Page 1 20121XC0P5 20242XC0P3 20242XC0P5 Dukane Part No. 403–594-02 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797–4900 • FAX (630) 797–4949 ISO 9001 Dukane products are manufactured www.dukane.com/us in ISO registered facilities...
Page 2 The information contained in this manual is distributed on an “As is” basis, without warranty. While every precaution has been taken in the preparation of this manual, Dukane Corporation shall not have any liability to any person or entity with respect to any liability, loss, or damage caused or alleged to be caused directly or indirectly by the instructions contained in this manual, or by the hardware products described herein.
Page 3 Revision History Revision Revision Number Summary Date - 00 Original release. 06/05/2014 - 01 Removed Encoder Option and update 10/4/2016 Agency Compliance - 02 Added stack surface temperature warning 06/15/2017 Page iii Dukane Manual Part No. 403-594-02...
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Page 5: Table Of Contents
Distance Encoder ........76 Continued Page v Dukane Manual Part No. 403-594-02...
Page 6 Section 9 - System Maintenance . . . . . . . . . . . . . . . 97 Section 10 - Contacting Dukane . . . . . . . . . . . . . . 101 Section 11 - Specifications .
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Page 9: Section 1- Introduction
Drawings and Tables ....3 Press System Overview ....4 Page 1 Dukane Manual Part No. 403-594-02...
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Page 11: General User Information
Roman sequence numerals (e.g. –I, –II, –III). As an ex- ample, Figure 3–2 would be the second illustration in sec- Condition Operator Electrical tion three while Table 3–II would be the second table in or Practice Protection Safety Issue section three. (hearing) Page 3 Dukane Manual Part No. 403-594-02...
Page 12: Press System Overview
In addition, a complete system for welding would include a transducer, booster, horn, and fixture. The i220 generator has rugged internal ultrasonic cir- cuitry and ensures a continuous resonant frequency lock at the start of each weld.
Page 13: Section 2 - Health And Safety
Pneumatic Safety ......10 Lifting the Equipment ......11 Page 5 Dukane Manual Part No. 403-594-02...
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Page 15: General Considerations
No Unauthorized Modifications - Do not modify your ducer, booster, horn, and a fixture. system in any way unless authorized to do so by Dukane Corporation. Unauthorized modifications could cause equipment damage and/or injury to the operator. In ad- dition, unauthorized modifications will void equipment warranty.
Page 16: Plastics Health Notice
. Inquiries should be made to the U.S. Department of Labor concerning OSHA regulations for a particular plastic prior to processing with Dukane ultrasonic equipment Electrical Safety CAUTION The iQ Series press provides the operating power and power returns.
Page 17: Domestic Power Grounding
100/120 AC systems is permanently Provided Cable attached to the rear of the press. Units with this Figure 2–2 International 220/240V Grounding power cord are for use in North America or Japan. Page 9 Dukane Manual Part No. 403-594-02...
Page 18: Pneumatic Safety
Filter Service Indicator - Green = Filter Element is OKAY; = Replace Filter Element Filtered Air to Press Compressed Air Filter Safety Isolation Lockout Valve Compressed Air In Figure 2–3 Compressed Air Filter Page 10 Dukane Manual Part No. 403-594-02...
Page 19: Lifting The Equipment
How to Lift Safely Use a mechanical lifting device to safely lift this system. CAUTION The iQ Series Ultrasonic Integrated Press System i220 is too heavy to lift manually. Use a mechanical lift device to assist in safely lifting system When lifting anything follow these common sense steps: components.
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Page 21: Section 3 - Installation
Automation System ....31 Flange Template ....32 Page 13 Dukane Manual Part No. 403-594-02...
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Page 23: Before Installation
When to Use Lockout / Tagout Devices Figure 3-1 Lockout Device In Open Position, Unlocked The typical kind of LOTO device for an i220 press is a clam shell type device (with lockout capability). The LOTO device is placed over the plug end of the electrical cord.
Page 24 Lockout/Tagout Utilities Procedure to use BEFORE making any internal Provide for electricity to meet the equipment adjustments to the i220 press: specifications as shown in Section 11, Specifications. 1. Push the press AC power switch/breaker to the OFF position. 2. Unplug the press electrical cord from its source.
Page 25: Install The Press System
Raise the assembly until the bottom edge of the base is even with the top of the work area as shown in Figure 3-14. Then, carefully slide the press system on to the work area. Page 17 Dukane Manual Part No. 403-594-02...
Page 26: Rear Layout Overview
Attaches to an IEC style power cord. • Chassis Grounding Stud Chassis connection for a protective earth ground. See Page 25. Base Connections • Base Grounding Stud • J35 - Base Interface Connector Figure 3-3 Press Rear View Page 18 Dukane Manual Part No. 403-594-02...
Page 27: Power Inlet Panel
Grounding. operation by simply changing the power cord. The 240VAC i220 systems include a 16/20 amp rated IEC inlet. 120VAC systems include a non-detachable power cord. An appropriately rated power cord must be securely at- tached to the welding system’s IEC inlet connector.
Page 28: System I/O Panel
I/O connector, can configure switch closure inputs to op- erate referenced to press chassis ground (non-isolated), without adding a separate power supply, if desired. Refer to Application Note AN515 (i220 Integrated Press - Automation Interface) at http://www.dukane.com/us/ DL_ApplData.asp for wiring diagrams of example ap- Continued plications.
Page 29 RED/BLK/WHT Isolated U/S Activate/Cycle Start. U/S Activate/Cycle Start GRN/BLK/WHT Isolated input referenced to Isolated U/S Activate/Cycle Start Input Input Common that starts a cycle when activated. Table 3-I System Input/Output Connector Signals (J1) Continued Page 21 Dukane Manual Part No. 403-594-02...
Page 30 Pin 8 (+22VDC Power Supply) This pin can supply +22VDC. Pin 9 (+22VDC Power Supply) This pin can supply +22VDC. Page 22 Dukane Manual Part No. 403-594-02...
Page 31 Pin 12 (System Latch Reset input). Faults that will activate the Any Fault output: • Overload (Average, Peak, or Frequency) • Overtemperature Fault • System Power Fault Continued Page 23 Dukane Manual Part No. 403-594-02...
Page 32: Base/Abort Connector (J6)
Fixture Screw Install a plastic insulator between the fixture and the base plate. Base Plate Figure 3-6 Ground Detect Fixture Installation EtherNet (J9) (Dukane Use Only) USB (J3) (Dukane Use Only) Page 24 Dukane Manual Part No. 403-594-02...
Page 33: Base Connections
Base/Abort connector (J6) on the thruster. See Figure 3-4 for the J6 location. Figure 3-7 Press Base Rear - Grounding Stud and J35 the Base Interface Connector Page 25 Dukane Manual Part No. 403-594-02...
Page 34: Rfi Grounding
Series Ultrasonic Integrated Press System i 220 User’s Manual RFI Grounding CAUTION i220 Press provides the operating power and power To minimize electrical noise returns. Make sure the press is grounded properly. and eliminate ground cur- rents, ground the chassis In addition to the safety considerations, proper grounding as shown.
Page 35: Connecting Press Cables
A.C. Power Cord needed. These include: Grounding J1 - System I/O; Stud J2 - Ground Detect; J9 - EtherNet (DUKANE USE ONLY); and, J3 - USB (DUKANE USE ONLY). Figure 3-8 Press Connections Page 27 Dukane Manual Part No. 403-594-02...
Page 36 200 - 1111 240V, 16A Continental Europe 200 - 1542 240V, 10A Table 3-II Power Cords NOTE Under normal usage, do not apply more than 24 VDC @ 2 Amps to the contacts at J1. Page 28 Dukane Manual Part No. 403-594-02...
Page 37 – – Loosen Tighten Figure 3-10 Using Handles to Make Adjustments Figure 3-11 To Relocate Handles Page 29 Dukane Manual Part No. 403-594-02...
Page 38: Install The Press Without Machine Base
These signals will be generated by user-supplied external sources. Connect a Dukane cable - Part Number 200-1546-xxM - from the J6 connector on the System I/O Panel to user- supplied automation equipment.
Page 39: Automation System
J6 on the Press System I/O Panel. With the open end of the cable the user can make connections from user-supplied equipment to provide for the functions the Dukane cable typically has. See the table below. Pin No. Type...
Page 40: Flange Template
.6 5 inches .6 5 inches (66.675 mm) (66.675 mm) . 5 inches . 5 inches (57.15 mm) (57.15 mm) Figure 3-12 Flange Template No Scaling - Actual Size F n e Tem Page 32 Dukane Manual Part No. 403-594-02...
Page 41: Section 4 - Controls
Indicators ..... . .43 Press Ergonomic Base ....45 Page 33 Dukane Manual Part No. 403-594-02...
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Page 43: Front Panel Controls
POWER, ABORT, TRIGGER LEDs Hot Keys (8) POST WELD LIMITS SETUP LIVE OPERATE WELD WELD INFO Key ONLINE INFO ENTER Navigation Keys (4) OFFLINE TEST ENTER Key CANCEL Key Figure 4-1 Front Panel Controls Page 35 Dukane Manual Part No. 403-594-02...
Page 44: System Operating Mode Keys
PEAK POWER : point settings. DISTANCE PROCESS STATISTICS The word, Offline appears in a white outlined box in the display's upper right corner. Figure 4-3 Display Detail, Power Output Level Page 36 Dukane Manual Part No. 403-594-02...
Page 45: Navigation Keys
PRESS ENTER TO ACCEPT PRESS CANCEL TO ABORT PRE POST AMP WELD LIMITS SETUPS OPERATE LIVE SETUP WELD WELD Figure 4-6 Active Soft Keys, Example Continued Page 37 Dukane Manual Part No. 403-594-02...
Page 46: Hot Keys
Amplitude, Power, Operating Frequency, menu that is being displayed. and Position. (If position is not supported, it is not displayed.) See the next section, OPERATION for more detail on the functions of these hot key sub-menus. Page 38 Dukane Manual Part No. 403-594-02...
Page 47: System Power Output Level
GREEN. This indicates AC power press start-up sequence. has activated the press. When the AC power switch is turned to the OFF position, the front panel POWER goes out indicating the press no longer has power. Page 39 Dukane Manual Part No. 403-594-02...
Page 48: Screen Basics
RAMP DOWN TIME 0.000s PRE POST AMP WELD LIMITS SETUPS OPERATE LIVE SETUP WELD WELD Figure 4-9 Arrows Indicate Direction of More Text Page 40 Dukane Manual Part No. 403-594-02...
Page 49: Press Controls
Weld (Pressure Regulator) The weld (pressure regulator) knob is used to set the amount of air pressure applied to the air cylinder during the press downstroke, the weld, and the hold cycle. Continued Page 41 Dukane Manual Part No. 403-594-02...
Page 50 LCD front display. POST WELD LIMITS LIVE SETUP OPERATE WELD WELD ONLINE INFO ENTER Thruster Height Adjustment OFFLINE TEST Locking Handle Trigger Control Knob Figure 4-10 Press Controls and Indicators - Front View Page 42 Dukane Manual Part No. 403-594-02...
Page 51: Indicators
The stroke position indicator flag is not preset prior to press operation. It moves with the slide assembly as the assembly moves down and up. Mechanical Stop Indicator Flag This setting indicates where the downstroke will end. Continued Page 43 Dukane Manual Part No. 403-594-02...
Page 52 Continued from Previous Page Loosen or tighten the mechanical stop lock with a M5 Hex wrench. Stroke Position Indicator Flag Mechanical Stop Slot Indicator Flag Slot Figure 4-12 Press Left Side View with Detail Continued Page 44 Dukane Manual Part No. 403-594-02...
Page 53: Press Ergonomic Base
(red palm switch). At the back of the base is a cable connector for an interface between the i220 thruster and the base front panel. Base Plate The machined base plate is bolted to the top of the ergo-...
Page 54 The abort switch applies 24 VDC power to the thruster/ electrical codes is also required . press. Pressing the abort switch causes the press to: Dukane Corporation does not assume • Immediately turn off the ultrasound, any responsibility or liability for circuit- •...
Page 55: Section 5 - Operation
Alarms ........69 Page 47 Dukane Manual Part No. 403-594-02...
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Page 57: Press Start-Up Sequence
2) The front panel POWER light (See Figure 5-2.) will flash GREEN a few times, then will glow a steady (OFF) GREEN The display's initial screen identifies the Dukane iQ Figure 5–1 Rear Panel AC Breaker Switch Integrated Press and its major components.
Page 58: Stopping The Weld Cycle
Customer-supplied external controls provide the means to stop the cycle for an automated system. The 200-1546-xxM cable can be used to connect these external controls to the I/O panel at connector J6. See Page 30 for more information. Page 50 Dukane Manual Part No. 403-594-02...
Page 59: Using The Menus
Page 59 SETUP parameters. Display Only - Page 60 Real time Process OPERATE Characteristics. Display Only - Amplitude, Page 61 LIVE Power, Operating Frequency, Distance. Continued Figure 5-3 i220 Integrated Press Menu Overview Page 51 Dukane Manual Part No. 403-594-02...
Page 60: Amp
PRESS CANCEL TO ABORT PRE POST AMP WELD LIMITS SETUPS OPERATE LIVE SETUP WELD WELD Figure 5-5 Setting Weld Amplitude with Afterburst Enabled Continued Page 52 Dukane Manual Part No. 403-594-02...
Page 61 Figure 5-7 Setting Weld Amplitude For more information about Trigger by Power, refer to our Application Note 506 on the Dukane website at: http:// www.dukane.com/us/DL_ApplData.asp If AFTERBURST is enabled in the POST WELD menu, then the AFTERBURST soft key is also displayed as ONLINE ...
Page 62: Pre-Weld
PRESS CANCEL TO ABORT PRE POST AMP WELD LIMITS LIVE SETUPS OPERATE SETUP WELD WELD Figure 5-12 Pre Weld Menu, Pre-Trigger Menu, Amplitude Adjustment Continued Page 54 Dukane Manual Part No. 403-594-02...
Page 63 (Watts), and MAX TIME need to be entered. AMP WELD LIMITS LIVE SETUPS OPERATE SETUP WELD WELD Figure 5-15 Pre Weld Menu, Trigger Selected is Power Page 55 Dukane Manual Part No. 403-594-02...
Page 64: Weld
SETUPS OPERATE SETUP WELD WELD the cycle. This does not result in a fault. Figure 5-19 Weld Menu, Mode: Manual/Automated Press, Energy Entry NOTE Weld Time: Range is 0-30 seconds. Page 56 Dukane Manual Part No. 403-594-02...
Page 65: Post-Weld
WELD LIMITS LIVE SETUPS OPERATE SETUP WELD WELD Figure 5-23 shows the entry box for afterbust amplitude is highlighted. Figure 5-23 Post Weld Menu, Afterburst Enabled Page 57 Dukane Manual Part No. 403-594-02...
Page 66: Limits
WELD SETUP Figure 5-27 Limits Menu, Bad Parts Limits Enabled for Time NOTE The Limits menu items, Weld Distance and Weld Position would not appear in units that do not support distance. Page 58 Dukane Manual Part No. 403-594-02...
Page 67 0.250s AFTERBURST Figure 5-28 displays a typical setup. PRE POST AMP WELD LIMITS LIVE SETUP OPERATE WELD WELD Figure 5-28 Setup, Typical Display Page 59 Dukane Manual Part No. 403-594-02...
Page 68: Operate
As an example, here is a list of all possible characteristics that a distance press could have. (If distance is not sup- ported, then the distance related characteristics would not be available.) Weld Time Peak Power Energy Weld Distance Weld End Position Page 60 Dukane Manual Part No. 403-594-02...
Page 69: Live
POST AMP WELD LIMITS SETUPS LIVE SETUP OPERATE WELD WELD If DISTANCE is not supported, it would not be displayed. Figure 5-32 Test Screen Page 61 Dukane Manual Part No. 403-594-02...
Page 70: Using The Info Menus
See Figure 5-36. METRIC UNITS BACK PRE POST AMP WELD LIMITS LIVE SETUP SETUPS OPERATE WELD WELD Figure 5-36 Regional Settings, Units Menu Continued Page 62 Dukane Manual Part No. 403-594-02...
Page 71 RAMP DOWN TIME 0.000s PRE POST AMP WELD LIMITS LIVE SETUPS OPERATE SETUP WELD WELD Figure 5-38 Advanced Process Control Menu Continued Page 63 Dukane Manual Part No. 403-594-02...
Page 72 Figure 5-38. PRE POST AMP WELD LIMITS SETUPS OPERATE LIVE SETUP WELD WELD Figure 5-40 Restore Defaults, Confirmed, Advanced Process Control Continued Page 64 Dukane Manual Part No. 403-594-02...
Page 73 RAMP UP TIME 0.150s For more information about Frequency Tracking, refer RAMP DOWN TIME 0.000s to our Application Note 513 on the Dukane website at: http://www.dukane.com/us/DL_ApplData.asp ENABLE ONLINE ADV PROCESS CONTROL 2) Free Run Frequency 0°...
Page 74 WELD WELD For more detail on the Scan Stack feature please refer Figure 5-42 Scan Stack - 1 to our website to download: Application Note 512 at http://www.dukane.com/us/ DL_ApplData.asp ONLINE Online FREQUENCY CHECK SCAN 3) Freq Lock and Hold...
Page 75 Range is 0.000 to 0.250 seconds. stresses encountered during the process of shutting off the ultrasound. It is especially recommended for very large horns, or when the ultrasound is shut off in air. Continued Page 67 Dukane Manual Part No. 403-594-02...
Page 76 YES or NO. ONLINE FACTORY DEFAULTS HAVE BEEN RESTORED. If YES is chosen, then another message is displayed as shown to the right. Figure 5-44 Miscellaneous Sub-menu Items Page 68 Dukane Manual Part No. 403-594-02...
Page 77: Alarms
U 308 G enerator o r P ress N ot R eady Table 5-I Alarm Messages Page 69 Dukane Manual Part No. 403-594-02...
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Page 79: Section 6 - Options
Overview........73 Power Inlet Options ......74 Page 71 Dukane Manual Part No. 403-594-02...
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Page 81: Overview
Section 6 - Options Overview This section of the User’s Manual provides a general overview of some options/upgrades for the i220 Integrated Press, all of which are subject to availability. These options/upgrades are: • Power Inlet • Distance Encoder Additional Options Dukane can provide high-quality automation equipment for efficient handling and assembly of parts.
Page 82: Power Inlet Options
See Table 11-II in Section 11, Specifications. any local codes and ordinances that apply. Electrical Safety 120V Power Ground For safety, the power cords used on all Dukane prod- CAUTION ucts have a three-prong, grounding-type plug. If there is any question...
Page 83 (RFI) that is common in an industrial environ- ment. The chassis ground stud is in Figure 6-2. Proper system grounding is discussed on Page 9. Page 75 Dukane Manual Part No. 403-594-02...
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Page 85: Section 7 - Acoustic Stack/Fixture Setup
Fixture Alignment ....85 Fixture Leveling ....86 Page 77 Dukane Manual Part No. 403-594-02...
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Page 87: Overview
Section 7 - Acoustic Stack/Fixture Setup Overview A Dukane iQ i220 integrated press can be used to assemble an unlimited variety of parts for every conceivable market segment, including automotive, medical, appliance, consumer, packaging and toy industries. Various techniques and processes, such as welding, staking, swaging, inserting, and spot welding can be used for the different applications.
Page 88: Stack Description
It also makes it easier to perform regular inspections and/or maintenance of the stack components. TRANSDUCER Contact Button BOOSTER Transducer Housing HORN Anti–Rotation Pins Mounting Stud Mounting Ring Spanner Wrench Hole (Typical) Figure 7-1 Stack Components Page 80 Dukane Manual Part No. 403-594-02...
Page 89: Changing Stack Components
There may be an electri- cal charge stored in the transducer. To avoid any electrical shock, do not touch the contact button when re- moving the stack. CAUTION The stack may be hot. Figure 7-2 Stack Removal Page 81 Dukane Manual Part No. 403-594-02...
Page 90: Stack Disassembly
Doing so will result in damage to the unit. CAUTION  3. Use only the tools recommended by Dukane. To avoid possible injury, NEVER clamp a horn, booster, or transducer in a press down on the vise or use tools such as pliers, visegrips, etc.
Page 91: Stack Assembly And Torque Values
Any of these irregularities will affect the operation of the stack and could cause further damage. Contact the Dukane Ultrasonics Tooling Department concerning a damaged component. When the components have been inspected and are found...
Page 92: Installing A Detachable Tip
Stack Installation 5. Finish tightening the socket head bolts until snug. DO NOT OVER-TIGHTEN! NOTE When all door screws are tightened, a small gap between the door and stack housing is normally present. Page 84 Dukane Manual Part No. 403-594-02...
Page 93: Fixture Installation
Rigidly securing the fixture to the mounting surface. guarded as necessary . Fixture Alignment Dukane Corporation does not assume any responsibility or liability for fixtures To safely align the fixture under the horn, use the following manufactured by the customer or any procedure.
Page 94: Fixture Leveling
Do not overtighten the cap screws. This may flex the fixture plate. Figure 7-10 Tightening the Hold–Down Figure 7-9 Loosening the Hold–Down Cap Screws and Jack Screws Cap Screws and Jack Screws Continued Page 86 Dukane Manual Part No. 403-594-02...
Page 95 All carbon markings will be uniform when all adjustments have been made properly. Adjust the leveling of the fixture and repeat this proce- dure as necessary until you are confident that the fixture is level. Page 87 Dukane Manual Part No. 403-594-02...
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Page 97: Section 8 - Stack Maintenance
Torque Values....... . 93 Page 89 Dukane Manual Part No. 403-594-02...
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Page 99: Inspection Of The Acoustic Stack Components
This condition indicates that contact between the parts occurs only at the burnished areas and not across the full faces of the mating surfaces. See Figure 8-1. The following flatness tolerances are specified for Dukane transducers, boosters, and horns used in 20 kHz Burnished applications: Area Transducer .0005 inch...
Page 100: Reconditioning Stack Components
Tighten the stud to the torque specifications listed the interface surface to in Table 7-I. the centering axis of the part may render the welding system inoperative. Continued Page 92 Dukane Manual Part No. 403-594-02...
Page 101 Table 7-I - Stud Torque Values Table 7-II - Horn/Booster Torque Values NOTE Table 7-III - Replaceable Tip Torque Values Overtightening stack com- ponents may result in horn/ booster studs loosening and unexplained overloads. Page 93 Dukane Manual Part No. 403-594-02...
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Page 103: Section 9 - System Maintenance
Section 9 - System Maintenance SECTION 9 System Maintenance Press Six-Month Periodic Maintenance ... 97 Page 95 Dukane Manual Part No. 403-594-02...
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Page 105 If they do show wear or rubbing then reroute to eliminate the problem. 7. Remount and secure the press/thruster covers and reconnect the press AC power cord to the AC line receptacle. Page 97 Dukane Manual Part No. 403-594-02...
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Page 107: Section 10 - Contacting Dukane
Section 10 - Contact Dukane SECTION 10 Contacting Dukane Page 99 Dukane Manual Part No. 403-594-02...
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Page 109 Section 10 - Contact Dukane Contacting Dukane Identify Equipment When contacting Dukane about a service–related problem, be prepared to give the following information: • Model number, line voltage and serial number. • Alarm indicators from the press display. • Software version.
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Page 111: Section 11 - Specifications
Replacement and Repair Parts ....111 Regulatory Agency Compliance ....112 Page 103 Dukane Manual Part No. 403-594-02...
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Page 113: Layout Drawing
Section 11 - Specifications 8.1 [206] 6.61 [167.9] 6.00 [152.4] 3.50 [88.9] 2.63 [66.7] 2.25 [57.2] 2.25 [57.1] 2.63 [66.7] 3.50 [88.9] 6.00 [152.4] 6.61 [167.9] 8.1 [206] Figure 11-1 Layout - i220 Press System Page 105 Dukane Manual Part No. 403-594-02...
Page 114: Pneumatic Schematic
3) ALL TUBING 1/4" DIA. UNLESS NOTED. PROVISION FOR 1/4" AIR LINE INLET. 4) SEE TUBING KIT FOR MORE DETAILS ON TUBING. 1/4 NPT FEMALE THREAD ON CHECK VALVE. TUBE NUMBERS CIRCLED. 430-07-0030 TUBING KIT Figure 11-2 Pneumatic Schematic Page 106 Dukane Manual Part No. 403-594-02...
Page 115: Electrical Schematic
Section 11 - Specifications TRIG TRIG Figure 11-3 Electric Schematic i220 Page 107 Dukane Manual Part No. 403-594-02...
Page 116: Weights, Dimensions, Operating Environment
Non Operating storage guidelines: Temperature: -4°F to 158°F (-20°C to +70°C) Air Particulates: Keep the equipment dry. Minimize exposure to moisture, dust, dirt, smoke and mold. Humidity: 5% to 95% Non–condensing @ 0°C to +30°C Page 108 Dukane Manual Part No. 403-594-02...
Page 117: Compressed Air Requirements
Section 11 - Specifications Compressed Air Requirements For all press/thruster models, Dukane recommends 60-110 psi of clean, dry air. Maximum available clamping pressure: NOTE Model Force Generated at Standard Air Cylinder 110 psi (lb) Diameter (in) A representative model was 20122XC0P3 2.50...
Page 118: Models, Ultrasonic Pressure
Series Ultrasonic Integrated Press System i 220 User’s Manual Models - iQ Series Integrated Press System i220 Model Number Description 20121XC0P3 iQ Integrated 20kHz 1200 W 120V System with Time and Energy 20122XC0P3 iQ Integrated 20kHz 1200 W 220V System with Time and Energy...
Page 119: Replacement And Repair Parts
Section 11 - Specifications Replacement and Repair Parts - iQ Series i220 Press System Replacement Parts Model Part Number Part Description 43i220 474-33 High pressure grease packet 403-594-XX User's Manual iQ Series Ultrasonic Integrated Press System i220 430-03-0026 iQ main valve assembly...
Page 120: Regulatory Agency Compliance
DO NOT make any modi- IP (International Protection) fications to the press or Rating associated cables as the The iQ i220 Integrated Press has an IP rating from the IEC changes may result in (International Electrotechnical Commission). violating one or more reg- The rating is IP2X, in compliance with finger-safe industry ulations under which this equipment standards.
Page 121: Section 12 - Appendices
Appendix A, List of Figures....115 Appendix B, List of Tables ....118 Page 113 Dukane Manual Part No. 403-594-02...
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Page 123 Ergonomic Base Controls ....................45 4-14 Right Operate Switch in Standby Mode, One LED Dimly Lit .........45 4-15 Right Switch in Operate Mode, Both LEDs Brightly Lit ..........45 4-16 Setting and Resetting the E-STOP ................46 Continued Page 115 Dukane Manual Part No. 403-594-02...
Page 124 Description Page Rear Panel AC Breaker Switch ..................49 Front Panel with Power On Light ...................49 i220 Integrated Press Menu Overview ................51 Setting Weld Amplitude ....................52 Setting Weld Amplitude with Afterburst Enabled ............52 Setting Weld Amplitude, Pre-Trigger Available ..............53 Setting Weld Amplitude ....................53 Setting Weld Amplitude with Afterburst Enabled ............53...
Page 125 Tightening the Hold-Down Cap Screws and Jack Screws ..........88 Example of Burnished Area ...................93 Example of Crowning ....................93 Example of Center Depression ..................93 Method of Component Resurfacing ................94 11-1 Layout - i220 Press System ..................107 11-2 Pneumatic Schematic ....................108 11-3 Electric Schematic i220 ....................109 Page 117...
Page 126: Appendix B - List Of Tables
List of Tables Description Page System Input/Output Connector Signals (J1) ..............21 3-II Power Cords ........................28 3-III Dukane Cable 200-1546-00 Signals ................31 Alarm Messages ......................69 Stud Torque Values .......................85 7-II Horn/Booster Torque Values ..................85 7-III Replaceable Tip Torque Values ..................86 11-I Weights........................110...
Page 127: Index
Section 13 - Index SECTION 13 Index Page 119 Dukane Manual Part No. 403-594-02...
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Page 129 Fixture Alignment 87 Connecting Cables 27 Flange Template 32 Connecting Generator Cables 27 Free Run Freq 65 Connector Freq Lock and Hold 66 Ergonomic Base Connector 25 Controls 33 Generator Front Panel Controls Hot Keys 38 Continued Page 121 Dukane Manual Part No. 403-594-02...
Page 130 Without Machine Base 30 AC Power Inlet Panel 75 Introduction 1 Distance Encoder 76 General User Information 3 Power Inlet Options 74 Key Generator Features 4 Press System Overview 4 IP (International Protection) Rating 114 Continued Page 122 Dukane Manual Part No. 403-594-02...
Page 131 Stack Maintenance 91 Inspection of the Acoustic Stack Components 93 Reconditioning Stack Components 94 Stopping the Weld Cycle 50 System Freq Limits 66 System Inputs Connector 20 System I/O Panel 20 System Inputs Connector 20 Continued Page 123 Dukane Manual Part No. 403-594-02...
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Page 133 By passing its audit, Dukane can assure based on partnership for continuous improve- you that we have in place a well–defined and ment. This concept is key in that Dukane no systematic approach to quality design, manu- longer focuses on inspection, but on individual facturing, delivery and service.
Page 134 Series Ultrasonic Integrated Press System i 220 User's Manual www.dukane.com/us Part No. 403 – 594– 02 Printed in the United States of America Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949...

Dukane i220 User Manual

Table of Contents

Section 2

Section 3

Section 4

Section 4 - Controls

Front Panel Controls

System Operating Mode Keys

Screen Basics

Press Controls

Press Ergonomic Base

Section 5

Section 5 - Operation

Press Start-Up Sequence

Stopping the Weld Cycle

Using the Menus

Alarms

Section 6 - Options

Section 7

Section 7 - Acoustic Stack/Fixture Setup

Overview

Stack Description

Changing Stack Components

Fixture Installation

Section 8 - Stack Maintenance

Inspection of the Acoustic Stack Components

Section 9 - System Maintenance

Section 10 - Contacting Dukane

Section 11 Specifications

Section 11 - Specifications

Appendix A, List of Figures

Section 12 - Appendices

Appendix B - List of Tables

Index

Quick Links

Chapters

Related Manuals for Dukane i220

Summary of Contents for Dukane i220

Table of Contents