Intelligent Assembly Solutions iQ Series ULTRASONIC POWER SUPPLY AL AUTOMATED HAND PROBE PRESS User’s Manual Dukane Part No. 403 – 583– 00 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949 ISO 9001:2008 Products are manufactured in ISO registered facilities. www.dukane.
iQ Series, Ultrasonic Power Supply AL User’s Manual Copyright © 2010 Notice of Rights: All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical, photocopying, recording, or by any information storage and retrieval system, without written permission from the manufacturer.
Revision History Revision Number - 00 Revision Summary Date Original release. 11/02/2010 Dukane Manual Part No.
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 . . . . . .
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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 organized to allow you to learn how to safely operate this generator. The examples given are chosen for their simplicity to illustrate basic operation concepts. Notes, Cautions and Warnings NOTE Note statements provide additional information or highlight procedures.
iQ Series, Ultrasonic Power Supply AL User’s Manual System Overview Your iQ Series Ultrasonic Power Supply AL, an ultrasonic generator, provides a versatile stand-alone workstation. vides consistent system performance regardless of line voltage fluctuations. It also eliminates the need for bulky, external constant–voltage transformers. • Load Regulation provides constant amplitude automatically regardless of power draw.
Section 2 – Health and Safety SECTION 2 Health and Safety General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Plastics Health Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Lifting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Dukane Manual Part No.
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Section 2 – Health and Safety General Considerations 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.
iQ Series, Ultrasonic Power Supply AL User’s Manual Electrical Safety Domestic Power Grounding 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.
Section 3 – Installation Lifting the Equipment lb kg Generator Only 12 5.44 Generator + Packing Materials 17 7.71 Table 2–I iQ Generator Weights 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.
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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 .
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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 exist inside the generator chassis. Before making any internal adjustments to the generator, apply a lockout/tagout (LOTO) device to the generator chassis.
iQ Series, Ultrasonic Power Supply AL User’s Manual Lockout/Tagout Continued from previous page Procedure to use BEFORE making any internal adjustments to the generator: 1. Push the generator's AC power switch/ breaker to the OFF position. 2. Unplug the generator's electrical cord from its source. 3. 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.
Section 3 – Installation Unpacking 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. Placement Make certain generator placement and cable routing do not interfere with normal operation. Maintain easy access to your equipment. The operator should have unobstructed access to cables and wiring.
iQ Series, Ultrasonic Power Supply AL User’s Manual Connecting Cables - Quick Start Guide NOTE AC Power Inlet Complete the basic connections as shown below: • AC Line Input • I/O (Input/Output) Connector • Grounding Stud • 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.
Section 3 – Installation Power Cords Automation Controlled System 200/240 Volt Systems Step 1. Ground the generator chassis using the supplied 14-Gauge wire, and attach it to the grounding stud:C in Figure 3-3. The IEC AC power inlet connector mounted on the rear panel requires a properly configured IEC compliant power cord. 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.
iQ Series, Ultrasonic Power Supply AL User’s Manual System I/O Connector Pinout Table 3-II lists the signal names and descriptions, with more detailed descriptions listed on the next page.
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.
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Section 4 – Controls and Connections SECTION 4 Controls Front Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 LCD Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Dukane Manual Part No.
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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 actuator switch that will activate or deactivate the AC power to the system.
iQ Series, Ultrasonic Hand Held Systems User’s Manual Control Keys Continued AMP Set the ultrasound amplitude output level in the range of 20 to 100%. Typically amplitude is set to 100%. 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. Set the weld energy (joules). HOLD Hold is a time period beginning after the weld portion of the cycle is complete.
Section 4 – Controls and Connections Start-up Sequence After all connections have been completed. 1. Push the Power Switch to ON (Figure 4-2). Push ON Push OFF Figure 4-2 Power Switch The generator performs a self-diagnostics sequence. 2. Two Power-up screens appear briefly - Figure 4-3, and Figure 4-3A. 3. The next screen is an Operate screen ready for a new weld to be done. The display shows: The setup used for the last weld, and zeros for any weld parameters.
iQ Series, Ultrasonic Hand Held Systems User’s Manual 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. Data from last weld cycle. Setup number. Automation Weld Weld Mode Automation, Time, or Energy Weld Time 0.500 S Weld Energy 18 J #2 Figure 4-4 Example of an Operate Screen An In Cycle screen activates when the ultrasound signal has been activated.
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 . . . . . . . . . . . . . . . . .
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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 controls the weld cycle.
iQ Series, Ultrasonic Hand Held Systems User’s Manual 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. Navigate to Time Mode 1. 2. 3. mode, press the Weld Time 0.000 S Weld Energy 0 J #2 Follow the sequence shown in the figures to the right to navigate from Automation mode to Time mode. In Automation (Figure 5-2).
Section 5 - Process Control Settings Navigate to Energy Mode 1. Weld by Time Follow the sequence shown in the figures to the right to navigate from Time mode to Energy mode. Weld Time 0.500 S Weld Energy 00 J #2 Figure 5-5 Time Weld Mode ENERGY key Weld By Time In Time mode (Figure 5-5), press the ENERGY key, and the screen as shown in Figure 5-6 appears. Weld By Energy OFF Enter Changes Mode Figure 5-6 Navigate to Energy Mode - 1 Weld ENTER key 2.
iQ Series, Ultrasonic Hand Held Systems User’s Manual 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. Hold Time (A maximum of 5.
Section 5 - Process Control Settings System Information, Advanced Settings iQ Information When the INFO key is pressed the display looks like Figure 5-11: Using the + - keys, move the pointer to indicate: System Information, or Advanced Settings Press ENTER to make the selection. 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 shows an example of this information. 2.
iQ Series, Ultrasonic Hand Held Systems User’s Manual 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: http://www.dukane.
Section 5 - Process Control Settings Setup Maintenance Setup Maintenance Introduction 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. Delete Load Setup # 1 EMPTY Figure 5-17 Setup Maintenance - 1 Navigating 1. 2. 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.
iQ Series, Ultrasonic Hand Held Systems User’s Manual 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. 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.
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................
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Section 6 – Probes and Probe Stacks Ultrasonic Probe Overview 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. See Section 8, Specifications for more detail. Dukane Manual Part No. 403-583-00 CAUTION The ultrasonic cable carries high electrical current when in operation. Do not nick or cut this cable.
iQ Series, Ultrasonic Hand Held Systems User’s Manual Theory of Operation 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.
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.
iQ Series, Ultrasonic Hand Held Systems User’s Manual Stack Assembly 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. 2. Apply an extremely thin layer of a high temperature, high pressure silicon grease to the back surface that mates with the horn.
Section 6 – Probes and Probe Stacks Attaching the Mounting Stud to a Horn or a Booster 1. Inspect the stud for cracks or damaged threads. Replace the stud if it is cracked or otherwise damaged. 2. Remove any foreign matter from the threaded stud and the mating hole. 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, resulting in excessive heat. In some cases, this can melt the tooling material. 3.
iQ Series, Ultrasonic Hand Held Systems User’s Manual Attaching the Horn to a Booster, Booster to a Probe, or Horn to a Probe 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. 2. Ensure that the mating surfaces of the two components are clean and smooth.
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. In-lb Ft-lb N-m 540 45 420 35 47.5 20 kHz stack 216 18 24.4 30 kHz stack 216 18 24.
iQ Series, Ultrasonic Hand Held Systems User’s Manual Stack Disassembly Stack disassembly is required when changing the booster or 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. 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.
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 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.
iQ Series, Ultrasonic Hand Held Systems User’s Manual 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. 3.
Section 7 – Troubleshooting SECTION 7 Troubleshooting No Ultrasonic Output...................................... 51 System Power Output Level..........................51 Welding Problems.......................................... 52 Pop-up Fault Status Screens........................53 Dukane Manual Part No.
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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 Overload 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.
iQ Series, Ultrasonic Hand Held Systems User’s Manual 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.
Section 7 – Troubleshooting Pop-up Fault Status Screens Generator Fault Status Screens - Automation Mode Status Text Displayed Generator Fault Average Overload Generator Fault Peak Overload Generator Fault Frequency Overload Generator Fault System Status or Fault Explanation An Average Overload fault tripped. Output power exceeded rated wattage. Lower the welding pressure or amplitude. Fault will reset when next weld cycle starts. A Peak Overload fault tripped. Peak IGBT transistor current exceeded.
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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 Dukane Manual Part No.
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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 Dukane Manual Part No.
iQ Series, Ultrasonic Hand Held Systems User’s Manual 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: 40°F to 100°F (+5°C to +38°C) Air Particulates: Keep the equipment dry. Minimize exposure to moisture, dust, dirt, smoke and mold.
Section 8 – Specifications AC Power Requirements Overload Power Rating (Watts) Operating Frequency Generator Model Number 20kHz 20ALP060-1E 100-120 VAC, 50/60 Hz @ 9.0 Amps 20kHz 20ALP060-2E 200-240 VAC, 50/60 Hz @ 4.5 Amps 30kHz 30AL060-1E 30kHz 30AL060-2E 40kHz 40AL060-1E 100-120 VAC, 50/60 Hz @ 9.0 Amps 40kHz 40AL060-2E 200-240 VAC, 50/60 Hz @ 4.5 Amps 600 Input AC Power Requirements Nominal AC Volt 100-120 VAC, 50/60 Hz @ 9.0 Amps 200-240 VAC, 50/60 Hz @ 4.
iQ Series, Ultrasonic Hand Held Systems User’s Manual Regulatory Agency Compliance FCC 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.
Section 9 – Contacting Dukane SECTION 9 Contacting Dukane Dukane Manual Part No.
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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.
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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 Dukane Manual Part No.
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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 iQ Auto System I/O Connector (Pin 1) Enable Out (Pin 2) Enable In Relay contact block Master control relay User automation control hardware Figure A-1 E-Stop Circuitry Dukane Manual Part No.
iQ Series, Ultrasonic Hand Held Systems User’s Manual Appendix B No. Description List of Figures Page 2-1 Example of 125 Volt, Grounded, 3-prong Plug and Receptacle.......................................8 2-2 Example of 250 Volt, Grounded, 3-prong Plug and Receptacle.......................................8 2-3 International 220/240V Grounding...................................................................................8 3-1 Lockout Device in Open Position, Unlocked..........................
Appendices Appendix B Continued List of Figures 5-15 Trigger Watts..................................................................................................................34 5-16 Trigger Timeout..............................................................................................................34 5-17 Setup Maintenance - 1...................................................................................................35 5-17A Pop-up Load Defaults?...........................
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Dukane ISO ISO CERTIFICATION Dukane chose to become ISO 9001:2008 certified 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, manufacturing, delivery and service. This certificate reinforces Dukane's status as a quality vendor of technology and products.
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 www.dukane.com/us Printed in the United States of America Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St.