Page 1 HAND PROBE PRESS User's Manual Dukane Part No. 403–586-02 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797–4900 • FAX (630) 797–4949 ISO 9001:2008 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 Date - 00 Original release. 08/01/2012 - 01 Pages Affected: 11/19/2012 Page 91 - Figure 6-3 corrected (Stroke flag position) Page 154 - Regulatory Agency Compliance Updated Added stack surface temperature warning 06/15/2017 Page iii Dukane Manual Part No. 403-586-02...
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Page 5: Table Of Contents
Alarms......... . . 83 Continued Page v Dukane Manual Part No. 403-586-02...
Page 6 Press/Thruster Six-Month Periodic Maintenance ..135 Section 11 - Contacting Dukane . . . . . . . . . . . . . . 137...
Page 7 Section 14 - Index . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Page vii Dukane Manual Part No. 403-586-02...
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Page 9: Section 1- Introduction
Press System Overview ....4 Key Generator Features ....4 Page 1 Dukane Manual Part No. 403-586-02...
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Page 11: General User Information
(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. 403-586-02...
Page 12: Press System Overview
• Load Regulation provides constant ultrasound am- plitude automatically regardless of power draw. The An iQ Series Ultrasonic Press System LE consists of these ultrasonic output amplitude level is held to within components: the iQ generator, and press (with thruster, ±1% to provide weld process consistency and re-...
Page 13: Section 2 - Health And Safety
International Power Grounding ....9 Lifting the Equipment ......10 Page 5 Dukane Manual Part No. 403-586-02...
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Page 15: General Considerations
No Unauthorized Modifications - Do not modify your transducer, booster, horn, and 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-...
Page 16: Plastics Health Notice
OSHA regulations for a particular plastic prior to processing with Dukane ultrasonic equipment Electrical Safety CAUTION The iQ Series generator provides the operating power When making cable connec- and power returns. Make sure the generator is grounded tions to system equipment properly.
Page 17: Domestic Power Grounding
100/120 AC systems is permanently Provided Cable attached to the rear of the generator. 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. 403-586-02...
Page 18: Lifting The Equipment
To place the object below the level of your waist, follow the same procedures in re- verse order. Remember, keep your back as vertical as possible and bend at the knees. Page 10 Dukane Manual Part No. 403-586-02...
Page 19: Section 3 - Installation
Connecting Press Cables ... . . 32 Flange Template ....35 Page 11 Dukane Manual Part No. 403-586-02...
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Page 21: Before Installation
See the example of one such device in the figure above. The figure to the right shows the lockout device in the closed, locked position. Figure 3-2 Bottom Lockout Device In Closed Position, Locked Continued Page 13 Dukane Manual Part No. 403-586-02...
Page 22: Utilities
Open the shell, exposing the electrical cord end. Remove the LOTO device, and set it aside. 2. Plug the generator's electrical cord into its AC power source. 3. Push the generator's AC power switch/breaker to the ON position. Page 14 Dukane Manual Part No. 403-586-02...
Page 23 Rack- Mounting Install the four brackets from Dukane's rack-mount kit to the generator. See Table 3-I, and Figure 3-3 (showing a System Type Dukane Part Number low profile unit) below.
Page 24 SIDES FOR COOLING. FOR COOLING. from what is shown here. OPTIONAL HOLD DOWN BRACKETS 147-1398 OPTIONAL HOLD [mm] DOWN BRACKETS Figure 3-4 Securing iQ Generator to Benchtop - Representative High-Profile Model Shown Page 16 Dukane Manual Part No. 403-586-02...
Page 25: Rear Panel Layout Overview
Ultrasound Output Connector (J1) – Coaxial high See Section 6, Options for more voltage connection to ultrasonic stack. information about the Press Interface Module. Configuration Port Connector (J4) – Digital control port to modify system parameters. Page 17 Dukane Manual Part No. 403-586-02...
Page 26 24V. All inputs sink or source 10mA of current from a 24VDC power supply. Continued Page 18 Dukane Manual Part No. 403-586-02...
Page 27 Table 3-II, to assist with custom automation system wir- ing and assembly. Figure 3-7 System I/O Panel (Standard Panel Shown) NOTE Refer to Section 6, Options for information on optional features. Continued Page 19 Dukane Manual Part No. 403-586-02...
Page 28 Pin 4 is the Remote Setup Selection Bit 1, which is the Figure 3-9 HD-15M, Generator Input Cable second least significant bit used to select different welding Connector setups with an automation control system. Continued Page 20 Dukane Manual Part No. 403-586-02...
Page 29 This pin must be left open whenever a press control board is installed. Connecting this pin to chassis ground will inhibit press operation. Page 21 Dukane Manual Part No. 403-586-02...
Page 30 Figure 3–11 DB-25M, Generator Output Cable power levels, referenced to the Monitor Common (Pin 13). Connector This is at system chassis ground potential (non-isolated). Continued Page 22 Dukane Manual Part No. 403-586-02...
Page 31 Pin 8 is a digital status output that activates when the specified trigger type has occurred. It will remain ac- tive until the end of cycle. This output will be an open circuit when a trigger condition hasn’t been detected. Continued Page 23 Dukane Manual Part No. 403-586-02...
Page 32 Pin 14 (Not Used) Pin 14 is connected to the system chassis ground. Continued Page 24 Dukane Manual Part No. 403-586-02...
Page 33 Pin 25 is an open connection. ous welding cycle are outside of the programmed bad part limits. This output will be an open circuit when a bad part has not been detected. Page 25 Dukane Manual Part No. 403-586-02...
Page 34 (black carbon deposits) port features. on either the ultrasound output connector or the ultrasound cable connectors. Figure 3-13 Configuration Port Connector Page 26 Dukane Manual Part No. 403-586-02...
Page 35: Rfi Grounding
Section 3 - Installation RFI Grounding CAUTION iQ Series generator provides the operating power To minimize electrical noise and power returns. Make sure the generator is grounded and eliminate ground cur- properly. rents, ground the chassis as shown. Use a STAR con- In addition to the safety considerations, proper grounding figuration (illustrated below).
Page 36: Connecting Generator Cables
CAUTION Step 2. Ultrasound (J1) - This output connects the Ul- The power cord is equipped trasound Output of the iQ Series generator to the with a three-prong, ground- transducer, through a coaxial cable. The electrical ed-type plug for your welding signal is transmitted through this cable.
Page 37: Installing 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 29 Dukane Manual Part No. 403-586-02...
Page 38: Installing The Press Without Machine Base
To rotate the handles out of the way without loosen- ing or tightening, pull the handles outward, rotate and release, as shown in Figure 3-16. – – Loosen Tighten Figure 3-15 Using Handles to Make Adjustments Figure 3-16 To Relocate Handles Page 30 Dukane Manual Part No. 403-586-02...
Page 39: Installing The Thruster
Figure 3-17. Align the thruster with the work surface in both the horizontal and vertical planes to assure parallel- ism. Tighten the bolts. When mounted to a Dukane column as in the press Mounting Bolts configuration, the height of the thruster is adjustable on the column.
Page 40: Connecting Press Cables
Cable dicate to the controlling mechanism (supplied by the end user) when the slide assembly is fully retracted. A Dukane cable (Part Number 438-528) mates with this receptacle to allow access to the switch contacts. Air Filter NOTE...
Page 41 “Air In” fitting. supplied J207 J207 control Thruster systems require that Dukane's cable (Part Dukane's cable (Part Number 200-1546-03) is Number 200-1546-03) is installed in the generator's installed in the generator's J7 receptacle.
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Page 43: 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 3-20 Flange Template No Scaling - Actual Size F n e Tem Page 35 Dukane Manual Part No. 403-586-02...
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Page 45: Section 4 - Controls
Thruster Indicators ....50 Press Ergonomic Base ....50 Page 37 Dukane Manual Part No. 403-586-02...
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Page 47: Generator Front Panel Controls
Section 4 - Controls Generator Front Panel Controls This section introduces the iQ Series ultrasonic generator LE control panel and LCD display with this information: • Functions of the panel components shown in Figure NOTE 4-1 below are discussed. Do not touch the display.
Page 48: System Operating Mode Keys
The word, Offline appears in a white outlined box in the PART COUNT: WELD TIME : 0.000s display's upper right corner. ENERGY: PEAK POWER : DISTANCE PROCESS STATISTICS Figure 4-3 Display Detail, Power Output Level Page 40 Dukane Manual Part No. 403-586-02...
Page 49: Navigation Keys
PRESS ENTER TO ACCEPT PRESS CANCEL TO ABORT PRE POST AMP WELD LIMITS SETUPS OPERATE LIVE WELD WELD Figure 4-6 Active Soft Keys, Example Continued Page 41 Dukane Manual Part No. 403-586-02...
Page 50: Hot Keys
Hot Key menu is and Position. (If position is not supported, it is not being displayed. displayed.) See the next section, OPERATION for more detail on the functions of these hot key sub-menus. Page 42 Dukane Manual Part No. 403-586-02...
Page 51: System Power Output Level
When the AC power switch is turned to the OFF position, Sequence for an explanation of the the front panel light goes out indicating the generator no generator start-up sequence. longer has power. Page 43 Dukane Manual Part No. 403-586-02...
Page 52: Screen Basics
# 7 - SETUP# 7 PRE POST AMP WELD LIMITS SETUPS LIVE OPERATE WELD WELD Figure 4-9 Arrows Indicate Direction of More Text Page 44 Dukane Manual Part No. 403-586-02...
Page 53 PEAK POWER : DISTANCE PROCESS STATISTICS PRE POST AMP WELD LIMITS LIVE SETUPS OPERATE WELD WELD Figure 4-10 Main Menu Detail - Setup Identification Page 45 Dukane Manual Part No. 403-586-02...
Page 54: Press Controls
(177.8 mm) of total available downstroke distance that the This is the thruster's maximum available hydraulic Speed Control engages. distance of travel. Refer to Section 6: Options, for detailed information on the Hydraulic Slow Speed Control. Continued Page 46 Dukane Manual Part No. 403-586-02...
Page 55 The Regulator Select switch is used to select Pressure 1 regulator (Weld Pressure) or Pressure 2 regulator (Hold Pressure) to set the required pressure on each regulator and for monitoring the pressure gauge. Continued Page 47 Dukane Manual Part No. 403-586-02...
Page 56 UNLOCK KNOB Slow Speed LOWERS Trigger Control Adjustment SPEED CONTROL (Numbers displayed are (Velocity TRIGGER for reference only.) Damping) 3 5 0 Figure 4-11 (Manual) Press/Thruster Controls and Indicators - Model 220 Shown Page 48 Dukane Manual Part No. 403-586-02...
Page 57 To ensure safe operation, adjust the pre-trig- ger so the ultrasound signal will not activate if the horn is more than ¼ in (7 mm) from the part to be welded. Continued Page 49 Dukane Manual Part No. 403-586-02...
Page 58: Press Ergonomic Base
(red palm switch), and a status display wer i t re screen. At the back of the base is a cable connector for an wer i t re interface between the iQ Series generator and the base front panel. Base Plate St p Switc h The machined base plate is bolted to the top of the ergo- nomic base.
Page 59 ANSI requirements . Compliance with all local building and electrical codes is also required . Dukane Corporation does not assume any responsibility or liability for circuit- ry modifications made by the customer or by any third party manufacturer .
Page 60 . ABORT • - When the abort switch is pushed in, the Dukane Corporation does not assume red ABORT status indicator illuminates. Press opera- any responsibility or liability for circuit- tion is no longer possible.
Page 61: Section 5 - Operation
Alarms ........83 Page 53 Dukane Manual Part No. 403-586-02...
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Page 63: Overview
Section 5 - Operation Overview NOTE The iQ Series generator, model LE, is typically part of a Press, acoustic stack, and tooling will system. System major components would be: require their own individual adjustments as • iQ generator, those components are integrated into your •...
Page 64: Stopping The Weld Cycle
An auxiliary cable connects these external controls to the iQ generator at connector J2. Control input labeled, “Automation Cycle Stop Input” (Pin 15) when activated will stop the weld cycle if configured as “End of Weld”. Page 56 Dukane Manual Part No. 403-586-02...
Page 65: Using The Menus
Page 69 SETUPS Copy Setup Erase Setup Display Only - Page 72 Real time Process OPERATE Characteristics. Display Only - Page 74 LIVE Amplitude, Power, Frequency, Position. Continued Figure 5-3 Generator Menu Overview Page 57 Dukane Manual Part No. 403-586-02...
Page 66: Amp
PRE POST AMP WELD LIMITS LIVE SETUPS OPERATE WELD WELD Figure 5-5 Setting Weld Amplitude with Afterburst Enabled Continued Page 58 Dukane Manual Part No. 403-586-02...
Page 67 POST AMP WELD LIMITS SETUPS OPERATE LIVE WELD WELD Figure 5-7 Setting Weld Amplitude with Trigger By Power Enabled NOTE Amplitude Range = 20 -100% Page 59 Dukane Manual Part No. 403-586-02...
Page 68: Pre-Weld
WELD WELD PROBE DELAY menu is shown in Figure 5-9 at right. Figure 5-9 Pre Weld Menu, Probe Delay NOTE PROBE DELAY is only available in AUTO- MATED PROBE MODE. Continued Page 60 Dukane Manual Part No. 403-586-02...
Page 69 PRESS ENTER TO CHANGE PRE POST AMP WELD LIMITS SETUPS LIVE OPERATE WELD WELD Figure 5-13 Pre Weld Menu, Trigger By Power Selected Continued Page 61 Dukane Manual Part No. 403-586-02...
Page 70 PRESS ENTER TO SELECT PRE POST AMP WELD LIMITS SETUPS OPERATE LIVE WELD WELD Figure 5-17 Pre Weld Menu, Press Supports Distance Continued Page 62 Dukane Manual Part No. 403-586-02...
Page 71 PRE-TRIGGER TRIGGER PRESS ENTER TO CHANGE PRE POST AMP WELD LIMITS SETUPS OPERATE LIVE WELD WELD Figure 5-22 Pre-Trigger Menu, Position Selected Page 63 Dukane Manual Part No. 403-586-02...
Page 72: Weld
PRESS CANCEL TO ABORT be entered. PRE POST AMP WELD LIMITS LIVE SETUPS OPERATE WELD WELD Figure 5-26 Weld Menu, Mode: Manual/Automated Press, Energy Selection Continued Page 64 Dukane Manual Part No. 403-586-02...
Page 73 POST AMP WELD LIMITS LIVE SETUPS OPERATE WELD WELD Figure 5-28 Weld Menu, Mode: Manual/Automated Press, Energy Entry NOTE Weld Time: Range is 0-30 seconds. Page 65 Dukane Manual Part No. 403-586-02...
Page 74: Post-Weld
PRESS ENTER TO ACCEPT PRESS CANCEL TO ABORT PRE POST AMP WELD LIMITS LIVE SETUPS OPERATE WELD WELD Figure 5-32 Post Weld Menu, Afterburst Enabled Page 66 Dukane Manual Part No. 403-586-02...
Page 75: Limits
TOTAL CYCLE TIME ENABLED PRE POST AMP WELD LIMITS SETUPS LIVE OPERATE WELD WELD Figure 5-35 Limits Menu, Press Mode, Distance Is Supported Continued Page 67 Dukane Manual Part No. 403-586-02...
Page 76 BAD PART LIMITS are enabled for TIME. SUSPECT DISABLED PRE POST AMP WELD LIMITS LIVE SETUPS OPERATE WELD WELD Figure 5-38 Limits Menu, Bad Parts Limits Enabled for Time Page 68 Dukane Manual Part No. 403-586-02...
Page 77: Setups
A total of 8 (eight) setups can be made. When the setup name is not highlighted, there is a box around it. This indicates that pressing the soft key next to the box allows the box to be edited. Continued Page 69 Dukane Manual Part No. 403-586-02...
Page 78 Figure 5-44 is displayed - for about 5 seconds. Figure 5-44 Setups Menu, Setup Copied Confirmation The next screen displayed is the COPY SETUP screen as shown in Figure 5-42 above. Continued Page 70 Dukane Manual Part No. 403-586-02...
Page 79 5 seconds. Then, the ERASE setup menu is shown. Figure 5-47 Setups Menu, Confirm Erase If ALL SETUPS was chosen in the setup menu, the mes- sage would be: ALL SETUPS ERASED. Page 71 Dukane Manual Part No. 403-586-02...
Page 80: Operate
Weld Distance Downstroke Time Weld End Position Downstroke Distance Hold End Position Trigger Delay Time Hold Time Trigger Delay Distance Hold Distance Time Total Cycle Time Peak Power Total Cycle Distance Energy Continued Page 72 Dukane Manual Part No. 403-586-02...
Page 81 SETUPS OPERATE WELD WELD Example: Number of GOOD parts divided by the total PART COUNT multiplied by 100 equals the percentage Figure 5-49 Operate Screen - II of GOOD parts. Page 73 Dukane Manual Part No. 403-586-02...
Page 82: Live
PRE POST AMP WELD LIMITS SETUPS OPERATE LIVE WELD WELD If DISTANCE is not supported, it would not be displayed. Figure 5-52 Test Screen Page 74 Dukane Manual Part No. 403-586-02...
Page 83: Using The Info Menus
See Figure 5-56. METRIC UNITS BACK PRE POST AMP WELD LIMITS LIVE SETUPS OPERATE WELD WELD Figure 5-56 Regional Settings, Units Menu Continued Page 75 Dukane Manual Part No. 403-586-02...
Page 84 0.150s RAMP DOWN TIME 0.000s PRE POST AMP WELD LIMITS SETUPS LIVE OPERATE WELD WELD Figure 5-58 Advanced Process Control Menu Continued Page 76 Dukane Manual Part No. 403-586-02...
Page 85 Figure 5-58. PRE POST AMP WELD LIMITS SETUPS OPERATE LIVE WELD WELD Figure 5-60 Restore Defaults, Confirmed, Advanced Process Control Continued Page 77 Dukane Manual Part No. 403-586-02...
Page 86 When > is next to RAMP DOWN TIME, and the down key (minus) is pressed, the next sub-menu for System Status IO replaces the Adv Process Figure 5-61 Advanced Process Control Sub-menu Items Control sub-menu. Continued Page 78 Dukane Manual Part No. 403-586-02...
Page 87 6) Ramp Down Time Ramp down time decreases the amplitude linearly to zero in the programmed time period following the end of the weld, when ultrasound is shutting off. Range is 0.000 to 0.250 seconds. Page 79 Dukane Manual Part No. 403-586-02...
Page 88 5-64 is shown for 5 seconds. BEEN RESTORED TO DEFAULT VALUES After that, the display will once again appear as it does in Figure 5-62. Figure 5-64 System Status I/O Defaults Restored Continued Page 80 Dukane Manual Part No. 403-586-02...
Page 89 When > is next to OUTPUT DURATION, and the down > OUTPUT DURATION MAINTAINED key (minus) is pressed, the next sub-menu for MISCEL- LANEOUS replaces the SYSTEM STATUS IO sub- menu. Figure 5-65 System Status I/O Sub-menu Items Page 81 Dukane Manual Part No. 403-586-02...
Page 90 BE RESTORED. ARE YOU SURE YOU WANT TO PROCEED? If confirmed, then another message is displayed ONLINE as shown to the right. FACTORY DEFAULTS HAVE BEEN RESTORED. Figure 5-66 Miscellaneous Sub-menu Items Page 82 Dukane Manual Part No. 403-586-02...
Page 91: Alarms
U 308 G enerator o r P ress N ot R eady Table 5-I Alarm Messages Page 83 Dukane Manual Part No. 403-586-02...
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Page 93: Section 6 - Options
Hydraulic Speed Control..... . . 91 Distance Encoder ......93 Page 85 Dukane Manual Part No. 403-586-02...
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Page 95: Overview
Dukane can also provide standard and custom sound enclosures. The additional options are not covered in this manual due to their specialized applications. Contact your local Dukane representative for more spe- cific information, or visit the Dukane website: www.dukane.com/us/PCU_custom.htm...
Page 96: Power Inlet Options
See Table 12-II in Section 12, 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 97 (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 89 Dukane Manual Part No. 403-586-02...
Page 98: Press Interface Module
Series iQ Series The iQ Series module, P4, supports press system op- The iQ Series module, P5, adds support for distance, eration through two connectors: and that requires a third connector: • J5 - Thruster - Provides control for thruster...
Page 99: Hydraulic Speed Control
The hydraulic cylinder is mounted in a clamping block. The optional air cylinders (1.5", 2", and The block is threaded onto a long rod. 3" in diameter) are factory installed and do not require any field adjustments. Continued Page 91 Dukane Manual Part No. 403-586-02...
Page 100 Zero (0) is the fastest setting, and thirty (30) is the slowest setting. Decrease Increase Figure 6-6 Adjustment Using the Slot Page 92 Dukane Manual Part No. 403-586-02...
Page 101: Distance Encoder
Figure 6-7 Distance Encoder Mounting encoder head cable, being careful not to interfere with the press movement. 4. Connect the encoder cable to the generator connector J-11 (Encoder). 5. Replace the rear panel on the press. Continued Page 93 Dukane Manual Part No. 403-586-02...
Page 102 Allow the thruster to return to top of stroke. • If the encoder position reads -0.06" to 0.30", then the encoder is set correctly. • Secure the two screws. Proceed to Step 7. Continued Page 94 Dukane Manual Part No. 403-586-02...
Page 103 ±.005. This is a range of from .034 to .044 inches (.864 to 1.12 mm). 9. Tighten all the screws and check the measurements again. 10. Replace the press/thruster right side panel. Page 95 Dukane Manual Part No. 403-586-02...
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Page 105: Section 7 - Acoustic Stack/Fixture Setup
Fixture Alignment ....105 Fixture Leveling ....106 Page 97 Dukane Manual Part No. 403-586-02...
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Page 107: Overview
Section 7 - Acoustic Stack/Fixture Setup Overview A Dukane press/thruster and a iQ Series generator 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 108: 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 100 Dukane Manual Part No. 403-586-02...
Page 109: 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 101 Dukane Manual Part No. 403-586-02...
Page 110: 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 111: 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 112: 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 104 Dukane Manual Part No. 403-586-02...
Page 113: 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 114: 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 106 Dukane Manual Part No. 403-586-02...
Page 115 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 107 Dukane Manual Part No. 403-586-02...
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Page 117: Section 8 - Stack Maintenance
Torque Values....... 113 Page 109 Dukane Manual Part No. 403-586-02...
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Page 119: 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 120: 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 112 Dukane Manual Part No. 403-586-02...
Page 121 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 113 Dukane Manual Part No. 403-586-02...
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Page 123: Section 9 - Troubleshooting
Staking ........128 Continuous Welding ......131 Page 115 Dukane Manual Part No. 403-586-02...
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Page 125: Overview
The switch is generally not used with a system that contains a process controller with a distance measurement function or a press/thruster equipped with an optical distance encoder. Page 117 Dukane Manual Part No. 403-586-02...
Page 126: Welding
Weld time is too long. Reduce the weld time. Non-uniform joint dimensions. Re-dimension the joint. Redesign the joint to be a shear joint or a tongue-in-groove joint. Contact Dukane's Applications Lab. Check the processing conditions. Part fit or tolerances. Loosen the part fit.
Page 127 Too much energy is being transmitted Reduce the air pressure. to the part. Reduce the weld time/primary weld characteristic. Change to a lower gain booster to reduce the horn amplitude. Reduce downstroke speed. _______________________________________________________________________________ Continued Page 119 Dukane Manual Part No. 403-586-02...
Page 128 A long weld time. Decrease the weld time and increase the horn amplitude and/or the air pressure. Inherent stress. Check the molding conditions. Check the part design. Reduce the horn amplitude. __________________________________________________________________________________ Continued Page 120 Dukane Manual Part No. 403-586-02...
Page 129 Redesign the fixture to improve the the fixture. support in critical areas. Change to a rigid fixture. If large sections of urethane are deflecting with a resilient fixture, add a rigid backup. _______________________________________________________________________________ Continued Page 121 Dukane Manual Part No. 403-586-02...
Page 130 Check with the molder. Check the molding conditions. There is moisture in the molded parts. Specify the parts to be “dry as molded”. Dry the parts by heating them prior to welding. _________________________________________________________________________________ Continued Page 122 Dukane Manual Part No. 403-586-02...
Page 131 Incorrect part tolerances. Tighten the part tolerances. Check the part dimensions. Check the molding dimensions. There are cavity-to-cavity variations. Check the part dimensions and tolerances. Check for cavity wear. Check the molding conditions. ________________________________________________________________________________ Continued Page 123 Dukane Manual Part No. 403-586-02...
Page 132 Check the horn/part fit. Check the part/fixture fit. Level the fixture, where necessary. Rigid fixture reflects vibratory energy. Dampen the energy by using teflon, neoprene, cork, or urethane in the nest of the fixture. __________________________________________________________________________________ Page 124 Dukane Manual Part No. 403-586-02...
Page 133: Insertion
If required, re-level or shim the fixture. Measure the horn tip length to check for dimensional consistency. If a varying length is found, send the horn to Dukane for modification. _______________________________________________________________________________ Continued Page 125 Dukane Manual Part No. 403-586-02...
Page 134 The area of the part being inserted Support the part directly under the boss. is not being rigidly supported. Install a metal post directly under the part being inserted. The down speed is slow. Increase the down speed. Continued Page 126 Dukane Manual Part No. 403-586-02...
Page 135 There is too much interference Increase the hole diameter. between the hole and the insert. Use smaller inserts. The insert is being driven too deep. Reset the bottom stop. Decrease the primary weld characteristic. _________________________________________________________________________________ Page 127 Dukane Manual Part No. 403-586-02...
Page 136: Stacking
There is a loose fit between the staked head and the part being attached. Probable Cause Solution The hole diameter relative to Reduce the hole diameter. the stud diameter is too large. Continued Page 128 Dukane Manual Part No. 403-586-02...
Page 137 The trigger force is too high. Reduce the trigger force. Pre-trigger the ultrasound. The horn amplitude is insufficient. Increase the amplitude. The downstroke speed is too fast. Use hydraulic speed control. Use a slower downstroke speed. _________________________________________________________________________________ Continued Page 129 Dukane Manual Part No. 403-586-02...
Page 138 The horn tip is heating and not Cool the horn tip. allowing the stud to solidify. Use afterburst. _________________________________________________________________________________ NOTE The use of a knurled horn tip and a pointed stud can help solve many of the above problems. Page 130 Dukane Manual Part No. 403-586-02...
Page 139: Continuous Welding
Probable Cause Solution Not enough air flow to dissipate Continuous duty applications require heat buildup. cooling air (refrigerated air, in some applications). Supply air to the stack interfaces and the horn tips. ________________________________________________________________________________ Continued Page 131 Dukane Manual Part No. 403-586-02...
Page 140 Booster failure. Replace booster. Stack operating frequency shifted Cool stack with air. out of tolerance. _________________________________________________________________________________ NOTE Table 5-I, Page 83, shows alarm messages that indicate generator status, and appear only on display-capable generators. Page 132 Dukane Manual Part No. 403-586-02...
Page 141: Section 10 - System Maintenance
Section 10 - System Maintenance SECTION 10 System Maintenance Press/Thruster Six-Month Periodic Maintenance . . . 135 Page 133 Dukane Manual Part No. 403-586-02...
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Page 143: Press/Thruster Six-Month Periodic Maintenance
If they do show wear or rubbing then reroute to eliminate the problem. 7. Remount and secure the press/thruster covers and reconnect the generator AC power cord to the AC line receptacle. Page 135 Dukane Manual Part No. 403-586-02...
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Page 145: Section 11 - Contacting Dukane
Section 11 - Contacting Dukane SECTION 11 Contacting Dukane Page 137 Dukane Manual Part No. 403-586-02...
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Page 147 Section 11 - Contacting 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 generator display. • Software version.
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Page 149: Section 12 - Specifications
Replacement Parts ......153 Regulatory Agency Compliance ....154 Page 141 Dukane Manual Part No. 403-586-02...
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Page 151: Outline Drawings
Section 12 - Specifications OPTIONAL IQ GENERATOR Figure 12-1 Layout - 220 Thruster Page 143 Dukane Manual Part No. 403-586-02...
Page 152 Series Ultrasonic Press System LE User’s Manual (PART HEIGHT+FIXTURE) 15.00 MAX. [381] TYPICAL HORN 5.38 STROKE [137] 7.00 MAX. [178] Figure 12-2 Layout - 220 Press Page 144 Dukane Manual Part No. 403-586-02...
Page 153 Section 12 - Specifications Figure 12-3 Pneumatic Schematic (All iQ LE Presses) Page 145 Dukane Manual Part No. 403-586-02...
Page 154 Series Ultrasonic Press System LE User’s Manual Figure 12-4 Electric Schematic 220 Page 146 Dukane Manual Part No. 403-586-02...
Page 155 Section 12 - Specifications Figure 12-5 iQ LE Basic Generator Layout Page 147 Dukane Manual Part No. 403-586-02...
Page 156 Series Ultrasonic Press System LE User’s Manual Figure 12-6 iQ LE 4800W Generator Layout Page 148 Dukane Manual Part No. 403-586-02...
Page 157: 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 149 Dukane Manual Part No. 403-586-02...
Page 158: Compressed Air Requirements
Clamping Pressure AC Power Requirements he press/thruster uses 24VDC @ 2 Amps, obtained from the iQ Series generator to which it is connected. The AC line voltage and current needed depend on whichever generator has been chosen for your system. See the table below.
Page 159: Interpreting The Model Number Codes
Model numbers use combinations of letters and numbers to identify each system and its major components. Codes are given here for: • iQ Series LE - Overall System Models (See Figure 12-7 below), • Thruster Models (See Table 12-V below), and •...
Page 160 Series Ultrasonic Press System LE User’s Manual Figure 12- 8 Generator Model Numbers Page 152 Dukane Manual Part No. 403-586-02...
Page 161: Replacement Parts List
Part Description 43Q215 43Q220 474-33 High pressure grease packet 403-586 User's Manual iQ Series Ultrasonic Press System LE 430-03-0026 iQ main valve assembly 697-113 Air pressure gauge (NOT needed if standard option E is installed) 721-31-00056 Transducer door hex key 43Q220/43Q340...
Page 162: Regulatory Agency Compliance
Machines Part 1: General Requirements. IP (International Protection) Rating The iQ generator has an IP rating from the IEC (Interna- tional Electrotechnical Commission). The rating is IP2X, in compliance with finger-safe industry standards. Page 154 Dukane Manual Part No. 403-586-02...
Page 163: Section 13 - Appendices
Appendix A, List of Figures....157 Appendix B, List of Tables ....161 Page 155 Dukane Manual Part No. 403-586-02...
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Page 165: Appendix A List Of Figures
Display Detail, Power Output Level ................43 Making Selections ......................44 Arrows Indicate Direction of More Text ................44 4-10 Main Menu Detail- Setup Identification ................45 4-11 (Manual) Press/Thruster Controls and Indicators (Model 220 Shown) ......48 Continued Page 157 Dukane Manual Part No. 403-586-02...
Page 166 Weld Menu, Mode: Manual/Automated Press, Distance is Supported ......65 5-28 Weld Menu, Mode: Manual/Automated Press, Energy Entry ........65 5-29 Post Weld Menu, Mode: Automated Probe ..............66 5-30 Post Weld Menu, Time Setting ..................66 Continued Page 158 Dukane Manual Part No. 403-586-02...
Page 167 Restore Defaults, Confirmed, Advanced Process Controls ...........77 5-61 Advanced Process Control Sub-menu Items ..............78 5-62 System Status I/O Sub-menu ..................80 5-63 System Status I/O Restore Defaults? ................80 5-64 System Status I/O Defaults Restored ................80 Continued Page 159 Dukane Manual Part No. 403-586-02...
Page 168 Pneumatic Schematic (All iQ LE Presses) ..............145 12-4 Electrical Schematic 220 .....................146 12-5 iQ LE Basic Generator Layout ..................147 12-6 iQ LE 4800W Generator Layout ..................148 12-7 System Model Numbers ....................151 12-8 Generator Model Numbers ..................152 Continued Page 160 Dukane Manual Part No. 403-586-02...
Page 169: Appendix B List Of Tables
Weld Characteristics and Equipment Requirements ............. 117 12-I Weights ......................... 149 12-II Dimensions ........................149 12-III Clamping Pressure ....................... 150 12-IV AC Power Requirements ....................150 12-V Interpreting the Thruster Model Number ...............151 12-VI Replacement Parts .......................153 Page 161 Dukane Manual Part No. 403-586-02...
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Page 171: Section 14 - Index
Section 14 - Index SECTION 14 Index Page 163 Dukane Manual Part No. 403-586-02...
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Page 173 Mechanical Stop Indicator Flag 50 Pressure Gauge 50 Base Plate 50 Slow Speed Indicator Flag (Optional) 50 Base Status Display 52 Stroke Position Indicator Flag 50 Benchtop Mounting 16 Ultrasound Active Status Light 50 Continued Page 165 Dukane Manual Part No. 403-586-02...
Page 174 Linear Ramp Soft-Start 4 Line Voltage Regulation 4 Press System Overview 4 IP (International Protection) Rating 154 Load Regulation 4 ISO 9001 Certificatio 4 Low Line Voltage Power Supply 4 Multiple Electronic Overload 4 Continued Page 166 Dukane Manual Part No. 403-586-02...
Page 175 Replacement Parts 153 INFO 75 RFI Grounding 27 ADVANCED SETTINGS 76 RS232 4 REGIONAL SETTINGS 75 SYSTEM INFO 75 UNITS 75 LIMITS 67 OPERATE 72 POST-WELD 66 PRE-WELD 60 SETUPS 69 WELD 64 Continued Page 167 Dukane Manual Part No. 403-586-02...
Page 176 System Outputs Signal Descriptions 23 System Power Output Level 43 System Status I/O Auto Start Input 81 Auto Stop Input 81 J3 Pin 4 81 J3 Pin 5 81 Output Duration 81 SYSTEM STATUS I/O 80 Page 168 Dukane Manual Part No. 403-586-02...
Page 177 By passing its audit, Dukane can assure traditional inspection–oriented quality system you that we have in place a well–defined and...
Page 178 Series Ultrasonic Press System LE User's Manual www.dukane.com/us Part No. 403 – 586– 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 iq series User Manual

Page IV

Section 2

Section 3

Section 3 - Installation

Before Installation

Installing the Thruster

Connecting Press Cables

Flange Template

Section 4

Section 4 - Controls

Generator Front Panel Controls

System Operating Mode Keys

Screen Basics

Press Controls

Press Ergonomic Base

Section 5

Section 5 - Operation

Overview

Generator Start-Up Sequence

Stopping the Weld Cycle

Using the Menus

Alarms

Section 6

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

Section 9 - Troubleshooting

Section 10 - System Maintenance

Section 11 - Contacting Dukane

Section 12 - Specifications

Section 13 - Appendices

Appendix A List of Figures

Appendix B List of Tables

Section 14 - Index

Quick Links

Chapters

Related Manuals for Dukane iq series

Summary of Contents for Dukane iq series

Table of Contents