Dukane iQ Series HP-E Hand Probe Systems User Manual

iQ Series
ULTRASONIC HAND HELD SYSTEMS
HP-E
AUTOMATED
HAND PROBE
PRESS
User’s Manual
Applicable System Models:
HP 20.61-P
HP 35.61-P
HP 20.61-H
HP 35.61-H
HP 20.62-P
HP 35.62-P
HP 20.62-H
HP 35.62-H
HP 30.61-P
HP 40.61-P
HP 30.61-H
HP 40.61-H
HP 30.62-P
HP 40.62-P
HP 30.62-H
HP 40.62-H
Dukane Part No. 403 –606– 00
Dukane IAS LLC • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949
Products are manufactured in ISO
registered facilities.
www.dukane.com/us
Copyright © 2016
Dukane
2900 Dukane Drive
St. Charles, IL 60174 USA
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 Dukane.
Notice of Liability:
The information contained is this manual is distributed on an
“As is” basis, without warranty. While every precaution has
been taken in the preparation of this manual, Dukane shall not
have any liability to any person or entity with respect to any
liability, loss, or damaged caused or alleged to be caused directly
or indirectly by the instructions contained in this manual, or by
the hardware and software products described herein.
Printed in the United States of America.
Dukane Part Number: 403-606-00
Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents:
3,772,538
4,277,710
7,819,158
Page
ii
3,780,926
5,798,599
8,052,816
3,825,481
5,880,580
8,245,748
3,832,019
6,984,921
8,720,516
4,131,505
7,225,965
8,721,817
4,208,001
7,475,801
9,144,937
Dukane Manual Part No. 403-606-00
Revision History
Revision
Number
Revision
Summary
- 00
Initial Release
Dukane Manual Part No. 403-606-00
Date
19, July 2017
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Dukane Manual Part No. 403-606-00
Contents
Section 1 - Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 2 - Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Section 3 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Placing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
System Outputs (Optional Connections) . . . . . . . . . . . . . . . . . . . . . . . 14
Section 4 - Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front Panel and Power Switch Overview. . . . . . . . . . . . . . . . . . . . . . . 17
Start-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LCD Display Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Section 5 - Process Control Settings ����������������������������������������� 21
Selecting the Weld Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Navigating Through the Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Amplitude Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Trigger by Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
System Information, Hardware Settings, Generator Settings��������������� 28
Setup Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Section 6 - Probes and Probe Stacks ����������������������������������������� 33
Section 7 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Section 8 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Section 9 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Section 10 - Outputs Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Section 11 - Contacting Dukane . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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Dukane Manual Part No. 403-606-00
Section 1 – Introduction
SECTION 1
Introduction
General User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Read This Manual First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drawings and Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dukane Manual Part No. 403-606-00
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Dukane Manual Part No. 403-606-00
Section 1 – Introduction
General User Information
Read This Manual First
Before operating the Ultrasonic Hand Held System, read
this User’s Manual to become familiar with the system.
This will ensure correct and safe operation. The manual
is organized to allow you to learn how to safely operate
this system. The examples given are chosen for their
simplicity to illustrate basic setup procedures.
Notes and Tips
Throughout this manual we use NOTES to provide
information that is important for the successful
application and understanding of the system. A NOTE
block is shown to the right.
Cautions and Warnings
In addition, we use special notices to make you aware
of safety considerations. These are the CAUTION and
WARNING blocks as shown here. They represent
increasing levels of important information. These
statements help you to identify and avoid hazards and
recognize the consequences. Different symbols also
accompany the CAUTION and WARNING blocks to
indicate whether the notice pertains to a general condition
or practice, an electrical safety issue, a hand protection
issue or other condition.
NOTE
Note statements provide additional
information or highlight procedures.
CAUTION
Caution statements
identify conditions or
practices that could result
in damage to the equipment or other property.
WARNING
Warning statements
point out conditions or
practices that could result in personal injury or
loss of life.
Drawings and Tables
The figures and tables are identified by the section
number followed by a sequence number. The sequence
number 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
example, Figure 3–2 would be the second illustration
in section three while Table 3—II would be the second
table in section three.
Dukane Manual Part No. 403-606-00
Condition
or Practice
Electrical
Hazard
Page
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iQ Series, Ultrasonic Hand Held Systems User’s Manual
System Overview
Key Features
The iQ Series Ultrasonic Hand Held System has two
major components: an ultrasonic generator, and a hand
probe.
•
Compact Generator - The generator is easily
transported and setup. Its compact size allows for
additional space at any table top or work bench.
•
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 efficient switch-mode generator
operation and increased reliability.
•
Linear Ramp Soft Start circuitry allows the acoustic
stack to ramp up to operating amplitude smoothly,
minimizing start-up surges and abnormal stress to the
stack and generator.
•
Digi-Trac Tuning tracks the resonant frequency of
the acoustic stack and adjusts the generator output
frequency to match. 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
deviation. The available output power is maintained
with any voltage input within the specified range.
This provides consistent system performance
regardless of line voltage fluctuations. It also
eliminates the need for bulky, external constant–
voltage transformers.
•
Load Regulation provides constant amplitude
regardless of power draw. The ultrasonic output
amplitude level is held to within ±1% to provide weld
process consistency and reduced weld cycle times.
•
Industrial Line–Power Source - standard systems
will operate worldwide at all industrial high line
voltage levels. There are no internal transformer taps
to change for worldwide operation. North American
systems are optionally available to operate on the
120VAC line voltage level.
•
Multiple Electronic Overload protection circuits
prevent instantaneous component failure in the event
of extreme output overload conditions, and the rated
overload power limit is based on the actual true RMS
power output level.
•
Trigger by Power produces greater weld consistency
by requiring that a sufficient amont of pressure/force
is applied to the part before the actual weld begins.
Generator
The generator is specifically designed for ultrasonic
applications using hand held probes. Using the available
system control inputs and outputs, the generator provides
a versatile stand-alone workstation.
This product’s rugged internal circuitry ensures a
continuous resonant frequency lock at the start of each
weld.
Standard to this line of generators is 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.
It also includes an RFI line filter that passes strict CE test
specifications for global applications.
Hand Probes
The probes are perfect for manual spot welding, staking,
cutting and inserting applications. Both the HP and PG
(pistol grip) models include hangers so, when not needed,
a probe can be hung on a counterbalanced hook. Fittings
for air-cooling are also standard on all probes.
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Dukane Manual Part No. 403-606-00
Section 2 – Health & Safety
SECTION 2
Health and Safety
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Plastics Health Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
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Dukane Manual Part No. 403-606-00
Section 2 – Health & 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.
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.
Proper Installation - Operate system components only
after they are properly installed and checked.
No Unauthorized Modifications - Do not modify your
system in any way unless authorized to do so by the manufacturer. Unauthorized modifications may cause injury
to the operator and/or equipment damage. In addition,
unauthorized modifications will void the equipment warranty.
Keep the Cover On - Do not remove any equipment cover unless specifically directed to do so by the manufacturer. The generator produces hazardous electrical voltages
which could cause injury.
IMPORTANT
Never operate the generator with the cover off.
This is an unsafe practice and may cause injury.
CAUTION
Parts being joined ultrasonically sometimes vibrate at
audible frequencies. Wear
ear protection to reduce
annoying or uncomfortable sounds. In addition,
sound absorbing materials, enclosures or sound
deflectors may be installed
to reduce the noise level.
Grounded Electrical Power - Operate this equipment
only with a properly grounded electrical connection.
(See Page 11 for grounding information.)
Comply with Regulations - You may be required to add
accessories to bring the system into compliance with applicable 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. Department 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.
Dukane Manual Part No. 403-606-00
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iQ Series, Ultrasonic Hand Held Systems User’s Manual
Electrical Safety
Domestic Power Grounding
For safety, the power cords used on this product are a
three-wire, grounding-type power cord. Figures 2-1 and
2-2 illustrate the appropriate electrical outlet and plug
style for the 100-120 volt and 200-240 volt systems. This
information applies to systems shipped to North America
or Japan.
Grounding Contacts
Typical Outlet
Provided Cable
Figure 2–3 International 220/240V Grounding
Approved 2 pole, 3 wire grounding receptacle
HUBBELL No. HBL 5262 or equivalent
NEMA Configuration 5–15R or 5–20R
Figure 2–1 Example of 120 Volt, Grounded, 3-Prong Plug and Receptacle
Approved 2 pole, 3 wire grounding receptacle
HUBBELL No. HBL 5662 or equivalent
NEMA Configuration 6–15R or 6–20R
Figure 2–2 Example of 240 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 Continental European countries. Refer to Figure 2–3. However,
if your application requires another type of power cord,
check with your equipment supplier, and follow local regulations concerning proper wiring and grounding.
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8
CAUTION
If you have a two-prong
electrical receptacle, we
strongly recommend that
you replace it with a properly
grounded three-prong type.
Have a qualified electrician
replace it following the
National Electric Code
and any local codes and
ordinances that apply.
See Figures 2–1 and
2–2 for suggested parts.
CAUTION
If there is any question about
the grounding of your receptacle, have it checked by
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 extension cord with this product.
Dukane Manual Part No. 403-606-00
Section 3 – Installation
SECTION 3
Installation
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connnecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
System Outputs Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Dukane Manual Part No. 403-606-00
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.
Placing
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.
RFI Grounding
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.
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
To m i n i m i z e e l e c t r i cal noise and eliminate
ground currents, ground
the chassis as shown.
Use a STAR configuration
(illustrated below). Do not
DAISY CHAIN the grounds.
Chassis Grounding
Stud
Recommended protective
earth ground connection
wire color: green or green
with yellow stripe.
Fixed Probe Mount
or 2nd Chassis
Grounding Stud
#14 Gauge
Stranded or
Solid Wire
Earth
Ground
3rd Chassis
Grounding
Stud
NOTE
Chassis Grounding Stud
The chassis grounding stud is used to
attach 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 environment. Stud location is
shown in Figure 3-1 on the following page.
CAUTION
If you have any questions
about the grounding of your
equipment and/or the electrical box, contact a qualified
electrician.
Dukane Manual Part No. 403-606-00
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iQ Series, Ultrasonic Hand Held Systems User’s Manual
Connecting Cables - Quick
Start Guide
NOTE
AC Power Inlet
Complete the basic connections as shown below:
Depending on your generator model, line
voltage required for the generator is either
100-120 VAC at 50/60 Hertz or
200-240 VAC at 50/60 Hertz.
The unit has a power switch, and is powered ON whenever the AC line power is
live and the switch is in the ON position as
shown in Figure 3-2 below.
• AC Line Input
• HAND PROBE Connector
• Grounding Stud
• AC Power Cord Connection
Step 1. Attach the female end of the power cord
(200/240V only) to the generator’s power inlet
connector - A in Figure 3-1.
(The 100/120V model’s power cord is permanently
attached to the unit.)
Step 2. Attach the hand probe’s cable connector to the
generator’s HAND PROBE connection. - B in
Figure 3-1. Secure the connector to the system using the two jack screws attached to the connector
hood.
Push ON
Push OFF
Figure 3-2 Rocker-style Power Switch/Circuit Breaker
Step 3. Ground the generator chassis with a user–supplied
14-Gauge wire. Attach one end to the grounding
stud - C in Figure 3-1. Attach the other end to the
nearest grounded metal pipe or equal earth ground.
Step 4. Attach the male end of the power cord to a suitable line receptacle.
Optional Connections - See Page 14 for information
about the rear panel OUTPUTS connector.
Power Cord Strain Relief
B
HANDPROBE
100-120 Vac
50/60Hz
Fuse: 15 A
OUTPUTS
0V
PE
1
2
HANDPROBE
200-240 Vac
50/60Hz
Breaker: 10 A
OUTPUTS
A
0V
3
-WARNING-
PE
POWER LINE OUTLET
MUST BE GROUNDED.
DISCONNECT LINE POWER
BEFORE REMOVING COVER.
Optional
Connections
REAR VIEW
100/120 VOLT MODEL
C
C
1
2
3
-WARNING-
POWER LINE OUTLET
MUST BE GROUNDED.
DISCONNECT LINE POWER
BEFORE REMOVING COVER.
REAR VIEW
200/240 VOLT MODEL
Figure 3-1 Generator Detail - Rear Views
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Dukane Manual Part No. 403-606-00
Section 3 – Installation
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 output power
rating and the continent of specified use. See Table 3-I.
Continent of Use
Power Cord
Part Number
Power
North America
200 - 1541
240V, 10A
Europe
200 - 1542
240V, 10A
India
200 - 1624
240V, 10A
Table 3- I Standard IEC AC Power Cord Part Numbers
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.
HAND PROBE Connector
Ultrasound Output
The ultrasound output connector used with this generator
is integrated into a D-Sub style connector. This connector
provides superior shielding of electrical noise. The output
connector mates with a fully shielded ultrasound cable
that is secured to the generator with two simple, reliable
thumbscrews.
The ultrasonic output from this connector (that drives the
attached ultrasonic load) is a very high AC voltage. At
high power levels there is high current, and the cable must
be securely attached to the hand probe for safe operation.
Only use original equipment ultrasound cables for safe
and reliable system operation.
Dukane Manual Part No. 403-606-00
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iQ Series, Ultrasonic Hand Held Systems User’s Manual
System Outputs
(Optional Connections)
The OUTPUTS connector is a four-position wire
receptacle-type terminal block. If needed, it can provide
the operator with basic system welding status. Everything
connected to the OUTPUTS connector is customersupplied. Typically indicator lights or sound modules are
powered by these output signals. (The lights or sound
modules can be mounted on widely available Stack Light
assemblies.) Each output signal is rated to operate on a
24VDC power source and can activate an attached load
up to a maximum of 500 mA.
Table 3-II lists the signal names.
Pin
Signal Name
0V
Output Common
1
End of Weld Alarm
2
Any Fault Alarm
3
Bad Part
Table 3-II System OUTPUTS Connector Signals
NOTE
All outupt signals are non-isolated and
sink current to chassis ground when
activated.
Pin 0V (Output Common)
Pin 0V is connected to chassis ground.
Pin 1 (End of Weld Alarm)
Non-isolated NPN output that sinks current at the End of
Weld cycle. It activates when ultrasound switches off, or
at the end of a preset Hold period. The signal lasts for one
second, then deactivates.
Pin 2 (Any Fault Alarm)
Pin 2 is a non-isolated digital NPN status output that sinks
current to chassis ground if any fault condition is sensed.
This output is active until the start of the next cycle or
until ENTER is pressed if in non-latching fault mode.
In latching fault mode the user must press ENTER to clear
this output.
If a hardware fault like Over Temperature or a power fault
occurs, Any Fault is active until the fault is cleared in nonlatching fault mode. In latching fault mode, the user must
press ENTER to clear this output. However if the fault
persists, pressing ENTER has no effect.
Pin 3 (Bad Part)
Pin 3 is a non-isolated digital NPN status output that sinks
current to chassis ground if a Bad Part is detected. This
output is active until the start of the next cycle or until
ENTER is pressed if in a non-latching fault mode. It is
active until ENTER is pressed if in a latching fault mode.
NOTE
Refer to Figure 9-1, OUTPUTS Interface Example, Page 65.
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Dukane Manual Part No. 403-606-00
Section 4 – Controls and Connections
SECTION 4
Controls
Front Panel & Power Switch Overview . . . . . . . . . . . . . . . . . . 17
Start-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LCD Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dukane Manual Part No. 403-606-00
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Dukane Manual Part No. 403-606-00
Section 4 – Controls and Connections
Front Panel and Power Switch Overview
This section gives an overview of the front panel and
power switch functions: powering the generator on/off,
monitoring the process with the display, and programming
with the control keys.
LCD Display
Power
Switch
Control Keys
Figure 4-1 Front and rear views of the generator
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. The power ON position is marked with the
internationally recognized I symbol, the power OFF position is marked with the 0 symbol. This power switch also
integrates an appropriately sized over-current protection
circuit breaker function in the generator.
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.
CAUTION
If, when resetting the circuit
breaker after it has tripped, it
immediately trips again, there
is likely an internal system
malfunction, and the generator
will need service. Do NOT
repeatedly try to reset the
circuit breaker. If it trips, this
will only cause more damage
to the generator.
Dukane Manual Part No. 403-606-00
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
hardware settings.
System Information - Identifies the current
version of system software.
Advanced Process Settings - Weld Mode,
Buzzer, and Fault latching features.
Advanced Generator Settings - Freerun, Ramp
up, and Lock and Hold features. Global Settings:
Language, and Keyboard features.
SETUP
Use the SETUP key to Load, Store, or Delete as many as
eight setups.
Continued
Page
17
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%.
Default amplitude is set to 100%.
TRIGGER
This key is use to enable trigger by power.
TIME
Use this key to select time as the primary method of
welding. Set the weld time (seconds).
ENERGY
Use this key to select energy as the primary method of
welding. Set the weld energy (joules).
System LCD Display
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.
Power Bar Graph
The Power Bar Graph appears at the bottom of the LCD
display. It is a high resolution graph that represents
readings from 0% to 100 %. Above 80% power, the
indication is yellow. Above 90%, the indication is red.
In the example below, 40% of the available power is used
during the weld cycle. The display shows an In Cycle
screen (while U/S is active).
40% of
power used
In Cycle
screen
HOLD
Hold is a time period beginning after the weld portion
of the cycle is complete. The operator 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 30 seconds.
CANCEL
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.
Figure 4-1A Power Bar Graph - In Cycle
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).
Operate
screen
ENTER
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.
Arrow Keys
Press the right and left arrow keys to move the cursor to
the right or left.
+ and - Keys
Press these keys to increase or decrease the value of a
selected digit.
Page
18
40% of power delivered in previous weld
Figure 4-1B Power Bar Graph - Operate
CAUTION
Make sure the stack is properly assembled before it is
connected to the system. The
horn should never come in
direct contact with a metal fixture or anvil when ultrasound
is activated.
Dukane Manual Part No. 403-606-00
Section 4 – Controls and Connections
Start-up Sequence
Push ON
After all connections have been completed.
Push OFF
1. Press the Power Switch to the ON position (Figure
4-2). The generator will then perform a self-diagnostics
sequence.
Figure 4-2
Power Switch
2. The Power-up screen will appear briefly - Figure 4-3.
3. The next screen is the Operate screen indicating that
the welder is ready for a new weld to begin. The
display shows the weld method and part data for the
previous weld (See Figure 4-3a).
Figure 4-3
Power-up Screen
Note: On power up, the display will read zeros,
because the previous weld data is not stored when the
power is off.
Figure 4-3a
Starting a Weld Cycle
1. If the generator is not powered, press its Power Switch/
Circuit Breaker to the ON position.
2. Select the setup you want to use, if appropriate.
3. Apply the probe tip to the components to be
ultrasonically joined, and press the hand probe’s
trigger switch to activate ultrasound.
4. After meeting the weld parameters (and with the Hold
time set to zero) - in either Manual, Time or Energy
modes - an internal alarm beeps once after the weld
setting is met, or after the trigger switch is released.
Depending on optional customer OUTPUTS
connections - System Outputs, Page 14 - external
audible or visual alerts can be activated as well.
5. Release the probe’s activation switch (trigger), and
if appropriate, apply pressure while an optional Hold
time elapses. The generator signals when that period is
over by sounding an audible alert.
Operate Screen
Appears After Power-up
Stopping a Weld Cycle
1.
Release the hand probe’s activation switch (trigger)
to abort a weld cycle and stop ultrasound.
2.
In addition, press the generator’s Power Switch/
Circuit Breaker to the OFF position to power down
the generator.
NOTE
The system will not beep as described
here if the Audible Alarm is OFF.
See Hardware Settings, Page 27 to
learn how to turn the Alarm ON or OFF.
The user can release the activation switch during the
Hold time, but there will not be an audible beep until
the preset Hold time ends.
Dukane Manual Part No. 403-606-00
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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.
Weld Mode Manual, Time, or
Energy
Data from
last weld
cycle.
Asterisk indicates
setup is modified
but not stored in
memory.
Setup
number.
Figure 4-4 Example of an Operate Screen
An In Cycle screen activates when the probe activation
switch (trigger) is pressed.
Status Indication
Stack Frequency
Power Draw
Power Bar Graph %
Figure 4-5 Example of an In Cycle Screen
Page
20
Dukane Manual Part No. 403-606-00
Section 5 - Process Control Settings
SECTION 5
Process Control Settings
Select the Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Navigating Through the Modes . . . . . . . . . . . . . . . . . . . . . . . . 24
Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Amplitude Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Trigger by Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
System Info, Hardware Settings, Generator Settings . . . . . . . 28
Setup Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Dukane Manual Part No. 403-606-00
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Dukane Manual Part No. 403-606-00
Section 5 - Process Control Settings
Process Controller
Settings
This section of the manual helps the user 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: Manual, Time, and Energy.
Select the Welding Mode
Manual - In MANUAL mode the operator controls
the weld cycle. The cycle starts when the operator presses
the hand probe’s trigger switch, and the ultrasonic signal
(U/S) activates. When the trigger switch is released,
the ultrasonic signal stops, and the cycle is complete.
(Manual mode is the default selection.)
Time - In TIME mode the operator sets a maximum
time (seconds) the ultrasonic signal will be active for
each weld cycle. The cycle starts when the hand probe’s
trigger switch is activated, and the U/S activates. The
U/S stops when the programmed time is reached. The
trigger switch must be held activated for the entire
welding cycle. Then it is released so that a new weld
cycle can begin.
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 hand probe’s trigger switch is pressed, and U/S is
activated. When the programmed energy is reached, U/S
stops. The trigger switch must be held activated for the
entire welding cycle. Then it is released so that a new
weld cycle can begin.
Dukane Manual Part No. 403-606-00
NOTE
With one exception, U/S is activated
anytime the probe’s trigger switch
is pressed regardless of operating
mode, or what is displayed on the
LCD screen.
The EXCEPTION - When a fault has
occurred in Latching Fault Mode. In
that case ENTER must be pressed
to clear the fault before U/S can be
activated.
Page
23
iQ Series, Ultrasonic Hand Held Systems User’s Manual
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.
Navigate to Time Mode
1.
Follow the sequence shown in the figures to the right
to navigate from Manual mode to Time mode.
Figure 5-1 Manual Weld Mode
In Manual mode, press the TIME key (Figure 5-2).
2.
Set the time.
TIME key
Use the
and the + - keys to move the cursor
and to set the digits for the weld time you want (See
Figure 5-3).
3.
Press the ENTER key to accept the time that has been
set
Press the CANCEL key if you decide not to set the
time.
Figure 5-2 Navigate to Time Mode
NOTE
Navigating to Manual Mode
Set Time or Energy (depending on mode) to
OFF, and press ENTER.
This will put the welder back in Manual mode.
Set the time.
Alternately:
Press the info key, select Weld Mode, and then
push ENTER. A pop up screen appears. Use
the up arrow to select Manual and press enter.
ENTER key
Figure 5-3 Enter Weld Time
Figure 5-4 Select manual mode
Page
24
Dukane Manual Part No. 403-606-00
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.
Figure 5-5 Time Weld Mode
ENERGY
key
In Time mode (See Figure 5-5), press the ENERGY
key, and the screen as shown in Figure 5-6 appears.
Figure 5-6 Navigate to Energy Mode - 1
2.
3.
Use the
and the + - keys to move the
cursor and to set the digits for the energy you want
(See Figure 5-7).
Set energy
level.
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
4.
If you set the energy level, a maximum weld time
needs to be set as well. Set a time that is reasonable
for your application. The maximum weld time is 30
seconds.
The time can not be set below 0.001 second.
ENTER key
Use the
and the + - keys to move the cursor
and to set the digits to the time you want (See Figure
5-8).
Figure 5-8 Energy Weld Mode - 2
Dukane Manual Part No. 403-606-00
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iQ Series, Ultrasonic Hand Held Systems User’s Manual
Hold
HOLD is used most 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.
During HOLD the operator typically applies pressure to
the part being welded. The operator will hear an audible
alarm that serves as an indicator that HOLD has finished,
and the probe can be lifted.
NOTE
The generator’s end of HOLD signal
will only be heard if the audible alarm
is ON.
The Audible Alarm can be set ON or
OFF. See Hardware Settings on the
next page.
HOLD does not allow the operator to begin a new cycle
until the HOLD cycle has finished.
To set a HOLD period:
1. Select the weld mode (Manual, 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 5-9a.
Figure 5-9a HOLDTime - 1
4. Set the time with the + - keys.
(A maximum of 30 seconds.)
Figure 5-9b shows a setting for 2.0 seconds.
5. Press the ENTER key to confirm your selection.
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.
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 5-9b HOLDTime - 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 left right arrow keys
and the + - keys.
3. Press ENTER to confirm your amplitude setting.
Figure 5-10 Amplitude
Page
26
Dukane Manual Part No. 403-606-00
Section 5 - Process Control Settings
Trigger by Power
Push ENTER to toggle from OFF to ON.
When Trigger by Power is selected, three additional
settings are presented:
•
Trigger Amplitude -This is the percentage of
amplitude that the generator applies to the horn prior
to reaching the Trigger Power setting (See Figure
5-11b).
•
Trigger Power -This is the power level that must be
reached at the Trigger Amplitude setting for the weld
cycle to start (See Figure 5-12).
•
Trigger Timeout -This is the maximum time the
welder remains at the Trigger Amplitude setting
before aborting the weld cycle (See Figure 5-13).
NOTE
Trigger by Power is only available
when the weld mode is either Time
or Energy.
Figure 5-11a Trigger By Power
For a more detailed explanation of Trigger by Power,
please refer to Application Note 506 found on our website
at:
http://www.dukane.com/us/DL_ApplData.asp
Figure 5-11b Start Amplitude
Figure 5-12 Trigger Power
Figure 5-13 Trigger Timeout
Dukane Manual Part No. 403-606-00
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iQ Series, Ultrasonic Hand Held Systems User’s Manual
System Information,
Hardware Settings, Generator
Settings
When the INFO key is pressed the display appears as seen
in Figure 5-14a. From here System Information can be
viewed, Hardware Settings can be updated, and Generator
Settings can be updated.
1. System Information
Figure 5-14a INFO Screen
Push enter to display model type and firmware information.
Figure 5-14b shows an example of this information.
2. Hardware Settings
Weld Mode
Displays the mode (See Figure 5-15). Push ENTER to
change the mode.
Figure 5-14b System Information Example Screen
Buzzer
Push ENTER to change the status of buzzer from OFF
to ON. When ON, buzzer will activate at the end of the
cycle.
Latch On Fault
Push enter to toggle mode from OFF to ON
If Latch on Fault is on, and a fault occurs, the alarm
sounds twice (beep, beep) indicating the generator
is latched and it will not weld again until the fault is
cleared.
Pressing ENTER clears the fault, and the next cycle
can begin.
If Latch on Fault is off, and a fault occurs, the audible
alarm (beep, beep) will be heard, but welding can
continue.
Figure 5-15 Weld Mode
NOTE
Changes in Hardware Settings take
place after ENTER is pressed.
Figure 5-16a Generator Settings Screen
Page
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Dukane Manual Part No. 403-606-00
Section 5 - Process Control Settings
3. Generator Settings
Free Run Frequency
Free run is the frequency at which the generator
drives the ultrasound ouput pulses until a valid
feedback signal is detected. Typically this value
should be below the operating frequency of the probe
(See Figure 5-16a).
Push ENTER to change the current value.
Figure 5-16b Generator Settings Screen - 2
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.
Push ENTER to change the current value.
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.com/us/DL_ApplData.asp
Push ENTER to change the current value.
Figure 5-17 Language Selection
Language
This enables one to select which language is displayed.
Press ENTER to select language (Figure 5-17).
Keyboard
Pushing the enter button enables the keyboard function.
This facilitates entering weld time and energy values
directly by number. Pushing the ENTER button will
toggle the feature on and off. As shown in Figure 5-16.
Figure 5-18 & 5-19 Numerical Input
When the TIME or ENERGY button is pushed, a
numerical keypad will be displayed (Figure 5-18).
Use the left and right arrows along with the up and
down arrows to highlight the desired value and push
ENTER. The value will be entered from left to right.
(Figure 5-18) Highlight the displayed value and push
ENTER to accept. (Figure 5-19).
Select “Weld Time” or “Energy” as shown in Figure
5-20. A pop-up screen will appear that will enable
one to use the up and down arrows to select the weld
method. Figure 5-21
Dukane Manual Part No. 403-606-00
Figure 5-20 & 5-21 Selection Input
Page
29
iQ Series, Ultrasonic Hand Held Systems User’s Manual
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.
Navigating
When the SETUP key is pressed, the screen will display
the weld method and the value for each parameter. Use the
up and down arrow to select a setup.
•
Figure 5-22a Setup
Maintenance - 1
Figure 5-22b Pop-up Load Setup
Load - (Load means to put data into the generator’s
memory, or to program a setup.)
With the desired setup selected (Figure 5-22a) press
ENTER. A pop-up screen asks to confirm loading the
selected setup (See Figure 5-22b).
Select NO, and the display will go back to the previous
Operate screen with the previous setup still loaded.
Select YES, and the display will change to an Operate
Screen as well, but the number of the selected setup
will appear in the lower right corner of the screen (See
Figure 4-4). This indicates that the desired setup has
been loaded.
•
Figure 5-23a Setup
Maintenance - 2
Store - (Store means to save the setup data.)
Tap the right arrow key once to highlight Store. See
Figure 5-23a.
Figure 5-23b Pop-up Overwrite Setup
Press ENTER, and a pop-up screen as shown in Figure
5-23b appears.
Select YES if you want to overwrite (replace) what
was in the setup with what has been updated in the
setup, and select NO if you do not want to change
anything in that setup.
Press the ENTER key to save your selection.
•
Delete -To delete the setup, select Delete as shown
in Figure 5-24, and press the ENTER key. A pop-up
screen appears to ask you to confirm your choice (See
Figure 5-24b).
Figure 5-24a Setup
Maintenance - 3
Select YES or NO, and press ENTER again.
Continued
Page
30
Figure 5-24b Pop-up Delete Setup
Dukane Manual Part No. 403-606-00
Section 5 - Process Control Settings
Setup Maintenance
Continued
Storing the Current Setup
The following example will demonstrate how to load and
store a setup:
1. Follow instructions on Page 24 to set the mode to
Weld by Time. Set the time to 1.520 seconds (See
Figure 5-25).
2.
Press SETUP and then press the + key to select an
unused setup (See Figure 5-26a).
3.
Use the right arrow key to select Store, and then
press ENTER. A pop-up screen will be displayed to
confirm overwriting the selected setup (See Figure
5-26b). Select YES, and then push ENTER. You will
be returned to the Operate screen.
4.
Confirm that your setup has been stored in memory
by going back to SETUP and selecing the setup you
just saved. Your new setup should appear as it does in
Figure 5-27 with the new Weld by Time value.
Figure 5-25 Set Weld by Time (Storing)
Loading a Setup
To load a setup previously stored:
1.
Press SETUP and with Load highlighted, use the
+ - keys to select the number of the setup you
want to load.
3.
Press ENTER, and a pop-up screen will ask you to
confirm your selection. Make your choice, and press
ENTER
4.
The Operate screen will display this setup selection
as a number in the lower right hand corner.
Figure 5-26a Store in
Setup Maintenance
Figure 5-26b Pop-up
Overwrite Setup
Deleting a Setup
To delete a setup previously stored:
1.
Press SETUP and with Delete highlighted, use the
+ - keys to select the the setup you want to delete.
3.
Press ENTER, and a pop-up screen will ask you to
confirm your selection. Make your choice, and press
ENTER.
4.
Check that the setup is deleted. Press SETUP, and the
Setup Maintenance screen will show EMPTY for the
setup you just deleted.
Dukane Manual Part No. 403-606-00
Figure 5-27 New Setup Stored
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Dukane Manual Part No. 403-606-00
Section 6 – Probes and Probe Stacks
SECTION 6
Probes and Probe Stacks
Ultrasonic Probe Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Probe Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultrasonic Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Booster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
36
37
37
Stack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installing Replaceable Tips . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Stud to Horn/Booster. . . . . . . . . . . . . . . . . . . . . . . .
Horn to Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Booster to Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn to Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
39
40
40
40
Stack Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Booster Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Dukane Manual Part No. 403-606-00
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Dukane Manual Part No. 403-606-00
Section 6 – Probes and Probe Stacks
Ultrasonic Probe
Overview
The three types of probes used with the iQ Hand Held
CAUTION
The ultrasonic cable carries high electrical current
when in operation. Do not
nick or cut this cable. If
cut, there would be a high
potential for electric shock!
Systems are shown in Figure 6-1 below.
Operating Notes
Compressed Air Fitting - In continuous duty
operation, it is important to keep the probe cool with
compressed air. Use the air fitting to connect the air source
to the probe.
See Section 7, Specifications for more detail.
NOTE
Compressed air supply: Make sure
the air is clean, oil-free, and dry.
Models 41PG20S & 41PG40S
Hanger
Compressed Air Fitting
Strain Relief
U/S Cable
Typical Horn Less Tip
Trigger
Rear View
Pistol-style Grip
Models 41HP20S, 41HP30S, 41HP35S, 41HP40S
Trigger Actuator
Compressed Air Fitting
Hanger
Strain Relief
U/S Cable
Hand Grip
Typical Horn Less Tip
Rear View
Models 41PG30S & 41PG35S
Air Cooling Tube
Hanger
Strain Relief
Typical Horn Less Tip
Trigger
Figure 6-1
Typical Hand Held
Probes
Dukane Manual Part No. 403-606-00
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35
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. 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.
CAUTION
Never use the hand probe if
the cable insulating jacket is
cut or damaged in any way.
Probe Configuration
A basic ultrasonic probe package consists of:
1. A probe which houses the transducer to convert the electrical 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 hand–held probe system is shown in Figure 6-2.
The hand probe is easily identified by its trigger actuator
and permanently attached cable. Normally a booster is not
used with a hand 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.
Hand
Probe
Standard
Horn
Custom
Horn
Tip
Figure 6–2 Hand Probe, Horn and Tip
Page
36
Dukane Manual Part No. 403-606-00
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, 35kHz, 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 6–3. This is commonly referred to
as a stack. As indicated, the components are secured with
threaded studs.
Booster
Horn
Figure 6–3 Probe, Booster and Horn
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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. 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 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. 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 6-4. 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.
NOTE
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.
CAUTION
NEVER clamp the horn
in a vise. The resulting
scratches or gouges in the
surface are stress risers
which may result in cracks.
Tighten
Figure 6–4 Replaceable Tip Installation
Replaceable Tips to Horn
inch-lb
ft-lb
N-m
Size
360
30
40.7
1/2” x 20 tpi tip threads
336
28
38
3/8” x 24 tpi tip threads
300
25
33.9
5/16” x 24 tpi tip threads
240
20
27.1
1/4” x 28 tpi tip threads
Table 6-I Tip Torque Unit Conversions
Page
38
NOTE
Dukane Part No. for the 20kHz spanner wrenches is 721–68.
Dukane Part No. for 30kHz, 35kHz,
and 40kHz spanner wrenches is
721–44.
Dukane Manual Part No. 403-606-00
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. 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 measurements.
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
12-18
1 - 1.5
1.4 - 2
1/2” x 20 tpi studs
NOTE
12-18
1 - 1.5
1.4 - 2
3/8” X 20 tpi studs
12-18
1 - 1.5
1.4 - 2
8 mm studs
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
Size
Stud Torque Unit Conversions
* Always assemble the mounting studs that mate
boosters, transducers and horns to the input end of
the horn or the input end of the booster first. This is
shown in Figure 6-6.
NEVER thread a stud into the transducer or the
output end of the booster first. See Booster Notes in
this section for correctly identifying the output end of
a booster.
Dukane Manual Part No. 403-606-00
Torque specifications have a tolerance of
about ± 10%.
See Figure 10–4 for a handy conversion
graph.
Page
39
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. These surfaces must make intimate 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.
3. Make sure that the stud in the horn or booster is tight.
See the preceding mounting stud assembly instructions
for torque specifications.
NOTE
Always remove a probe stack from the
machine in which it is mounted before
attaching or removing a horn.
CAUTION
Never leave a horn or booster
assembly hand tight. Torque
it to the proper specifications
before proceeding. If the assembly is installed without
being properly torqued down,
the assembly may vibrate
severely, damaging the mating surfaces and causing
the generator to overload.
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 systems that require frequent changes. Mylar is plastic and
will creep under compression, so mylar is not recommended for system 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 6–5 Stack Assembly Procedure
Page
40
Dukane Manual Part No. 403-606-00
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 6–5 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
24.4 35 kHz stack
216
18
24.4 40 kHz stack
Table 6-III
61
kHz
15 kHz stack
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.
Horn/Booster Torque Unit Conversions
Dukane Manual Part No. 403-606-00
Page
41
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. 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.
CAUTION
Never hold a probe by the
housing when tightening or
loosening an adjoining component. The probe housing
has anti–rotation devices
to keep the transducer
aligned. These could shear
under excessive torque.
The assembly and disassembly procedures for a hand probe
are shown in Figure 6–6. It makes no difference whether
the horn is attached to the booster first, or the booster is
attached to the probe first.
ASSEMBLY
HAND
PROBE
HOUSING
Output End
Mounting Stud
(Insert Into Horn
First and Tighten
to Torque Specs)
HAND
PROBE
HOUSING
Spanner
Wrench
Holes
HAND
PROBE
ASSEMBLY
Input End
HORN
HORN
DISASSEMBLY
Figure 6–6 Hand Probe Assembly and Disassembly
Page
42
Dukane Manual Part No. 403-606-00
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 6–7.
Loosen
NOTE
Figure 6–7 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.
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 on horns and boosters
with spanner wrench holes. Use an open
end wrench on horns and boosters with
wrench flats.
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 6–8 for the
correct tip removal procedure.
Dukane Manual Part No. 403-606-00
Figure 6–8 Removing a Replaceable Tip from the Horn
Page
43
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.
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.
Page
44
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. Reversing
them will not give the expected results and may cause
damage to the system.
Dukane Manual Part No. 403-606-00
Section 7 – Troubleshooting
SECTION 7
Troubleshooting
No Ultrasonic Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
System Power Output Level . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Welding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Pop-up Fault Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . 49
Dukane Manual Part No. 403-606-00
Page
45
iQ Series, Ultrasonic Hand Held Systems User’s Manual
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Page
46
Dukane Manual Part No. 403-606-00
Section 7 – Troubleshooting
No Ultrasonic Output
Probe
Make sure that the hand probe cable is connected to the
generator connector (HAND PROBE) and that the thumb
screws are tightened to the rear panel. Also, make sure the
hand 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 hand probe to one that
is known to be good.
NOTE
The LCD screen displays a variety
of pop-up status changes as they
occur. Check Tables 7-I and 7-II
- Pop-up Fault Status Screens Pages 49- 50.
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.
Generator Fault Does Not Reset
NOTE
When Latching Faults is enabled,
ENTER must be pressed to clear
a fault.
When a system fault condition does not automatically
reset, the generator needs servicing.
System Power Diagnostic
Procedures
Information regarding power diagnostic faults can be
found by visiting: www.dukane.com/EasyAlarm
Dukane Manual Part No. 403-606-00
Page
47
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.
NOTE
Primary factors in achieving consistent, quality welds - especially when
using hand held probes - are the skill
and training of the operator.
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 inspect the mating surfaces to insure they
are clean and flat. Also, inspect the horn for damage or
cracks. When this is complete reassemble the stack.
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.
Page
48
Dukane Manual Part No. 403-606-00
Section 7 – Troubleshooting
Pop-up Alarm Status Screens
Process Alarms
Pop-Up Alarm Displayed
Latch On Fault ENABLED
Latch On Fault DISABLED
Alarm Description
Set Weld Time Not Reachedappears if the weld ends
before the set time is reached
due to operator error, or
because the weld was
intentionally aborted.
Set Weld Energy Not
Reached - appears if the
weld ends before the set
energy is reached due to
operator error, or because
the weld was intentionally
aborted.
Trigger By Power Not
Reached is displayed When
Trigger by Power is enabled
and the programmed power
threshold is not reached
within the trigger timeout
period.
When triggering by power
a maximum time limit must
be entered. This is the time
between when the operator
presses the initiate switch
and begins to put pressure
on the part.
The maximum weld time
when Frequency Lock and
Hold is enabled is 5 seconds.
Reduce the weld time to 5
seconds or less.
Table 7-I Pop-Up Fault Status Screens - Process Alarms
Dukane Manual Part No. 403-606-00
Continued
Page
49
iQ Series, Ultrasonic Hand Held Systems User’s Manual
Overload alarms
Many overload alarms can be the result of damage to the Ultrasonic stack assembly (probe and horn). More information
regarding maintenance to the stack assembly can be found at:
http://www.dukane.com/us/SE_Stackarticle.htm
Overload Alarms
Pop-Up Alarm Displayed
Latch On Fault ENABLED
Latch On Fault DISABLED
Alarm Description
Generator was not able to
find the resonant frequency of
the probe and horn. This can
be a result from applying too
much force at startup, or the
result of a damaged probe, or
horn. Alarm will reset when
the next cycle starts.
Instantaneous current
exceeds the rating of
the internal generator
components. Caused by a
severe frequency mismatch.
Alarm will reset when next
cycle starts.
Ultrasound voltage exceeded
input voltage. Caused by a
severe frequency mismatch
between generator and stack.
Alarm will reset when next
cycle starts.
Output power exceeded
the rated power of the
generator. Reduce the power
requirement by reducing
force against the part. Alarm
will reset when next weld
cycle starts.
Table 7-II Pop-Up Fault Status Screens - Overload Alarms
Page
50
Dukane Manual Part No. 403-606-00
Section 7 – Troubleshooting
General Alarms
Pop-Up Alarm Displayed
System Status or Alarm Explanation
Generator model number does not match
internal components. Cycle power. If fault
persists, contact Dukane Technical Support.
AC line voltage is not within the specified
limits. Review incoming AC line voltage
to insure it is correct. If AC line voltage
measurement is correct, and alarm persists,
contact Dukane Technical Support.
System Over temperature fault detected.
Fault will reset when system cools down.
If the cycle initiate signal was held on during
power up, the generator will be prevented
from turning on ultrasound. Remove the
cycle initiate signal and begin a new cycle.
Make sure the cycle initiate signal is not
active during power up.
Table 7- I Pop-Up Alarm Status Screens - General Alarms
Dukane Manual Part No. 403-606-00
Page
51
iQ Series, Ultrasonic Hand Held Systems User’s Manual
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Page
52
Dukane Manual Part No. 403-606-00
Section 8 – Options
SECTION 8
Options
iQ Hand Probe Foot Switch Kit . . . . . . . . . . . . . . . . . . . . . . . . 55
Dukane Manual Part No. 403-606-00
Page
53
iQ Series, Ultrasonic Hand Held Systems User’s Manual
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Page
54
Dukane Manual Part No. 403-606-00
Section 8 – Options
iQ Hand Probe Options
Foot Switch Kit (Part No. 438-976)
This kit allows the customer to add their own external
foot switch to replace the trigger on the hand probe.
An external breakout box with cabling is supplied. The
box connects to the generator and to the hand probe.
Dukane Manual Part No. 403-606-00
Page
55
iQ Series, Ultrasonic Hand Held Systems User’s Manual
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Page
56
Dukane Manual Part No. 403-606-00
Section 9 – Specifications
SECTION 9
Specifications
Generator Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Probes Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . 63
Dukane Manual Part No. 403-606-00
Page
57
iQ Series, Ultrasonic Hand Held Systems User’s Manual
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Page
58
Dukane Manual Part No. 403-606-00
Section 9 – Specifications
Figure 9-1 Generator Outline Drawing
Dukane Manual Part No. 403-606-00
IN
[mm]
Page
59
iQ Series, Ultrasonic Hand Held Systems User’s Manual
B
C
Part Numbers
41HP20S
41HP30S
41HP35S
41HP40S
A
2.59 in
(66 mm)
1.25 in (32 mm)
Diameter
Air fitting for cooling
.25 in O.D. tubing
Soft grip handle
Standard single connector for
iQ generator
A
B
Air fitting for cooling
.25 in O.D. tubing
C
1.25 in (31.75 mm)
Diameter
Part Numbers
41PG20S
41PG40S
D
Standard cable
9 ft (3 m)
1.20 in
(30 mm)
Soft grip handle
Standard single connector for
iQ generator
A
B
C
RING FOR TETHER
COOLING TUBE
FTG FOR .25" OD
AIR COOLING
1.00 DIA
[25mm]
Part Numbers
41PG30S
41PG35S
STANDARD CABLE
9 FT (3M)
D
Figure 9-2 Probes Outline Drawings and Dimensions
Page
60
Dukane Manual Part No. 403-606-00
Section 9 – Specifications
System
Model
Number
Generator
Model Number
Probe
Part
Number
Probe
Weight
lb (kg)
HP 20.61-P
20HP060-1H
41PG20S
1.80 (.82)
HP 20.61-H
20HP060-1H
41HP20S
1.60 (.73)
HP 20.62-P
20HP060-2H
41PG20S
1.80 (.82)
HP 20.62-H
20HP060-2H
41HP20S
HP 30.61-P
30HP060-1H
HP 30.61-H
A
Diameter
in (mm)
B
Length
w/Strain Relief
in (mm)
C
Body
Length
in (mm)
D
Handle
Length
in (mm)
8.75 (222)
5.10 (130) 5.38 (137)
10.00 (254)
5.02 (129)
8.75 (222)
5.10 (130) 5.38 (137)
1.60 (.73)
10.00 (254)
5.02 (129)
na
41PG30S
2.50 (1.14) 2.21 (56)
8.22 (209)
3.82 (97)
5.79 (147)
30HP060-1H
41HP30S
1.40 (.64)
1.90 (48)
9.00 (229)
5.10 (130)
na
1.90 (48)
Probe
Cable
Length
na
HP 30.62-P
30HP060-2H
41PG30S
2.50 (1.14) 2.21 (56)
8.22 (209)
3.82 (97)
5.79 (147)
HP 30.62-H
30HP060-2H
41HP30S
1.40 (.64)
1.90 (48)
9.00 (229)
5.10 (130)
na
HP 35.61-P
35HP060-1H
41PG35S
2.50 (1.14) 2.21 (56)
8.53 (217)
3.82 (97)
5.79 (147)
HP 35.61-H
35HP060-1H
41HP35S
1.40 (.64)
1.90 (48)
9.15 (232)
5.10 (130)
na
HP 35.62-P
35HP060-2H
41PG35S
2.50 (1.14) 2.21 (56)
8.53 (217)
3.82 (97)
5.79 (147)
HP 35.62-H
35HP060-2H
41HP35S
1.40 (.64)
1.90 (48)
9.15 (232)
5.10 (130)
na
HP 40.61-P
40HP060-1H
41PG40S
1.65 (.75)
2.10 (53)
8.20 (208)
5.02 (129) 5.38 (137)
HP 40.61-H
40HP060-1H
41HP40S
1.35 (.61)
1.90 (48)
8.58 (225)
4.80 (122)
HP 40.62-P
40HP060-2H
41PG40S
1.65 (.75)
2.10 (53)
8.20 (208)
5.02 (129) 5.38 (137)
HP 40.62-H
40HP060-2H
41HP40S
1.35 (.61)
1.90 (48)
8.58 (225)
4.80 (122)
9 ft (3 m)
na
na
Table 9-I Hand Probe Dimensions
Weights
Generator:
11 pounds (4.99 kg)
Probes:
Please see the table on the previous page.
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.
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
Dukane Manual Part No. 403-606-00
Page
61
iQ Series, Ultrasonic Hand Held Systems User’s Manual
AC Power Requirements
Overload
Power
Rating
(Watts)
Operating
Frequency
System
Model
Number
Generator
Model Number
20kHz
HP 20.61-P
20HP060-1H
100-120 VAC, 50/60 Hz @ 9.0 Amps
20kHz
HP 20.61-H
20HP060-1H
100-120 VAC, 50/60 Hz @ 9.0 Amps
20kHz
HP 20.62-P
20HP060-2H
200-240 VAC, 50/60 Hz @ 4.5 Amps
20kHz
HP 20.62-H
20HP060-2H
200-240 VAC, 50/60 Hz @ 4.5 Amps
30kHz
HP 30.61-P
30HP060-1H
100-120 VAC, 50/60 Hz @ 9.0 Amps
30kHz
HP 30.61-H
30HP060-1H
100-120 VAC, 50/60 Hz @ 9.0 Amps
30kHz
HP 30.62-P
30HP060-2H
200-240 VAC, 50/60 Hz @ 4.5 Amps
30kHz
HP 30.62-H
30HP060-2H
35kHz
HP 35.61-P
35HP060-1H
35kHz
HP 35.61-H
35HP060-1H
100-120 VAC, 50/60 Hz @ 9.0 Amps
35kHz
HP 35.62-P
35HP060-2H
200-240 VAC, 50/60 Hz @ 4.5 Amps
35kHz
HP 35.62-H
35HP060-2H
200-240 VAC, 50/60 Hz @ 4.5 Amps
40kHz
HP 40.61-P
40HP060-1H
100-120 VAC, 50/60 Hz @ 9.0 Amps
40kHz
HP 40.61-H
40HP060-1H
100-120 VAC, 50/60 Hz @ 9.0 Amps
40kHz
HP 40.62-P
40HP060-2H
200-240 VAC, 50/60 Hz @ 4.5 Amps
40kHz
HP 40.62-H
40HP060-2H
200-240 VAC, 50/60 Hz @ 4.5 Amps
600 Watts
Input AC Power Requirements
Nominal AC Volt
200-240 VAC, 50/60 Hz @ 4.5 Amps
100-120 VAC, 50/60 Hz @ 9.0 Amps
North America/
Japan
AC Outlet Rating
15.0 Amps
Table 9- II AC Power Requirements
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Section 9 – Specifications
Regulatory Agency Compliance
FCC
UL & CSA
The Hand Probe Plus Welder 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.
The Hand Probe Plus Welder complies with these
standards:
Underwriters Laboratories (UL):
UL61010-1
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
Hand Probe Plus Welder complies with the following CE
requirements.
• The EMC Directive 2014/30/EU for Heavy Industrial
—
EN 61000-6-4
EN 55011
EN 61000-6-2
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 2014/35/EU
•
•
The Machinery Directive 2006/42/EC
EN 60204: Safety of Machinery - Electrical
Equipment of Machines Part 1: General
Requirements.
EN ISO 12100: Safety of Machinery - General
principles of design, risk assessment, and risk
reduction.
National Standards of Canada (CSA):
CAN/CSA C22.2 No. 61010-1
as verified by TÜV Rheinland.
CAUTION
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.
IP Rating
The Hand Probe Plus Welder has an IP (International
Protection) rating from the IEC (International
Electrotechnical Commission).
The rating is IP2X, in compliance with finger-safe industry
standards.
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Section 10 – I/O Interface
SECTION 10
Outputs Interface
Outputs Connection Example . . . . . . . . . . . . . . . . . . . . . . . . . 67
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Section 10 – I/O Interface
iQ Hand Probe Generator
Rear Panel Detail
HAND PROBE
OUTPUTS
0V
1
2
3
Provided by Customer
NOTE
0V
(Output
Common)
is
connected
to
Chassis
Ground
(Earth).
Power Supply
+ 30 VDC Maximum
To OUTPUTS:
1, 2, or 3
+ 24 V
X1
+
_
X2
0V
Status
Indicator or
Audible
Alarm
(333mA
maximum)
Figure 10-1 OUTPUTS Connection Example
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Section 11 – Contacting Dukane
SECTION 11
Contacting Dukane
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Section 11 – Contacting Dukane
Contacting Dukane
Equipment Identification and
Problem Details
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
Some problems can be solved over the telephone, so it is
best to call from a telephone located near the equipment.
Ultrasonics Division
Mailing Address:
Dukane IAS LLC.
2900 Dukane Drive
St. Charles, IL 60174 USA
Main Phone:
(630) 797–4900
Main Fax:
(630) 797–4949
Service & Parts Fax:
(630) 584–0796
Website
The website has information about our products, processes,
solutions, and technical data (including 3D CAD models).
Downloads are available for many kinds of literature.
Main page:
www.dukane.com/us
Downloads page:
www.dukane.com/us/Downloads.asp
You can locate your local representative at:
www.dukane.com/us/SA_IntSales.htm
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Appendices
APPENDICES
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
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Appendices
List of Figures
No.
Description
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
Generator Detail - Rear Views.......................................................................................12
3-2
Rocker-style Power Switch/Circuit Breaker....................................................................12
4-1
Front Panel.....................................................................................................................17
4-1A
Power Bar Graph - In Cycle...........................................................................................18
4-1B
Power Bar Graph - Operate...........................................................................................18
4-2
Power Switch..................................................................................................................19
4-3
Power-up Screen............................................................................................................19
4-3A
Operate Screen Appears After Power-up.......................................................................19
4-4
Example of an Operate Screen......................................................................................20
4-5
Example of an In Cycle Screen......................................................................................20
5-1
Manual Weld Mode........................................................................................................24
5-2
Navigate To Weld Mode.................................................................................................24
5-3
Enter Weld Time.............................................................................................................24
5-4
Select Manual Mode.......................................................................................................24
5-5
Time Weld Mode............................................................................................................25
5-6
Navigate to Energy Mode -1...........................................................................................25
5-7
Energy Weld Mode - 1....................................................................................................25
5-8
Energy Weld Mode - 2....................................................................................................25
5-9a
HOLD Time - 1...............................................................................................................26
5-9b
HOLD Time - 2...............................................................................................................26
5-10
Amplitude.......................................................................................................................26
5-11a
Trigger By Power............................................................................................................27
5-11b
Start Amplitude...............................................................................................................27
5-12
Trigger By Power............................................................................................................27
5-13
Trigger Timeout..............................................................................................................27
5-14a
INFO screen...................................................................................................................28
5-14b
System Information Screen............................................................................................28
5-15
Weld Mode.....................................................................................................................28
5-16a
Generator Settings Screen.............................................................................................28
5-16b
Generator Settings Screen-2..........................................................................................29
5-17
Language Selection........................................................................................................29
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List of Figures continued
5-18
Numerical Input..............................................................................................................29
5-19
Numerical Input..............................................................................................................29
5-20
Selection Input................................................................................................................29
5-21
Selection Input................................................................................................................29
5-22a
Setup Maintenance - 1...................................................................................................30
5-22b
Pop-up Load Setup........................................................................................................30
5-23a
Setup Maintenance - 2...................................................................................................30
5-23b
Pop-up Overwrite Setup.................................................................................................30
5-24a
Setup Maintenance - 3...................................................................................................30
5-24b
Pop-up Delete Setup......................................................................................................30
5-25
Set Weld By Time(Storing).............................................................................................31
5-26a
Store In Setup Maintenance...........................................................................................31
5-26b
Pop-up Overwrite Setup.................................................................................................31
5-27
New Setup Stored..........................................................................................................31
6-1
Typical Hand Held Probes..............................................................................................35
6-2
Hand Probe, Horn and Tip..............................................................................................36
6-3
Probe, Booster and Horn................................................................................................37
6-4
Replaceable Tip Installation...........................................................................................38
6-5
Stack Assembly Procedure............................................................................................40
6-6
Hand Probe Assembly and Disassembly.......................................................................42
6-7
Separating the Horn from the Booster............................................................................43
6-8
Removing a Replaceable Tip From the Horn.................................................................43
9-1
Generator Outline Drawing.............................................................................................59
9-2
Probes Outline Drawings and Dimensions.....................................................................60
10-1
OUTPUTS Interface Example........................................................................................67
List of Tables
No.
Description
3-I
Standard IEC AC Power Cord Part Numbers..................................................................13
3-II
System OUTPUTS Connector Signals............................................................................14
6-I
Tip Torque Unit Conversions............................................................................................38
6-II
Stud Torque Unit Conversions.........................................................................................39
6-III
Horn/Booster Torque Unit Conversions............................................................................41
7-I
Pop-up Alarm Screens - Process Alarms.........................................................................49
7-II
Pop-up Alarm Screens - Overload Alarms.......................................................................50
7-III
Pop-up Alarm Screens - General Alarms.........................................................................51
9-I
Hand Probe Dimensions..................................................................................................61
9-II
AC Power Requirements.................................................................................................62
Page
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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 Hand Held Systems User's Manual
Part No. 403 – 606– 00
www.dukane.com/us
Printed in the United States of America
Dukane IAS LLC • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949