Page 2 - iQ
Page ii iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Printed in the United States of America. Part Number: 403–583–00 This ultrasonic equipment is manufactured under one or more of the following U.S. Patents:3,780,926 3,825,481 4,131,505 4,277,710 5,798,59...
Page 3 - Revision History; Revision
Page iii Dukane Manual Part No. 403-583-00 Revision History Revision Revision Number Summary Date - 00 Original release. 11/02/2010
Page 4 - This page intentionally left blank
Page iv iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 This page intentionally left blank
Page 5 - Contents; Section 8 - Specifications
Page v Dukane Manual Part No. 403-583-00 Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . 1 Section 2- Health and Safety . . . . . . . . . . . . . . . . . . . 5 Section 3- Installation . . . . . . . . . . . . . . . . . . . . . . . 11 Before Installation . . . . . . . ....
Page 7 - SECTION 1; Introduction
Page Section 1 – Introduction Dukane Manual Part No. 403-583-00 SECTION 1 Introduction General User Information . . . . . . . . . . . . . . . . . . 3 Read the Manual First . . . . . . . . . . . . . . . . . . . . . . 3 Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . 3 Drawings and T...
Page 9 - General User Information; Read the 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. 403-583-00 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...
Page 10 - System Overview; Key Features
Page 4 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 System Overview Your iQ Series Ultrasonic Power Supply AL, an ultra- sonic generator, provides a versatile stand-alone worksta-tion. This product’s rugged internal circuitry ensures a continu-ous resonan...
Page 11 - SECTION 2; Health and Safety
Page 5 Section 2 – Health and Safety Dukane Manual Part No. 403-583-00 SECTION 2 Health and Safety General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical Safety . . . . ....
Page 13 - General Considerations; Plastics Health Notice; or sound deflectors may be in
Page Section 2 – Health and Safety Dukane Manual Part No. 403-583-00 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 wi...
Page 14 - Electrical Safety; Domestic Power Grounding; qualified electrician replace
Page 8 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 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 - Lifting the Equipment; T a k e c a r e i n l i f t -; How to Lift Safely
Page Section 3 – Installation Dukane Manual Part No. 403-583-00 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 bac...
Page 17 - SECTION 3; Installation
Page Section 3 – Installation Dukane Manual Part No. 403-583-00 SECTION 3 Installation Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 When to Use Lockout/Tagout Devices . . . . . . . . . . . . . . . . . . . . . . . 13 Unpacking . . . . . . . . . . . . . . . ....
Page 19 - Before Installation; When to Use Lockout /; Continued
Page 3 Section 3 – Installation Dukane Manual Part No. 403-583-00 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 Safet...
Page 20 - Wait a minimum of five minutes for the
Page 4 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Lockout/Tagout 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 elec...
Page 21 - Unpacking; Use a STAR configuration
Page 5 Section 3 – Installation Dukane Manual Part No. 403-583-00 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 ...
Page 22 - Connecting Cables - Quick; AC Power Inlet; or
Page iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Connecting Cables - Quick Start Guide Complete the basic connections as shown below: • AC Line Input • I/O (Input/Output) Connector • Grounding Stud • AC Power Cord Connection Step 1. Conne...
Page 23 - Power Cords; Automation Controlled System
Page Section 3 – Installation Dukane Manual Part No. 403-583-00 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 ultrasonic ...
Page 24 - System I/O Connector Pinout; circuit wiring examples.
Page 8 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Pin Color Description 1 BLK Enable Out 2 WHT Enable In 3 RED System Overload Status Output 4 GRN Ultrasound Active Status Output 5 ORN Any Fault Status Output 6 BLU System Power Status Out...
Page 25 - Configuration Port Connector
Page Section 4 – Controls and Connections Dukane Manual Part No. 403-583-00 Pin 7 (Status Output Common) Pin 7 is connected to chassis ground. The non-isolated NPN status output signals can drive isolated PNP inputs on the automation control system. Pin 8 (System Ready Status Output) This status ou...
Page 27 - SECTION 4; Controls
Page Section 4 – Controls and Connections Dukane Manual Part No. 403-583-00 Front Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 LCD Display Overview . . . . . . . . . . . . . . ....
Page 29 - Front Panel Overview; INFO; System Information -; SETUP; Power Switch/Circuit Breaker
Page 3 Section 4 – Controls and Connections Dukane Manual Part No. 403-583-00 40100 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...
Page 30 - Make sure the stack is prop-; Power Bar Graph; IN CYCLE
Page 4 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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 31 - Starting a Weld Cycle; Stopping the Weld Cycle; Normal Conditions; Automated System; Weld by Time; DUKANE
Page 5 Section 4 – Controls and Connections Dukane Manual Part No. 403-583-00 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. Two Power-up screens appear briefly - Figure 4-3, and Figure...
Page 32 - LCD Display Overview; Automation Weld
Page iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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 HzPower: 40 ...
Page 33 - SECTION 5; Process Control Settings
Page Section 5 - Process Control Settings Dukane Manual Part No. 403-583-00 SECTION 5 Process Control Settings Select the Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Navigating the Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Hold . . . . . . . ....
Page 35 - Process Controller; Select the Welding Mode; Automation; Time; Energy
Page Section 5 - Process Control Settings Dukane Manual Part No. 403-583-00 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 t...
Page 36 - Navigating the Modes; Navigating to Automation Mode; TIME key; ENTER key; ENTER key
Page 30 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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. N...
Page 37 - Navigate to Energy Mode; ENERGY; Weld By Energy; Set energy; Weld By Energy
Page 3 Section 5 - Process Control Settings Dukane Manual Part No. 403-583-00 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 38 - Hold; Amplitude Adjustment; Amplitude; Hold Time
Page 3 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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 finis...
Page 39 - System Information; iQ Information; Advanced Settings; Warning; Modified settings
Page 33 Section 5 - Process Control Settings Dukane Manual Part No. 403-583-00 System Information, 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 , or Advanced Settings Press ENTER to make the select...
Page 40 - Trigger By Power
Page 34 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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 ...
Page 41 - Load; ontinued; Setup Maintenance
Page 35 Section 5 - Process Control Settings Dukane Manual Part No. 403-583-00 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. Navi...
Page 42 - Changing the Current Setup; Selecting a Setup
Page 3 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 Setup Maintenance C ontinued Changing 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 tim...
Page 43 - SECTION 6; Probe Configuration
Page 3 Section 6 – Probes and Probe Stacks Dukane Manual Part No. 403-583-00 SECTION 6 Probes and Probe Stacks Ultrasonic Probe Overview ...........................39 Theory of Operation ............................................ 40 Probe Configuration ...............................................
Page 45 - Ultrasonic Probe; Operating Notes; Compressed Air Fitting
Page 3 Section 6 – Probes and Probe Stacks Dukane Manual Part No. 403-583-00 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 prob...
Page 46 - Theory of Operation; Probe; Never use a probe if the; Ultrasonic Acoustic Stack Mounting
Page 40 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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 47 - Ultrasonic Horn; Booster
Page 4 Section 6 – Probes and Probe Stacks Dukane Manual Part No. 403-583-00 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...
Page 48 - Stack Assembly; Attaching a Replaceable; NEVER clamp the horn
Page 4 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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 49 - Attaching the Mounting; Torque specifications have a tolerance of
Page 43 Section 6 – Probes and Probe Stacks Dukane Manual Part No. 403-583-00 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 ma...
Page 50 - Attaching the Horn to; it to the proper specifications
Page 44 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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 51 - Horn and booster torque specifications
Page 45 Section 6 – Probes and Probe Stacks Dukane Manual Part No. 403-583-00 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 w...
Page 52 - Stack Disassembly
Page 4 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 HORN HORN PROBE ASSEMBLY PROBE HOUSING PROBE HOUSING A SSEMBLY D ISASSEMBLY Output End Input End Spanner Wrench Holes Mounting Stud (Insert Into Horn First and Tighten to Torque Specs)...
Page 54 - Booster Notes; How to Tell the Booster; How to Tell if the Booster
Page 48 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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 55 - SECTION 7
Section 7 – Troubleshooting Page 4 Dukane Manual Part No. 403-583-00 SECTION 7 Troubleshooting No Ultrasonic Output ..................................... 51 System Power Output Level .........................51 Welding Problems ......................................... 52 Pop-up Fault Status Screen...
Page 57 - No Ultrasonic Output; System Power Output Level; Overload; Overtemperature
Section 7 – Troubleshooting Page 5 Dukane Manual Part No. 403-583-00 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 Whe...
Page 58 - Welding Problems; Weak Welds; Inconsistent Welds
Page 5 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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 59 - Generator Fault Status Screens - Automation Mode; Pop-up Fault Status Screens
Section 7 – Troubleshooting Page 53 Dukane Manual Part No. 403-583-00 Generator Fault Status Screens - Automation 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 re...
Page 61 - SECTION 8
Section 8 – Specifications Page 55 Dukane Manual Part No. 403-583-00 SECTION 8 Specifications Generator Outline Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Operating Environment. . . . ...
Page 64 - Operating Environment; Weights
Page 58 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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 moistu...
Page 66 - Regulatory Agency; FCC; Rating; DO NOT make any modifications to
Page 0 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 Regulatory Agency Compliance FCC The generator complies with the following Federal Communications Commission regulations. • The limits for FCC measurement procedure MP-5, “Methods of M...
Page 67 - SECTION 9
Section 9 – Contacting Dukane Page Dukane Manual Part No. 403-583-00 SECTION 9 Contacting Dukane
Page 69 - Contacting Dukane; Identify Equipment; Intelligent Assembly; Mailing Address; Website
Section 9 – Contacting Dukane Page 3 Dukane Manual Part No. 403-583-00 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 dis...
Page 71 - APPENDICES
Page 5 Appendices Dukane Manual Part No. 403-583-00 APPENDICES Appendix A - E-Stop Circuitry Examples . . . . . . . . . . . . . . . . 67 Appendix B - List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Appendix C - List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . ...
Page 73 - Dedicated E-Stop Switch Wiring Diagram; Appendix A
Page Appendices Dukane Manual Part No. 403-583-00 Figure A-1 E-Stop Circuitry iQ Auto Enable Out Enable In Dedicated E-Stop Switch Wiring Diagram System I/O Connector (Pin 1) (Pin 2) User suppliedE-stop switch iQ Auto Enable Out Enable In Automation System Safety Circuit Wiring Diagram System I/O C...
Page 74 - List of Figures; Appendix B
Page 8 iQ Series , Ultrasonic Hand Held Systems User’s Manual Dukane Manual Part No. 403-583-00 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 .....
Page 75 - List of Tables; Appendix C
Page Appendices Dukane Manual Part No. 403-583-00 No. Description Page 2-I iQ Generator Weights ........................................................................................................9 3-I Standard IEC AC Power Cord Part Numbers ........................................................
Page 77 - Dukane ISO; ISO CERTIFICATION; System Infrastructure.; C E R T I F I E D
Dukane ISO ISO CERTIFICATION Dukane chose to become ISO 9001:2008 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-...
Page 78 - Please refer to our website at:
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 iQ Series , Ultrasonic Power Supply AL User's Manual Printed in the United States of America www.dukane.com/us Please refer to our website at...
