Dukane Power Supply ISO 90012008 User Manual

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  
Products are manufactured in ISO  
registered facilities.  
ISO 9001:2008  
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Revision History  
Revision  
Number  
Revision  
Summary  
Date  
- 00  
Original release.  
11/02/2010  
DukaneꢀManualꢀPartꢀNo.ꢀ403-583-00  
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Contents  
Section 1- Introduction                                               1  
Section 2- Health and Safety                                      5  
Section 3- Installation                                               11  
Before Installation . . . . . . . . . . . . . . . . . . . . . .13  
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . .15  
Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . .15  
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . .15  
Connecting Cables . . . . . . . . . . . . . . . . . . . . .16  
System I/O Connector Pinout . . . . . . . . . . . . . . . . 18  
Section 4 - Controls                                                   21  
Front Panel Overview . . . . . . . . . . . . . . . . . . .23  
Start-up Sequence . . . . . . . . . . . . . . . . . . . . .25  
LCD Display Overview . . . . . . . . . . . . . . . . . .26  
Section 5 - Process Control Settings                       27  
Selecting the Weld Mode . . . . . . . . . . . . . . . .29  
Navigating the Modes . . . . . . . . . . . . . . . . . . .30  
Hold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32  
Amplitude Adjustment . . . . . . . . . . . . . . . . . . .32  
System Information, Advanced Settings . . . . .33  
Setup Maintenance . . . . . . . . . . . . . . . . . . . . .35  
Section 6 - Probes and Probe Stacks                      37  
Section 7 - Troubleshooting                                     49  
Section 8 - Specifications                                         55  
Section 9 - Contacting Dukane                                 61  
Appendices                                                               65  
Appendix A - E-Stop Circuitry Examples . . .67  
Appendix B - List of Figures . . . . . . . . . . . .68  
Appendix C - List of Tables . . . . . . . . . . . . .69  
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Section 1 – Introduction  
SECTION 1  
Introduction  
General User Information . . . . . . . . . . . . . . . . . . 3  
Read the Manual First . . . . . . . . . . . . . . . . . . . . . .3  
Notes, Cautions and Warnings. . . . . . . . . . . . . . . . . .3  
Drawings and Tables . . . . . . . . . . . . . . . . . . . . . . .3  
System Overview . . . . . . . . . . . . . . . . . . . . . . 4  
Key Features . . . . . . . . . . . . . . . . . . . . . . . . 4  
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Section 1 – Introduction  
General User Information  
Read the Manual First  
Before operating your ultrasonic system, read this User’s  
Manual to become familiar with the equipment. This will  
ensure correct and safe operation. The manual is orga-  
nized to allow you to learn how to safely operate this gen-  
erator. The examples given are chosen for their simplicity  
to illustrate basic operation concepts.  
NOTE  
Note statements provide additional  
information or highlight procedures.  
Notes, Cautions and Warnings  
Throughout this manual we use NOTES to provide in-  
formation that is important for the successful applica-  
tion and understanding of the product. A NOTE block is  
shown to the right.  
CAUTION  
In addition, we use special notices to make you aware  
of safety considerations. These are the CAUTION and  
WARNING blocks as shown here. They have important  
information that, if ignored, could have increasingly se-  
vere outcomes. These statements help you to identify and  
avoid hazards and recognize the consequences. One of  
three different symbols also accompany the CAUTION  
and WARNING blocks to indicate whether the notice  
pertains to a condition or practice, an electrical safety is-  
sue or an operator protection issue.  
Caution statements  
identify conditions or  
practices that could result  
in damage to the equip-  
ment or other property.  
WARNING  
Warning statements  
point out conditions or  
practices that could re-  
sult in personal injury or  
loss of life  
Drawings and Tables  
The figures and tables are identified by the section num-  
ber followed by a sequence number. The sequence num-  
ber begins with one in each section. The figures and  
tables are numbered separately. The figures use Arabic  
sequence numbers (e.g. –1, –2, –3) while the tables use  
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  
or Practice  
Hearing  
Protection  
Electrical  
Hazard  
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iQSeries, UltrasonicꢀPowerꢀSupplyꢀALꢀUser’sꢀManual  
vides consistent system performance regardless  
of line voltage fluctuations. It also eliminates the  
need for bulky, external constant–voltage trans-  
formers.  
System Overview  
Your iQ Series UltrasonicꢀPowerꢀSupplyꢀAL,ꢀan ultra-  
sonic generator, provides a versatile stand-alone worksta-  
tion.  
Load Regulation provides constant amplitude  
automatically regardless of power draw. The ul-  
trasonic output amplitude level is held to within  
±1% to provide weld process consistency and re-  
duced weld cycle times.  
This product’s rugged internal circuitry ensures a continu-  
ous resonant frequency lock at the start of each weld.  
Standard to this line of generators are time and energy  
control. The brightly lit display is easy to read. The menu  
structure makes programming simple, and the one-touch  
hot keys give the operator even more flexibility.  
Industrial Line–Power Source means that  
standard systems will operate worldwide at all  
industrial high line voltage levels, whether it is  
200VAC @60Hz in Japan, 240VAC @50Hz in  
Europe or 208VAC @60Hz in the United States.  
There are no internal transformer taps to change  
for worldwide operation. North American sys-  
tems are optionally available to operate on the  
120VAC line voltage level.  
The generator also includes an RFI line filter that passes  
strict CE test specifications for global applications.  
Key Features  
Trigger by Power is a Dukane patented feature that  
produces greater weld consistency by requiring that  
a sufficient amount of pressure/force is applied to the  
part before the actual weld begins. Trigger by Power is  
a cost effective alternative to trigger by force because  
it does not require additional, expensive components  
such as a load cell, amplifier board or cabling.  
Multiple  
Electronic  
Overload  
protec-  
tion circuits prevent instantaneous com-  
ponent failure in the event of extreme out-  
put overload conditions, and rated overload  
power limit is based on the actual true RMS  
power output level.  
Compact Generator is small and easily moved, and  
this allows your table or work bench to accommodate  
more of the items needed for your process.  
CE Certification means that the system meets  
the required European standards to be sold and  
used in Europe.  
Pulse Width Modulation incorporates patented  
circuitry giving the power supply the ability to  
efficiently change the output amplitude. This makes  
it possible to start large horns with reduced power. It  
also provides more power efficient switch-mode gen-  
erator operation and increased reliability.  
ISO 9001 Certification means that this system  
has been manufactured to high quality standards  
and assures you of manufacturing excellence.  
Linear Ramp Soft Start circuitry allows the acous-  
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 acoustic stack (horn, booster, transducer) and ad-  
justs the generator output frequency to match it. This  
is done for every weld cycle and eliminates the need  
to manually tune the generator.  
Line Voltage Regulation automatically maintains  
constant amplitude regardless of line voltage devia-  
tion. The available output power is maintained with  
any voltage input within the specified range. This pro-  
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Section 2 – Health and Safety  
SECTION 2  
Health and Safety  
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
Lifting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
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Section 2 – Health and Safety  
General Considerations  
WARNING  
Please observe these health and safety recommendations for  
safe, efficient, and injury-free operation of your equipment.  
In this manual, the term system refers to a complete group  
of components associated with the welding of plastic or  
metal parts, also known as an ultrasonic assembly system.  
A typical system consists of a generator and/or ultrasonic  
process controller, start and stop switches, power controls,  
connecting cables, and the probe assembly which includes  
the transducer, booster, horn and replaceable horn tip.  
Never operate the gen-  
erator with the cover  
off  This is an unsafe  
practice and may cause  
injury  
Proper Installation - Operate system components only  
after they are properly installed and checked.  
CAUTION  
No Unauthorized Modifications - Do not modify your  
system in any way unless authorized to do so by the man-  
ufacturer. Unauthorized modifications may cause injury  
to the operator and/or equipment damage. In addition,  
unauthorized modifications will void the equipment war-  
ranty.  
Parts being joined ultrasoni-  
cally sometimes vibrate at  
audible frequencies. Wear  
ear protection to reduce  
annoying or uncomfortable  
sounds. In addition, sound ab-  
sorbing materials, enclosures  
or sound deflectors may be in-  
stalledtoreducethenoiselevel.  
Keep the Cover On - Do not remove any equipment cov-  
er unless specifically directed to do so by the manufactur-  
er. The generator produces hazardous electrical voltages  
which could cause injury.  
Grounded Electrical Power - Operate this equipment  
only with a properly grounded electrical connection.  
(See Page 8 for grounding information.)  
Comply with Regulations - You may be required to add  
accessories to bring the system into compliance with ap-  
plicable OSHA regulations for noise exposure.  
Plastics Health Notice  
Before using any ultrasonic welding system, be sure you  
are familiar with OSHA regulations from the U.S. Depart-  
ment of 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.  
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Electrical Safety  
Domestic Power Grounding  
Grounding Contacts  
For safety, the power cords used on this product have a  
three-wire, grounding-type power cord. Figures 2-1 and  
2-2 illustrate the appropriate electrical outlet to use with  
the power cords included with 100-120 volt and 200-240  
volt systems respectively. This information applies to  
systems shipped to North America or Japan.  
Typical Outlet  
Provided Cable  
Figure 2–3 International 220/240V Grounding  
CAUTION  
If you have a two-prong elec-  
trical receptacle, we strongly  
recommend that you replace  
it with a properly grounded  
Approved 2 pole, 3 wire grounding receptacle  
HUBBELL No. HBL 5262 or equivalent  
three-prong type. Have a  
qualified electrician replace  
it following the National Elec-  
tricCodeandanylocalcodes  
and ordinances that apply.  
NEMA Configuration 5–15R or 5–20R  
Figure 2–1 Example of 125 Volt,  
Grounded, 3-Prong Plug and Receptacle  
See Figures 2–1 and 2–2.  
CAUTION  
If there is any question about  
the grounding of your recep-  
tacle, have it checked by  
Approved 2 pole, 3 wire grounding receptacle  
HUBBELL No. HBL 5662 or equivalent  
NEMA Configuration 6–15R or 6–20R  
a qualified electrician. Do  
not cut off the power cord  
grounding prong, or alter  
the plug in any way. If an  
extension cord is needed,  
use a three-wire cord that is  
in good condition. The cord  
should have an adequate  
power rating to do the job  
safely. It must be plugged  
into a grounded receptacle.  
Do not use a two-wire exten-  
sion cord with this product.  
Figure 2–2 Example of 250 Volt,  
Grounded, 3-Prong Receptacle  
International Power Grounding  
The power cable normally provided for international use  
is compatible with the power outlet used in many Con-  
tinental European countries. Refer to Figure 2–3. How-  
ever, if your application requires another type of power  
cord, check with your equipment supplier, and follow lo-  
cal regulations concerning proper wiring and grounding.  
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Section 3 – Installation  
Lifting the Equipment  
lb  
kg  
Generator Only  
12  
5.44  
Generator + Packing  
Materials  
17  
7.71  
CAUTION  
Table 2–I iQ Generator Weights  
Ta k e c a r e i n l i f t -  
ing the equipment. We  
recommend using a me-  
chanicalliftdevicetoassist.  
How to Lift Safely  
Before lifting, take a moment to think about what  
you’re about to do.  
Examine the object for sharp corners, slippery spots  
or other potential hazards. Know your limit and don’t  
try to exceed it.  
Ask for help if needed, or if possible, divide the load  
to make it lighter.  
Know where you are going to set the item down, and  
make sure it and your path are free of obstructions.  
Then follow these steps:  
Step 1. Stand close to the load with your feet  
spread apart about shoulder width, with  
one foot slightly in front of the other for  
balance.  
Step 2. Squat down bending at the knees (not your  
waist). Tuck your chin while keeping your  
back as vertical as possible.  
Step 3. Get a firm grasp of the object before be-  
ginning the lift. Begin slowly lifting with  
your LEGS by straightening them. Never  
twist your body during this step.  
Step 4. Once the lift is complete, keep the object  
as close to the body as possible. As the  
load’s center of gravity moves away from  
the body, there is a dramatic increase in  
stress to the lumbar region of the back.  
Step 5. If you must turn while carrying the load,  
turn using your feet-not your torso. 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.  
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Section 3 – Installation  
SECTION 3  
Installation  
Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13  
When to Use Lockout/Tagout Devices . . . . . . . . . . . . . . . . . . . . . . . 13  
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15  
Connecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
Power Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
Automation Controlled System . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
System I/O Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
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Section 3 – Installation  
Before Installation  
As you plan for the installation of your generator,  
please consider these important subjects as listed  
below:  
• When to use lockout / tagout devices  
• Lifting the generator safely - See Section 2,  
Health and Safety, Page 9  
When to Use Lockout /  
Tagout Devices  
WARNING  
Electrical safety hazards  
existinsidethegenerator  
chassis  Before making  
any internal adjustments  
to the generator, apply a  
lockout/tagout (LOTO)  
device to the generator  
chassis  
Figure 3-1 Lockout Device In Open Position,  
Unlocked  
The typical kind of LOTO device for this generator  
is a clam shell type device (with lockout capability).  
The LOTO device is placed over the plug end of the  
generator electrical cord. This effectively prevents  
access to the energy isolation point. 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  
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Lockout/Tagout  
Continued from previous page  
Procedure to use BEFORE making any internal  
adjustments to the generator:  
1.  
2.  
3.  
Push the generator's AC power switch/  
breaker to the OFF position.  
Unplug the generator's electrical cord from  
its source.  
Authorized personnel apply a lockout/  
tagout (LOTO) device to the plug end of the  
generator's electrical cord. Using a typical  
clam shell type LOTO device:  
1) Open the clam shell.  
2) Place the electrical cord plug end  
inside the shell.  
3) Close the shell.  
4) Secure the shell with its lock, and  
lock it.  
4.  
Wait a minimum of five minutes for the  
generator to discharge its electrical energy.  
After taking these steps, make the necessary  
adjustments to the generator.  
5.  
Assuming the generator is being put back into  
service. . .  
Procedure to use AFTER making any internal  
adjustments to the generator:  
1. Authorized personnel remove the lockout/  
tagout device from the plug end of the  
generator's electrical cord. Using a typical clam  
shell type LOTO device:  
1) Unlock the protective shell.  
2) Open the shell, exposing the electrical  
cord end.  
3) 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.  
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Section 3 – Installation  
Unpacking  
CAUTION  
Carefully open your shipping container, and make sure  
it contains the items shown on the shipping documents.  
Inspect all items, and report any missing items or damage  
immediately.  
To minimize electri-  
cal noise and eliminate  
ground currents, ground  
the chassis as shown.  
Use a STAR configuration  
(illustrated below). Do not  
DAISYCHAINthegrounds.  
Placement  
Make certain generator placement and cable routing do  
not interfere with normal operation. Maintain easy access  
to your equipment.  
Chassis Grounding  
Fixed Probe Mount  
or 2nd Chassis  
Stud  
Grounding Stud  
#14 Gauge  
Stranded or  
Solid Wire  
The operator should have unobstructed access to cables  
and wiring.  
Recommended protective  
earth ground connection  
wire color: green or green  
with yellow stripe.  
3rd Chassis  
Grounding  
Stud  
RFI Grounding  
Earth  
Ground  
Proper grounding for the generator chassis is essential  
for the effective suppression of electrical noise or  
RFI (Radio Frequency Interference). Every ultrasonic  
generator contains a RFI filter that blocks noise on the  
AC power line from entering the system control circuitry.  
This filter also prevents ultrasonic frequency noise from  
being fed back into the AC power line. For the RFI filter  
to operate effectively, it is necessary to correctly ground  
the system.  
NOTE  
Chassis Grounding Stud  
Thechassisgroundingstudisusedtoattach  
a protective earth ground to the generator.  
This will aid in the suppression of electrical  
interference or radio frequency interference  
(RFI) that is common in a industrial environ-  
ment. Stud location is shown in Figure 3-3  
on the following page.  
Connect a grounding wire from the grounding stud  
connection (see Figure 3-1) to the nearest grounded metal  
pipe or equivalent earth ground.  
See Connecting Cables on the next page.  
CAUTION  
If you have any questions  
about the grounding of your  
equipment and/or the electri-  
cal box, contact a qualified  
electrician.  
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Connecting Cables - Quick  
NOTE  
AC Power Inlet  
Depending on your generator model, line  
voltage required for the generator is either  
100-120 VAC at 50/60 Hertz or  
Start Guide  
Complete the basic connections as shown below:  
AC Line Input  
I/O (Input/Output) Connector  
Grounding Stud  
200-240 VAC at 50/60 Hertz.  
The unit has a power switch, and is pow-  
ered ON whenever the AC line power is  
live and the switch is in the ON position as  
shown in Figure 3-4 below.  
AC Power Cord Connection  
Step 1. Connect the AC line. For the 100/120V model,  
plug the permanently attached power cord into a  
suitable receptacle.  
For the 200/240V model, attach the female end of  
the power cord to the generator’s power inlet con-  
nector - A in Figure 3-3.  
Push ON  
Step 2. Attach the I/O cable connector to the generator’s  
input/output connection. - B in Figure 3-3.  
Push OFF  
Secure the connector to the system using the two  
jack screws attached to the connector hood.  
Figure 3-4 Rocker-style Power Switch/Circuit Breaker  
Step 3. Ground the generator chassis with the supplied 14-  
Gauge wire. Attach one end to the grounding stud  
- C in Figure 3-2. Attach the other end to the near-  
est grounded metal pipe or equal earth ground.  
Step 4. Attach the male end of the power cord to a suit-  
able line receptacle.  
Connector - See Page 19 for information about the rear  
panel CONFIGURATION connector E.  
A
Power Cord with Strain Relief  
B
D
PE  
PE  
INPUTS / OUTPUTS  
U/S  
CONFIGURATION  
C
DUKANE CORP  
ST. CHARLES IL 60174  
MADE IN U.S.A.  
-WARNING-  
POWER LINE OUTLET  
MUST BE GROUNDED.  
U.S. PATENT 5,880,580  
OTHER PATENTS PENDING  
DISCONNECT LINE POWER  
BEFORE REMOVING COVER.  
IEC Connector Detail  
200/240V Model  
Figure 3-3 Generator Detail - Rear View  
E
(100/120 Volt Model)  
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Section 3 – Installation  
Power Cords  
Automation Controlled System  
Step 1. Ground the generator chassis using the supplied  
14-Gauge wire, and attach it to the grounding  
stud:C in Figure 3-3.  
200/240 Volt Systems  
The IEC AC power inlet connector mounted on the rear  
panel requires a properly configured IEC compliant power  
cord.  
Step 2. Optional – Ground the probe support. This is a  
user–supplied 14-Gauge wire.  
The 200/240 AC power cords supplied with the  
generators are matched to the ultrasonic output power  
rating and the continent of specified use. See Table 3-I.  
Step 3. Input/Output Cable - Attach the automation  
control cable from the user–supplied automa-  
tion equipment to the system HD-15 connector,  
INPUTS/OUTPUTS on the rear panel: B in  
Figure 3-3.  
Continent of Use  
Power Cord  
Part Number  
Power  
Step 4. Attach the high voltage coaxial cable from the  
probe to the ultrasound output connector, D in  
Figure 3-3.  
North America  
Europe  
200 - 1541  
200 - 1542  
200 - 1624  
240V, 10A  
240V, 10A  
240V, 10A  
India  
Step 5. Connect the AC power cord to the generator  
IEC power inlet connector, and plug the other  
end into an approved AC outlet:  
Table 3-I Standard IEC AC Power Cord Part Numbers  
A in Figure 3-3.  
100/120 Volt Systems (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.  
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iQSeries, UltrasonicꢀPowerꢀSupplyꢀALꢀUser’sꢀManual  
System I/O Connector Pinout  
Table 3-II lists the signal names and descriptions, with  
more detailed descriptions listed on the next page.  
Pin  
1
Color  
BLK  
Description  
Enable Out  
Enable In  
2
WHT  
3
4
RED  
System Overload Status Output  
Ultrasound Active Status Output  
Any Fault Status Output  
GRN  
5
ORN  
6
BLU  
System Power Status Output  
7
WHT/BLK  
RED/BLK  
GRN/BLK  
ORN/BLK  
BLU/BLK  
BLK/WHT  
RED/WHT  
GRN/WHT  
BLU/WHT  
Status Output Common (iQ Chassis Ground)  
System Ready Status Output  
8
9
Power Signal Monitor Output (1mV = 1 Watt)  
Power Signal Monitor Common (IQ Chassis Ground)  
Fault Reset Input  
10  
11  
12  
13  
14  
15  
Ultrasound Activate/Cycle Start Input  
Isolated Input Common (Sourcing or Sinking Inputs)  
No Connection  
No Connection  
Table 3-II Generator Input/Output Signals  
Pin 4 (Ultrasound Active Status Output)  
Pin 4 is a non-isolated digital NPN status output that  
activates when the system is delivering ultrasonic power  
to the load attached to the ultrasound output connector.  
This output will be an open circuit when the ultrasound  
output is off.  
Pin 1 (Enable Out)  
This is a current limited voltage source output intended  
to connect to an E-Stop circuit. If an E-Stop circuit is  
not used, Pin 1 must be jumpered to Pin 2 for ultrasound  
operation to be enabled.  
Pin 2 (Enable In)  
Pin 5 (Any Fault Status Output)  
The output from the E-Stop circuit is connected to this  
pin when an E-Stop circuit is used. Otherwise, this pin  
must be jumpered to Pin 1 for ultrasound operation to  
be enabled. See Figure A-1 in Appendix A for E-Stop  
circuit wiring examples.  
Pin 5 is a non-isolated digital NPN status output that  
activates whenever any fault condition is detected that  
inhibits ultrasound output and normal system operation.  
This output will be an open circuit when no system fault  
conditions are active.  
Pin 3 (System Overload Status Output)  
Pin 6 (System Power Status Output)  
Pin 3 is a non-isolated digital NPN status output that  
activates when an output overload condition is tripped.  
This output will be an open circuit if an output overload  
condition is not tripped. This output will remain latched  
ON until the U/S Activate input is switched OFF and  
then ON again.  
Pin 6 is a non-isolated digital NPN status output that  
activates when no fault conditions are detected by any of  
the power fault detection circuits included in the system.  
This output will be an open circuit when any power  
related fault condition is detected.  
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Section 4 – Controls and Connections  
Pin 7 (Status Output Common)  
Configuration Port Connector  
Pin 7 is connected to chassis ground. The non-isolated  
NPN status output signals can drive isolated PNP inputs  
on the automation control system.  
This connector - E in Figure 3-3 - is a DB-9M  
(standard D-subminiature nine circuit, male)  
typically used for RS-232 serial communications.  
This serial port (DTE) connects to a serial port (DCE)  
on a computer via a standard 9-pin serial cable. If the  
computer does not have a serial port, you may use a  
USB-to-serial conversion cable.  
Pin 8 (System Ready Status Output)  
This status output signal will activate only when the system  
is ready to activate ultrasound or begin a weld cycle.  
Pin 8 is a digital active low status output that activates  
when a weld processing cycle is completed and the welding  
process control system is ready to start the next welding  
cycle. This output will be an open circuit when the welding  
process controller determines that the next welding cycle  
cannot be started. This includes system faults or E-Stop  
active, but not a process fault like Overload.  
This port is used for field updates to the generator  
firmware, without removing the enclosure cover.  
This port can also be used with a software application  
running on a Windows PC to modify the factory  
default system settings and hardware configurations.  
Contact your local sales representative for software  
availability information and access to documentation  
that will allow you to make use of the configuration  
port features.  
Pin 9 (Power Signal Monitor Output)  
Pin 9 is an analog output signal proportional to the true  
RMS ultrasound power output level. This signal is scaled  
so 1mV = 1 Watt.  
Pin 10 (Power Signal Monitor Common)  
Pin 10 is a signal ground (non-isolated chassis ground) for  
the Analog Power output signal on Pin 9.  
Pin 11 (Fault Reset Input)  
Pin 11 is an isolated input control signal that will reset  
any output faults when it is activated. It can be used  
by the automation control system to simplify PLC  
programming.  
Pin 12 (U/S Activate/Cycle Start Input)  
Pin 12 is used to activate the generator ultrasound output.  
Activating this isolated control input will switch the  
ultrasound output ON, and deactivating this signal will  
switch ultrasound OFF.  
Pin 13 (Isolated Input Common)  
[Electrically connected to Pin 5 on MPC I/O connector if  
MPC Interface option is installed.]  
Pin 13 is electrically isolated from chassis ground. Using  
sourcing (PNP) output drivers, this common line would be  
connected to the automation system power supply common.  
Using sinking (NPN) output drivers, this common line  
would be connected to the automation system positive  
supply output. See Figure A-1 in Appendix A for E-Stop  
circuit wiring examples.  
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Section 4 – Controls and Connections  
SECTION 4  
Controls  
Front Panel Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
LCD Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26  
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Section 4 – Controls and Connections  
Front Panel Overview  
This section gives an overview of the front panel functions:  
powering the generator on/off; monitoring the process with  
the display; and, programming with the control keys.  
Power  
Switch  
40100  
LCD Display  
Control Keys  
Figure 4-1 Front Panel  
Power Switch/Circuit Breaker  
The power switch/circuit breaker has a rocker-style actua-  
tor switch that will activate or deactivate the AC power  
to the system. The power ON position is marked with the  
internationally recognized I symbol, the power OFF posi-  
tion is marked with the 0 symbol. This power switch also  
integrates an appropriately sized over-current protection  
circuit breaker function in the generator.  
Control Keys  
The control keys shown in Figure 4-1 and described  
below, are used to display information, and to program  
the generator.  
INFO  
Press this key to get system information or to modify the  
advanced settings.  
If an over-current condition trips the circuit breaker, it will  
automatically switch to the OFF position. If the overload  
current that caused the circuit breaker to trip is due to a  
transient condition, the circuit breaker can be reset by  
switching the actuator back to the ON position.  
System Information - Identifies the current  
version of system software.  
Advanced Settings - Select features that can be  
turned on or off including theAudibleAlarm or Fault  
Latching options.  
CAUTION  
If when resetting the circuit  
breaker after it has tripped,  
it immediately trips again, an  
SETUP  
Use the SETUP key to Load, Store, or Delete as many as  
eight setups.  
internal system malfunction,  
is likely, and the generator will  
need service. Do NOT repeat-  
edly try to reset the circuit  
breaker. If it trips, this will only  
cause more damage to the  
generator.  
ꢀꢀContinued  
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Continued  
System LCD Display  
Control Keys  
This high resolution, multi-line display provides a clear  
graphic interface to the operate and in-cycle screens  
needed to monitor and program the system.  
AMP  
Set the ultrasound amplitude output level in the range of  
20 to 100%. Typically amplitude is set to 100%.  
Power Bar Graph  
The Power Bar Graph appears at the bottom of the  
LCD display. It contains 20 segments that represent the  
generator’s range of power from 0% at the far left of  
the bar graph to 100% of power at the far right. Each  
segment equals 5% of the total.  
TIME  
Use this key to select time as the method of welding. Set  
the weld time (seconds).  
ENERGY  
Use this key to select energy as the method of welding.  
In the example below, 40% of the available power is used  
during the weld cycle. The display shows an In Cycle  
screen (while ultrasound [U/S] is active).  
Set the weld energy (joules).  
HOLD  
Hold is a time period beginning after the weld portion  
of the cycle is complete. The automation program holds  
the probe in place applying pressure to the weld, and an  
audible alarm indicates that the Hold time is finished. Hold  
can be set to a maximum of 5.0 seconds.  
40% of  
power used  
IN CYCLE  
In Cycle  
screen  
Frequency: 40087 Hz  
Power:  
225 W  
#2  
Figure 4-1A Power Bar Graph - In Cycle  
ENTER  
In the example below, 40% of the generator power was  
the maximum (peak) power delivered in the previous  
weld. The display shows an Operate screen (while U/S is  
inactive).  
Press the ENTER key to select a menu item, and move to  
the next level of the menu. Think of it as a “forward” key.  
When pressed, it also confirms and stores a selection in  
memory. It is also used to reset a latched condition.  
Weld by Time  
Operate  
Arrow Keys  
Press the right and left arrow keys to move the cursor to  
Weld Time 1.500 S  
screen  
Weld Energy 301 J  
the right or left.  
#1  
40% of power delivered in previous weld  
+ and - Keys  
Figure 4-1B Power Bar Graph - Operate  
Press these keys to increase or decrease the value of a  
selected digit.  
CAUTION  
CANCEL  
Make sure the stack is prop-  
erly assembled before it is  
connected to the system. The  
Press CANCEL to return to the previous screen. Think of  
it as a “back” key. Press this key when you do not want to  
store the selection in memory.  
horn should never come in  
direct contact with a metal fix-  
ture or anvil when ultrasound  
is activated.  
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Section 4 – Controls and Connections  
Push ON  
Start-up Sequence  
After all connections have been completed.  
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  
Setup  
2. Two Power-up screens appear briefly - Figure 4-3,  
DUKANE  
Software  
version  
and Figure 4-3A.  
iQ AL Series xxkHz  
xxxxxxxxx  
Website  
Address  
3. The next screen is an Operate screen ready for a  
new weld to be done. The display shows:  
xxxxxx  
Setup #1  
MB FPGA  
version  
The setup used for the last weld, and zeros for any  
weld parameters.  
Figure 4-3 Power-up Screen 1  
See Figure 4-3B.  
Trigger by Power  
available  
Starting a Weld Cycle  
1. If the generator is not powered, press its Power  
U.S. Patent #7475801  
Figure 4-3A Power-up Screen 2  
Switch/Circuit Breaker to the ON position.  
Weld by Time  
Weld Time 0.000 S  
Weld Energy 0 J  
2. Select the setup you want to use, if appropriate.  
3. The generator is ready to start a weld cycle when  
the Ultrasound Activate/Cycle Start Input (Pin 12) is  
activated.  
#1  
Figure 4-3B Operate Screen, After Power-up  
Stopping the Weld Cycle  
Normal Conditions  
The cycle stops when the programmed welding cycle ends  
if the generator is configured to weld by time or energy.  
If it is configured to weld by automation, the cycle ends  
when the Ultrasound Activate/Cycle Start Input (Pin 12)  
is deactivated.  
Emergency Conditions  
Manual System  
Push the Power Switch to OFF (See Figure 4-2.) to  
stop the ultrasound signal. This may be done under any  
conditions.  
Automated System  
Customer-supplied external controls provide the means  
to stop the cycle for an automated system.  
An auxiliary cable connects these external controls to the  
iQ generator at the INPUTS/OUTPUTS connector.  
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LCD Display Overview  
There are two basic kinds of screen displays:  
Operate screens, and In Cycle screens.  
An Operate screen tells the operator  
what happened in the last weld cycle.  
Weld Mode -  
Automation, Time,  
or Energy  
Data from  
last weld  
cycle.  
Automation Weld  
Weld Time 0.500 S  
Weld Energy 18 J  
#2  
Setup  
number.  
Figure 4-4 Example of an Operate Screen  
An In Cycle screen activates when the ultrasound signal  
has been activated.  
Status Indication  
Stack Frequency  
IN CYCLE  
Frequency: 40087 Hz  
Power:  
40 W  
#2  
Power Draw  
Power Bar Graph %  
Figure 4-5 Example of an In Cycle Screen  
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Section 5 - Process Control Settings  
SECTION 5  
Process Control Settings  
Select the Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29  
Navigating the Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
Amplitude Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32  
System Information, Advanced Settings. . . . . . . . . . . . . . . . . 33  
Setup Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36  
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Section 5 - Process Control Settings  
Process Controller  
Settings  
This section of the manual helps the reader become  
familiar with the operating modes, and illustrates some  
typical programming steps.  
There are three welding modes available. These  
correspond to the three ways in which the welder can be  
used: Automation, Time, and Energy.  
Select the Welding Mode  
Automation - In AUTOMATION mode the PLC  
controlstheweldcycle.Thecyclestarts,andtheultrasonic  
signal (U/S) activates when Ultrasound Activate/Cycle  
Start Input (Pin 12) is activated. When the Ultrasound  
Activate/Cycle Start Input (Pin 12) is deactivated, the  
ultrasonic signal stops and the cycle is complete unless  
there is a hold time programmed.  
Time - In TIME mode the operator sets a maximum  
time (seconds) that the ultrasonic signal will be active for  
each weld cycle. The cycle starts when the Ultrasound  
Activate/Cycle Start Input (Pin 12) is activated. The U/S  
stops when the programmed time is reached.  
Energy - In ENERGY mode the operator sets a  
maximum energy (Joules) the generator will reach  
during the weld cycle. [A maximum weld time must be  
set when welding by energy. If the energy level is not  
reached, the preset for time will determine when the  
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.  
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Navigating the Modes  
When the generator is first powered up, the default  
operating mode is Automation, and Automation Weld  
is shown at the top of the display as shown in Figure 5-1.  
Automation Weld  
Weld Time 0.000 S  
Weld Energy 0 J  
#2  
Navigate to Time Mode  
Figure 5-1 Automation Weld Mode  
1. Follow the sequence shown in the figures to the right  
to navigate from Automation mode to Time mode.  
In Automation mode, press the TIME key  
TIME key  
(Figure 5-2).  
Automation Weld  
2. The phrase, Enter Changes Mode, means when the  
ENTER key is pressed, the mode will change. So  
press the ENTER key, and the Weld by Time screen  
seen in Figure 5-3 appears.  
Weld By Time  
OFF  
Enter Changes Mode  
Figure 5-2 Navigate to Time Mode  
3. Set the time.  
Use the  
and the  
keys to move the cursor  
+ -  
and to set the digits for the weld time you want.  
ENTER key  
4. Press the ENTER key to accept the time that has  
been set (Figure 5-4).  
Weld by Time  
Press the CANCEL key if you decide not to set the  
time.  
Weld By Time  
OFF  
Set the time.  
S
Press Enter To Accept  
Press Cancel To Abort  
NOTE  
Figure 5-3 Time Weld Mode - 1  
Navigating to Automation Mode  
Set Time or Energy (depending on mode) to  
OFF, and press ENTER.  
This will put you back in Automation mode.  
Weld by Time  
Weld Time  
Alternately:  
Find an empty setup. Press SETUP.  
Press ENTER.  
ENTER key  
0.500 S  
Press Enter To Accept  
Press Cancel To Abort  
Figure 5-4 Time Weld Mode - 2  
A pop-up screen about defaults appears.  
Setup #1Empty  
Load Defaults?  
YES NO  
Select YES to load the default operating mode  
which is Automation, and you can weld using  
the Automation mode.  
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Section 5 - Process Control Settings  
Navigate to Energy Mode  
1. Follow the sequence shown in the figures to the right  
to navigate from Time mode to Energy mode.  
Weld by Time  
Weld Time 0.500 S  
Weld Energy 00 J  
#2  
Figure 5-5 Time Weld Mode  
ENERGY  
key  
Weld By Time  
Weld By Energy  
OFF  
In Time mode (Figure 5-5), press the ENERGY key,  
and the screen as shown in Figure 5-6 appears.  
Enter Changes Mode  
Figure 5-6 Navigate to Energy Mode - 1  
ENTER key  
2. The phrase, Enter Changes Mode, means when the  
ENTER key is pressed, the mode will change. So  
press the ENTER key, and the Weld by Energy  
screen seen in Figure 5-6A appears.  
Weld By Energy  
Weld Energy  
OFF J  
Press Enter To Accept  
Press Cancel To Abort  
Figure 5-6A Navigate to Energy Mode - 2  
3. Use the  
and the  
keys to move the  
+ -  
Weld By Energy  
cursor and to set the digits for the energy you want.  
See Figure 5-7.  
Weld Energy  
Set energy  
27 J  
level.  
Press Enter To Accept  
Press Cancel To Abort  
4. Press the ENTER key to accept the energy that has  
been set. Press the CANCEL key if you decide not to  
set the energy.  
Figure 5-7 Energy Weld Mode - 1  
5. If you set the energy level, a maximum weld time  
needs to be set also. Set a time that is reasonable for  
your application. [The factory default for this time is  
30 seconds (also the maximum).]  
Weld By Energy  
Maximum Weld Time  
ENTER key  
1.000 S  
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.  
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Hold  
HOLD is used more often with Time or Energy modes, but  
it can be used with the Automation mode.  
HOLD does not allow the automation program to begin a  
new cycle until HOLD is finished.  
To set a HOLD period:  
1. Select the weld mode (Automation, Time, Energy).  
2. Set the time and energy parameters as needed.  
3. Press the HOLD key. The screen will appear as it  
does in Figure 5-9.  
4. Set the time with the  
keys.  
+ -  
(A maximum of 5.0 seconds.)  
Hold Time  
OFF S  
Figure 5-9A shows a setting for 2.0 seconds.  
5. Press the ENTER key to confirm your selection.  
Figure 5-9 HOLD Time - 1  
Amplitude Adjustment  
Amplitude refers to the movement of the horn at its  
workface. The higher the amplitude setting, the higher the  
power output level will be at a particular pressure level.  
Hold Time  
2.0 S  
Amplitude settings are given as a percent of the horn’s  
nominal amplitude in the range of 20% to 100%.  
It is typical to leave the amplitude setting at 100% for  
maximum power output.  
Figure 5-9A HOLD Time - 2  
To adjust amplitude:  
1. Press the AMP key. The screen will appear as in  
Figure 5-10.  
2. Set the amplitude level using the  
keys and the  
keys.  
+ -  
3. Press ENTER to confirm your amplitude setting.  
Amplitude  
100 %  
Figure 5-10 Amplitude  
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Section 5 - Process Control Settings  
System Information,  
Advanced Settings  
When the INFO key is pressed the display looks like  
Figure 5-11:  
iQ Information  
> System Information  
Advanced Settings  
Using the  
keys, move the pointer to indicate:  
+ -  
System Information, or  
Advanced Settings  
Figure 5-11 INFO Screen  
Press ENTER to make the selection.  
Dukane Corporation  
iQ AL Series 40kHz  
FP v1.08 MB v2.56  
FPGA v7  
1. System Information  
Manufacturer’s information is shown including the  
manufacturer’s name, the name of the system, and the  
software identification.  
Figure 5-11A System Information Example Screen  
Figure 5-11A shows an example of this information.  
2. Advanced Settings  
Warning  
Modified settings  
may affect operation  
of this unit!  
After Advanced Settings is selected, a warning  
screen is displayed as shown in Figure 5-12.  
Adjusting these settings may affect the operation of  
your unit. Before you change a setting, please check  
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.  
NOTE  
See Figure 5-13.  
Trigger by Power is only avail-  
able when the weld mode is  
either Time or Energy.  
Adjustments can be made to: Free Run Frequency;  
Ramp Up Time; Frequency Lock and Hold; a n d ,  
Trigger By Power, but note that Trigger by Power  
is only available when the weld mode is Time or  
Energy.  
Advanced Settings  
Free Run Frequency  
19900Hz  
150mS  
ON OFF  
Free Run Freq  
Ramp Up Time  
Lock and Hold  
Free Run is the frequency at which the generator  
drives the ultrasound output pulses until a valid  
resonant frequency feedback signal is detected.  
Typically this value should be below the operating  
frequency of the probe.  
> Trigger By Power  
Press Enter To Accept  
Press Cancel To Abort  
ON OFF  
Figure 5-13 Advanced Settings Screen  
Follow the on screen prompts to make setting adjust-  
ments.  
Continued  
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Continued  
Ramp Up Time  
This parameter increases the amplitude linearly in  
the programmed time period at the start of the weld  
from zero to the programmed amplitude level. This  
brings the probe up to operating amplitude smoothly  
preventing shock stress.  
Follow the on screen prompts to make setting  
adjustments.  
Lock and Hold  
For an explanation of Frequency Lock and Hold,  
please refer to Application Note 505 found on our  
website at:  
Follow the on screen prompts to make setting  
adjustments.  
Trigger By Power  
Amplitude  
Trigger by Power  
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:  
40 %  
_
Figure 5-14 Trigger Amplitude  
When Trigger by Power is selected, three additional  
settings screens are presented:  
Trigger By Power  
Watts  
Trigger Amplitude;  
Trigger Power; and,  
Trigger Timeout  
80 W  
_
Figure 5-15 Trigger Watts  
See Figures 5-14, 5-15, and 5-16 for previews of  
these screens  
Trigger By Power  
Timeout  
1.100 S  
_
Figure 5-16 Trigger Timeout  
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Section 5 - Process Control Settings  
Setup Maintenance  
Setup Maintenance  
Introduction  
Delete  
Load  
The screens available in Setup Maintenance allow the  
operator to Load, Store, or Delete generator weld setups.  
As many as eight (8) setups can be loaded and stored for  
your convenience.  
Setup # 1  
EMPTY  
Figure 5-17 Setup Maintenance - 1  
Navigating  
1. When the SETUP key is pressed for the first time, the  
display looks like Figure 5-17. This screen indicates  
that Setup #1 is Empty. Because there is not yet any  
data available, this setup has nothing in it, and is  
empty. You will see that Load is highlighted.  
Press ENTER.  
Setup #1 Empty  
Load Defaults?  
NO  
YES  
Figure 5-17A Pop-up Load Defaults?  
2. Load - (Load means to put data into the generator’s  
memory, or to program a setup.)  
A pop-up screen asks if defaults should be loaded for  
Setup #1. See Figure 5-17A.  
Setup Maintenance  
Delete  
Load  
Select NO, and the display will change to an Operate  
screen.  
Mode: Automation  
Setup # 1  
T: 0.000 S  
A: 100%  
H: 0.0 S  
E:  
0 J  
TBP: OFF  
Select YES, and Automation Weld shows at the top  
of the Operate screen that will display next. The setup  
number appears in the lower left corner of the screen.  
Refer to Figure 4-4.  
Figure 5-18 Setup Maintenance - 2  
3. After selecting YES, press SETUP, and the display  
will look like Figure 5-19.  
Setup Maintenance  
4. Delete -To delete the setup, select Delete as shown  
in Figure 5-19, and press the ENTER key. A pop-up  
screen appears to ask you to confirm your choice.  
Delete  
Load  
Setup # 1 Mode: Automation  
T: 0.000 S  
E: 0 J  
TBP: OFF  
A: 100%  
H: 0.0 S  
Select YES or NO, and press ENTER again.  
Figure 5-19 Setup Maintenance - 3  
Continued  
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Setup Maintenance  
Continued  
Changing the Current Setup  
Weld by Time  
Try using your navigation skills on this example:  
1. Follow instructions on Page 24 to set the mode to  
Weld by Time. Set the time to 1.520 seconds.  
See Figure 5-20.  
Weld Time  
1.520 S  
Press Enter To Accept  
Press Cancel To Abort  
Figure 5-20 Set Time  
2. Press SETUP, and you will notice that the time  
just set appears in the current setup.The new time  
replaced whatever time was in the current setup. It  
was changed, or overwritten.  
3. To avoid having your current setup changed: Press  
SETUP, and with LOAD highlighted, use the + -  
keys to select an empty setup. Press ENTER.  
Then, maketheTime(and/orEnergy)entries. Nothing  
will be overwritten because your entries were made  
in an empty setup.  
Setup Maintenance  
Delete  
Load  
4. Confirm that your setup has been saved in memory  
by going back to SETUP. Your new setup should  
appear, as it does in Figure 5-22.  
Setup # 1  
Mode: Automation  
T: 1.520 S  
A: 100%  
H: 0.0 S  
E:  
0 J  
TBP: OFF  
Figure 5-21 New Setup Saved  
Selecting a Setup  
To select a setup previously loaded:  
1. Press SETUP.  
2. With Load highlighted, use the  
keys to select  
+ -  
the number of the setup you want.  
3. Press ENTER.  
NOTE  
4. The Operate screen will display this setup selection  
as a number in the display’s lower left hand corner.  
The power supply program always has  
one default setup (as shown below).  
This can be overwritten, but can not be  
deleted.  
Deleting a Setup  
To delete a setup previously stored:  
1. Press SETUP.  
Setup Maintenance  
2.  
keys to select  
With Delete highlighted, use the + -  
Delete  
Load  
the number of the setup you want.  
Mode: Manual  
Setup # 1  
T: 0.000 S  
A: 100%  
H: 0.0 S  
E:  
0 J  
3. Press ENTER, and a pop-up screen will ask you to  
confirm your selection. Make your choice, and press  
ENTER.  
TBP: OFF  
Figure 5-22 Default Setup Screen  
4. Check that the setup is deleted. Press SETUP, and  
the Setup Maintenance screen will show EMPTY for  
the setup you just deleted.  
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Section 6 – Probes and Probe Stacks  
SECTION 6  
Probes and Probe Stacks  
Ultrasonic Probe Overview...........................39  
Theory of Operation............................................40  
Probe Configuration............................................40  
Ultrasonic Horn ...................................................41  
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  
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Section 6 – Probes and Probe Stacks  
Ultrasonic Probe  
Overview  
CAUTION  
The ultrasonic cable car-  
ries high electrical current  
when in operation. Do not  
nick or cut this cable. If  
cut, there would be a high  
potential for electric shock!  
Operating Notes  
Compressed Air Fitting - In continuous duty  
operation, it is important to keep the probe cool with  
compressed air. 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.  
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iQSeries, UltrasonicꢀHandꢀHeldꢀSystemsꢀUser’sꢀManual  
Theory of Operation  
CAUTION  
Plastic welding is the most common application of  
ultrasonic assembly. To perform ultrasonic plastic  
welding, the vibrating tip is brought into contact with  
one of the work pieces. Pressure is applied and ultrasonic  
energy travels through the material generating frictional  
heat at the contact point of the two parts. The frictional  
heat melts a molded ridge of plastic on one of the pieces  
and the molten material flows between the two surfaces.  
When the vibration stops, the material solidifies forming a  
permanent bond.  
Never use a probe if the  
cable insulating jacket is  
cut or damaged in any way.  
Probe Configuration  
A basic ultrasonic probe package consists of:  
1. Aprobe which houses the transducer to convert the elec-  
trical energy supplied by the generator into mechanical  
vibrations.  
2. A horn to transfer the mechanical vibrations from the  
probe to the parts to be welded.  
Optional components include special replaceable tips  
which can be threaded on to the tip of the horn, and a  
booster to amplify the mechanical vibrations of the horn.  
A basic probe system is shown in Figure 6-1.  
Probe  
Normally a booster is not used with a probe as this  
increases the length and weight and reduces its versatility.  
The optional threaded titanium tip can be used when the  
application calls for a staking profile or a pointed spot  
weld. Replaceable tips are not commonly used in high–  
volume production environments.  
Standard  
Horn  
Custom  
Horn  
Tip  
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’sApplication Note  
#504 - UltrasonicꢀAcousticꢀStackꢀMountingꢀ  
Guidelines - found on our website at http://  
www dukane com/us/DL_ApplData asp  
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Section 6 – Probes and Probe Stacks  
Ultrasonic Horn  
The horn transfers the ultrasonic mechanical vibrations  
(originating at the transducer in the probe housing) to the  
plastic parts through direct physical contact. The horn  
is precision machined and designed to vibrate at either  
20kHz, 30kHz, 40kHz, 50kHz or 70kHz. The tuning is  
accomplished using electronic frequency measurement.  
Inherent variations in material composition prevent tuning  
by dimensional machining alone.  
There are many different horn profile styles depending  
upon the process requirements. Factors which affect  
the horn design are the materials to be welded and the  
method of assembly. Horns are usually constructed from  
aluminum, hardened steel or titanium. As the frequency  
increases, vibration amplitude typically decreases, but  
internal stress in the horn increases. Higher frequencies  
are used for delicate parts that cannot handle a lot of  
amplitude. Some factors to keep in mind for high–  
frequency (e.g. 40kHz) ultrasonic welding versus low–  
frequency (e.g. 20kHz) ultrasonic welding are listed here.  
1. Stress in the horn is higher at high frequencies.  
Probe  
Housing  
2. Wear on the horn is greater at high frequencies.  
3. Clean and flat mating surfaces between the horn, booster  
and transducer are more critical at high frequencies.  
Booster  
The function of a booster is to alter the gain (i.e. output  
amplitude) of the probe. A booster is amplifying if its gain  
is greater than one and reducing if its gain is less than one. A  
neutral or coupling booster is used to provide an additional  
clamping location for added probe stack stability. A probe  
designed to be mounted in a fixture along with a booster and  
horn is shown in Figure 6–2. This is commonly referred to  
as a stack. As indicated, the components are secured with  
threaded studs.  
Booster  
Horn  
Figure 6–2 Probe, Booster and Horn  
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NOTE  
Stack Assembly  
Do not apply any grease to the threads  
of the replaceable tip. This may cause  
the tip to loosen from the horn resulting  
in inconsistent operation.  
Attaching a Replaceable  
Tip to a Horn  
1. Inspect all horn and tip surfaces for stress cracks,  
chips, or gouges.Any of these irregularities will affect  
operation and could lead to further equipment damage.  
Contact the Dukane Ultrasonics Tooling Department  
concerning damaged horn components.  
CAUTION  
NEVER clamp the horn  
in a vise. The resulting  
scratches or gouges in the  
surface are stress risers  
which may result in cracks.  
2. Apply an extremely thin layer of a high temperature,  
high pressure silicon grease to the back surface that  
mates with the horn. The grease will allow both  
surfaces to intimately mate and become acoustically  
transparent which improves the energy transfer. Do  
not apply any grease to the threads. We recommend  
Dow–Corning #4 (or #111 as an alternate). A small  
packet of Dow–Corning #4 is supplied with the system.  
If you cannot use a silicon–based grease in your facil-  
ity, a petroleum–based grease may be used. However, it  
is likely to leave carbonaceous deposits on the surface,  
and require more frequent joint maintenance. Failure  
to follow these instructions, may result in the mating  
surfaces bonding and difficulty removing the tip from  
the horn.  
3. Thread the tip into the horn and tighten to the torque  
specifications below using an open end wrench of the  
correct size to fit the wrench flats of the tip. This is  
illustrated in Figure 6-3. If necessary, use a spanner  
wrench (on horns with spanner wrench holes) or an  
open end wrench (on horns with wrench flats) to keep  
the horn from turning in your hand. A canvas strap  
wrench is permissible if it does not gouge or scratch  
the horn.  
Tighten  
Figure 6–3 Replaceable Tip Installation  
Replaceable Tips to Horn  
NOTE  
inch-lb ft-lb N-m  
Size  
40.7 1/2” x 20 tpi tip threads  
38 3/8” x 24 tpi tip threads  
Dukane Part No. for the 20kHz span-  
ner wrenches is 721–68.  
360  
336  
300  
240  
30  
28  
25  
20  
33.9 5/16” x 24 tpi tip threads  
27.1 1/4” x 28 tpi tip threads  
Dukane Part No. for the 40kHz span-  
ner wrenches is 721–44.  
Table 6-I Tip Torque Unit Conversions  
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Section 6 – Probes and Probe Stacks  
Attaching the Mounting  
Stud to a Horn or a  
Booster  
NOTE  
Do not apply any grease to the stud  
threads or the tapped hole. This may  
cause the stud to loosen. If the stud  
wanders within the joint, it can vibrate, re-  
sulting in excessive heat. In some cases,  
this can melt the tooling material.  
1. Inspect the stud for cracks or damaged threads.  
Replace the stud if it is cracked or otherwise dam-  
aged.  
2. Remove any foreign matter from the threaded stud  
and the mating hole.  
3. Thread the mounting stud into the input* end of the  
horn or the input* end of the booster and tighten to  
the following torque specifications using an Allen  
wrench in the socket head of the mounting stud.  
Table 6-II lists the torque specifications in units  
for both English and Metric systems of measure-  
ments.  
DO NOT hold the booster by the mounting rings  
when tightening stud. The mounting rings have a  
shear pin which could snap under excessive torque.  
Use a spanner wrench (on horns with spanner  
wrench holes) or an open end wrench (on horns  
with wrench flats) to keep the horn or booster from  
turning in your hand.  
in-lb  
ft-lb  
N-m  
Size  
12-18  
12-18  
12-18  
1 - 1.5 1.4 - 2 1/2” x 20 tpi studs  
1 - 1.5 1.4 - 2 3/8” X 20 tpi studs  
1 - 1.5 1.4 - 2 8 mm studs  
NOTE  
To convert inch-lbs to ft-lbs, divide by 12.  
To convert inch-lbs to Nm, divide by 8.852.  
To convert ft-lbs to Nm, multiply by 1.356.  
To convert Nm to ft-lbs, multiply by  
0.7376.  
Table 6-II Stud Torque Unit Conversions  
*
Always assemble the mounting studs that mate  
Torque specifications have a tolerance of  
about ± 10%.  
boosters, transducers and horns to the input end of  
the horn or the input end of the booster first. 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.  
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Attaching the Horn to  
a Booster, Booster to a  
Probe, or Horn to a Probe  
NOTE  
Always remove a probe stack from the  
machine in which it is mounted before  
attaching or removing a horn.  
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  
concerning a damaged booster.  
CAUTION  
Never leave a horn or booster  
assembly hand tight. Torque  
it to the proper specifications  
2. Ensure that the mating surfaces of the two components  
are clean and smooth. These surfaces must make inti-  
mate contact for the mechanical energy to pass from  
one component to the next. Pitting or a buildup of old  
grease and dirt on a mating surface will interfere with  
the energy transfer and reduce the power delivered.  
before proceeding. If the as-  
sembly is installed without  
being properly torqued down,  
the assembly may vibrate  
severely, damaging the mat-  
ing surfaces and causing  
the generator to overload.  
3. Make sure that the stud in the horn or booster is tight.  
See the preceding mounting stud assembly instructions  
for torque specifications.  
4. Remove any foreign matter from the threaded stud and  
mating hole.  
5. Apply an extremely thin layer of a high temperature,  
high pressure silicon grease to the surface that mates  
with the horn. The grease will allow both surfaces to  
intimately mate and become acoustically transparent  
which improves the energy transfer. We recommend  
Dow–Corning #4 (or #111 as an alternate). A small  
packet of Dow–Corning #4 is supplied with the system.  
If you cannot use a silicon–based grease in your facility,  
a petroleum–based grease may be used. However, it is  
likely to leave carbonaceous deposits on the surface,  
and require more frequent joint maintenance. Grease  
may be omitted if mylar washers are preferred on sys-  
tems that require frequent changes. Mylar is plastic and  
will creep under compression, so mylar is not recom-  
mended for systems that are not changed frequently.  
Failure to follow these instructions, may result in the  
mating surfaces bonding and difficulty removing the  
horn from the booster or the booster from the probe.  
Tighten  
Figure 6–4 Stack Assembly Procedure  
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Section 6 – Probes and Probe Stacks  
6. Thread the components together and tighten to the  
following torque specifications using only the correct  
size wrenches. Use spanner wrenches on components  
with spanner wrench holes or an open end wrench on  
components with wrench flats. See Figure 6–4 for the  
correct procedure. Refer to Table 6-III for torque unit  
conversions. Be careful not to overtighten.  
NOTE  
Horn and booster torque specifications  
are higher than stud torque specs. Be  
sure to tighten the horn or booster joints  
to the higher torque limits.  
Do not tighten the studs to these higher  
ratings as it may induce unnecessary  
stress in the assembly.  
In-lb Ft-lb N-m  
kHz  
540  
420  
216  
216  
45  
61 15 kHz stack  
35 47.5 20 kHz stack  
18 24.4 30 kHz stack  
18 24.4 40 kHz stack  
Table 6-III Horn/Booster Torque Unit Conversions  
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Stack Disassembly  
CAUTION  
Stackdisassemblyisrequiredwhenchangingtheboosteror  
horn, or for a thorough inspection of all stack components.  
In mounted systems, always remove the stack from its  
mounting to disassemble the stack components.  
Never hold a probe by the  
housing when tightening or  
loosening an adjoining com-  
ponent. The probe housing  
has anti–rotation devices  
to keep the transducer  
aligned. These could shear  
under excessive torque.  
To establish a maintenance schedule, inspect the mating  
surfaces after the first 200–400 hours of operation. If they  
require cleaning, halve the time between inspections. If  
the surfaces do not require reconditioning, then double the  
time between inspections. Each system is different due  
to the large number of operational parameters and stress  
factors.  
The assembly and disassembly procedures for a probe  
are shown in Figure 6–5. It makes no difference whether  
the horn is attached to the booster first, or the booster is  
attached to the probe first.  
ASSEMBLY  
PROBE  
HOUSING  
Output End  
PROBE  
HOUSING  
PROBE  
ASSEMBLY  
Spanner  
Wrench  
Mounting Stud  
(Insert Into Horn  
Holes  
First and Tighten  
to Torque Specs)  
Input End  
HORN  
HORN  
DISASSEMBLY  
Figure 6–5 Probe Assembly and Disassembly  
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Section 6 – Probes and Probe Stacks  
Separating the Horn from  
a Booster, Booster from  
a Probe or Horn from a  
Probe  
On all transducers and horns with spanner wrench holes,  
use only the correct size spanner wrench that came with  
your system to provide sufficient torque to loosen a joint.  
See Figure 6–6.  
Loosen  
NOTE  
Do not hold a booster by the mounting  
rings when removing the stud from the  
booster. Use a spanner or open–end  
wrench to provide opposite force and  
keep the horn or booster from turning in  
your hand when loosening the stud. Use  
a spanner wrench onhorns and boosters  
with spanner wrench holes. Use an open  
end wrench on horns and boosters with  
wrench flats.  
Figure 6–6 Separating the Horn from the Booster  
On boosters and horns with wrench flats, use only the  
correct size wrench to provide sufficient torque to loosen a  
joint when necessary.  
Removing the Mounting  
Stud from a Horn or  
Booster  
Only use an Allen wrench of the correct size in the socket  
head’s stud to remove the stud from the horn or booster.  
Loosen  
Removing Replaceable  
Tips from a Horn  
Use an open end wrench of the correct size to fit the wrench  
flats of the detachable tip. Use a spanner wrench (on horns  
with spanner wrench holes) or an open wrench (on horns  
with wrench flats) to provide an opposite force to keep the  
horn from turning in your hand. Refer to Figure 6–7 for the  
correct tip removal procedure.  
Figure 6–7 Removing a Replaceable Tip from the  
Horn  
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Booster Notes  
How to Tell the Booster  
Input End from the Output  
1. The depth of the threaded hole on the output end is  
always deeper than the threaded hole on the input  
end.  
2. On an amplifying booster (gain > 1.0), the larger  
diameter end is the input end. On a reducing booster  
(gain < 1.0) the larger diameter end is the output end.  
On a neutral acting booster the diameters are equal.  
CAUTION  
NEVER install a booster  
upside down to change  
an amplifying system to  
a reducing system. The  
boosters are dimensionally  
asymmetric. They are tuned  
from input to output to act  
like an acoustic lens. Re-  
versing them will not give the  
expected results and may  
causedamagetothesystem.  
3. The cap screws on the booster mounting rings are  
always inserted from the output end toward the input  
end.  
How to Tell if the Booster  
Is Amplifying or Reducing  
Boosters have a die-stamped number on their surface that  
indicates their gain or reduction. If the number is greater than  
1.0 (e.g. 1.5), it is an amplifying booster. If the number is  
less than 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.  
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Section 7 – Troubleshooting  
SECTION 7  
Troubleshooting  
No Ultrasonic Output.....................................51  
System Power Output Level.........................51  
Welding Problems.........................................52  
Pop-up Fault Status Screens........................53  
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Section 7 – Troubleshooting  
No Ultrasonic Output  
Probe  
Make sure that the probe cable is connected to the generator  
connector (PROBE) and secured to the rear panel. Also,  
make sure the probe stack is properly assembled.  
System Power Output Level  
NOTE  
Overload  
The LCD screen displays a variety of  
pop-up status changes as they oc-  
cur. Check Table 7-I - Pop-up Fault  
Status Screens - Page 53.  
When an overload occurs, it will automatically reset  
when the next ultrasound activation signal begins. If the  
condition persists:  
Turn the generator OFF and:  
1. Check the system. Change the probe to one that is  
known to be good.  
2. Turn the generator ON, and see if the fault condition  
has been corrected.  
Overtemperature  
When the system overheats, and the generator’s internal  
temperature exceeds 85°C (185°F) an overtemperature  
fault condition will trip.  
When the system cools, the system automatically resets  
the overtemperature fault.  
NOTE  
When Latching Faults is enabled,  
ENTER must be pressed to clear  
a fault.  
Generator Fault Does Not Reset  
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.  
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Welding Problems  
Weak Welds  
Weak welds, or underwelding, is caused by insufficient  
energy being transmitted to the part. You can increase  
the weld pressure, increase the weld duration (Time or  
Energy) or change to a higher gain booster to increase  
the amplitude to increase the energy delivered to the  
weld.  
Inconsistent Welds  
Variations in plastic due to filler materials and moisture  
absorption may lead to inconsistent welds. Fillers can  
be especially troublesome if they are not uniformly  
distributed, the content is too high or it contains too  
much or poor quality regrind or degraded plastic.  
Try welding by energy. This eliminates many  
inconsistencies. There should be no unusual or loud  
noise from the acoustic stack. If there is, disassemble  
the stack and reassemble.  
Exchange the probe with another unit to see if the problem  
disappears. If not, exchange the generator with another  
unit to try and isolate the problem.  
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.  
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Section 7 – Troubleshooting  
Pop-up Fault Status Screens  
Generator Fault Status Screens - Automation Mode  
Status Text Displayed  
System Status or Fault Explanation  
An Average Overload fault tripped.  
Generator Fault  
Output power exceeded rated wattage.  
Lower the welding pressure or amplitude.  
Fault will reset when next weld cycle starts.  
Average Overload  
A Peak Overload fault tripped.  
Generator Fault  
Peak IGBT transistor current exceeded.  
Caused by a severe frequency mis-match.  
Fault will reset when next weld cycle starts.  
Peak Overload  
Resonant frequency not found, or lost.  
Check for a defective stack component.  
Check for stack coupling to the fixture.  
Fault will reset when next weld cycle starts.  
Generator Fault  
Frequency Overload  
System Overtemperature fault detected.  
Fault will reset when system cools down.  
Generator Fault  
Over Temperature  
Internal communications error.  
Generator Fault  
Turn generator power off and back on.  
Call Dukane service if the fault persists.  
Cycle Power  
Table 7- I Pop-Up Fault Status Screens  
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Section 8 – Specifications  
SECTION 8  
Specifications  
Generator Outline Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . 57  
Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58  
Operating Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58  
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59  
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . 60  
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Section 8 – Specifications  
ALLOW 5" (127 mm) BEHIND UNIT  
FOR CABLE CONNECTIONS  
12.41  
[315.2]  
10.00  
[254]  
3.95  
[100.3]  
3.51  
[89.2]  
IN  
[mm]  
Figure 8-1 Generator Outline Drawing  
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Weights  
Generator:  
12 pounds (5.44 kg)  
Shipping:  
Add 5 pounds (2.27 kg) to unit weight for packing materials.  
Operating Environment  
Operate the equipment within these guidelines:  
Temperature:  
Air Particulates: Keep the equipment dry.  
Minimize exposure to moisture, dust, dirt, smoke  
40°F to 100°F (+5°C to +38°C)  
and mold.  
Humidity:  
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  
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Section 8 – Specifications  
AC Power Requirements  
Overload  
Power  
Rating  
North America/  
Japan  
AC Outlet Rating  
Operating  
Frequency  
Generator  
Model Number  
Input AC Power Requirements  
Nominal AC Volt  
(Watts)  
20kHz  
20kHz  
20ALP060-1E  
20ALP060-2E  
100-120 VAC, 50/60 Hz @ 9.0 Amps  
200-240 VAC, 50/60 Hz @ 4.5 Amps  
30kHz  
30kHz  
30AL060-1E  
30AL060-2E  
100-120 VAC, 50/60 Hz @ 9.0 Amps  
200-240 VAC, 50/60 Hz @ 4.5 Amps  
600  
15.0 Amps  
40kHz  
40kHz  
40AL060-1E  
40AL060-2E  
100-120 VAC, 50/60 Hz @ 9.0 Amps  
200-240 VAC, 50/60 Hz @ 4.5 Amps  
Table 8-I AC Power Requirements  
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Regulatory Agency  
Compliance  
FCC  
NOTE  
DO NOT make any modifications to  
the generator or associated cables  
as the changes may result in violating  
one or more regulations under which  
this equipment is manufactured.  
The generator complies with the following Federal  
Communications Commission regulations.  
The limits for FCC measurement procedure MP-5,  
“Methods of Measurement of Radio Noise Emissions  
from ISM Equipment”, pursuant to FCC Title 47 Part  
18 for Ultrasonic Equipment.  
CE Marking  
This mark on your equipment certifies that it meets the  
requirements of the EU (European Union) concerning  
interference causing equipment regulations. CE stands  
for Conformité Europeéne (European Conformity). The  
generator complies with the following CE requirements.  
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 Machinery Directive 2006/42/EC.  
EN 60204: 2006  
Safety of Machinery - Electrical Equipment of  
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.  
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Section 9 – Contacting Dukane  
SECTION 9  
Contacting Dukane  
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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 INFO. With pointer at System  
Information, press ENTER to get this data.)  
• Problem description and steps taken to resolve it  
Many problems can be solved over the telephone, so it is  
best to call from a telephone located near the equipment.  
Intelligent Assembly  
Solutions  
Mailing Address: Dukane Ultrasonics  
2900 Dukane Drive  
St. Charles, IL 60174 USA  
Phone:  
E-mail:  
(630) 797–4900  
Fax:  
Main  
(630) 797–4949  
Service & Parts (630) 584–0796  
Website  
The website has information about our products, processes,  
solutions, and technical data. Downloads are available for  
many kinds of literature.  
Here is the address for the main website:  
You can locate your local representative at:  
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Appendices  
APPENDICES  
Appendix A - E-Stop Circuitry Examples . . . . . . . . . . . . . . . . 67  
Appendix B - List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . 68  
Appendix C - List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . 69  
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Appendices  
Appendix A  
Dedicated E-Stop Switch Wiring Diagram  
System I/O Connector  
iQ Auto  
(Pin 1)  
Enable Out  
User supplied  
E-stop switch  
(Pin 2)  
Enable In  
Automation System Safety Circuit Wiring Diagram  
System I/O Connector  
iQ Auto  
(Pin 1)  
Enable Out  
Relay contact block  
Master  
control  
relay  
(Pin 2)  
Enable In  
User automation  
control hardware  
Figure A-1 E-Stop Circuitry  
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List of Figures  
Appendix B  
No.  
Description  
Page  
2-1  
2-2  
2-3  
Example of 125 Volt, Grounded, 3-prong Plug and Receptacle......................................8  
Example of 250 Volt, Grounded, 3-prong Plug and Receptacle......................................8  
International 220/240V Grounding ..................................................................................8  
3-1  
3-2  
3-3  
3-4  
Lockout Device in Open Position, Unlocked .................................................................13  
Bottom Lockout Device in Closed Position, Locked......................................................13  
Generator Detail - Rear Views.......................................................................................16  
Rocker-style Power Switch/Circuit Breaker...................................................................16  
4-1  
Front Panel....................................................................................................................23  
4-1A  
4-1B  
4-2  
Power Bar Graph - In Cycle ..........................................................................................24  
Power Bar Graph - Operate ..........................................................................................24  
Power Switch.................................................................................................................25  
Power-up Screen 1........................................................................................................25  
Power-up Screen 2........................................................................................................25  
Operate Screen Appears After Power-up......................................................................25  
Example of an Operate Screen.....................................................................................26  
Example of an In Cycle Screen.....................................................................................26  
4-3  
4-3A  
4-3B  
4-4  
4-5  
5-1  
Manual Weld Mode........................................................................................................30  
Navigate to Time Mode .................................................................................................30  
Time Weld Mode - 1 ......................................................................................................30  
Time Weld Mode - 2 ......................................................................................................30  
Time Weld Mode ...........................................................................................................31  
Navigate to Energy Mode -1..........................................................................................31  
Navigate to Energy Mode -2..........................................................................................31  
Energy Weld Mode - 1...................................................................................................31  
Energy Weld Mode - 2...................................................................................................31  
HOLD Time - 1 ..............................................................................................................32  
HOLD Time - 2 ..............................................................................................................32  
Amplitude ......................................................................................................................32  
INFO Screen .................................................................................................................33  
5-2  
5-3  
5-4  
5-5  
5-6  
5-6A  
5-7  
5-8  
5-9  
5-9A  
5-10  
5-11  
5-11A System Information Example Screen............................................................................33  
5-12  
5-13  
5-14  
Warning Screen.............................................................................................................33  
Advanced Settings Screen............................................................................................33  
Trigger Amplitude ..........................................................................................................34  
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Appendices  
List of Figures  
Appendix B  
Continued  
5-15  
5-16  
5-17  
Trigger Watts.................................................................................................................34  
Trigger Timeout .............................................................................................................34  
Setup Maintenance - 1 ..................................................................................................35  
5-17A Pop-up Load Defaults?..................................................................................................35  
5-18  
5-19  
5-20  
5-21  
5-22  
Setup Maintenance - 2 ..................................................................................................35  
Setup Maintenance - 3 ..................................................................................................35  
Set Time ........................................................................................................................36  
New Setup Saved..........................................................................................................36  
Default Setup Screen ....................................................................................................36  
6-1  
6-2  
6-3  
6-4  
6-5  
6-6  
6-7  
Probe, Horn and Tip ......................................................................................................40  
Probe, Booster and Horn...............................................................................................41  
Replaceable Tip Installation ..........................................................................................42  
Stack Assembly Procedure ...........................................................................................44  
Probe Assembly and Disassembly................................................................................46  
Separating the Horn from the Booster...........................................................................47  
Removing a Replaceable Tip From the Horn ................................................................47  
8-1  
Generator Outline Drawing............................................................................................57  
Appendix C  
List of Tables  
No.  
Description  
Page  
2-I  
iQ Generator Weights........................................................................................................9  
Standard IEC AC Power Cord Part Numbers .................................................................17  
Generator Input/Output Signals ......................................................................................18  
Tip Torque Unit Conversions...........................................................................................42  
Stud Torque Unit Conversions ........................................................................................43  
Horn/Booster Torque Unit Conversions...........................................................................45  
Pop-up Fault Status Screens..........................................................................................53  
AC Power Requirements ................................................................................................59  
3-I  
3-II  
6-I  
6-II  
6-III  
7-I  
8-I  
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Dukane ISO  
ISO CERTIFICATION  
Dukane chose to become ISO 9001:2008 certi-  
fied in order to demonstrate to our customers  
our continuing commitment to being a quality  
vendor. By passing its audit, Dukane can assure  
you that we have in place a well–defined and  
systematic approach to quality design, manu-  
facturing, delivery and service. This certificate  
reinforces Dukane's status as a quality vendor  
of technology and products.  
The ISO 9001:2008 standard establishes a  
minimum requirement for these requirements  
and starts transitioning the company from a  
traditional inspection–oriented quality system  
to one based on partnership for continuous  
improvement. This concept is key in that Du-  
kane no longer focuses on inspection, but on  
individual processes.  
Dukane's quality management system is based  
on the following three objectives:  
1. Customer oriented quality. The aim is to  
improve customer satisfaction.  
2. Quality is determined by people. The aim  
is to improve the internal organization and  
cooperation between staff members.  
3. Quality is a continuous improvement.  
The aim is to continuously improve the  
internal organization and the competitive  
position.  
To achieve ISO 9001:2008 certification, you  
must prove to one of the quality system regis-  
trar groups that you meet three requirements:  
1. Leadership  
2. Involvement  
3. Quality in Line Organizations and Quality  
System Infrastructure.  
ISO 9001:2008  
C E R T I F I E D  
Dukane products are manufactured in ISO  
registered facilities.  
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Please refer to our website at:  
www dukane com/us/sales/intsales htm  
to locate your local representative.  
iQ Series, Ultrasonic Power Supply AL User's Manual  
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  
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