Dukane iQ Series Ultrasonic Power Supply AL-E Manual

Dukane iQ Series Ultrasonic Power Supply AL-E Manual
iQ Series
ULTRASONIC POWER SUPPLY
AL-E
AUTOMATED
HAND PROBE
PRESS
Users Manual
Applicable System Models:
20AL060-1H
35AL060-1H
20AL060-2H
35AL060-2H
30AL060-1H
40AL060-1H
30AL060-2H
40AL060-2H
Dukane Part No. 403 – 607 – 00
Dukane • 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
iQ Series, Ultrasonic Power Supply AL - E Users Manual
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: 403-607-00
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. 403-607-00
Revision History
Revision
Number
Revision
Summary
- 00
Original release.
Dukane Manual Part No. 403-607-00
Date
August 30th, 2017
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Dukane Manual Part No. 403-607-00
Contents
Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 2- Health and Safety . . . . . . . . . . . . . . . . . . . 5
Section 3- Installation . . . . . . . . . . . . . . . . . . . . . . . . . 9
Before Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Placement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Connecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . 14
Section 4 - Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Controls Overview . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Start-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . 23
LCD Display Overview. . . . . . . . . . . . . . . . . . . . . . . 24
Section 5 - Process Control Settings . . . . . . . . . . . 25
Selecting the Weld Mode. . . . . . . . . . . . . . . . . . . . . 27
Navigating the Modes. . . . . . . . . . . . . . . . . . . . . . . . 28
Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Amplitude Adjustment. . . . . . . . . . . . . . . . . . . . . . . . 30
Trigger by Power . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
System Information, Advanced Settings. . . . . . . . . . 32
Setup Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . 34
Section 6 - Probes and Probe Stacks . . . . . . . . . . . 37
Section 7 - Troubleshooting . . . . . . . . . . . . . . . . . . . 49
Section 8 - Specifications . . . . . . . . . . . . . . . . . . . . . 57
Section 9 - Contacting Dukane . . . . . . . . . . . . . . . . . 63
Section 10 - Appendices . . . . . . . . . . . . . . . . . . . . . 67
Appendix A - E-Stop Circuitry Examples . . . . . . . . . 69
Appendix B - List of Figures. . . . . . . . . . . . . . . . . . . 70
Appendix C - List of Tables. . . . . . . . . . . . . . . . . . . . 71
Dukane Manual Part No. 403-607-00
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Dukane Manual Part No. 403-607-00
Section 1 – Introduction
SECTION 1
Introduction
Important User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Read the Manual First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drawings and Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dukane Manual Part No. 403-607-00
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Dukane Manual Part No. 403-607-00
Section 1 – Introduction
Important User Information
Read This Manual First
Before operating the iQ Series Ultrasonic Power Supply
AL-E, 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. 403-607-00
Condition
or Practice
Electrical
Hazard
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iQ Series, Ultrasonic Power Supply AL - E Users Manual
System Overview
Your iQ Series Ultrasonic Power Supply AL-E, an ultrasonic generator, provides a versatile stand-alone workstation.
vides consistent system performance regardless
of line voltage fluctuations. It also eliminates the
need for bulky, external constant–voltage transformers.
•
Load Regulation provides constant amplitude
automatically regardless of power draw. The ultrasonic output amplitude level is held to within
±1% to provide weld process consistency and reduced weld cycle times.
•
Industrial Line–Power Source means that
standard systems will operate worldwide at all
industrial high line voltage levels, whether it is
200VAC @60Hz in Japan, 240VAC @50Hz in
Europe or 208VAC @60Hz in the United States.
There are no internal transformer taps to change
for worldwide operation. North American 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 rated overload
power limit is based on the actual true RMS
power output level.
This product’s rugged internal circuitry ensures a continuous resonant frequency lock at the start of each weld.
Standard to this line of generators are time and energy
control. The brightly lit display is easy to read. The menu
structure makes programming simple, and the one-touch
hot keys give the operator even more flexibility.
The generator also includes an RFI line filter that passes
strict CE test specifications for global applications.
Key Features
•
Trigger by Power is a Dukane patented feature that
produces greater weld consistency by requiring that
a sufficient amount of pressure/force is applied to the
part before the actual weld begins. Trigger by Power is
a cost effective alternative to trigger by force because
it does not require additional, expensive components
such as a load cell, amplifier board or cabling.
•
Compact Generator is small and easily moved, and
this allows your table or work bench to accommodate
more of the items needed for your process.
•
CE Certification means that the system meets
the required European standards to be sold and
used in Europe.
•
Pulse Width Modulation incorporates patented
circuitry giving the power supply the ability to
efficiently change the output amplitude. This makes
it possible to start large horns with reduced power. It
also provides more power efficient switch-mode generator operation and increased reliability.
•
ISO 9001 : 2008 Certification means that this
system has been manufactured to high quality
standards and assures you of manufacturing excellence.
•
TUV Certification - TÜV Rheinland certifies
Dukane products comply with applicable UL
(Underwriters Laboratories) and CSA (Canadian
Standards Association) requirements.
•
Linear Ramp Soft Start circuitry allows the acoustic stack to ramp up to operating amplitude smoothly,
minimizing the start-up surges and abnormal stress to
the stack and generator.
•
Digi-Trac Tuning tracks the resonant frequency of
the acoustic stack (horn, booster, transducer) and adjusts the generator output frequency to match it. This
is done for every weld cycle and eliminates the need
to manually tune the generator.
•
Line Voltage Regulation automatically maintains
constant amplitude regardless of line voltage deviation. The available output power is maintained with
any voltage input within the specified range. This pro-
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Dukane Manual Part No. 403-607-00
Section 2 – Health and Safety
SECTION 2
Health and Safety
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dukane Manual Part No. 403-607-00
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Dukane Manual Part No. 403-607-00
Section 2 – Health and Safety
General Considerations
Please observe these health and safety recommendations for
safe, efficient, and injury-free operation of your equipment.
In this manual, the term system refers to a complete group
of components associated with the welding of plastic or
metal parts, also known as an ultrasonic assembly system.
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.
WARNING
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, ultrasound baffles,
sound enclosures or materials
that absorb sound may be
located to surround the
system. Ultrasound pressure
level could exceed 110dB.
Grounded Electrical Power - Operate this equipment
only with a properly grounded electrical connection.
(See Page 8 for grounding information.)
Comply with Regulations - You may be required to add
accessories to bring the system into compliance with 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. 403-607-00
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iQ Series, Ultrasonic Power Supply AL - E Users Manual
Electrical Safety
Domestic Power Grounding
For safety, the power cords used on this product have a
three-wire, grounding-type power cord. Figures 2-1 and
2-2 illustrate the appropriate electrical outlet to use with
the power cords included with 100-120 volt and 200-240
volt systems respectively. This information applies to
systems shipped to North America or Japan.
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. 403-607-00
Section 3 – Installation
SECTION 3
Installation
Before Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
When to Use Lockout/Tagout Devices. . . . . . . . . . . . . . . . . . . 11
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Automation Controlled System. . . . . . . . . . . . . . . . . . . . . . . . 15
System I/O Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . 16
Dukane Manual Part No. 403-607-00
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Dukane Manual Part No. 403-607-00
Section 3 – Installation
Before Installation
As you plan for the installation of your generator, please
consider these importants subjects as listed below:
• When to use lockout / tagout devices
When to Use Lockout /
Tagout Devices
The typical kind of LOTO device for this generator is a
clam shell type device (with lockout capability). The LOTO
device is placed over the plug end of the generator electrical cord. This effectively prevents access to the energy
isolation point. See the example of one such device in the
figure above.
WARNING
Electrical safety hazards
exist inside the generator
chassis. Before making any
internal adjustments to the
generator, apply a lockout/
tagout (LOTO) device to the
generator chassis.
The figure to the right shows the lockout device in the
closed, locked position.
Figure 3-1 Lockout Device In Open Position, Unlocked
Figure 3-2
Bottom Lockout Device In
Closed Position, Locked
Continued
Dukane Manual Part No. 403-607-00
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iQ Series, Ultrasonic Power Supply AL - E Users Manual
Continued from Previous Page
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 electrical cord from
its source.
3.
Authorized personnel apply a lockout/
tagout (LOTO) device to the plug end of the
generator’s electrical cord. Using a typical
clam shell type LOTO device:
1) Open the clam shell.
2) Place the electrical cord plug end
inside the shell.
3) Close the shell.
4) Secure the shell with its lock, and
lock it.
4.
Wait a minimum of five minutes for the
generator to discharge its electrical energy.
5.
After taking these steps, make the necessary
adjustments to the generator.
Assuming the generator is being put back into
service. . .
Procedure to use AFTER making any internal
adjustments to the generator:
1. Authorized personnel remove the lockout/tagout
device from the plug end of the generator's
electrical cord. Using a typical clam shell type
LOTO device:
1) Unlock the protective shell.
2) Open the shell, exposing the electrical
cord end.
3) Remove the LOTO device, and set it
aside.
2. Plug the generator's electrical cord into its AC
power source.
3. Push the generator's AC power switch/breaker to
the ON position.
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Dukane Manual Part No. 403-607-00
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.
Placement
Make certain generator placement and cable routing do
not interfere with normal operation. Maintain easy access
to your equipment. The operator should have unobstructed
access to cables and wiring.
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 minimize electrical 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 an industrial environment. Stud location is shown in Figure 3-3
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. 403-607-00
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iQ Series, Ultrasonic Power Supply AL - E Users Manual
Connecting Cables - Quick
Start Guide
NOTE
AC Power Inlet
Depending on your generator model, line
voltage required for the generator is either
100-120 VAC at 50/60 Hertz or
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 3-4 below.
Complete the basic connections as shown below:
• AC Line Input
• I/O (Input/Output) Connector
• Grounding Stud
• AC Power Cord Connection
Step 1. Connect the AC line. For the 100/120V model,
plug the permanently attached power cord into a
suitable receptacle.
For the 200/240V model, attach the female end of
the power cord to the generator’s power inlet connector - A in Figure 3-3.
Push ON
Step 2. Attach the I/O cable connector to the generator’s
input/output connection. - B in Figure 3-3.
Secure the connector to the system using the two
jack screws attached to the connector hood.
Push OFF
Step 3. Ground the generator chassis with the supplied 14Gauge wire. Attach one end to the grounding stud
- C in Figure 3-2. Attach the other end to the nearest grounded metal pipe or equal earth ground.
Figure 3-4 Rocker-style Power Switch/Circuit Breaker
Step 4. Attach the male end of the power cord to a suitable line receptacle.
Connector - See Page 19 for information about the rear
panel CONFIGURATION connector E.
Power Cord with Strain Relief
D
A
B
E
C
Figure 3-3a Generator Detail - Rear View
(100/120 Volt Model)
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14
Figure 3-3b Generator Detail - Rear View
(200/240 Volt Model)
Dukane Manual Part No. 403-607-00
Section 3 – Installation
Power Cords
Automation Controlled System
200/240 Volt Systems
Step 1. Ground the generator chassis using the supplied
14-Gauge wire, and attach it to the grounding
stud:C in Figure 3-3.
The IEC AC power inlet connector mounted on the rear
panel requires a properly configured IEC compliant power
cord.
The 200/240 AC power cords supplied with the
generators are matched to the ultrasonic output power
rating and the continent of specified use. See Table 3-I.
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)
Step 2. Optional – Ground the probe support. This is a
user–supplied 14-Gauge wire.
Step 3. Input/Output Cable - Attach the automation
control cable from the user–supplied automation equipment to the system HD-15 connector,
INPUTS/OUTPUTS on the rear panel: B in
Figure 3 -3.
Step 4. Attach the high voltage coaxial cable from the
probe to the ultrasound output connector, D in
Figure 3 -3.
Step 5. Connect the AC power cord to the generator
IEC power inlet connector, and plug the other
end into an approved AC outlet:
A in Figure 3 -3.
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.
Dukane Manual Part No. 403-607-00
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iQ Series, Ultrasonic Power Supply AL - E Users Manual
System I/O Connector Pinout
Table 3-II lists the signal names and descriptions, with
more detailed descriptions listed on the next page.
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
No Connection
7
WHT/BLK
Isolated Status Output Common
8
RED/BLK
System Ready Status Output
9
GRN/BLK
No Connection
10
ORN/BLK
No Connection
11
BLU/BLK
Fault Reset Input
12
BLK/WHT
Ultrasound Activate/Cycle Start Input
13
RED/WHT
Isolated Input Common (Sourcing or Sinking Inputs)
14
GRN/WHT
No Connection
15
BLU/WHT
No Connection
Table 3-II Generator Input/Output Signals
Pin 1 (Enable Out)
Pin 4 (Ultrasound Active Status Output)
This is a current limited voltage source output intended
to connect to an E-Stop circuit. If an E-Stop circuit is
not used, Pin 1 must be jumpered to Pin 2 for ultrasound
operation to be enabled.
Pin 4 is an isolated digital NPN/PNP status output that
activates when the system is delivering ultrasonic power
to the load attached to the ultrasound output connector.
This output will be an open circuit when the ultrasound
output is off.
Pin 2 (Enable In)
The output from the E-Stop circuit is connected to this
pin when an E-Stop circuit is used. Otherwise, this pin
must be jumpered to Pin 1 for ultrasound operation to
be enabled. See Figure A-1 in Appendix A for E-Stop
circuit wiring examples.
Pin 3 (System Overload Status Output)
Pin 3 is an isolated digital NPN/PNP status output that
activates when an output overload condition is tripped.
This output will be an open circuit if an output overload
condition is not tripped. This output will remain latched
ON until the U/S Activate input is switched OFF and
then ON again.
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16
Pin 5 (Any Fault Status Output)
Pin 5 is an isolated digital NPN/PNP status output that
activates whenever any fault condition is detected that
inhibits ultrasound output and normal system operation.
This output will be an open circuit when no system fault
conditions are active.
Pin 6 (No Connection)
Pin 7 (Isolated Status Output Common)
Pin 7 is electrically isolated from chassis ground. This
common line should be connected to the negative
output of a user-provided isolated 24VDC power supply
for a PLC sourcing input card. For a PLC Sinking input
card this line is connected to the positive output of the
Continued
isolated 24VDC power supply.
Dukane Manual Part No. 403-607-00
Section 3 – Installation
Continued from Previous Page
Pin 8 (System Ready Status Output)
Configuration Port Connector
This status output signal will activate only when the system
is ready to activate ultrasound or begin a weld cycle.
This connector - E in Figure 3-3 - is a DB-9M (standard
D-subminiature nine circuit, male) typically used for
RS-232 serial communications. This serial port (DTE)
connects to a serial port (DCE) on a computer via a
standard 9-pin serial cable. If the computer does not have
a serial port, you may use a USB-to-serial conversion
cable.
Pin 8 is an isolated digital NPN/PNP status output that
activates when a weld processing cycle is completed and
the welding process control system is ready to start the
next welding cycle. This output will be an open circuit
when the welding process controller determines that
the next welding cycle cannot be started. This includes
system faults or E-Stop active, but not a process fault like
Overload.
Pin 9 (No Connection)
Pin 10 (No Connection)
Pin 11 (Fault Reset Input)
Pin 11 is an isolated input control signal that will reset any
output faults when it is activated. It can be used by the
automation control system to simplify PLC programming.
This port is used for field updates to the generator
firmware, without removing the enclosure cover. This
port can also be used with a software application running
on a Windows PC to modify the factory default system
settings and hardware configurations. Contact your local
sales representative for software availability information
and access to documentation that will allow you to make
use of the configuration port features.
Pin 12 (U/S Activate/Cycle Start Input)
Pin 12 is used to activate the generator ultrasound output.
When welding in Automation mode, activating this
isolated control input will switch the ultrasound output
ON, and deactivating this signal will switch ultrasound
OFF. When welding by Time or by Energy, this input
functions as a cycle initiate. A momentary signal with a
minimum duration of 50msec is required to initiate the
cycle.
Pin 13 (Isolated Input Common)
[Electrically connected to Pin 5 on MPC I/O connector if
MPC Interface option is installed.]
Pin 13 is electrically isolated from chassis ground. Using
sourcing (PNP) output drivers, this common line would be
connected to the automation system power supply common.
Using sinking (NPN) output drivers, this common line
would be connected to the automation system positive
supply output. See Figure A-1 in Appendix A for E-Stop
circuit wiring examples.
Pin 14 (No Connection)
Pin 15 (No Connection)
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Dukane Manual Part No. 403-607-00
Section 4 – Controls and Connections
SECTION 4
Controls
Controls Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
LCD Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Dukane Manual Part No. 403-607-00
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Dukane Manual Part No. 403-607-00
Section 4 – Controls and Connections
Controls Overview
This section gives an overview of the controls 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 Controls
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.
Control Keys
The control keys shown in Figure 4-1 and described
below, are used to display information, and to program
the generator.
INFO
Press this key to get system information or to modify the
advanced settings.
System Information - Identifies the current
version of system software.
Generator Settings - Weld Mode, Freerun, Ramp
CAUTION
If when resetting the circuit
breaker after it has tripped,
it immediately trips again, an
internal system malfunction, is
likely, 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.
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
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iQ Series, Ultrasonic Power Supply AL - E Users Manual
Continued from Previous Page
Control Keys
System LCD Display
AMP
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.
Set the ultrasound amplitude output level in the range of
20 to 100%. Typically amplitude is set to 100%.
TRIGGER
This key is use to enable trigger by power.
TIME
Use this key to select time as the method of welding. Set
the weld time (seconds).
ENERGY
Use this key to select energy as the method of welding.
Set the weld energy (joules).
HOLD
Hold is a time period beginning after the weld portion
of the cycle is complete. The automation program holds
the probe in place applying pressure to the weld, and an
audible alarm indicates that the Hold time is finished. Hold
can be set to a maximum of 30 seconds.
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.
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.
Page
22
Power Bar Graph
The Power Bar Graph appears at the bottom of the
LCD display. It is a high resolution graph that represent
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 ultrasound [U/S] is active).
40% of
power used
In Cycle
screen
Figure 4-2A 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
40% of power delivered in previous weld
Figure 4-2B 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. 403-607-00
Section 4 – Controls and Connections
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.
Push ON
Push OFF
Figure 4-3 Power Switch
2. When the operate screen is displayed, the welder is
ready to begin welding. the display shows:
The weld method and part data for the last weld.
Note: On power up, the display will read zeros. The
previous weld data is not stored when the power is
off.
See Figure 4-3.
Figure 4-4 Operate Screen after power up.
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.
The generator is ready to start a weld cycle when
the Ultrasound Activate/Cycle Start Input (Pin 12) is
activated.
Stopping a Weld Cycle
Normal Conditions
The cycle stops when the programmed welding cycle ends
if the generator is configured to weld by time or energy.
If it is configured to weld by automation, the cycle ends
when the Ultrasound Activate/Cycle Start Input (Pin 12)
is deactivated.
Emergency Conditions
Manual System
Push the Power Switch to OFF (See Figure 4-2.) to stop the
ultrasound signal. This may be done under any conditions.
Automated System
Customer-supplied external controls provide the means to
stop the cycle for an automated system.
Stopping the cycle is done by removing the ENABLE
connection between pins 1 and 2. When this connection
is removed, the screen turns red and the cycle is aborted.
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iQ Series, Ultrasonic Power Supply AL - E Users 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 Automation, Time,
or Energy
Data from
last weld
cycle.
Setup
number.
Figure 4-5 Example of an Operate Screen
An In Cycle screen activates when the ultrasound signal
has been activated.
Status Indication
Stack Frequency
Power Draw
Power Bar Graph %
Figure 4-6 Example of an In Cycle Screen
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24
Dukane Manual Part No. 403-607-00
Section 5 - Process Control Settings
SECTION 5
Process Control Settings
Select the Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Navigating the Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Amplitude Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Trigger By Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
System Information, Advanced Settings . . . . . . . . . . . . . . . . . 32
Setup Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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Dukane Manual Part No. 403-607-00
Section 5 - Process Control Settings
Process Controller
Settings
This section of the manual helps the reader become
familiar with the operating modes, and illustrates some
typical programming steps.
There are three welding modes available. These
correspond to the three ways in which the welder can be
used: Automation, Time, and Energy.
Select the Welding Mode
Automation
- In AUTOMATION mode the
PLC controls the weld cycle. The cycle starts, and the
ultrasonic signal (U/S) activates when Ultrasound
Activate/Cycle Start Input (Pin 12) is activated. When
the Ultrasound Activate/Cycle Start Input (Pin 12) is
deactivated, the ultrasonic signal stops and the cycle is
complete unless there is a hold time programmed.
Time - In TIME mode the operator sets a maximum
time (seconds) that the ultrasonic signal will be active for
each weld cycle. The cycle starts when the Ultrasound
Activate/Cycle Start Input (Pin 12) is activated. The U/S
stops when the programmed time is reached.
Energy
- In ENERGY mode the operator sets a
maximum energy (Joules) the generator will reach
during the weld cycle. [A maximum weld time must be
set when welding by energy. If the energy level is not
reached, the preset for time will determine when the
U/S is deactivated.] When the preset energy level is
reached, the U/S will be deactivated. The cycle starts
when the Ultrasound Activate/Cycle Start Input (Pin 12)
is activated. When the programmed energy is reached,
ultrasound stops.
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iQ Series, Ultrasonic Power Supply AL - E Users Manual
Navigating the Modes
When the generator is first powered up, the default
operating mode is Automation, and Automation Weld
is shown at the top of the display as shown in Figure 5-1.
Navigate to Time Mode
1.
Follow the sequence shown in the figures to the right
to navigate from Automation mode to Time mode.
In Automation mode, press the TIME key
(Figure 5-2).
Figure 5-1 Automation Weld Mode
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 5-2).
3.
Press the ENTER key to accept the time that has
been set (Figure 5-3).
Press the CANCEL key if you decide not to set the
time.
NOTE
Navigating to Automation Mode
Set Time or Energy (depending on mode) to
OFF, and press ENTER. This will put you back
in Automation mode.
Figure 5-2 Time Weld Mode - 1
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 Automation and
press enter
ENTER key
Figure 5-3 Time Weld Mode - 2
Figure 5-4 Select Weld Mode pop-up
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Dukane Manual Part No. 403-607-00
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
2.
ENERGY
key
In Time mode (Figure 5-5), press the ENERGY key,
and the screen as shown in Figure 5-6 appears.
Figure 5-6 Energy Weld Mode - 1
3.
4.
5.
Use the
and the + - keys to move the
cursor and to set the digits for the energy you want.
See Figure 5-7.
Press the ENTER key to accept the energy that has
been set. Press the CANCEL key if you decide not to
set the energy.
If you set the energy level, a maximum weld time
needs to be set also. Set a time that is reasonable for
your application. [The factory default for this time is
30 seconds (also the maximum).]
Set energy
level.
Figure 5-7 Energy Weld Mode - 2
ENTER key
The time can not be set below 0.001 second.
Use the
and the + - keys to move the cursor
and to set the digits for the time you want.
Figure 5-8 Energy Weld Mode - 3
See Figure 5-8.
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iQ Series, Ultrasonic Power Supply AL - E Users Manual
Hold
HOLD is used more often with Time or Energy modes, but
it can be used with the Automation mode.
HOLD does not allow the automation program to begin a
new cycle until HOLD is finished.
Figure 5-9a HOLD Time - 1
To set a HOLD period:
1.
Select the weld mode (Automation, Time, Energy).
2.
Set the time and energy parameters as needed.
3.
Press the HOLD key. The screen will appear as it
does in Figure 5-9.
4.
Set the time with the
+ -
keys.
(A maximum of 30 seconds.)
Figure 5-9A shows a setting for 1 seconds.
5.
Press the ENTER key to confirm your selection.
Figure 5-9b HOLD Time - 2
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.
To adjust amplitude:
1.
Press the AMP key. The screen will appear as in
Figure 5-10.
2.
Set the amplitude level using the
+ - keys.
3.
Press ENTER to confirm your amplitude setting.
Page
30
Figure 5-10 Amplitude
keys and the
Dukane Manual Part No. 403-607-00
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
NOTE
Trigger by Power is only available
when the weld mode is either Time or
Energy.
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).
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
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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.
3. Generator Settings
Figure 5-14a System Information Example Screen
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.
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.
Figure 5-15 Weld Mode
NOTE
Changes in Hardware Settings take
place after ENTER is pressed.
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 5-16a Generator Settings Screen - 1
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Dukane Manual Part No. 403-607-00
Section 5 - Process Control Settings
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.
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
Figure 5-16b Generator Settings Screen - 2
Figure 5-17 Language Selection
Figure 5-18 & 5-19 Numerical Input
Figure 5-20 & 5-21 Selection Input
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iQ Series, Ultrasonic Power Supply AL - E Users Manual
Setup Maintenance
Introduction
The screens available in Setup Maintenance allow the
operator to Load, Store, or Delete generator weld setups.
The current program is stored automatically into the
selected setup. Any time a setting is changed, the current
setup is overwritten automatically. 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 for the
current setup. Use the up and down arrow to select a setup.
•
Load - (Load means to put data into the generator’s
memory from a stored setup.)
Figure 5-22a Setup
Maintenance - 1
With the desired setup selected (Figure 5-17) press
ENTER. A pop-up screen asks to confirm loading the
selected setup (See Figure 5-17A).
Figure 5-22b Pop-up Load Setup
Select YES, and the display will change to an Operate
Screen. 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.
Select NO, and the display will go back to the
previous operate screen with the previous setup still
loaded.
•
Delete -To delete the setup, select Delete as shown
in Figure 5-18, and press the ENTER key. A pop-up
screen appears to ask you to confirm your choice (See
Figure 5-18A). Select YES or NO, and press ENTER
again.
Figure 5-23a Setup
Maintenance - 2
Figure 5-23b Pop-up Delete Setup
Continued
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34
Dukane Manual Part No. 403-607-00
Section 5 - Process Control Settings
Continued from Previous Page
Setup Maintenance
Changing the Current Setup
The following example will demonstrate how to change
setups:
1. Follow the instructions on page 28 to set the mode
to Weld By Time. Set the weld time to 1.520 seconds
(See Figure 5-24).
Figure 5-24 Weld Time
2. The generator will automatically store this programed
value in the current setup location. Press the SETUP to
confirm (See Figure 5-25).
3. To change setups, push the up arrow to a new setup.
With LOAD selected, push enter. Push ENERGY
and program for 200J, with a max weld time of 1
second. The generator will weld by energy to 200J
(See Figure 5-26).
Figure 5-25 Setup 1 with Weld Time set
4. Press SETUP. The display will show the values for
weld energy and time that you have just programed.
This confirms the generator has stored the new values
you have entered (See Figure 5-27).
Selecting a Setup
1. Push the down arrow and with LOAD highlighted,
select the setup number you first entered. The display
will show the weld time of 1.520 seconds. The display
will show values as displayed in Figure 5-25.
Figure 5-26 Weld By Energy
2. Press ENTER and the screen will return to the operate
screen. The generator will weld for 1.520 seconds.
Deleting the Current Setup
1. Press SETUP.
2. With the + - arrows, select the second setup you
previously programed to weld by energy (See Figure
5-27). Highlight DELETE by pushing the right arrow.
3. Push ENTER. A pop up screen will ask you to confirm
deletion of the selected setup. Press YES, and the
setup will be deleted. You can confirm the setup has
been deleted as the display will show Automation
Weld. The Time and Energy values will display OFF
(See Figure 5-28).
Dukane Manual Part No. 403-607-00
Figure 5-27 Setup 2 with Weld By Energy set
Figure 5-28 Setup 2 after being deleted
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Dukane Manual Part No. 403-607-00
Section 6 – Probes and Probe Stacks
SECTION 6
Probes and Probe Stacks
Ultrasonic Probe Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Theory of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Probe Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultrasonic Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Booster. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
39
39
40
40
41
Stack Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Attaching Replaceable Tips. . . . . . . . . . . . . . . . . . . . . . . . . . .
Attaching Mounting Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attaching Horn to Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attaching Booster to Probe . . . . . . . . . . . . . . . . . . . . . . . . . . .
Attaching Horn to Probe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
42
43
44
44
44
Stack Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Booster Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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Dukane Manual Part No. 403-607-00
Section 6 – Probes and Probe Stacks
Ultrasonic Probe
Overview
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
motion 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 a probe if the
cable insulating jacket is
cut or damaged in any way.
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!
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
vibration.
2. A horn to transfer the mechanical vibration 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 vibration of the horn. A
basic probe system is shown in Figure 6-1.
Normally a booster is not used with a probe as this
increases the length and weight and reduces its versatility.
The optional threaded titanium tip can be used when the
application calls for a staking profile or a pointed spot
weld. Replaceable tips are not commonly used in high–
volume production environments.
NOTE
For automated systems we recommend that
you use a booster with the probe as shown in
Figure 6-2. Read Dukane’s Application Note
#504 - Ultrasonic Acoustic Stack Mounting Guidelines - found on our website at:
http://www.dukane.com/us/DL_ApplData.
asp
Dukane Manual Part No. 403-607-00
Probe
Standard
Horn
Custom
Horn
Tip
Figure 6–1 Probe, Horn and Tip
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iQ Series, Ultrasonic Power Supply AL - E Users Manual
Ultrasonic Horn
The horn transfers the ultrasonic mechanical vibrations
(originating at the transducer in the probe housing) to the
plastic parts through direct physical contact. The horn
is precision machined and designed to vibrate at either
20kHz, 30kHz, 40kHz, 50kHz or 70kHz. The tuning is
accomplished using electronic frequency measurement.
Inherent variations in material composition prevent tuning
by dimensional machining alone.
There are many different horn profile styles depending
upon the process requirements. Factors which affect
the horn design are the materials to be welded and the
method of assembly. Horns are usually constructed from
aluminum, hardened steel or titanium. As the frequency
increases, vibration amplitude typically decreases, but
internal stress in the horn increases. Higher frequencies
are used for delicate parts that cannot handle a lot of
amplitude. Some factors to keep in mind for high–
frequency (e.g. 40kHz) ultrasonic welding versus low–
frequency (e.g. 20kHz) ultrasonic welding are listed here.
Probe
Housing
1. Stress in the horn is higher at high frequencies.
2. Wear on the horn is greater at high frequencies.
3. Clean and flat mating surfaces between the horn, booster
and transducer are more critical at high frequencies.
Booster
The function of a booster is to alter the gain (i.e. output
amplitude) of the probe. A booster is amplifying if its gain
is greater than one and reducing if its gain is less than one. A
neutral or coupling booster is used to provide an additional
clamping location for added probe stack stability. A probe
designed to be mounted in a fixture along with a booster and
horn is shown in Figure 6–2. This is commonly referred to
as a stack. As indicated, the components are secured with
threaded studs.
Booster
Horn
Figure 6–2 Probe, Booster and Horn
Page
40
Dukane Manual Part No. 403-607-00
Section 6 – Probes and Probe Stacks
Operating Notes
Cooling
The Dukane Probe is designed with a cooling port.
Depending on the type of weld process, air cooling may be
necessary. Low power and/or low duty cycle applications
typically do not require cooling. However in a production
environment, a determination will need to be made if
external cooling is required. To make this determination,
the surface temperature of the probe and horn will need to
be monitored.
NOTE
Compressed air supply: Make sure the air
is clean, oil-free, and dry.
No part of the probe or horn surface should exceed 110
degrees F. If at any time, any part of the probe or horn
exceeds 110 degrees, one should stop welding and allow
the system to cool. Continuing to operate the system with
component temperatures exceeding 110 degrees has the
potential to damage the system. As a general guide, no part
of the system should be too hot to touch, when monitoring
the surface temperature in between cycles.
If it is determined that cooling is necessary, air should be
supplied to the hand probe cooling port. The air must be
clean and dry as the air is blowing directly on electrical
components inside the probe. It may also be necessary to
provide cooling air to the horn surface as well.
Note: The horn does not need to get hot to melt the plastic.
High frequency motion at the horn tip creates friction at
the point of contact, which results in heat that melts the
plastic.
Dukane Manual Part No. 403-607-00
Page
41
iQ Series, Ultrasonic Power Supply AL - E Users 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 6-3. If necessary, use a spanner wrench
(on horns with spanner wrench holes) or an open end
wrench (on horns with wrench flats) to keep the horn
from turning in your hand. A canvas strap wrench is
permissible if it does not gouge or scratch the horn.
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 6–3 Replaceable Tip Installation
NOTE
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
Dukane Part No. for the 20kHz spanner
wrenches is 721–68.
Dukane Part No. for the 40kHz spanner
wrenches is 721–44.
Table 6-I Tip Torque Unit Conversions
Page
42
Dukane Manual Part No. 403-607-00
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
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
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 6-5.
NEVER thread a stud into the transducer or the output
end of the booster first. See Booster Notes in this section
for correctly identifying the output end of a booster.
NOTE
To convert inch-lbs to ft-lbs, divide by 12.
To convert inch-lbs to Nm, divide by 8.852.
To convert ft-lbs to Nm, multiply by 1.356.
To convert Nm to ft-lbs, multiply by 0.7376.
Torque specifications have a tolerance of
about ± 10%.
See Figure 10–4 for a handy conversion
graph.
Dukane Manual Part No. 403-607-00
Page
43
iQ Series, Ultrasonic Power Supply AL - E Users 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 systems that are not changed frequently.
Failure to follow these instructions, may result in the
mating surfaces bonding and difficulty removing the
horn from the booster or the booster from the probe.
Tighten
Figure 6–4 Stack Assembly Procedure
Continued
Page
44
Dukane Manual Part No. 403-607-00
Section 6 – Probes and Probe Stacks
Continued from Previous Page
6. Thread the components together and tighten to the
following torque specifications using only the correct
size wrenches. Use spanner wrenches on components
with spanner wrench holes or an open end wrench on
components with wrench flats. See Figure 6–4 for the
correct procedure. Refer to Table 6-III for torque unit
conversions. Be careful not to overtighten.
NOTE
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 40 kHz stack
Table 6-III
61
kHz
15 kHz stack
Horn/Booster Torque Unit Conversions
Dukane Manual Part No. 403-607-00
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.
Page
45
iQ Series, Ultrasonic Power Supply AL - E Users 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 probe
are shown in Figure 6–5. It makes no difference whether
the horn is attached to the booster first, or the booster is
attached to the probe first.
ASSEMBLY
PROBE
HOUSING
Output End
PROBE
HOUSING
Spanner
Wrench
Holes
Mounting Stud
(Insert Into Horn
First and Tighten
to Torque Specs)
PROBE
ASSEMBLY
Input End
HORN
HORN
DISASSEMBLY
Figure 6–5 Probe Assembly and Disassembly
Page
46
Dukane Manual Part No. 403-607-00
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 6–6.
Loosen
NOTE
Figure 6–6 Separating the Horn from the Booster
On boosters and horns with wrench flats, use only the
correct size wrench to provide sufficient torque to loosen a
joint when necessary.
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 6–7 for the
correct tip removal procedure.
Dukane Manual Part No. 403-607-00
Figure 6–7 Removing a Replaceable Tip from the
Horn
Page
47
iQ Series, Ultrasonic Power Supply AL - E Users 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
48
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. 403-607-00
Section 7 – Troubleshooting
SECTION 7
Troubleshooting
No Ultrasonic Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
System Power Output Level . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Welding Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Pop-up Fault Status Screens . . . . . . . . . . . . . . . . . . . . . . . . . 53
Process Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Overload Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
General Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Dukane Manual Part No. 403-607-00
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50
Dukane Manual Part No. 403-607-00
Section 7 – Troubleshooting
No Ultrasonic Output
Probe
Make sure that the probe cable is connected to the generator
connector (PROBE) and secured to the rear panel. Also,
make sure the probe stack is properly assembled.
System Power Output Level
Overload
When an overload occurs, it will automatically reset
when the next ultrasound activation signal begins. If the
condition persists:
NOTE
The LCD screen displays a variety of pop-up
status changes as they occur. Check Table
7-I - Pop-up Fault Status Screens - Page 53.
Turn the generator OFF and:
1. Check the system. Change the probe to one that is
known to be good.
2. Turn the generator ON, and see if the fault condition
has been corrected.
Overtemperature
When the generator overheats, and it’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. 403-607-00
Page
51
iQ Series, Ultrasonic Power Supply AL - E Users Manual
Welding Problems
Weak Welds
Weak welds, or underwelding, is caused by insufficient
energy being transmitted to the part. You can increase
the weld pressure, increase the weld duration (Time or
Energy) or change to a higher gain booster to increase the
amplitude to increase the energy delivered to the weld.
Inconsistent Welds
Variations in plastic due to filler materials and moisture
absorption may lead to inconsistent welds. Fillers can
be especially troublesome if they are not uniformly
distributed, the content is too high or it contains too much
or poor quality regrind or degraded plastic.
Try welding by energy. This eliminates many
inconsistencies. There should be no unusual or loud noise
from the acoustic stack. If there is, disassemble the stack
and reassemble.
Exchange the probe with another unit to see if the problem
disappears. If not, exchange the generator with another unit
to try and isolate the problem.
The horn amplitude may not be uniform if it has been
machined, altered or damaged. All of these will change
the resonant frequency of the horn. You can have the horn
analyzed.
Page
52
Dukane Manual Part No. 403-607-00
Section 7 – Troubleshooting
Pop-up Fault Status Screens
Process Alarms
Pop-Up Alarm Displayed
Alarm Description
When Trigger by Power is enabled and the
programmed power threshold is not reached,
this alarm is displayed. Decrease the power
threshold or increase the load during the
trigger phase of the cycle.
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 Process Alarms
Dukane Manual Part No. 403-607-00
Page
53
iQ Series, Ultrasonic Power Supply AL - E Users 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
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. Most often
caused by a severe frequency mismatch.
Alarm will reset when next cycle starts.
Ultrasound voltage exceeded input voltage.
Most often caused by a severe frequency
mismatch between the 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 Overload Alarms
Page
54
Dukane Manual Part No. 403-607-00
Section 7 – Troubleshooting
General Alarms
Pop-Up Alarm Displayed
Alarm Description
System over temperature fault detected in the
output stage of the generator. Fault will reset
when system cools down.
Generator model number does not match
internal generator configuration. 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.
If the cycle initiate signal was active 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- III Pop-Up General Alarms
Dukane Manual Part No. 403-607-00
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Dukane Manual Part No. 403-607-00
Section 8 – Specifications
SECTION 8
Specifications
Generator Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . 62
Dukane Manual Part No. 403-607-00
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58
Dukane Manual Part No. 403-607-00
Section 8 – Specifications
ALLOW 5" (150mm)
BEHIND GENERATOR
FOR CABLE CONNECTIONS
10.0 [254]
100/130 VAC
CORD SHOWN.
200/240 VAC
HAS IEC CONNECTOR
AND SEPARATE CABLE
5.3 [134]
5.4 [137]
1.6 [41]
FAN
ALLOW 2" (50mm)
FREE SPACE FOR
COOLING AIR.
HANDPROBE AND
AUTOMATION CONNECTIONS
ON BACK OF GENERATOR.
REFER TO MANUAL FOR
CONNECTION DIAGRAM.
FOLDING
HANDLE
59
Page
Dukane Manual Part No. 403-607-00
2.8 [72]
12.4 [315]
3.9 [99]
2.1 [53]
Figure 8-1 Generator Outline Drawing
IN
[mm]
iQ Series, Ultrasonic Power Supply AL - E Users Manual
Weights
lb
kg
Generator Only
12
5.44
Generator + Packing
Materials
17
7.71
Table 8–I
iQ Generator Weights
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
Page
60
Dukane Manual Part No. 403-607-00
Section 8 – Specifications
AC Power Requirements
Overload
Power
Rating
(Watts)
Operating
Frequency
Generator
Model Number
20kHz
20AL060-1H
100-120 VAC, 50/60 Hz @ 9.0 Amps
20kHz
20AL060-2H
200-240 VAC, 50/60 Hz @ 4.5 Amps
30kHz
30AL060-1H
100-120 VAC, 50/60 Hz @ 9.0 Amps
30kHz
30AL060-2H
200-240 VAC, 50/60 Hz @ 4.5 Amps
Input AC Power Requirements
Nominal AC Volt
600
North America/
Japan
AC Outlet Rating
15.0 Amps
35kHz
35AL060-1H
100-120 VAC, 50/60 Hz @ 9.0 Amps
35kHz
35AL060-2H
200-240 VAC, 50/60 Hz @ 4.5 Amps
40kHz
40AL060-1H
100-120 VAC, 50/60 Hz @ 9.0 Amps
40kHz
40AL060-2H
200-240 VAC, 50/60 Hz @ 4.5 Amps
Table 8- II AC Power Requirements
Ultrasonic Pressure
Ultrasonic Pressure
iQ Generator Models - kHz
15
20
Useful Beam
30
40
50
360 degrees
Ultrasonic Pressure @ Operator's Position - dB
125
140
130
130
130
Ultrasonic Pressure 1 m from the Equipment- dB
110
130
110
105
110
Table 8-III iQ Generator Ultrasonic Pressure
NOTE
All measurements taken with Data Physics
Dynamic 4-Channel Signal Analyzer with
calibrated 377C01 Microphone and 426B02
Preamplifier.
Dukane Manual Part No. 403-607-00
Page
61
iQ Series, Ultrasonic Power Supply AL - E Users Manual
Regulatory Agency Compliance
FCC
The iQ AL-E Power Supply 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.
UL & CSA
The iQ AL-E Power Supply complies with these standards:
Underwriters Laboratories (UL):
UL61010-1
National Standards of Canada (CSA):
CAN/CSA C22.2 No. 61010-1
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
iQ AL-E Power Supply complies with the following CE
requirements.
•
The EMC Directive
Industrial —
EN 61000-6-4
EN 55011
2014/30/EU
•
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
for
Heavy
EN 60204: Safety of Machinery - Electrical
Equipment of Machines Part 1: General
Requirements.
•
as verified by TÜV Rheinland.
CAUTION
DO NOT make any modifications
to the iQ AL-E Power Supply or
associated cables. The changes
may result in violating one or
more regulations under which
this equipment is manufactured.
EN ISO 12100: Safety of Machinery - General
principles of design, risk assessment, and risk
reduction.
IP Rating
The iQ AL-E Power Supply has an IP (International
Protection) rating from the IEC (International
Electrotechnical Commission).
The rating is IP2X, in compliance with finger-safe industry
standards.
Page
62
Dukane Manual Part No. 403-607-00
Section 9 – Contacting Dukane
SECTION 9
Contacting Dukane
Dukane Manual Part No. 403-607-00
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Dukane Manual Part No. 403-607-00
Section 9 – Contacting Dukane
Contacting Dukane
Equipment Identification and
Problem Details
When contacting Dukane about a service related problem,
be prepared to give the following information:
• iQ AL-E Power Supply model number and serial
number.
• Any fault/error indicators from the LCD display.
• Software version. Press INFO, and with the 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
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:
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Dukane Manual Part No. 403-607-00
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Appendices
APPENDICES
Appendix A - E-Stop Circuitry Examples . . . . . . . . . . . . . . . . . 69
Appendix B - List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Appendix C - List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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Appendices
Appendix A
E-Stop Circuitry Examples
Dedicated E-Stop Switch Wiring Diagram
System I/O Connector
iQ Auto
(Pin 1)
Enable Out
User supplied
E-stop switch
(Pin 2)
Enable In
Automation System Safety Circuit Wiring Diagram
iQ Auto
System I/O Connector
(Pin 1)
Enable Out
(Pin 2)
Enable In
Relay contact block
Master
control
relay
User automation
control hardware
Figure A-1 E-Stop Circuitry
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Appendix B
No.
Description
List of Figures
Page
2-1
Example of 120 Volt, Grounded, 3-prong Plug and Receptacle.......................................8
2-2
Example of 240 Volt, Grounded, 3-prong Plug and Receptacle.......................................8
2-3
International 220/240V Grounding...................................................................................8
3-1
Lockout Device in Open Position, Unlocked..................................................................11
3-2
Bottom Lockout Device in Closed Position, Locked....................................................... 11
3-3a
Generator Detail 100/120 Volt - Rear Views..................................................................14
3-3b
Generator Detail 200/240 Volt - Rear Views..................................................................14
3-4
Rocker-style Power Switch/Circuit Breaker....................................................................14
4-1
Controls..........................................................................................................................21
4-2a
Power Bar Graph - In Cycle...........................................................................................24
4-2b
Power Bar Graph - Operate...........................................................................................24
4-3
Power Switch..................................................................................................................25
4-4
Operate screen after power up.......................................................................................25
4-5
Example of an Operate Screen......................................................................................26
4-6
Example of an In Cycle Screen......................................................................................26
5-1
Automation Weld Mode..................................................................................................28
5-2
Time Weld Mode - 1.......................................................................................................28
5-3
Time Weld Mode - 2.......................................................................................................28
5-4
Load Default Operating Mode........................................................................................28
5-5
Time Weld Mode............................................................................................................29
5-6
Energy Weld Mode - 1....................................................................................................29
5-7
Energy Weld Mode - 2....................................................................................................29
5-8
Energy Weld Mode - 3....................................................................................................29
5-9a
HOLD Time - 1...............................................................................................................30
5-9b
HOLD Time - 2...............................................................................................................30
5-10
Amplitude.......................................................................................................................32
5-11
Trigger By Power............................................................................................................31
5-11a
Start Amplitude...............................................................................................................31
5-12
Trigger Power.................................................................................................................31
5-13
Trigger Timeout..............................................................................................................31
5-14a
INFO Screen..................................................................................................................32
5-14b
System Info....................................................................................................................32
5-15
Weld Mode.....................................................................................................................32
5-16a
Generator Settings - 1....................................................................................................32
5-16b
Generator Settings - 2....................................................................................................33
Continued
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Appendices
Appendix B
No.
Description
Continued from Previous Page
List of Figures
Page
5-17
Language Selection........................................................................................................33
5-18
Numerical Input..............................................................................................................33
5-19
Numerical Input..............................................................................................................33
5-20
Selection Input................................................................................................................33
5-21
Selection Input................................................................................................................33
5-22a
Setup Maintenance - 1...................................................................................................34
5-22b
Pop-up Load Setup........................................................................................................34
5-23a
Setup Maintenance - 2...................................................................................................34
5-23b
Pop-up Delete Setup......................................................................................................34
5-24
Weld Time......................................................................................................................35
5-25
Setup 1 with Weld Time set............................................................................................35
5-26
Weld By Energy..............................................................................................................35
5-27
Setup 2 with Weld By Energy set...................................................................................35
5-28
Setup 2 after being deleted............................................................................................35
6-1
Probe, Horn and Tip.......................................................................................................39
6-2
Probe, Booster and Horn................................................................................................40
6-3
Replaceable Tip Installation...........................................................................................42
6-4
Stack Assembly Procedure............................................................................................44
6-5
Probe Assembly and Disassembly.................................................................................46
6-6
Separating the Horn from the Booster............................................................................47
6-7
Removing a Replaceable Tip From the Horn.................................................................47
8-1
Generator Outline Drawing.............................................................................................59
Appendix C
List of Tables
No.
Description
3-I
Standard IEC AC Power Cord Part Numbers..................................................................15
3-II
Generator Input/Output Signals.......................................................................................16
6-I
Tip Torque Unit Conversions............................................................................................42
6-II
Stud Torque Unit Conversions.........................................................................................43
6-III
Horn/Booster Torque Unit Conversions............................................................................45
7-I
Pop-up Fault Process Alarms..........................................................................................53
7-II
Pop-up Overload Alarms..................................................................................................54
7-III
Pop-up General Alarms....................................................................................................55
8-I
iQ Generator Weights......................................................................................................60
8-II
AC Power Requirements.................................................................................................61
8-III
iQ Ultrasonic Pressure.....................................................................................................61
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Please Refer To Our Website At:
www.dukane.com/us/SA_IntSales.htm
To Locate Your Local Representative
iQ Series, Ultrasonic Power Supply AL - E Users Manual
Part No. 403 – 607-00
www.dukane.com/us
Printed in the United States of America
Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949
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