Dukane iQ Series User Manual
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Dukane iQ Series User Manual

Dukane iQ Series User Manual

Dukane iq series ultrasonic hand held systems
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ISO 9001:2000
Products are manufactured in ISO
registered facilities.
Intelligent Assembly Solutions
Ultrasonic Hand Held Systems
User's Manual
System Model
Generator Part #
HP 4.61-P
40HP060-1E
HP 4.61-H
40HP060-1E
HP 4.62-P
40HP060-2E
HP 4.62-H
40HP060-2E
HP 4.6E-P
40HP060-2E
HP 4.6E-H
40HP060-2E
Dukane Part No. 403–577-00
iQ
Series
Probe Part#
41PG40S
41HP40S
41PG40S
41HP40S
41PG40S
41HP40S
www.dukcorp.com/us

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  • Page 1 Probe Part# HP 4.61-P 40HP060-1E 41PG40S HP 4.61-H 40HP060-1E 41HP40S HP 4.62-P 40HP060-2E 41PG40S HP 4.62-H 40HP060-2E 41HP40S HP 4.6E-P 40HP060-2E 41PG40S HP 4.6E-H 40HP060-2E 41HP40S Dukane Part No. 403–577-00 ISO 9001:2000 Products are manufactured in ISO www.dukcorp.com/us registered facilities.
  • Page 2 Printed in the United States of America. Part Number: 403–577–00 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 and 7,225,965 Page ii Dukane Manual Part No. 403-577-00...

  • Page 3: Revision History

    Revision History Revision Revision Number Summary Date - 00 Original release. 08/01/2008 Dukane Manual Part No. 403-577-00 Page iii...
  • Page 4 User’s Manual This page intentionally left blank Page iv Dukane Manual Part No. 403-577-00...

  • Page 5: Table Of Contents

    Section 9 - Outputs Interface . . . . . . . . . . . . . . . . . . 57 Section 10 - Contacting Dukane . . . . . . . . . . . . . . . 61 Appendices .
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  • Page 7: Section 1- Introduction

    System Overview ..... . 4 Key Features ......4 Page  Dukane Manual Part No. 403-577-00...
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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. 403-577-00...

  • Page 10: Key Features

    • Digi-Trac Tuning tracks the resonant frequency of the acoustic stack (horn, booster, transducer) and adjusts Page 4 Dukane Manual Part No. 403-577-00...

  • Page 11: Section 2- Health And Safety

    Electrical Safety ........8 Page 5 Dukane Manual Part No. 403-577-00...
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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. 403-577-00...

  • Page 14: International 220/240V Grounding

    It must be plugged into a grounded receptacle. Do not use a two-wire exten- sion cord with this product. Page  Dukane Manual Part No. 403-577-00...

  • Page 15: Section 3- Installation

    System Outputs Connector ......14 Page  Dukane Manual Part No. 403-577-00...
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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  Dukane Manual Part No. 403-577-00...

  • Page 18: Connecting Cables

    OUTPUTS connector. 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  Dukane Manual Part No. 403-577-00...
  • Page 19 Only use original equipment ultrasound cables for safe and reliable system operation. Page 3 Dukane Manual Part No. 403-577-00...
  • Page 20 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 59 . Page 4 Dukane Manual Part No. 403-577-00...

  • Page 21: Section 4 - Controls

    Start-Up Sequence ......19 Display Overview ......19 Page 5 Dukane Manual Part No. 403-577-00...
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  • Page 23: Front Panel Overview

    Do not repeatedly try to reset the circuit breaker. If it trips, Use the SETUP key to Load, Store, or Delete as many as this will only cause more damage to the generator. eight setups. Page 7 Dukane Manual Part No. 403-577-00...
  • Page 24 The horn should never come in you do not want to store the selection in memory. direct contact with a metal fix- ture or anvil when ultrasound is activated. Page  Dukane Manual Part No. 403-577-00...

  • Page 25: Start-Up Sequence

    Release the probe’s activation switch (trigger), and OFF. See INFO, Page 27. if appropriate, apply any additional pressure while an optional Hold time elapses. The generator signals when that period is over with an audible alert. Page  Dukane Manual Part No. 403-577-00...

  • Page 26: Lcd Display Overview

    An In Cycle screen activates when the probe activation switch (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 Page 0 Dukane Manual Part No. 403-577-00...
  • Page 27 SETUP ........28 Dukane Manual Part No. 403-577-00...
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  • Page 29: Section 5 - Process Controller Settings

    U/S. 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. 403-577-00 Page 3 Page 3...

  • Page 30: Manual Mode

    Figure 5-3 Time Weld Mode - 1 Weld by Time Weld Weld Time ENTER key 0.500 S Hit Enter To Accept Hit Cancel To Abort Figure 5-4 Time Weld Mode - 2 Hit E Hit C Page 4 Page 4 Dukane Manual Part No. 403-577-00...

  • Page 31: Energy Mode

    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. See Figure 5-8. Dukane Manual Part No. 403-577-00 Page 5 Page 5...

  • Page 32: Hold

    To adjust amplitude: 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. Page  Page  Dukane Manual Part No. 403-577-00...

  • Page 33: Info

    If Latching Faults is off, and a fault occurs, the audible alarm (beep, beep) will be heard, but welding can NOTE continue. The Audible Alarm can be set ON or OFF. See INFO, Page 27. Dukane Manual Part No. 403-577-00 Page 7 Page 7...

  • Page 34: Setup

    E: 0 J H: 0.0 S choice. Figure 5-17 Setup Maintenance - 4 Select YES or NO, and press ENTER again. Page  Page  Dukane Manual Part No. 403-577-00...
  • Page 35 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. 403-577-00 Page  Page ...
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  • Page 37: Section 6 - Probes And Probe Stacks

    Stack Assembly ........35 Installing Replaceable Tips ......35 Mounting Stud to Horn/Booster ....36 Horn to Booster ........37 Booster to Probe ........37 Horn to Probe ..........37 Torque Unit Conversion Chart .... 38 Stack Disassembly ......39 Dukane Manual Part No. 403-577-00 Page 3...
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  • Page 39: Ultrasonic Probe Overview

    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. 403-577-00 Page 33...

  • Page 40: 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. 403-577-00 Page 34...

  • Page 41: 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. 403-577-00 Page 35...

  • Page 42: 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”...
  • Page 43 Figure 6-7. 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. 403-577-00 Page 37...

  • Page 44: Stack Assembly Procedure

    CAUTION  operation and could lead to further equipment damage. Never leave a horn or booster Contact the Dukane Ultrasonic Tooling Department assembly hand tight. Torque concerning a damaged booster. it to the proper specifications 2. Ensure that the mating surfaces of the two components before proceeding.

  • Page 45: Torque Value Conversion Graph

    24.4 40 kHz stack stress in the assembly. Table 6—III Horn/Booster Torque Unit Conversions 20kHz Stack x 20 Stud 40kHz Stack x 24 Stud 8mm Stud in-lbs ft-lbs Figure 6-6 Torque Value Conversion Graph Dukane Manual Part No. 403-577-00 Page 3...

  • Page 46: Stack Disassembly

    Output End PROBE HOUSING HAND PROBE ASSEMBLY Spanner Mounting Stud Wrench (Insert Into Horn Holes First and Tighten to Torque Specs) Input End HORN HORN ISASSEMBLY Figure 6–7 Hand Probe Assembly and Disassembly Dukane Manual Part No. 403-577-00 Page 40...

  • Page 47: Separating The Horn From The Booster

    Figure 6–9 Removing a Replaceable Tip From the the horn from turning in your hand. Refer to Figure 6–9 for Horn the correct tip removal procedure. Dukane Manual Part No. 403-577-00 Page 4...

  • Page 48: 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. 403-577-00 Page 4...

  • Page 49: Section 7 - Troubleshooting

    SECTION 7 Troubleshooting No Ultrasonic Output ......45 System Power Output Level ....45 Overtemperature ........45 Generator Fault Does Not Reset .....45 System Power Diagnostic Procedures ..45 Welding Problems ........46 Pop-up Fault Status Screens....47 Page 43 Dukane Manual Part No. 403-577-00...
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  • Page 51: No Ultrasonic Output

    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 45 Dukane Manual Part No. 403-577-00...

  • Page 52: 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. 403-577-00 Page 4...
  • Page 53 Fault will reset when next weld cycle starts. System Overtemperature fault detected. Generator Fault Fault will reset when system cools down. Over Temperature Table 7-I Pop-Up Fault Status Screens - Manual Mode Pop-Up Fault Status Screens continued on next page. Page 47 Dukane Manual Part No. 403-577-00...

  • Page 54: Pop-Up Fault Status Screens - Time And Energy Modes

    Process Fault Input Undervoltage Energy Not Reached Enter Clears Fault Table 7-2 Pop-Up Fault Status Screens - Time and Energy Modes Dukane Manual Part No. 403-577-00 Page 4...

  • Page 55: Section 8 - Specifications

    AC Power Requirements ..... . 54 Regulatory Agency Compliance ....55 Page 4 Dukane Manual Part No. 403-577-00...
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  • Page 57: Generator Outline Drawing

    Section 8 – 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 8-1 Generator Outline Drawing Page 5 Dukane Manual Part No. 403-577-00...

  • Page 58: Probe Outline Drawings

    41HP40 & 41HP40S 5.6 [141] 3.3 [84] 2.5 [63] IN [mm] Cable: 8ft. (3.75m) Probe shown with typical horn, less tip. Rear View Weight: 1.35 lb (620 g) Figure 8-2 Probes Outline Drawings Page 5 Dukane Manual Part No. 403-577-00...

  • Page 59: Weights

    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 53 Dukane Manual Part No. 403-577-00...

  • Page 60: Ac Power Requirements

    Overload Power Operating Generator Input AC Power Requirements Rating Frequency Model Number Nominal AC Volt (Watts) 40kHz 40HP060-1E 100-120 VAC, 50/60 Hz 40kHz 40HP060-2E 200-240 VAC, 50/60 Hz Table 8-I AC Power Requirements Page 54 Dukane Manual Part No. 403-577-00...

  • Page 61: Regulatory Agency Compliance

    EN61000–4–4 Electrical Fast Transient. Burst Immunity. EN61000–4–5 Surge Immunity. EN61000–4–6 Conducted RF, EN61000–4–8 Magnetic Field. EN61000-4-11 Voltage Dips, Short Interruptions & Variations. • The Low Voltage Directive 2006/95/EC. • The Machine Directive 898/37/EC EN60204–1: Safety of Machinery Page 55 Dukane Manual Part No. 403-577-00...
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  • Page 63: Section 9 - Outputs Interface

    Section 9 – I/O Interface SECTION 9 Outputs Interface Outputs Connection Example....59 Page 57 Dukane Manual Part No. 403-577-00...
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  • Page 65 Rear Panel Detail + 30 VDC Maximum + 24 V HAND PROBE OUTPUTS Status Indicator or Audible To: 1, 2, or 3 Alarm Chassis (333mA Ground maximum) (Earth) Figure 9-1 OUTPUTS Connection Example Page 5 Dukane Manual Part No. 403-577-00...
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  • Page 67: Section 10 - Contacting Dukane

    Section 10 – Contacting Dukane SECTION 10 Contacting Dukane Page  Dukane Manual Part No. 403-577-00...
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  • Page 69: Identify Equipment

    Section 10 – 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 List of Tables....... . 68 Page  65 Dukane Manual Part No. 403-574-00...
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  • Page 73: List Of Figures

    5-16 Overwrite Setuup? ......................28 5-17 Setup Maintenance 4 ....................28 Typical Hand Held Probes .....................32 Hand Probe, Horn and Tip .....................33 Probe, Booster and Horn ....................33 Replaceable Tip Installation ..................35 Stack Assembly Procedure ...................37 Page  67 Dukane Manual Part No. 403-574-00...

  • Page 74: List Of Tables

    List of Tables Description Page System OUPUTS Connector Signals ................14 Tip Torque Unit Conversion ..................... 35 6-II Stud Torque Unit Conversion ..................36 Pop-up Fault Status Screens ..................46 AC Power Requirements ....................52 Page  Dukane Manual Part No. 403-574-00...
  • Page 75 By passing its audit, Dukane can assure traditional inspection–oriented quality system you that we have in place a well–defined and...
  • Page 76 Series Ultrasonic Hand Held Systems User's Manual Part No. 403–577–00 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...

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