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Intelligent Assembly Solutions
iQ
Series
ULTRASONIC POWER SUPPLY
AL
AUTOMATED
HAND PROBE
PRESS
User's Manual
Dukane Part No. 403 – 583– 00
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949
ISO 9001:2008
Products are manufactured in ISO
www.dukane.com/us
registered facilities.
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Summary of Contents for Dukane iQ Series AL
- Page 1 User’s Manual Dukane Part No. 403 – 583– 00 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949 ISO 9001:2008 Products are manufactured in ISO www.dukane.com/us...
- Page 2 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: 3,780,926 3,825,481 4,131,505 4,277,710 5,798,599 5,880,580 6,984,921 7,225,965 7,475,801 and 7,819,158 B2 Page ii Dukane Manual Part No. 403-583-00...
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Page 3: Revision History
Revision History Revision Revision Number Summary Date - 00 Original release. 11/02/2010 Dukane Manual Part No. 403-583-00 Page iii... - Page 4 Series, Ultrasonic Power Supply AL User’s Manual This page intentionally left blank Page iv Dukane Manual Part No. 403-583-00...
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Page 5: Table Of Contents
Section 8 - Specifications . . . . . . . . . . . . . . . . . . . . 55 Section 9 - Contacting Dukane . . . . . . . . . . . . . . . . 61 Appendices . - Page 6 Series, Ultrasonic Power Supply AL User’s Manual This page intentionally left blank Page vi Dukane Manual Part No. 403-583-00...
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Page 7: Section 1- Introduction
System Overview ..... . 4 Key Features ......4 Page Dukane Manual Part No. 403-583-00... - Page 8 Series, Ultrasonic Power Supply AL User’s Manual This page intentionally left blank Page Dukane Manual Part No. 403-583-00...
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Page 9: General User Information
Roman sequence numerals (e.g. –I, –II, –III). As an ex- ample, Figure 3–2 would be the second illustration in Section three while Table 3–II would be the second table in Section three. Condition Hearing Electrical or Practice Protection Hazard Page 3 Dukane Manual Part No. 403-583-00... -
Page 10: System Overview
North American sys- Key Features tems are optionally available to operate on the 120VAC line voltage level. • Trigger by Power is a Dukane patented feature that produces greater weld consistency by requiring that • Multiple Electronic... -
Page 11: Section 2- Health And Safety
Electrical Safety ........8 Lifting the Equipment ....... . 9 Page 5 Dukane Manual Part No. 403-583-00... - Page 12 Series, Ultrasonic Power Supply AL User’s Manual This page intentionally left blank Page Dukane Manual Part No. 403-583-00...
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Page 13: General Considerations
Labor about the particular type of plastic(s) you are using. When plastic materials are being processed, they may emit fumes and/or gases that could be hazardous. Make sure you have adequate ventilation whenever these plastics are processed. Page Dukane Manual Part No. 403-583-00... -
Page 14: Electrical Safety
It must be plugged cal regulations concerning proper wiring and grounding. into a grounded receptacle. Do not use a two-wire exten- sion cord with this product. Page 8 Dukane Manual Part No. 403-583-00... -
Page 15: 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 Dukane Manual Part No. 403-583-00... - Page 16 Series, Ultrasonic Power Supply AL User’s Manual This page intentionally left blank Page 0 Dukane Manual Part No. 403-583-00...
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Page 17: Section 3- Installation
Automation Controlled System ......17 System I/O Connector Pinout ......18 Page Dukane Manual Part No. 403-583-00... - Page 18 Series, Ultrasonic Power Supply AL User’s Manual This page intentionally left blank Page Dukane Manual Part No. 403-583-00...
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Page 19: 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 3 Dukane Manual Part No. 403-583-00... - Page 20 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 4 Dukane Manual Part No. 403-583-00...
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Page 21: Unpacking
Stud location is shown in Figure 3-3 See Connecting Cables on the next page. on the following page. CAUTION If you have any questions about the grounding of your equipment and/or the electri- cal box, contact a qualified electrician. Page 5 Dukane Manual Part No. 403-583-00... -
Page 22: Connecting Cables
Connector - See Page 19 for information about the rear panel CONFIGURATION connector Power Cord with Strain Relief INPUTS / OUTPUTS CONFIGURATION DUKANE CORP -WARNING- ST. CHARLES IL 60174 POWER LINE OUTLET MADE IN U.S.A. MUST BE GROUNDED. -
Page 23: Power Cords
(North America or Japan) The power cord (including strain relief) supplied with the 100/120 AC systems is permanently attached to the rear of the generator. Units with this power cord are for use in North America or Japan. Page Dukane Manual Part No. 403-583-00... -
Page 24: System I/O Connector Pinout
This output will remain latched This output will be an open circuit when any power ON until the U/S Activate input is switched OFF and related fault condition is detected. then ON again. Page 8 Dukane Manual Part No. 403-583-00... -
Page 25: Configuration Port Connector
Using sinking (NPN) output drivers, this common line would be connected to the automation system positive See Figure A-1 in Appendix A for E-Stop supply output. circuit wiring examples. Page Dukane Manual Part No. 403-583-00... - Page 26 Series, Ultrasonic Hand Held Systems User’s Manual This page intentionally left blank Page 0 Dukane Manual Part No. 403-583-00...
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Page 27: Section 4 - Controls
Start-up Sequence ....... . . 25 LCD Display Overview ......26 Page Dukane Manual Part No. 403-583-00... - Page 28 Series, Ultrasonic Hand Held Systems User’s Manual This page intentionally left blank Page Dukane Manual Part No. 403-583-00...
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Page 29: Front Panel Overview
Do NOT repeat- edly try to reset the circuit breaker. If it trips, this will only cause more damage to the Continued generator. Page 3 Dukane Manual Part No. 403-583-00... - Page 30 “back” key. Press this key when you do not want to connected to the system. The store the selection in memory. horn should never come in direct contact with a metal fix- ture or anvil when ultrasound is activated. Page 4 Dukane Manual Part No. 403-583-00...
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Page 31: Start-Up Sequence
Push OFF 1. Push the Power Switch to ON (Figure 4-2). Figure 4-2 Power Switch The generator performs a self-diagnostics sequence. Current DUKANE 2. Two Power-up screens appear briefly - Figure 4-3, Setup Software and Figure 4-3A. iQ AL Series xxkHz... -
Page 32: Lcd Display Overview
Status Indication Stack Frequency IN CYCLE Frequency: 40087 Hz Power: 40 W Power Draw Power Bar Graph % Figure 4-5 Example of an In Cycle Screen Page Dukane Manual Part No. 403-583-00 ... -
Page 33: Section 5 - Process Control Settings
System Information, Advanced Settings....33 Setup Maintenance ....... . 36 Dukane Manual Part No. 403-583-00 Page ... - Page 34 Series, Ultrasonic Hand Held Systems User’s Manual This page intentionally left blank Page 8 Dukane Manual Part No. 403-583-00 ...
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Page 35: Selecting The Weld Mode
U/S is deactivated.] When the preset energy level is reached, the U/S will be deactivated. The cycle starts when the Ultrasound Activate/Cycle Start Input (Pin 12) is activated. When the programmed energy is reached, ultrasound stops. Dukane Manual Part No. 403-583-00 Page ... -
Page 36: Navigating The Modes
Figure 5-4 Time Weld Mode - 2 Setup #1Empty Load Defaults? Select YES to load the default operating mode which is Automation, and you can weld using the Automation mode. Page 30 Dukane Manual Part No. 403-583-00 ... - Page 37 The time can not be set below 0.001 second. Use the and the keys to move the cursor Figure 5-8 Energy Weld Mode - 2 and to set the digits for the time you want. Hit E Hit C See Figure 5-8. Dukane Manual Part No. 403-583-00 Page 3...
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Page 38: Hold
Press the AMP key. The screen will appear as in Figure 5-10. Set the amplitude level using the keys and the keys. Press ENTER to confirm your amplitude setting. Amplitude 100 % Figure 5-10 Amplitude Page 3 Dukane Manual Part No. 403-583-00 ... -
Page 39: System Information, Advanced Settings
Adjusting these settings may affect the operation of your unit. Before you change a setting, please check of this unit! with Dukane personnel for their recommendations. Figure 5-12 Warning Screen The warning screen is shown for a few seconds, then, the Advanced Settings screen appears. - Page 40 Lock and Hold For an explanation of Frequency Lock and Hold, please refer to Application Note 505 found on our website at: http://www.dukane.com/us/DL_ApplData.asp Follow the on screen prompts to make setting adjustments. Trigger By Power Trigger by Power Amplitude...
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Page 41: Setup Maintenance
Setup # Mode: Automation 0.000 S A: 100% screen appears to ask you to confirm your choice. H: 0.0 S TBP: OFF Select YES or NO, and press ENTER again. Figure 5-19 Setup Maintenance - 3 Continued Dukane Manual Part No. 403-583-00 Page 35... -
Page 42: Setup Maintenance
Figure 5-22 Default Setup Screen ENTER. Check that the setup is deleted. Press SETUP, and the Setup Maintenance screen will show EMPTY for the setup you just deleted. Page 3 Dukane Manual Part No. 403-583-00 ... -
Page 43: Section 6 - Probes And Probe Stacks
Booster ..............41 Stack Assembly ..........42 Attaching Replaceable Tips.........42 Attaching Mounting Stud to Horn/Booster ... 43 Attaching Horn to Booster ........44 Attaching Booster to Probe ......... 44 Attaching Horn to Probe ........44 Stack Disassembly ........46 Booster Notes ..........48 Dukane Manual Part No. 403-583-00 Page 3... - Page 44 Series, Ultrasonic Hand Held Systems User’s Manual This page intentionally left blank Dukane Manual Part No. 403-583-00 Page 38 ...
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Page 45: Ultrasonic Probe Overview
Use the probe’s air fitting to connect the air source to the probe. NOTE See Section 8, Specifications for more detail. Compressed air supply: Make sure the air is clean, oil-free, and dry. Dukane Manual Part No. 403-583-00 Page 3... -
Page 46: Theory Of Operation
Figure 6–1 Probe, Horn and Tip NOTE For automated systems we recommend that you use a booster with the probe as shown in Figure 6-2. Read Dukane’s Application Note #504 - Ultrasonic Acoustic Stack Mounting Guidelines - found on our website at http:// www .dukane .com/us/DL_ApplData .asp Dukane Manual Part No. 403-583-00... -
Page 47: Ultrasonic Horn
Figure 6–2. This is commonly referred to as a stack. As indicated, the components are secured with threaded studs. Horn Figure 6–2 Probe, Booster and Horn Dukane Manual Part No. 403-583-00 Page 4... -
Page 48: Stack Assembly
Replaceable Tips to Horn NOTE inch-lb ft-lb Size Dukane Part No. for the 20kHz span- 40.7 1/2” x 20 tpi tip threads ner wrenches is 721–68. 3/8” x 24 tpi tip threads 33.9 5/16” x 24 tpi tip threads Dukane Part No. -
Page 49: Attaching Mounting Stud To Horn/Booster
This is shown in Figure 6-5. NEVER thread a stud into the transducer or the output end of the booster first. See Booster Notes in this section for correctly identifying the output end of a booster. Dukane Manual Part No. 403-583-00 Page 43... -
Page 50: Attaching Horn To Booster
1. Inspect all surfaces to be joined for stress cracks, chips, or gouges. Any of these irregularities will affect operation and could lead to further equipment damage. Contact the Dukane Ultrasonic Tooling Department CAUTION concerning a damaged booster. - Page 51 47.5 20 kHz stack Do not tighten the studs to these higher 24.4 30 kHz stack ratings as it may induce unnecessary 24.4 40 kHz stack stress in the assembly. Table 6-III Horn/Booster Torque Unit Conversions Dukane Manual Part No. 403-583-00 Page 45...
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Page 52: Stack Disassembly
HOUSING PROBE ASSEMBLY Spanner Mounting Stud Wrench (Insert Into Horn Holes First and Tighten to Torque Specs) Input End HORN HORN ISASSEMBLY Figure 6–5 Probe Assembly and Disassembly Dukane Manual Part No. 403-583-00 Page 4 ... - Page 53 (on horns with wrench flats) to provide an opposite force to keep the Figure 6–7 Removing a Replaceable Tip from the horn from turning in your hand. Refer to Figure 6–7 for the Horn correct tip removal procedure. Dukane Manual Part No. 403-583-00 Page 4...
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Page 54: Booster Notes
1.0 (e.g. 0.6), it is a reducing or reverse booster. A neutral booster has no gain and has 1.0 stamped on it. A neutral or coupling booster is used to provide another probe stack clamping location for added stability. Dukane Manual Part No. 403-583-00 Page 48 ... -
Page 55: Section 7 - Troubleshooting
Section 7 – Troubleshooting SECTION 7 Troubleshooting No Ultrasonic Output ........51 System Power Output Level ......51 Welding Problems ......... 52 Pop-up Fault Status Screens......53 Page 4 Dukane Manual Part No. 403-583-00... - Page 56 Series, Ultrasonic Hand Held Systems User’s Manual This page intentionally left blank Dukane Manual Part No. 403-583-00 Page 50 ...
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Page 57: No Ultrasonic Output
Generator Fault Does Not Reset a fault. When a system fault condition does not automatically reset, the generator needs servicing. System Power Diagnostic Procedures The only fault indications available with these probe systems are the ones shown on the LCD display. Page 5 Dukane Manual Part No. 403-583-00... -
Page 58: Welding Problems
The horn amplitude may not be uniform if it has been machined, altered or damaged. All of these will change the resonant frequency of the horn. You can have the horn analyzed. Dukane Manual Part No. 403-583-00 Page 5 ... -
Page 59: Pop-Up Fault Status Screens
Fault will reset when system cools down. Over Temperature Internal communications error. Generator Fault Turn generator power off and back on. Cycle Power Call Dukane service if the fault persists. Table 7- I Pop-Up Fault Status Screens Page 53 Dukane Manual Part No. 403-583-00... - Page 60 Series, Ultrasonic Hand Held Systems User’s Manual This page intentionally left blank Dukane Manual Part No. 403-583-00 Page 54 ...
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Page 61: Section 8 - Specifications
AC Power Requirements ......59 Regulatory Agency Compliance ..... . . 60 Page 55 Dukane Manual Part No. 403-583-00... - Page 62 Series, Ultrasonic Hand Held Systems User’s Manual This page intentionally left blank Page 5 Dukane Manual Part No. 403-583-00...
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Page 63: Generator Outline Drawing
Section 8 – Specifications ALLOW 5" (127 mm) BEHIND UNIT FOR CABLE CONNECTIONS 12.41 [315.2] 10.00 [254] 3.95 3.51 [100.3] [89.2] [mm] Figure 8-1 Generator Outline Drawing Page 5 Dukane Manual Part No. 403-583-00... -
Page 64: Weights
- 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 58 Dukane Manual Part No. 403-583-00... -
Page 65: Ac Power Requirements
100-120 VAC, 50/60 Hz @ 9.0 Amps 15.0 Amps 30kHz 30AL060-2E 200-240 VAC, 50/60 Hz @ 4.5 Amps 40kHz 40AL060-1E 100-120 VAC, 50/60 Hz @ 9.0 Amps 40kHz 40AL060-2E 200-240 VAC, 50/60 Hz @ 4.5 Amps Table 8- I AC Power Requirements Page 5 Dukane Manual Part No. 403-583-00... -
Page 66: Regulatory Agency Compliance
Machines Part 1: General Requirements. IP (International Protection) Rating The iQ generator has an IP rating from the IEC (International Electrotechnical Commission). The rating is IP2X, in compliance with finger-safe industry standards. Page 0 Dukane Manual Part No. 403-583-00... -
Page 67: Section 9 - Contacting Dukane
Section 9 – Contacting Dukane SECTION 9 Contacting Dukane Page Dukane Manual Part No. 403-583-00... - Page 68 Series, Ultrasonic Hand Held Systems User’s Manual This page intentionally left blank Page Dukane Manual Part No. 403-583-00...
- Page 69 Section 9 – 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 • Fault/error indicators from the LCD display • Software version (Press .
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Page 71: Appendices
Appendix B - List of Figures ......68 Appendix C - List of Tables......69 Page 5 Dukane Manual Part No. 403-583-00... - Page 72 Series, Ultrasonic Hand Held Systems User’s Manual This page intentionally left blank Page Dukane Manual Part No. 403-583-00...
- Page 73 (Pin 2) Enable In Automation System Safety Circuit Wiring Diagram System I/O Connector iQ Auto (Pin 1) Relay contact block Enable Out Master (Pin 2) control Enable In relay User automation control hardware Figure A-1 E-Stop Circuitry Page Dukane Manual Part No. 403-583-00...
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Page 74: Appendix B List Of Figures
HOLD Time - 2 ......................32 5-10 Amplitude ........................32 5-11 INFO Screen .........................33 5-11A System Information Example Screen ................33 5-12 Warning Screen ......................33 5-13 Advanced Settings Screen ....................33 5-14 Trigger Amplitude ......................34 Page 8 Dukane Manual Part No. 403-583-00... -
Page 75: Appendix C - List Of Tables
Standard IEC AC Power Cord Part Numbers ..............17 3-II Generator Input/Output Signals ..................18 Tip Torque Unit Conversions ...................42 6-II Stud Torque Unit Conversions ..................43 6-III Horn/Booster Torque Unit Conversions ................45 Pop-up Fault Status Screens ..................53 AC Power Requirements ....................59 Page Dukane Manual Part No. 403-583-00... - Page 76 Series, Ultrasonic Hand Held Systems User’s Manual This page intentionally left blank Page 0 Dukane Manual Part No. 403-583-00...
- Page 77 By passing its audit, Dukane can assure traditional inspection–oriented quality system you that we have in place a well–defined and...
- Page 78 Series, Ultrasonic Power Supply AL User's Manual www.dukane.com/us Part No. 403 – 583– 00 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...