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Dukane iQ Series HP User Manual

Dukane iQ Series HP User Manual

Ultrasonic hand held systems
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Intelligent Assembly Solutions
iQ
Series
ULTRASONIC HAND HELD SYSTEMS
HP
AUTOMATED
HAND PROBE
PRESS
User's Manual
Dukane Part No. 403 – 577– 01
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949
ISO 9001:2000
Products are manufactured in ISO
www.dukane.com/us
registered facilities.

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  • Page 1 User’s Manual Dukane Part No. 403 – 577– 01 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949 ISO 9001:2000 Products are manufactured in ISO www.dukane.com/us...
  • Page 2 Printed in the United States of America. Part Number: 403–577–01 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, and 7,475,801 Page  ii  Dukane Manual Part No. 403-577-01...

  • Page 3: Revision History

    Revision History Revision Revision Number Summary Date - 00 Original release. 08/01/2008 - 01 Add 20kHz and 30kHz models. 11/12/2009 Update Pop-up Fault Status Screens. Add Trigger by Power feature. Add Options section. Dukane Manual Part No. 403-577-00 Page  iii...
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  • Page 5: Table Of Contents

    Section 10 - Outputs Interface . . . . . . . . . . . . . . . . . 63 Section 11 - Contacting Dukane . . . . . . . . . . . . . . . 67 Appendices .
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  • Page 7: Section 1- Introduction

    System Overview ..... . 4 Key Features ......4 Page  1 Dukane Manual Part No. 403-577-01...
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  • Page 9: Read This Manual First

    (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. 403-577-01...

  • Page 10: Key Features

    Linear Ramp Soft Start circuitry allows the acous- and assures you of manufacturing excellence. tic stack to ramp up to operating amplitude smoothly, minimizing the start-up surges and abnormal stress to the stack and generator. • Digi-Trac Tuning tracks the resonant frequency of the Page  4  Dukane Manual Part No. 403-577-01...

  • Page 11: Section 2- Health And Safety

    Electrical Safety ........8 Page  5 Dukane Manual Part No. 403-577-01...
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  • Page 13: Plastics Health Notice

    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  7 Dukane Manual Part No. 403-577-01...

  • Page 14: Example Of 125 Volt, Grounded, 3-Prong Plug And Receptacle

    It must be plugged ulations concerning proper wiring and grounding. into a grounded receptacle. Do not use a two-wire exten- sion cord with this product.           Page   Dukane Manual Part No. 403-577-01...

  • Page 15: Section 3- Installation

    Connnecting Cables ....... 12 System Outputs Connector ......14 Page   Dukane Manual Part No. 403-577-01...
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  • Page 17: Unpacking

    Figure 3-1 on the following See Connecting Cables on the next page. page. CAUTION  If you have any questions about the grounding of your equipment and/or the electri- cal box, contact a qualified electrician. Page  11 Dukane Manual Part No. 403-577-01...

  • Page 18: Connecting Cables

    Power Cord Strain Relief HAND PROBE HAND PROBE OUTPUTS OUTPUTS Optional Connections REAR VIEW REAR VIEW 100/12O VOLT MODEL 200/24O VOLT MODEL Figure 3-1 Generator Detail - Rear Views Page  1                  Dukane Manual Part No. 403-577-01...
  • Page 19 AC voltage. At high power levels there is high current, and the cable must be securely attached to the hand probe for safe operation. Only use original equipment ultrasound cables for safe and reliable system operation. Page  13 Dukane Manual Part No. 403-577-01...

  • Page 20: System Outputs (Optional Connections)

    ENTER is pressed if in a non-latching fault mode. It is active until ENTER is pressed if in a latching fault mode. NOTE Refer to Figure 9-1, OUTPUTS Inter- face Example, Page 65. Page  14                  Dukane Manual Part No. 403-577-01...

  • Page 21: Section 4 - Controls

    Start-Up Sequence ....... . . 19 LCD Display Overview ......20 Page  15 Dukane Manual Part No. 403-577-01...
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  • Page 23: Front Panel Overview

    Do NOT re- peatedly try to reset the circuit breaker. If it trips, this will only cause more damage to the    Continued generator. Page  17 Dukane Manual Part No. 403-577-01...
  • Page 24 “back” key. Press this key when you do not want to horn should never come in store the selection in memory. direct contact with a metal fix- ture or anvil when ultrasound is activated. Page  1                  Dukane Manual Part No. 403-577-01...

  • Page 25: Start-Up Sequence

    After all connections have been completed. Push OFF 1. Push the Power Switch to ON (Figure 4-2). The generator performs a self-diagnostics sequence. Figure 4-2 Power Switch Current DUKANE Setup 2. The Power-up screen appears briefly - Figure 4-3. Software iQ Hand Probe Setup #1...

  • Page 26: Lcd Display Overview

    (trigger) is pressed. Status Indication Stack Frequency IN CYCLE Frequency: 40087 Hz Power: 25 W Power Draw Power Bar Graph % Figure 4-5 Example of an In Cycle Screen Page  0                  Dukane Manual Part No. 403-577-01  ...

  • Page 27: Section 5 - Process Control Settings

    System Information, Hardware Settings, Advanced Settings. 27 Setup Maintenance ....... . 30 Dukane Manual Part No. 403-577-01 Page  1...
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  • Page 29: Selecting The Weld Mode

    U/S is activated. When the programmed energy is reached, U/S stops. The trigger switch must be held activated for the entire welding cycle. Then it is released so that a new weld cycle can begin. Dukane Manual Part No. 403-577-01 Page  3...

  • Page 30: Navigating Through The Modes

    Figure 5-4 Time Weld Mode - 2 Setup #1Empty Load Defaults? Select YES to load the default operating mode which is Manual, and you can weld using the Manual mode. Page  4                  Dukane Manual Part No. 403-577-01  ...

  • Page 31: Weld By Time

    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. 403-577-01 Page  5...

  • Page 32: Hold

    Press the AMP key. The screen will appear as in 100 % Figure 5-10. Set the amplitude level using the keys and the keys. Figure 5-10 Amplitude Press ENTER to confirm your amplitude setting. Page                    Dukane Manual Part No. 403-577-01  ...

  • Page 33: System Information, Hardware Settings, Advanced Settings

    Figure 5-11: Figure 5-11 INFO Screen Using the keys, move the pointer to indicate: System Information, Hardware Settings, or Advanced Settings Dukane Corporation Press ENTER to make the selection. iQ 20kHz Hand Probe FP v1.07 MB v2.56 System Information FPGA v6 Manufacturer’s information is shown including the...

  • Page 34: Warning Screen

    Before you change a setting, please check of this unit! with Dukane personnel for their recommendations. Figure 5-13 Warning Screen The warning screen is shown for a few seconds, then, the Advanced Settings screen appears.

  • Page 35: Trigger Amplitude

    For an explanation of Trigger by Power and the three settings that are connected with it, please refer to Application Note 506 found on our website at: http://www.dukane.com/us/DL_ApplData.asp When Trigger by Power is selected, three additional settings screens are presented: Trigger By Power •...

  • Page 36: Setup Maintenance

    T: 0.000 S A: 100% E: 0 J H: 0.0 S Select YES or NO, and press ENTER again. Figure 5-22 Setup Maintenance - 4 Continued Page  30                  Dukane Manual Part No. 403-577-01  ...

  • Page 37: Store In Setup Maintenance

    Press ENTER, and a pop-up screen will ask you to confirm your selection. Make your choice, and press ENTER. Check that the setup is deleted. Press SETUP, and the Setup Maintenance screen will show EMPTY for the setup you just deleted. Dukane Manual Part No. 403-577-01 Page  31...
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  • Page 39: Section 6 - Probes And Probe Stacks

    Probe Configuration ..........36 Ultrasonic Horn ...........37 Booster ..............37 Stack Assembly ..........38 Installing Replaceable Tips .........38 Mounting Stud to Horn/Booster ......39 Horn to Booster ...........40 Booster to Probe ..........40 Horn to Probe ............40 Stack Disassembly ........42 Booster Notes ..........44 Dukane Manual Part No. 403-577-01 Page  33...
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  • Page 41: Ultrasonic Probe Overview

    Typical Horn Less Tip Trigger Rear View Pistol-style Grip Models 41HP40 & 41HP40S Trigger Actuator Compressed Air Fitting Hanger Strain Relief U/S Cable Hand Grip Typical Horn Less Tip Rear View Figure 6-1 Typical Hand Held Probes Dukane Manual Part No. 403-577-01 Page  35...

  • Page 42: Theory Of Operation

    Replaceable tips are not commonly used in high–volume production environments. Standard Custom Horn Horn Figure 6–2 Hand Probe, Horn and Tip Dukane Manual Part No. 403-577-01 Page  3               ...

  • Page 43: Ultrasonic Horn

    Figure 6–3. This is commonly referred to as a stack. As indicated, the components are secured with threaded studs. Horn Figure 6–3 Probe, Booster and Horn Dukane Manual Part No. 403-577-01 Page  37...

  • Page 44: 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 45: Mounting Stud To Horn/Booster

    This is shown in Figure 6-6. 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. 403-577-01 Page  3...

  • Page 46: 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 47: Horn/Booster Torque Unit Conversions

    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. 403-577-01 Page  41...

  • Page 48: Stack Disassembly

    PROBE ASSEMBLY Spanner Mounting Stud Wrench (Insert Into Horn Holes First and Tighten to Torque Specs) Input End HORN HORN ISASSEMBLY Figure 6–6 Hand Probe Assembly and Disassembly Dukane Manual Part No. 403-577-01 Page  4                   ...

  • Page 49: Separating The Horn From The Booster

    (on horns with wrench flats) to provide an opposite force to keep the Figure 6–8 Removing a Replaceable Tip from the horn from turning in your hand. Refer to Figure 6–8 for the Horn correct tip removal procedure. Dukane Manual Part No. 403-577-01 Page  43...

  • Page 50: 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. 403-577-01 Page  44     ...

  • Page 51: Section 7 - Troubleshooting

    Section 7 – Troubleshooting SECTION 7 Troubleshooting o Ultrasonic Output ........47 System Power Output Level ......47 Welding Problems ......... 48 Pop-up Fault Status Screens....49-50 Page  45 Dukane Manual Part No. 403-577-01...
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  • Page 53: 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  47 Dukane Manual Part No. 403-577-01...

  • Page 54: 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. 403-577-01 Page  4       ...

  • Page 55: 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 - Manual Mode Continued      Page  4...
  • Page 56 Process Fault Input Undervoltage Energy Not Reached Enter Clears Fault Table 7-II Pop-Up Fault Status Screens - Time and Energy Modes Dukane Manual Part No. 403-577-01 Page  50           ...

  • Page 57: Section 8 - Options

    Section 8 – Options SECTION 8 Options iQ Hand Probe Buzzer Kit ......53 iQ Hand Probe Foot Switch Kit .....53 Page  51 Dukane Manual Part No. 403-577-01...
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  • Page 59 This kit allows the customer to add their own external foot switch to replace the trigger on the hand probe. An external breakout box with cabling is supplied. The box connects to the generator and to the hand probe. Page  53 Dukane Manual Part No. 403-577-01...
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  • Page 61: Section 9 - Specifications

    AC Power Requirements ......60 Regulatory Agency Compliance ..... . . 61 Page  55 Dukane Manual Part No. 403-577-01...
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  • Page 63: Generator Outline Drawing

    Section 9 – Specifications ALLOW 5" (125 mm) BEHIND UNIT FOR CABLE CONNECTIONS 12.41 [315.2] 10.00 [254] 3.95 3.51 [100.3] [89.2] [mm] Figure 9-1 Generator Outline Drawing Page  57 Dukane Manual Part No. 403-577-01...

  • Page 64: Probes Outline Drawings

    HP 4.62-P 40HP060-2E 1.65 (.75) 2.10 (53) 5.02 (129) 5.38 (137) 41PG40S HP 4.62-H 40HP060-2E 41HP40S 1.35 (.61) 1.90 (48) 4.80 (122) Figure 9-2 Probes Outline Drawings and Dimensions Page  5                    Dukane Manual Part No. 403-577-01...

  • Page 65: Weights

    5% to 95% non–condensing @ +5°C to +30°C Nonoperating 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  5 Dukane Manual Part No. 403-577-01...

  • Page 66: Ac Power Requirements

    HP 4.62-P 40HP060-2E 200-240 VAC, 50/60 Hz @ 4.5 Amps 41PG40S 40kHz HP 4.62-H 40HP060-2E 200-240 VAC, 50/60 Hz @ 4.5 Amps 41HP40S Table 9- I AC Power Requirements Page  0                    Dukane Manual Part No. 403-577-01...

  • Page 67: Regulatory Agency Compliance

    T h e E M C D i r e c t i v e 2 0 0 4 / 1 0 8 / E C for Heavy Industrial — EN 61000-6-4: 2001 EN 55011: 2003 EN 61000-6-2: 2001 EN61000–4–2 EN61000–4–3 EN61000–4–4 EN61000–4–5 EN61000–4–6 EN61000–4–8 EN61000–4–11 • The Low Voltage Directive 2006/95/EC. • The Machine Directive 98/37/EC. EN 60204-1: 2006 S afety of Machinery - Electrical Equip- m ent of Machines Part 1: Specification f or General Requirements. Effective 12/29/09: The Machinery Directive 2006/42/EC. EN 60204: 2006 S afety of Machinery - Electrical Equipment of Machines Part 1: General Requirements. Page  1 Dukane Manual Part No. 403-577-01...
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  • Page 69: Section 10 - Outputs Interface

    Section 10 – I/O Interface SECTION 10 Outputs Interface Outputs Connection Example......65 Page  3 Dukane Manual Part No. 403-577-01...
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  • Page 71 Provided by Customer Power Supply NOTE + 30 VDC Maximum To OUTPUTS: + 24 V (Output 1, 2, or 3 Common) Status connected Indicator or Audible Chassis Alarm Ground (333mA (Earth). maximum) Figure 10-1 OUTPUTS Connection Example Page  5 Dukane Manual Part No. 403-577-01...
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  • Page 73: Section 11 - Contacting Dukane

    Section 11 – Contacting Dukane SECTION 11 Contacting Dukane Page  7 Dukane Manual Part No. 403-577-01...
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  • Page 75: Identify Equipment

    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 • Fault/error indicators from the LCD display • Software version (Press .
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  • Page 77: Appendices

    List of Tables........74 Page  71 Dukane Manual Part No. 403-574-01...
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  • Page 79: List Of Figures

    Amplitude ........................26 5-11 INFO Screen .........................27 5-11A System Information Example Screen ................27 5-12 Hardware Settings Screen ....................27 5-13 Warning Screen ......................28 5-14 Advanced Settings Screen ....................28 5-15 Trigger Amplitude ......................29 5-16 Trigger Watts .........................29 5-17 Trigger Timeout ......................29 Page  73 Dukane Manual Part No. 403-574-01...

  • Page 80: List Of Tables

    Horn/Booster Torque Unit Conversions ................41 Pop-up Fault Status Screens - Manual Mode ..............49 7-II Pop-up Fault Status Screens - Time and Energy Modes ..........50 AC Power Requirements ....................60 Page  74                    Dukane Manual Part No. 403-574-01...
  • Page 81 By passing its audit, Dukane can assure traditional inspection–oriented quality system you that we have in place a well–defined and...
  • Page 82 Series, Ultrasonic Hand Held Systems User's Manual www.dukane.com/us Part No. 403 – 577– 01 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...

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