Page 2 - iQ
Page ii iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 Printed in the United States of America. Part Number: 403–577–01 This ultrasonic equipment is manufactured under one or more of the following U.S. Patents:3,780,926 3,825,481 4,131,505 4,277,710 5,798,...
Page 3 - Revision History; Revision
Page iii Dukane Manual Part No. 403-577-00 Revision History Revision Revision Number Summary Date - 00 Original release. 08/01/2008 - 01 Add 20kHz and 30kHz models. 11/12/2009 Update Pop-up Fault Status Screens. Add Trigger by Power feature. Add Options section.
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Page 5 - Contents; Section 9 - Specifications
Page v Dukane Manual Part No. 403-577-00 Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . 1 Section 2- Health and Safety . . . . . . . . . . . . . . . . . . . 5 Section 3- Installation . . . . . . . . . . . . . . . . . . . . . . . . 9 Unpacking . . . . . . . . . . . . ...
Page 7 - SECTION 1; Introduction
Page 1 Section 1 – Introduction Dukane Manual Part No. 403-577-01 SECTION 1 Introduction General User Information . . . . . . . . . . . . . . . . . . 3 Read The Manual First . . . . . . . . . . . . . . . . . . . . . . 3 Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . 3 Drawings and...
Page 9 - General User Information; Read This Manual First; CAUTION; C a u t i o n s t a t e m e n t s; WARNING; NOTE
Page 3 Section 1 – Introduction Dukane Manual Part No. 403-577-01 General User Information Read This 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 yo...
Page 10 - System Overview; Generator; Key Features; CE Certification
Page 4 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 System Overview Your iQ Series Ultrasonic Hand Held System has two basic components: an ultrasonic generator, and a hand probe. Generator The generator is specifically designed for ultrasonic appli -...
Page 11 - SECTION 2; Health and Safety
Page 5 Section 2 – Health & Safety Dukane Manual Part No. 403-577-01 SECTION 2 Health and Safety General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical Safety . . . ....
Page 13 - General Considerations; Proper Installation -; Grounded Electrical Power -; Plastics Health Notice
Page 7 Section 2 – Health & Safety Dukane Manual Part No. 403-577-01 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 associate...
Page 14 - Electrical Safety; Domestic Power Grounding
Page iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 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...
Page 15 - SECTION 3; Installation
Page Section 3 – Installation Dukane Manual Part No. 403-577-01 SECTION 3 Installation Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 RFI Grounding . . . . . . . ...
Page 17 - Unpacking
Page 11 Section 3 – Installation Dukane Manual Part No. 403-577-01 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. Placing Make certain generator placement a...
Page 18 - Connecting Cables - Quick; Optional Connections; AC Power Inlet; or
Page 1 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 Connecting Cables - Quick Start Guide Complete the basic connections as shown below: • AC Line Input • HAND PROBE Connector • Grounding Stud • AC Power Cord Connection Step 1. Attach the...
Page 19 - Power Cords; HAND PROBE Connector; Ultrasound Output
Page 13 Section 3 – Installation Dukane Manual Part No. 403-577-01 Power Cords 200/240 Volt Systems 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 ultrason...
Page 21 - SECTION 4; Controls
Page 15 Section 4 – Controls and Connections Dukane Manual Part No. 403-577-01 Front Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Start-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 LCD Display Overview . . . . . . . . . . . . . ...
Page 23 - Front Panel Overview; INFO; System Information -; SETUP; Power Switch/Circuit Breaker; Continued
Page 17 Section 4 – Controls and Connections Dukane Manual Part No. 403-577-01 Figure 4-1 Front Panel 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. Con...
Page 24 - Power Bar Graph; IN CYCLE; Weld by Time
Page 1 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 CAUTION Make sure the stack is prop- erly assembled before it is connected to the system. The horn should never come in direct contact with a metal fix- ture or anvil when ultrasound is ...
Page 25 - DUKANE; Starting a Weld Cycle; Stopping a Weld Cycle
Page 1 Section 4 – Controls and Connections Dukane Manual Part No. 403-577-01 Start-up Sequence After all connections have been completed. 1. Push the Power Switch to ON (Figure 4-2). The generator performs a self-diagnostics sequence. 2. The Power-up screen appears briefly - Figure 4-3. 3. The nex...
Page 26 - LCD Display Overview; Manual Weld; Operate
Page 0 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 LCD Display Overview There are two basic kinds of screen displays: Operate screens, and In Cycle screens. Figure 4-5 Example of an In Cycle Screen IN CYCLE Frequency: 40087 Hz Power: 2...
Page 27 - SECTION 5; Process Control Settings; System Information, Hardware Settings, Advanced Settings . 27
Page 1 Section 5 - Process Control Settings Dukane Manual Part No. 403-577-01 SECTION 5 Process Control Settings Select the Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Navigating Through the Modes . . . . . . . . . . . . . . . . . . . . . 24-25 Hold . . . . . . . . . . ....
Page 29 - Select the Welding Mode; Manual; Time; Energy
Page 3 Section 5 - Process Control Settings Dukane Manual Part No. 403-577-01 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...
Page 30 - Navigating Through the Modes; Navigating to Manual Mode; TIME key; ENTER key; ENTER key
Page 4 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 Navigating Through the Modes When the generator is first powered up, the default operating mode is Manual, and Manual Weld is shown at the top of the display as shown in Figure 5-1. Na...
Page 31 - Navigate to Energy Mode; ENERGY; Weld By Energy; Set energy; Weld By Energy
Page 5 Section 5 - Process Control Settings Dukane Manual Part No. 403-577-01 Navigate to Energy Mode 1. Follow the sequence shown in the figures to the right to navigate from Time mode to Energy mode. In Time mode (Figure 5-5), press the ENERGY key, and the screen as shown in Figure 5-6 appears. 2...
Page 32 - Hold; Amplitude Adjustment; Amplitude; Hold Time
Page iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 Hold HOLD is used more often with Time or Energy modes, but it can be used with the Manual mode. It is a period of time that can be set to follow release of the probe’s trigger switch. ...
Page 33 - Hardware Settings, Advanced; System Information; Audible Alarms; iQ Information; Hardware Settings
Page 7 Section 5 - Process Control Settings Dukane Manual Part No. 403-577-01 System Information, Hardware Settings, Advanced Settings When the INFO key is pressed the display looks like Figure 5-11:Using the keys, move the pointer to indicate: System Information, Hardware Settings, or Advanced Set...
Page 34 - Free Run Frequency; Warning; Modified settings
Page iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 3. Advanced Settings Continued After Advanced Settings is selected, a warning screen is displayed as shown in Figure 5-13. Adjusting these settings may affect the operation of your unit...
Page 35 - Trigger by Power; Trigger By Power
Page Section 5 - Process Control Settings Dukane Manual Part No. 403-577-01 Advanced Settings Continued 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: http://www.dukane.com/us/D...
Page 36 - Load; Setup Maintenance; Setup Maintenance; Setup Maintenance; ontinued
Page 30 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 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 ...
Page 37 - Saving the Current Setup; Selecting a Setup; Deleting a Setup
Page 31 Section 5 - Process Control Settings Dukane Manual Part No. 403-577-01 Setup Maintenance C ontinued Saving the Current Setup 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 5-23. 2....
Page 39 - SECTION 6
Page 33 Section 6 – Probes and Probe Stacks Dukane Manual Part No. 403-577-01 SECTION 6 Probes and Probe Stacks Ultrasonic Probe Overview ...........................35 Theory of Operation ............................................ 36 Probe Configuration ..............................................
Page 41 - Operating Notes; Compressed Air Fitting
Page 35 Section 6 – Probes and Probe Stacks Dukane Manual Part No. 403-577-01 Figure 6-1 Typical Hand Held Probes U/S Cable Typical Horn Less Tip Models Pistol-style Grip Hanger Trigger Typical Horn Less Tip U/S Cable Trigger Actuator Hand Grip Compressed Air Fitting Strain Relief Strain Relief Rea...
Page 42 - Theory of Operation; Tip; Never use the hand probe if
Page 3 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 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 ...
Page 43 - Ultrasonic Horn; Booster
Page 37 Section 6 – Probes and Probe Stacks Dukane Manual Part No. 403-577-01 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 designe...
Page 44 - Stack Assembly; Attaching a Replaceable; NEVER clamp the horn
Page 3 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 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 cou...
Page 45 - Attaching the Mounting; DO NOT
Page 3 Section 6 – Probes and Probe Stacks Dukane Manual Part No. 403-577-01 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 dam-aged. 2. Remove any foreign matter from the threaded stud and the mat...
Page 46 - Attaching The Horn to
Page 40 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 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 affe...
Page 48 - Stack Disassembly
Page 4 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 HORN HORN HAND PROBE ASSEMBLY HAND PROBE HOUSING HAND PROBE HOUSING A SSEMBLY D ISASSEMBLY Output End Input End Spanner Wrench Holes Mounting Stud (Insert Into Horn First and Tighten t...
Page 50 - Booster Notes; How to Tell the Booster; How to Tell if the Booster
Page 44 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 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 ...
Page 51 - SECTION 7
Section 7 – Troubleshooting Page 45 Dukane Manual Part No. 403-577-01 SECTION 7 Troubleshooting N o Ultrasonic Output ..................................... 47 System Power Output Level .........................47 Welding Problems ......................................... 48 Pop-up Fault Status Scre...
Page 53 - No Ultrasonic Output; Probe; System Power Output Level; Overload; Overtemperature
Section 7 – Troubleshooting Page 47 Dukane Manual Part No. 403-577-01 No Ultrasonic Output Probe Make sure that the hand probe cable is connected to the generator connector (HAND PROBE) and secured to the rear panel. Also, make sure the hand probe stack is properly assembled. System Power Output Le...
Page 54 - Welding Problems; Weak Welds; Inconsistent Welds
Page 4 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 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 ...
Page 55 - Generator Fault Status Screens - Manual Mode; Pop-up Fault Status Screens
Section 7 – Troubleshooting Page 4 Dukane Manual Part No. 403-577-01 Generator Fault Status Screens - Manual Mode Status Text Displayed System Status or Fault Explanation An Average Overload fault tripped.Output power exceeded rated wattage.Lower the welding pressure or amplitude.Fault will reset w...
Page 56 - Process Fault Status Screens - Time and Energy Modes
Page 50 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-577-01 Process Fault Status Screens - Time and Energy Modes Status Text Displayed System Status or Fault Explanation Latch On Fault ENABLED Latch On Fault DISABLED Set Weld Time Not Reached ...
Page 57 - SECTION 8
Section 8 – Options Page 51 Dukane Manual Part No. 403-577-01 SECTION 8 Options iQ Hand Probe Buzzer Kit ............................. 53 iQ Hand Probe Foot Switch Kit .....................53
Page 59 - Hand Probe Options; Buzzer Kit
Section 8 – Options Page 53 Dukane Manual Part No. 403-577-01 iQ Hand Probe Options Buzzer Kit (Part No. 438-971) In some noisy environments the built-in buzzer can not easily be heard. This buzzer kit is designed for those conditions, and it suits the customer that prefers not to provide their own...
Page 61 - SECTION 9
Section 9 – Specifications Page 55 Dukane Manual Part No. 403-577-01 SECTION 9 Specifications Generator Outline Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Probes Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Weights. . . . . . . . . . . . . . . . ....
Page 65 - Operating Environment; Weights
Section 9 – Specifications Page 5 Dukane Manual Part No. 403-577-01 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. Humidity : 5% to...
Page 67 - FCC
Section 9 – Specifications Page 1 Dukane Manual Part No. 403-577-01 Regulatory Agency Compliance CAUTION D O N O T m a k e a n y m o d i f i c a t i o n s t o t h e generator or associated cables as the changes may result in violating one or more regulations under which this equip- ment is manufact...
Page 69 - Outputs Interface
Section 10 – I/O Interface Page 3 Dukane Manual Part No. 403-577-01 SECTION 10 Outputs Interface Outputs Connection Example. . . . . . . . . . . . . . . . . . . . . . . . . 65
Page 71 - iQ Hand Probe Generator; Provided by Customer; Power Supply
Section 10 – I/O Interface Page 5 Dukane Manual Part No. 403-577-01 HAND PROBE OUTPUTS 0V 1 2 3 iQ Hand Probe Generator Rear Panel Detail X 1 X 2 To OUTPUTS: 1, 2, or 3 Provided by Customer StatusIndicator or AudibleAlarm(333mA maximum) + _ NOTE 0V(OutputCommon)isconnectedtoChassisGround(Earth). Po...
Page 73 - Contacting Dukane
Section 11 – Contacting Dukane Page 7 Dukane Manual Part No. 403-577-01 SECTION 11 Contacting Dukane
Page 75 - Identify Equipment; Intelligent Assembly; Mailing Address; Main; Website
Section 11 – Contacting Dukane Page Dukane Manual Part No. 403-577-01 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 disp...
Page 77 - APPENDICES
Page 71 Appendices Dukane Manual Part No. 403-574-01 APPENDICES List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Page 79 - List of Figures
Page 73 Appendices Dukane Manual Part No. 403-574-01 List of Figures 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 220/24...
Page 80 - List of Tables; continued
Page 74 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-574-01 No. Description Page 3-I Standard IEC AC Power Cord Part Numbers .................................................................13 3-II System OUTPUTS Connector Signals ...............
Page 81 - Dukane ISO; ISO CERTIFICATION; System Infrastructure.; C E R T I F I E D
Dukane ISO ISO CERTIFICATION Dukane chose to become ISO 9001:2000 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-...
Page 82 - Please refer to our website at:
Part No. 403 – 577– 01 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949 iQ Series , Ultrasonic Hand Held Systems User's Manual Printed in the United States of America www.dukane.com/us Please refer to our website ...
