Dukane ISO 9001:2008 manual

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Table of contents for the manual

  • 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[...]

  • Page 2

    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 ,[...]

  • Page 3

    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[...]

  • Page 4

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  • Page 5

    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[...]

  • Page 6

    Page  vi  iQ Series , Ultrasonic Power Supply  AL User’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 7

    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 . . . . . . . . . . . . . [...]

  • Page 8

    Page  2  iQ Series , Ultrasonic Power Supply  AL User’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 9

    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[...]

  • Page 10

    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[...]

  • Page 11

    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 [...]

  • Page 12

    Page  6        iQ Series , Ultrasonic Power Supply  AL User’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 13

    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 [...]

  • Page 14

    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[...]

  • Page 15

    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 [...]

  • Page 16

    Page  10                  iQ Series , Ultrasonic Power Supply  AL User’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 17

    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[...]

  • Page 18

    Page  12                  iQ Series , Ultrasonic Power Supply  AL User’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 19

    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[...]

  • Page 20

    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[...]

  • Page 21

    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 [...]

  • Page 22

    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[...]

  • Page 23

    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 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 24

    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[...]

  • Page 25

    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[...]

  • Page 26

    Page  20                  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 27

    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[...]

  • Page 28

    Page  22                  iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 29

    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[...]

  • Page 30

    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[...]

  • Page 31

    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 briey - Figure 4-3, and Figure 4-3A. 3. The next screen is [...]

  • Page 32

    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: [...]

  • Page 33

    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 [...]

  • Page 34

    Page  28                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 35

    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[...]

  • Page 36

    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[...]

  • Page 37

    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 ,[...]

  • Page 38

    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[...]

  • Page 39

    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[...]

  • Page 40

    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[...]

  • Page 41

    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[...]

  • Page 42

    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[...]

  • Page 43

    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 Conguration ............................................ 40 Ultrasonic Horn ............[...]

  • Page 44

    Page  38                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 45

    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[...]

  • Page 46

    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 [...]

  • Page 47

    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[...]

  • Page 48

    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 [...]

  • Page 49

    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[...]

  • Page 50

    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[...]

  • Page 51

    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 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 6–4 [...]

  • Page 52

    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) [...]

  • Page 53

    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 sufcient torque to loosen a joint. See[...]

  • Page 54

    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[...]

  • Page 55

    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[...]

  • Page 56

    Page  50                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 57

    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[...]

  • Page 58

    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 insufcient energy being transmitted to the part. Y ou can increase the weld pressure, increase the weld duration ([...]

  • Page 59

    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.[...]

  • Page 60

    Page  54                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 61

    Section 8 – Specications Page  55 Dukane Manual Part No. 403-583-00 SECTION 8 Specica 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[...]

  • Page 62

    Page  56                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 63

    Section 8 – Specications 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][...]

  • Page 64

    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 [...]

  • Page 65

    Section 8 – Specications 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-[...]

  • Page 66

    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[...]

  • Page 67

    Section 9 – Contacting Dukane Page  61 Dukane Manual Part No. 403-583-00 SECTION 9 Contacting Dukane[...]

  • Page 68

    Page  62                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 69

    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 ([...]

  • Page 70

    Page  64                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 71

    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  66                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

  • Page 73

    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[...]

  • Page 74

    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 .....[...]

  • Page 75

    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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    Page  70                    iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank[...]

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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[...]

  • Page 78

    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[...]