Dukane iQ Series User manual

Intelligent Assembly Solutions
iQ Series
Ultrasonic Hand Held Systems
User’s Manual
System Model
Generator Part #
Probe Part#
HP 4.61-P
40HP060-1E
41PG40S
HP 4.61-H
40HP060-1E
41HP40S
HP 4.62-P
40HP060-2E
41PG40S
HP 4.62-H
40HP060-2E
41HP40S
HP 4.6E-P
40HP060-2E
41PG40S
HP 4.6E-H
40HP060-2E
41HP40S
Dukane Part No. 403–577-00
ISO 9001:2000
Products are manufactured in ISO
registered facilities.
www.dukcorp.com/us
User’s Manual
Copyright © 2008
Notice of Rights:
All rights reserved. No part of this manual including the interior design, cover
design and icons may be reproduced, transmitted or utilized in any form or
by any means, electronic, mechanical, photocopying, recording, or by any
information storage and retrieval system, without written permission from the
manufacturer.
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, the manufacturer shall not have any liability to any person or entity with
respect to any liability, loss, or damage caused or alleged to be caused directly
or indirectly by the instructions contained in this manual, or by the hardware
products described herein.
Printed in the United States of America.
Part Number: 403–577–00
This ultrasonic equipment is manufactured under one or more of
the following U.S. Patents:
3,780,926 3,825,481 4,131,505 4,277,710 5,798,599 5,880,580 and 7,225,965
Page ii
Dukane Manual Part No. 403-577-00
Revision History
Revision
Number
Revision
Summary
Date
Original release.
08/01/2008
- 00
Dukane Manual Part No. 403-577-00
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User’s Manual
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Page iv
Dukane Manual Part No. 403-577-00
Contents
Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 2- Health and Safety . . . . . . . . . . . . . . . . . . . 5
Section 3- Installation . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . 11
Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . 12
Connecting Cables . . . . . . . . . . . . . . . . . . . 13
Section 4 - Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front Panel Overview . . . . . . . . . . . . . . . . . 17
Start-up Sequence . . . . . . . . . . . . . . . . . . . 19
Display Overview . . . . . . . . . . . . . . . . . . . . 19
Section 5 - Process Controller Settings . . . . . . . . . 23
Selecting the Weld Mode . . . . . . . . . . . . . . 23
HOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Amplitude Adjustment . . . . . . . . . . . . . . . . . 26
INFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Section 6 - Probes and Probe Stacks . . . . . . . . . . . 31
Section 7 - Troubleshooting . . . . . . . . . . . . . . . . . . . 43
Section 8 - Specifications . . . . . . . . . . . . . . . . . . . . . 49
Section 9 - Outputs Interface . . . . . . . . . . . . . . . . . . 57
Section 10 - Contacting Dukane . . . . . . . . . . . . . . . . 61
Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Dukane Manual Part No. 403-577-00
List of Figures . . . . . . . . . . . . . . . . . . . . . . . 67
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . 68
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Page vi
Dukane Manual Part No. 403-577-00
Section 1 – Introduction
SECTION 1
Introduction
General User Information . . . . . . . . . . . . . . . . . . . 3
Read The Manual First. . . . . . . . . . . . . . . . . . . . . . 3
Notes, Cautions and Warnings. . . . . . . . . . . . . . . . . . 3
Drawings and Tables. . . . . . . . . . . . . . . . . . . . . . . 3
System Overview. . . . . . . . . . . . . . . . . . . . . . . 4
Key Features . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dukane Manual Part No. 403-577-00
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Page Dukane Manual Part No. 403-577-00
Section 1 – Introduction
General User Information
Read This Manual First
Before operating your ultrasonic generator, read this
User’s Manual to become familiar with the equipment.
This will ensure correct and safe operation. The manual
is organized to allow you to learn how to safely operate
this generator. The examples given are chosen for their
simplicity to illustrate basic operation concepts.
Notes, Cautions and Warnings
NOTE
Note statements provide additional
information or highlight procedures.
Throughout this manual we use NOTES to provide information that is important for the successful application and understanding of the product. A NOTE block is
shown to the right.
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. One of three different symbols
also accompany the CAUTION and WARNING blocks
to indicate whether the notice pertains to a condition or
practice, an electrical safety issue or a operator protection
issue.
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.

Condition
or Practice
Dukane Manual Part No. 403-577-00
Electrical
Hazard
Hearing
Protection
Page User’s Manual
System Overview
Two basic components make up your iQ Series Ultrasonic Hand Held System - an ultrasonic generator, and
a hand probe.
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 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
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.
•
CE Certification means that the system meets
the required European standards to be sold and
used in Europe.
•
ISO 9001 Certification means that this system
has been manufactured to high quality standards
and assures you of manufacturing excellence.
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.
The generator’s compact size and its integrated hand grip
make it easy to carry.
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 that when a probe
is not needed it can be hung on a counterbalanced hook.
Fittings for air-cooling are also standard on all probes.
Key Features
•
Compact Generator means there will be more space
for other necessities on the table 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 power 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 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
Page Dukane Manual Part No. 403-577-00
Section 2 – Health & Safety
SECTION 2
Health and Safety
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Plastics Health Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dukane Manual Part No. 403-577-00
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Page Dukane Manual Part No. 403-577-00
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. 403-577-00
Page User’s Manual
Electrical Safety
Domestic Power Grounding
For safety, the power cords used on this product have a
three-wire, grounding-type power cord. Figures 2-1 and 22 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 125 Volt, Grounded, 3-Prong Plug and Receptacle
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.
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 250 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.
Page 
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. 403-577-00
Section 3 – Installation
SECTION 3
Installation
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connnecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
System Outputs Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Dukane Manual Part No. 403-577-00
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Page 10
Dukane Manual Part No. 403-577-00
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.
Chassis Grounding
Stud
Recommended protective
earth ground connection
wire color: green or green
with yellow stripe.
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.
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.

Dukane Manual Part No. 403-577-00
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.
CAUTION
If you have any questions
about the grounding of your
equipment and/or the electrical box, contact a qualified
electrician.
Page 11
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 (200/240
V 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.
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.
Push ON
Push OFF
Figure 3-2 Rocker-style Power Switch/Circuit Breaker
Step 4. Attach the male end of the power cord to a suitable line receptacle.
Optional Connections - See the next page for information
about the rear panel OUTPUTS connector.
Power Cord Strain Relief
B
HAND PROBE
HAND PROBE
OUTPUTS
A
C
OUTPUTS
C
Optional
Connections
REAR VIEW
REAR VIEW
100/12O VOLT MODEL
200/24O VOLT MODEL
Figure 3-1 Generator Detail - Rear Views
Page 12
Dukane Manual Part No. 403-577-00
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
240 V, 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. 403-577-00
Page 13
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 (30 VDC maximum) and can
activate an attached load up to a maximum of 0.33 Amps
(8 Watts maximum @ 24 VDC).
Table 3-II lists the signal names.
Pin
0V
Signal Name
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 59 .
Page 14
Dukane Manual Part No. 403-577-00
Section 4 – Controls and Connections
SECTION 4
Controls
Front Panel Overview . . . . . . . . . . . . . . . . . . . . . . . . 17
Start-Up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Dukane Manual Part No. 403-577-00
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Page 16
Dukane Manual Part No. 403-577-00
Section 4 – Controls and Connections
Front Panel Overview
This section gives an overview of the front panel functions:
powering the generator on/off; monitoring the process with
the display; and, programming with the control keys.
Power
Switch
LCD Display
Control Keys
Figure 4-1 Front Panel
Power Switch/Circuit Breaker
The power switch/circuit breaker has a rocker type 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. 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 require 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. 403-577-00
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.
Hardware Settings - Select features that can be
turned on or off including the Audible Alarm or Fault
Latching options.
SETUP
Use the SETUP key to Load, Store, or Delete as many as
eight setups.
Page 17
User’s Manual
Control Keys, continued
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 a range from
20 - 100%.
Typically amplitude is set to 100%.
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).
Power Bar Graph
The Power Bar Graph appears at the bottom of the
LCD display. It contains 20 segments that represent the
generator’s range of power from 0% at the far left of
the bar graph to 100% of power at the far right. Each
segment, then equals 5% of the total.
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).
HOLD
IN CYCLE
Hold is a time period beginning after the weld portion
of the cycle is complete. The operator holds the probe in
place until an audible alarm indicates that the Hold time is
finished. Hold can be set to a maximum of 5.0 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.
Frequency: 40087 Hz
Power:
225 W
In Cycle
screen
#2
40% of power used
In the example below, 10% of the available power was
used in the last weld. The display shows an Operate
screen (while U/S is inactive).
Weld by Time
Weld Time 1.500 S
Weld Energy 24 J
Arrow Keys
Press the right and left arrow keys to move the cursor to
the right or left.
Operate
screen
#1
10% of power used
+ and - Keys
Press these keys to increase or decrease the value of a
selected digit.
CANCEL
Press CANCEL to return to the previous screen or cursor
position. Think of it as a “back” key. Press this key when
you do not want to store the selection in memory.

Page 18
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. 403-577-00
Section 4 – Controls and Connections
Start-up Sequence
Push ON
After all connections have been completed.
Push OFF
1. Push the Power Switch to ON (Figure 4-2).
The generator performs a self-diagnostics sequence.
Figure 4-2 Power Switch
DUKANE
2. The Power-up screen appears briefly - Figure 4-3.
Software
version
3. The next screen to appear is an Operate screen
showing information from the last weld (if there
was one). See Figure 4-3A.
iQ Hand Probe
Setup #1
xxxxxxxxx
xxxxxxx
http://www.dukcorp.com
Current
Setup
Website
Address
Figure 4-3 Power-up Screen
Weld by Time
Weld Time 1.500 S
Weld Energy 24 J
#1
Figure 4-3A Operate Screen Appears After
Power-up
Starting a Weld Cycle
Stopping a Weld Cycle
1.
If the generator is not powered, press its Power
Switch/Circuit Breaker to the ON position.
1.
Release the hand probe’s activation switch (trigger)
to abort a weld cycle and stop ultrasound.
2.
Make a choice for the setup you want to use, if
appropriate.
2.
3.
Apply the probe tip to the components to be
ultrasonically joined, and press the hand probe’s
activation switch (trigger) to activate ultrasound.
In addition, press the generator’s Power Switch/
Circuit Breaker to the OFF position to power down
the generator.
4.
After meeting the weld parameters (and with no
programmed Hold time) - either in Manual, Time
or Energy modes, an end of weld signal activates
when the weld is finished. An internal alarm beeps
once. (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 any additional pressure while
an optional Hold time elapses. The generator signals
when that period is over with an audible alert.
Dukane Manual Part No. 403-577-00
NOTE
The Audible Alarm can be set ON or
OFF. See INFO, Page 27.
Page 19
User’s Manual
LCD Display Overview
There are two basic kinds of screen displays:
Operate screens, and In Cycle screens.
An Operate screen tells the operator
what happened in the last weld cycle.
Data from
last weld
cycle.
Setup
number.
Manual Weld
Weld Mode Manual, Time, or
Energy
Weld Time 0.500 S
Weld Energy 18 J
*
#2
Asterisk indicates setup
is modified but not
stored in memory.
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
IN CYCLE
Frequency: 40087 Hz
Power:
25 W
#2
Power Draw
Power Bar Graph %
Figure 4-5 Example of an In Cycle Screen
Page 20
Dukane Manual Part No. 403-577-00
Section 5 - Menu Structure
SECTION 5
Process Controller Settings
Select the Welding Mode . . . . . . . . . . . . . . . . . . . . . . 23
Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Time Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Energy Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
HOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Amplitude Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 26
INFO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Dukane Manual Part No. 403-577-00
Page 21
User’s Manual
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Page 22
Dukane Manual Part No. 403-577-00
Section 5 - Menu Structure
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: 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.
NOTE
U/S is started anytime
the probe’s activation switch (trigger) is
pressed regardless of
operating mode, or what
is displayed on the LCD
screen.
Energy
- In ENERGY mode the operator sets a
maximum energy (Joules) the generator will reach during
the weld cycle. [TIME is a secondary weld parameter
to be set. 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 activating the U/S. 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. 403-577-00
Page 23
User’s Manual
Manual Mode is the Default
When the generator is first powered up, the default
operating mode is Manual - 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.
In Manual mode, press the TIME key (Figure 5-2).
2.
The phrase, Enter Changes Mode, means when the
ENTER key is pressed, the mode will change. So
press the ENTER key, and the Weld by Time screen
seen in Figure 5-3 appears.
3.
Set the time.
Use the
and the + - keys to move the cursor
and to set the digits for the weld time you want.
4.
Press the ENTER key to accept the time that has been
set (Figure 5-4).
Press the CANCEL key if you decide not to set the
time.
Manual Weld
Weld Time 0.000 S
Weld Energy 0 J
#2
Figure 5-1 Manual Weld Mode
TIME key
Manual Weld
Weld by Time
OFF
Enter Changes Mode
Figure 5-2 Navigate to Time Mode
ENTER key
Weld by Time
Weld Time
OFF S
Set the time.
Weld
Wel
0
Hit Ent
Hit Can
Hit Enter To Accept
Hit Cancel To Abort
Figure 5-3 Time Weld Mode - 1
Weld by Time
Weld Time
0.500 S
ENTER key
Hit Enter To Accept
Hit Cancel To Abort
Figure 5-4 Time Weld Mode - 2
Page 24
Dukane Manual Part No. 403-577-00
Weld
We
Hit E
Hit C
Section 5 - Menu Structure
Navigate to Energy Mode
1.
Weld by Time
Follow the sequence shown in the figures to the right
to navigate from Time mode to Energy mode.
Weld Time 0.500 S
Weld Energy 00 J
#2
Figure 5-5 Time Weld Mode
ENERGY
key
Weld By Time
In Time mode (Figure 5-5), press the ENERGY key,
and the screen as shown in Figure 5-6 appears.
Weld By Energy
OFF
Enter Changes Mode
Figure 5-6 Navigate to Energy Mode - 1
We
ENTER key
2.
The phrase, Enter Changes Mode, means when the
ENTER key is pressed, the mode will change. So
press the ENTER key, and the Weld by Energy screen
seen in Figure 5-6A appears.
W
Weld By Energy
Hit
Hit C
Weld Energy
OFF J
Hit Enter To Accept
Hit Cancel To Abort
Figure 5-6A Navigate to Energy Mode - 2
3.
4.
5.
Use the
and the + - keys to move the cursor
and to set the digits for the energy you want - 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).]
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.
Weld By Energy
Weld Energy
27 J
Hit Enter To Accept
Hit Cancel To Abort
Set energy
level.
Figure 5-7 Energy Weld Mode - 1
Weld By Energy
Maximum Weld Time
1.000 S
ENTER key
Figure 5-8 Energy Weld Mode - 2
W
Hit
Hit
See Figure 5-8.
Dukane Manual Part No. 403-577-00
We
Page 25
User’s Manual
HOLD
HOLD is used more often with Time or Energy modes,
but it can be used with the Manual mode. It is a period of
time that can be set to follow the probe’s trigger switch
release.
During HOLD the operator typically applies pressure to
the part being welded. Next, the operator hears an audible
alarm that serves as a reminder that HOLD has finished,
and the probe can be lifted.
HOLD does not allow the operator to begin a new cycle
until HOLD is 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 5-9.
4.
Set the time with the
(A maximum of 5.0 seconds.)
Figure 5-9A shows a setting for 2.0 seconds.
5.
Press the ENTER key to confirm your selection.
+ -
keys.
NOTE
The Audible Alarm can be set ON or
OFF. See INFO, Page 27.
Hold Time
OFF S
Figure 5-9 HOLDTime - 1
Hold Time
2.0 S
Figure 5-9A HOLDTime - 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.
Amplitude
100 %
Figure 5-10 Amplitude
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.
keys and the
3.
Press ENTER to confirm your amplitude setting.
Page 26
Dukane Manual Part No. 403-577-00
Section 5 - Menu Structure
INFO
When the INFO key is pressed the display looks like
Figure 5-11:
Using the + - keys, move the pointer to indicate:
System Information or Hardware Settings.
Press ENTER to make the selection.
iQ Information
> System Information
Hardware Settings
Figure 5-11 INFO Screen
1. System Information
Manufacturer’s information is shown including the
manufacturer’s name, the name of the system (iQ Hand
Probe) and the software identification.
Figure 5-11A shows an example of this information.
2. Hardware Settings
Figure 5-12 gives a view of the Hardware Settings
screen.
Audible Alarms - With the pointer as shown in Figure
5-12, the operator can turn the audible alarms on or
off. Use the
keys to move from ON to OFF.
The current selection is highlighted.
Latching Faults - Latching faults can be turned on
or off.
If Latching Faults 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
corrected.
Pressing ENTER clears the fault, and the next cycle
can begin.
If Latching Faults is off, and a fault occurs, the audible
alarm (beep, beep) will be heard, but welding can
continue.
Dukane Manual Part No. 403-577-00
Dukane Corporation
iQ Hand Probe
FP v1.25 MB v2.76
FPGA v8
Figure 5-11A System Information Example Screen
Hardware Settings
> Audible Alarm
Latching Faults
ON OFF
ON OFF
Hit Enter To Accept
Hit Cancel To Abort
Figure 5-12 Hardware Settings Screen
NOTE
Changes in Hardware Settings take
place after ENTER is pressed.
NOTE
The Audible Alarm can be set ON or
OFF. See INFO, Page 27.
Page 27
User’s Manual
SETUP
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
Setup Maintenance
1.
Load
When the SETUP key is pressed for the first time, the
display looks like Figure 5-13. This screen indicates
that Setup #1 is EMPTY. No data was available to use
for this setup, so it is empty.
Press ENTER.
2.
Load - A pop-up screen asks if defaults should be
3.
loaded for Setup #1.
Select NO, and the previous setup mode screen
appears.
Select YES, and Manual mode is chosen as the current
mode, and the Operate screen is displayed..
After selecting YES, press SETUP, and the display
will look like Figure 5-14.
Setup # 1
Store - Tap the right arrow key once to highlight
Store. See Figure 5-15.
Delete
Empty
Figure 5-13 Setup Maintenance - 1
Setup Maintenance
Load
Store
Delete
Mode: Manual
T: 0.000 S
A: 100%
E: 0 J
H: 0.0 S
Setup # 1
Figure 5-14 Setup Maintenance - 2
Setup Maintenance
Load
4.
Store
Store
Delete
Mode: Manual
T: 0.000 S
A: 100%
E: 0 J
H: 0.0 S
Setup # 1
Figure 5-15 Setup Maintenance - 3
5. Press ENTER, and a pop-up screen appears.
See Figure 5-16.
6.
Select YES if you want to overwrite (replace)
whatever is in the setup, and select NO if you do not
want to replace anything for that setup.
Press the ENTER key to save your selection.
7.
Delete - If you want to delete the setup, select Delete
as shown in Figure 5-17, and press the ENTER key. A
pop-up screen will appear to ask you to confirm your
choice.
Select YES or NO, and press ENTER again.
Overwrite
Setup #1?
YES NO
Figure 5-16 Overwrite Setup?
Setup Maintenance
Load
Store
Delete
Mode: Manual
T: 0.000 S
A: 100%
E: 0 J
H: 0.0 S
Setup # 1
Figure 5-17 Setup Maintenance - 4
Page 28
Dukane Manual Part No. 403-577-00
Section 5 - Menu Structure
SETUP continued
Saving the Current Setup
Try using your navigation skills on this practical
example:
1. Follow instructions on Page 24 to set the mode to
Weld by Time. Set the time to 1.520 seconds.
See Figure 5-18.
2.
Press SETUP and then press the + key until you
get an EMPTY Setup Maintenance screen.
See Figure 5-19.
3.
Use the right arrow key to select Store, and then press
ENTER. You will be returned to the Operate screen.
Weld by Time
Weld Time
1.520 S
Hit Enter To Accept
Hit Cancel To Abort
Figure 5-18 Save Current Setup
Setup Maintenance
Load
Store
Delete
Setup # 1
EMPTY
Figure 5-19 Store in Setup Maintenance
4.
Confirm that your setup has been stored in memory
by going back to SETUP. Your new setup should
appear, just as it does in Figure 5-20.
Setup Maintenance
Load
Selecting a Setup
Store
Delete
Mode: Manual
T: 1.520 S
A: 100%
E: 0 J
H: 0.0 S
Setup # 6
To select a setup previously stored:
1.
Press SETUP.
2.
With Load highlighted, use the +
the number of the setup you want.
3.
Press ENTER.
4.
The Operate screen will display this selection as a
number in the lower left hand corner.
Figure 5-20 New Setup 3
-
keys to select
Deleting a Setup
To delete a setup previously stored:
1.
Press SETUP.
2.
With Delete highlighted, use the +
the number of the setup you want.
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. 403-577-00
-
keys to select
Page 29
User’s Manual
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Dukane Manual Part No. 403-577-00
Page 30
Section 6 – Probes and Probe Stacks
SECTION 6
Probes and Probe Stacks
Ultrasonic Probe Overview.................. 32
Theory of Operation..................................33
Probe Configuration..................................33
Ultrasonic Horn.........................................34
Booster.....................................................35
Stack Assembly................................... 35
Installing Replaceable Tips.......................35
Mounting Stud to Horn/Booster................36
Horn to Booster.........................................37
Booster to Probe.......................................37
Horn to Probe...........................................37
Torque Unit Conversion Chart............. 38
Stack Disassembly.............................. 39
Dukane Manual Part No. 403-577-00
Page 31
User’s Manual
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Dukane Manual Part No. 403-577-00
Page 32
Section 6 – Probes and Probe Stacks
Ultrasonic Probe
Overview

The two types of probes used with the iQ Hand Held
Systems are shown in Figure 6-1 below.
Operating Notes
Compressed Air Fitting - In continuous duty
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!
NOTE
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.
Compressed air supply: Make sure
the air is clean, oil-free, and dry.
Models 41PG40 & 41PG40S
Hanger
Compressed Air Fitting
Strain Relief
U/S Cable
Typical Horn Less Tip
Trigger
Rear View
Pistol-style Grip
Models 41HP40 & 41HP40S
Trigger Actuator
Compressed Air Fitting
Hanger
Strain Relief
Typical Horn Less Tip
Hand Grip
U/S Cable
Rear View
Figure 6-1 Typical Hand Held Probes
Dukane Manual Part No. 403-577-00
Page 33
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.
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
Dukane Manual Part No. 403-577-00
Page 34
Section 6 – Probes and Probe Stacks
Ultrasonic Horn
The horn transfers the ultrasonic mechanical vibrations
(originating at the transducer in the probe housing) to the
plastic parts through direct physical contact. The horn
is precision machined and designed to vibrate at either
20kHz, 30kHz, 40kHz, 50kHz or 70kHz. The tuning is
accomplished using electronic frequency measurement.
Inherent variations in material composition prevent tuning
by dimensional machining alone.
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
Dukane Manual Part No. 403-577-00
Page 35
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
NOTE
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
Dukane Manual Part No. 403-577-00
Page 36
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—I lists the torque specifications in units
for both English and Metric systems of measurements. Figure 6–5 is a handy conversion graph if
you require intermediate values not listed in the
tables.
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
Size
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 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 6-7.
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. 403-577-00
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%.
Page 37
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
Dukane Manual Part No. 403-577-00
Page 38
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 units conversions. Be careful not
overtighten.
In-lb Ft-lb N-m
61
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.
KHz
540
45
15 kHz stack
420
35
47.5 20 kHz stack
216
18
24.4 30 kHz stack
216
18
24.4 40 kHz stack
Table 6—III Horn/Booster Torque Unit Conversions
20
240
20kHz Stack
15
200
180
1/ x 20 Stud
2
160
40kHz Stack
10
130
120
3/ x 24 Stud
8
100
8mm Stud
70
60
5
in-lbs
ft-lbs
0
N-m
5
10
15
20
25
30
Figure 6-6 Torque Value Conversion Graph
Dukane Manual Part No. 403-577-00
Page 39
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 6–7. 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 6–7 Hand Probe Assembly and Disassembly
Dukane Manual Part No. 403-577-00
Page 40
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
(see Figures 6–8), use only the correct size spanner wrench
that came with your system to provide sufficient torque to
loosen a joint.
Loosen
NOTE
Figure 6–8 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 of 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 and keep
the horn from turning in your hand. Refer to Figure 6–9 for
the correct tip removal procedure.
Dukane Manual Part No. 403-577-00
Figure 6–9 Removing a Replaceable Tip From the
Horn
Page 41
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.

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. 403-577-00
Page 42
Section 7 – Troubleshooting
SECTION 7
Troubleshooting
No Ultrasonic Output.............................45
System Power Output Level................ 45
Overtemperature.......................................45
Generator Fault Does Not Reset..............45
System Power Diagnostic Procedures.....45
Welding Problems.................................46
Pop-up Fault Status Screens.............. 47
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User’s Manual
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Dukane Manual Part No. 403-577-00
Page 44
Section 7 – Troubleshooting
No Ultrasonic Output
Probe
Make sure that the hand probe cable is connected to the
generator connector (HAND PROBE) and secured to
the rear panel. Also, make sure the hand probe stack is
properly assembled.
System Power Output 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
47- 48.
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
The only fault indications available with these probe
systems are the ones shown on the LCD display.
Dukane Manual Part No. 403-577-00
Page 45
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
Without question key 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 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.
Dukane Manual Part No. 403-577-00
Page 46
Section 7 – Troubleshooting
Pop-up Fault Status Screens
Generator Fault Status Screens - Manual Mode
Status Text Displayed
Generator Fault
Average Overload
Generator Fault
Peak Overload
Generator Fault
Frequency Lock Lost
Generator Fault
System Status or Fault Explanation
An Average Overload fault tripped.
Output power exceeded rated wattage.
Lower the welding pressure or amplitude.
Fault will reset when next weld cycle starts.
A Positive Peak Overload fault tripped.
Peak IGBT transistor current exceeded.
Caused by a severe frequency mis-match.
Fault will reset when next weld cycle starts.
Resonant frequency lock not found, or lost.
Check for a defective stack component.
Check for stack coupling to the fixture.
Fault will reset when next weld cycle starts.
System Overtemperature fault detected.
Fault will reset when system cools down.
Over Temperature
Table 7-I Pop-Up Fault Status Screens - Manual Mode
Pop-Up Fault Status Screens continued on next page.
Dukane Manual Part No. 403-577-00
Page 47
User’s Manual
Process Fault Satus Screens - Time and Energy Modes
Status Text Displayed
Latch On Fault ENABLED
Process Fault
Set Weld
Time Not Reached
Process Fault
Set Weld
Time Not Reached
Enter Clears Fault
Process Fault
Set Weld
Energy Not Reached
System Status or Fault Explanation
Latch On Fault DISABLED
Process Fault
Set Weld
Energy Not Reached
Set Weld Time Not Reached, or
Set Weld Energy Not Reached - appears if the
weld ends before the set time or energy is reached
(respectively) due to operator error, or
because the weld was intentionally aborted.
Enter Clears Fault
Process Fault
Peak Overload
Time Not Reached
Process Fault
Average Overload
Time Not Reached
Enter Clears Fault
Process Fault
Process Fault
Frequency Lock Lost
Energy Not Reached
Over Temperature
Energy Not Reached
Enter Clears Fault
Process Fault
Peak Overload, Average Overload, Frequency Lock
Lost, Input Undervoltage, or Over Temperature is
displayed in place of Set Weld Time not Reached,
or Set Weld Energy not Reached, if the weld ends
before the set time or energy is reached due to a
process or generator fault.
Input Undervoltage
Energy Not Reached
Enter Clears Fault
Table 7-2 Pop-Up Fault Status Screens - Time and Energy Modes
Dukane Manual Part No. 403-577-00
Page 48
Section 8 – Specifications
SECTION 8
Specifications
Generator Outline Drawing . . . . . . . . . . . . . . . . . . . . 51
Probe Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . 52
Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . 53
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . 54
Regulatory Agency Compliance . . . . . . . . . . . . . . . . 55
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User’s Manual
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Page 50
Dukane Manual Part No. 403-577-00
Section 8 – Specifications
ALLOW 5" (125 mm) BEHIND UNIT
FOR CABLE CONNECTIONS
12.41
[315.2]
10.00
[254]
3.95
[100.3]
3.51
[89.2]
IN
[mm]
Figure 8-1 Generator Outline Drawing
Dukane Manual Part No. 403-577-00
Page 51
User’s Manual
Models 41PG40 & 41PG40S
4.9 [124]
2.5 [64]
IN [mm]
3.3 [84]
2.0 [50]
2.0 [50]
Cable: 8 ft. (3.75m)
1.2 [30]
Probe shown with typical horn, less tip.
Weight: 1.65 lb (750 g)
Rear View
Models 41HP40 & 41HP40S
2.5 [63]
3.0 [76]
5.6 [141]
3.3 [84]
IN [mm]
1.9 [47]
1.9 [49]
Cable: 8ft. (3.75m)
Probe shown with typical horn, less tip.
Weight: 1.35 lb (620 g)
01.9 [047]
Rear View
Figure 8-2 Probes Outline Drawings
Page 52
Dukane Manual Part No. 403-577-00
Section 8 – Specifications
Weights
Generator:
12 pounds (5.44 kg)
Probes:
Pistol Grip (Model 41PG40S)
1.65 pounds (750 g)
Hand Probe (Model 41HP40S)
1.35 pounds (612 g)
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. 403-577-00
Page 53
User’s Manual
AC Power Requirements
Operating
Frequency
Generator
Model Number
Overload
Power
Rating
(Watts)
Input AC Power Requirements
Nominal AC Volt
40kHz
40HP060-1E
600
100-120 VAC, 50/60 Hz
40kHz
40HP060-2E
600
200-240 VAC, 50/60 Hz
Table 8-I AC Power Requirements
Page 54
Dukane Manual Part No. 403-577-00
Section 8 – Specifications
Regulatory Agency
Compliance
FCC
The generator complies with the following Federal
Communications Commission regulations.
•
The limits for FCC measurement procedure MP-5,
“Methods of Measurement of Radio Noise Emissions
from ISM Equipment”, pursuant to FCC Title 47 Part
18 for Ultrasonic Equipment.
CE Marking (220/240 VAC Systems)
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.
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
generator complies with the following CE requirements.
• The Electromagnetic Compatibility Directive (EMC) 2004/108/EC
EN55011: 2003 Class B
EN61000-6-4 Generic Emission Standard Part 6-4. Industrial Environments.
EN61000-6-2 Generic Immunity Sandard Part 6-4. Industrial Environments.
EN 61000–4–2 Electrostatic Discharge.
EN 61000–4–3 Electromagnetic Field Immunity.
EN61000–4–4 Electrical Fast Transient. Burst Immunity.
EN61000–4–5 Surge Immunity.
EN61000–4–6 Conducted RF,
EN61000–4–8 Magnetic Field.
EN61000-4-11 Voltage Dips, Short Interruptions & Variations.
• The Low Voltage Directive 2006/95/EC.
• The Machine Directive 898/37/EC
EN60204–1: Safety of Machinery
Dukane Manual Part No. 403-577-00
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User’s Manual
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Page 56
Dukane Manual Part No. 403-577-00
Section 9 – I/O Interface
SECTION 9
Outputs Interface
Outputs Connection Example . . . . . . . . . . . . . . . . . . 59
Dukane Manual Part No. 403-577-00
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User’s Manual
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Page 58
Dukane Manual Part No. 403-577-00
Section 9 – I/O Interface
Provided by Customer
iQ Hand Probe Generator
Rear Panel Detail
Power Supply
+ 30 VDC Maximum
+ 24 V
HAND PROBE
OUTPUTS
OV
1
2
X1
3
To: 1, 2, or 3
Chassis
Ground
(Earth)
+
_
X2
OV
Status
Indicator or
Audible
Alarm
(333mA
maximum)
Figure 9-1 OUTPUTS Connection Example
Dukane Manual Part No. 403-577-00
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User’s Manual
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Page 60
Dukane Manual Part No. 403-577-00
Section 10 – Contacting Dukane
SECTION 10
Contacting Dukane
Dukane Manual Part No. 403-577-00
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User’s Manual
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Page 62
Dukane Manual Part No. 403-577-00
Section 10 – Contacting Dukane
Contacting Dukane
Identify Equipment
When contacting Dukane about a service–related problem,
be prepared to give the following information:
• Model number, line voltage and serial number
• Fault/error indicators from the LCD display
• Software version (Press INFO. With pointer at System
Information, press ENTER to get this data.)
• Problem description and steps taken to resolve it
Many problems can be solved over the telephone, so it is
best to call from a telephone located near the equipment.
Ultrasonics Division
Mailing Address:
Main Phone:
Main Fax:
Service Phone:
Service & Parts Fax:
Dukane Ultrasonics
2900 Dukane Drive
St. Charles, IL 60174 USA
(630) 797–4900
(630) 797–4949
(630) 584–xxxx
(630) 584–0796
Our Website
The website has lots of information about our products,
processes, solutions, and technical data. Downloads are
available for many kinds of literature.
You can locate your local representative at:
www.dukcorp.com/us/sales/intsales.htm
Dukane Manual Part No. 403-577-00
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User’s Manual
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Page 64
Dukane Manual Part No. 403-577-00
Appendices
APPENDICES
List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Dukane Manual Part No. 403-574-00
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Page 66Dukane Manual Part No. 403-574-00
Appendices
List of Figures
No.
Description
Page
2-1
Example of 110/120 Volt, Grounded, 3-prong Plug and Receptacle................................8
2-2
Example of 220/240 Volt, Grounded, 3-prong Plug and Receptacle................................8
2-3
International 220/240V Grounding...................................................................................8
3-1
Generator - Detail (Rear Views).....................................................................................13
3-2
Rocker-style Power Switch/Circuit Breaker....................................................................13
4-1
Front Panel.....................................................................................................................17
4-2
Power Switch..................................................................................................................19
4-3
Power-up Screen............................................................................................................19
4-4
Example of a Operate Screen........................................................................................20
4-5
Example of a In-Cycle Screen........................................................................................20
5-1
Manual Weld Mode........................................................................................................24
5-2
Navigate to Time Mode..................................................................................................24
5-3
Time Weld Mode 1.........................................................................................................24
5-4
Navigate to Energy Mode...............................................................................................25
5-5
Time Weld Mode............................................................................................................25
5-6
Navigate to Energy Mode...............................................................................................25
5-7
Energy Weld Mode 1......................................................................................................25
5-8
Energy Weld Mode 2......................................................................................................25
5-9
HOLD Time 1..................................................................................................................26
5-9A
HOLD Time 2..................................................................................................................26
5-10
Amplitude.......................................................................................................................26
5-11
INFO Button...................................................................................................................27
5-12
Hardware Settings Screen.............................................................................................27
5-13
Setup Maintenance 1.....................................................................................................28
5-14
Setup Maintenance 2.....................................................................................................28
5-15
Setup Maintenance 3.....................................................................................................28
5-16
Overwrite Setuup?..........................................................................................................28
5-17
Setup Maintenance 4.....................................................................................................28
6-1
Typical Hand Held Probes..............................................................................................32
6-2
Hand Probe, Horn and Tip..............................................................................................33
6-3
Probe, Booster and Horn................................................................................................33
6-4
Replaceable Tip Installation...........................................................................................35
6-5
Stack Assembly Procedure............................................................................................37
Dukane Manual Part No. 403-574-00
Page 67
User’s Manual
List of Figures continued
6-6
Torque Value Conversion Graph....................................................................................38
6-7
Hand Probe Assembly and Disassembly.......................................................................39
6-8
Separating the Horn from the Booster............................................................................40
6-9
Removing a Replaceable Tip From the Horn.................................................................40
7-1
Pop-up Fault Status Screens - Manual Mode................................................................77
7-2
Pop-up Fault Status Screens - Time and Energy Modes...............................................78
8-1
Generator Outline Drawing.............................................................................................49
8-2
Probes Outline Drawing.................................................................................................50
9-1
OUTPUTS Interface Example........................................................................................57
List of Tables
No.
Description
Page
3-I
System OUPUTS Connector Signals............................................................................... 14
6-I
Tip Torque Unit Conversion.............................................................................................. 35
6-II
Stud Torque Unit Conversion........................................................................................... 36
7-I
Pop-up Fault Status Screens........................................................................................... 46
8-I
AC Power Requirements................................................................................................. 52
Page 68Dukane Manual Part No. 403-574-00
Dukane ISO
ISO CERTIFICATION
Dukane chose to become ISO 9001:2000 certified in order to demonstrate to our customers
our continuing commitment to being a quality
vendor. By passing its audit, Dukane can assure
you that we have in place a well–defined and
systematic approach to quality design, manufacturing, delivery and service. This certificate
reinforces Dukane's status as a quality vendor
of technology and products.
To achieve ISO 9001:2000 certification, you
must prove to one of the quality system registrar groups that you meet three requirements:
1. Leadership
2. Involvement
3. Quality in Line Organizations and Quality
System Infrastructure.
The ISO 9001:2000 standard establishes a
minimum requirement for these requirements
and starts transitioning the company from a
traditional inspection–oriented quality system
to one based on partnership for continuous
improvement. This concept is key in that Dukane no longer focuses on inspection, but on
individual processes.
Dukane's quality management system is based
on the following three objectives:
1. Customer oriented quality. The aim is to
improve customer satisfaction.
2. Quality is determined by people. The aim
is to improve the internal organization and
cooperation between staff members.
3. Quality is a continuous improvement.
The aim is to continuously improve the
internal organization and the competitive
position.
ISO 9001:2000
CERTIFIED
Dukane products are manufactured in ISO
registered facilities
Please Refer to our Website At:
www.dukcorp.com/us/sales/intsales.htm
To Locate Your Local Representative
iQ Series Ultrasonic Hand Held Systems User's Manual
Part No. 403–577–00
www.dukcorp.com/us
Printed in the United States of America
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797–4949