connector (Pin 1) (Pin 2) User supplied E-stop switch iQ Auto Enable Out Enable In Automation System Safety Circuit Wiring Diagram System I/O C onnector (Pin 1) (Pin 2) User autom[...]
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Page 68 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 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 .....[...]
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Page 69 Appendices Dukane Manual Part No. 403-583-00 No. Description Page 2-I iQ Generator W eights ........................................................................................................9 3-I Standard IEC AC Power Cord Part Numbers ................................................................. 17 3-II Generator Input[...]
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Dukane ISO ISO CER TIFICA TION Duka ne chos e to beco me ISO 9001:2 008 certi- fied in order to demonstrate to our customers our continuing commitment to being a quality ve ndo r . By pas sin g its aud it , Duka ne can ass ur e you that we have in place a well–defined and systematic approach to quality design, manu- facturing, deliver y and ser[...]
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Par t No. 403 – 58 3 – 00 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • F AX (630) 797- 4949 iQ Series , Ultrasonic Power Supply AL User's Manual Printed in the United States of America www .dukane.com/us Please r ef er to our we bsite at: www .dukane.com/us/sale[...]