Dukane iQ User Manual
Intelligent Assembly Solutions
iQ Series
ULTRASONIC HAND HELD SYSTEMS
HP
AUTOMATED HAND PROBE PRESS
User’s Manual
Dukane Part No. 403 – 577– 01
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949
Products are manufactured in ISO
ISO 9001:2000
registered facilities.
www.dukane.com/us
iQ Series, Ultrasonic Hand Held Systems User’s Manual
Copyright © 2009
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: 403–577–01
This ultrasonic equipment is manufactured under one or more of
the following U.S. Patents:
3,780,926 3,825,481 4,131,505 4,277,710 5,798,599 5,880,580 6,984,921, 7,225,965, and 7,475,801
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Dukane Manual Part No. 403-577-01
Revision History
Revision Revision
Number Summary Date
- 00 Original release. 08/01/2008
- 01 Add 20kHz and 30kHz models. 11/12/2009
Update Pop-up Fault Status Screens.
Add Trigger by Power feature.
Add Options section.
Dukane Manual Part No. 403-577-00
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Dukane Manual Part No. 403-577-01
Contents
Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . 1
Section 2- Health and Safety . . . . . . . . . . . . . . . . . . . 5
Section 3- Installation . . . . . . . . . . . . . . . . . . . . . . . . 9
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Placing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . 11
Connecting Cables . . . . . . . . . . . . . . . . . . . . . 12
System Outputs (Optional Connections). . . . . 14
Section 4 - Controls . . . . . . . . . . . . . . . . . . . . . . . . . 15
Front Panel Overview . . . . . . . . . . . . . . . . . . . 17
Start-up Sequence . . . . . . . . . . . . . . . . . . . . . 19
LCD Display Overview . . . . . . . . . . . . . . . . . . 20
Section 5 - Process Control Settings . . . . . . . . . . . 24
Selecting the Weld Mode . . . . . . . . . . . . . . . . 23
Navigating Through the Modes . . . . . . . . . 24-25
Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Amplitude Adjustment . . . . . . . . . . . . . . . . . . . 26
System Information, Hardware Settings,
Advanced Settings . . . . . . . . . . . . . . . . . . . 27
Setup Maintenance . . . . . . . . . . . . . . . . . . . . . 30
Section 6 - Probes and Probe Stacks. . . . . . . . . . . 33
Section 7 - Troubleshooting . . . . . . . . . . . . . . . . . . 45
Section 8 - Options. . . . . . . . . . . . . . . . . . . . . . . . . . 51
Section 9 - Specications . . . . . . . . . . . . . . . . . . . . 55
Section 10 - Outputs Interface. . . . . . . . . . . . . . . . . 63
Section 11 - Contacting Dukane . . . . . . . . . . . . . . . 67
Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
List of Figures . . . . . . . . . . . . . . . . . . . . . . . 73
List of Tables . . . . . . . . . . . . . . . . . . . . . . . . 74
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Dukane Manual Part No. 403-577-01
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. 403-577-01
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Dukane Manual Part No. 403-577-01
General User Information
Read This Manual First
Before operating your ultrasonic system, read this User’s
Manual to become familiar with the equipment. This will
ensure correct and safe operation. The manual is 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
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.
Drawings and Tables
The gures and tables are identied by the section number followed by a sequence number. The sequence num-
ber begins with one in each section. The gures and
tables are numbered separately. The gures 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.
Section 1 – Introduction
NOTE
Note statements provide additional
information or highlight procedures.
CAUTION
C a u t i o n s t a t e m e n t s
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.
Condition
or Practice
Electrical
Hazard
Hearing
Protection
Dukane Manual Part No. 403-577-01
Page 3
iQ Series, Ultrasonic Hand Held Systems User’s Manual
System Overview
Your iQ Series Ultrasonic Hand Held System has two
basic components: an ultrasonic generator, and a hand
probe.
Generator
The generator is specically 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 exibility.
The generator’s compact size and its integrated hand grip
make it easy to carry.
It also includes an RFI line lter that passes strict CE test
specications 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 this component is easy to
•
move, and 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
efciently change the output amplitude. This makes
it possible to start large horns with reduced power. It
also provides more power efcient switch-mode generator operation and increased reliability.
Linear Ramp Soft Start circuitry allows the acous-
•
tic stack to ramp up to operating amplitude smoothly,
minimizing the start-up surges and abnormal stress to
the stack and generator.
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 specied range.
This provides consistent system performance regardless of line voltage uctuations. 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 protec-
•
tion 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.
Trigger by Power produces greater weld consis-
•
tency by requiring that a sufcient amont of pressure/force is applied to the part before the actual
weld begins.
CE Certication means that the system meets
•
the required European standards to be sold and
used in Europe.
ISO 9001 Certication means that this system
•
has been manufactured to high quality standards
and assures you of manufacturing excellence.
Digi-Trac Tuning tracks the resonant frequency of the
•
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Dukane Manual Part No. 403-577-01
Section 2 – Health & Safety
SECTION 2
Health and Safety
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Dukane Manual Part No. 403-577-01
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Dukane Manual Part No. 403-577-01
Section 2 – Health & Safety
General Considerations
Please observe these health and safety recommendations for
safe, efcient, 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 Modications - Do not modify your
system in any way unless authorized to do so by the man-
ufacturer. Unauthorized modications may cause injury
to the operator and/or equipment damage. In addition,
unauthorized modications will void the equipment warranty.
Keep the Cover On - Do not remove any equipment cover unless specically 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. 403-577-01
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iQ Series, Ultrasonic Hand Held Systems User’s Manual
Grounding Contacts
Typical Outlet
Provided Cable
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.
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
Figure 2–3 International 220/240V Grounding
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
qualied 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 8
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. 403-577-01
Section 3 – Installation
SECTION 3
Installation
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Connnecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
System Outputs Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
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Dukane Manual Part No. 403-577-01
Section 3 – Installation
Earth
Ground
#14 Gauge
Stranded or
Solid Wire
Fixed Probe Mount
or 2nd Chassis
Grounding Stud
3rd Chassis
Grounding
Stud
Chassis Grounding
Stud
Recommended protective
earth ground connection
wire color: green or green
with yellow stripe.
Unpacking
Carefully open your shipping container, and make sure
it contains the items shown on the shipping documents.
Inspect all items, and report any missing items or damage
immediately.
Placing
Make certain generator placement and cable routing do
not interfere with normal operation. Maintain easy access
to your equipment.
The operator should have unobstructed access to cables
and wiring.
RFI Grounding
Proper grounding for the generator chassis is essential
for the effective suppression of electrical noise or
RFI (Radio Frequency Interference). Every ultrasonic
generator contains a RFI lter that blocks noise on the
AC power line from entering the system control circuitry.
This lter also prevents ultrasonic frequency noise from
being fed back into the AC power line. For the RFI lter
to operate effectively, it is necessary to correctly ground
the system.
Connect a grounding wire from the grounding stud
connection (see Figure 3-1) to the nearest grounded metal
pipe or equivalent earth ground.
See Connecting Cables on the next page.
CAUTION
To m i n i m i z e e l e c t r i cal noise and eliminate
ground currents, ground
the chassis as shown.
Use a STAR conguration
(illustrated below). Do not
DAISY CHAIN the grounds.
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. 403-577-01
CAUTION
If you have any questions
about the grounding of your
equipment and/or the electrical box, contact a qualified
electrician.
Page 11
iQ Series, Ultrasonic Hand Held Systems User’s Manual
HAND PROBE
OUTPUTS
HAND PROBE
OUTPUTS
REAR VIEW
200/24O VOLT MODEL
REAR VIEW
100/12O VOLT MODEL
Connecting Cables - Quick
Start Guide
Complete the basic connections as shown below:
• AC Line Input
• HAND PROBE Connector
• Grounding Stud
• AC Power Cord Connection
Step 1. Attach the female end of the power cord
(200/240V only) to the generator’s power inlet
connector - A in Figure 3-1.
(The 100/120V model’s power cord is permanently
attached to the unit.)
Step 2. Attach the hand probe’s cable connector to the
generator’s HAND PROBE connection. - B in
Figure 3-1. Secure the connector to the system using the two jack screws attached to the connector
hood.
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.
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 3-2 below.
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 suit-
able line receptacle.
Optional Connections - See Page 14 for information
about the rear panel OUTPUTS connector.
Power Cord Strain Relief
C
Optional
Connections
Figure 3-1 Generator Detail - Rear Views
B
A
C
Page 12
Dukane Manual Part No. 403-577-01
Power Cords
200/240 Volt Systems
The IEC AC power inlet connector mounted on the rear
panel requires a properly congured 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 specied use. See Table 3-I.
Section 3 – Installation
Continent of Use Power Cord
North America 200 - 1541 240V, 10A
Europe 200 - 1542 240V, 10A
Table 3- I Standard IEC AC Power Cord Part Numbers
India 200 - 1624 240V, 10A
Part Number
Power
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. 403-577-01
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iQ Series, Ultrasonic Hand Held Systems User’s Manual
System Outputs
(Optional Connections)
The OUTPUTS connector is a four-position wire
receptacle-type terminal block. If needed, it can provide
the operator with basic system welding status. Everything
connected to the OUTPUTS connector is customersupplied. Typically indicator lights or sound modules are
powered by these output signals. (The lights or sound
modules can be mounted on widely available Stack Light
assemblies.) Each output signal is rated to operate on a
24VDC power source and can activate an attached load
up to a maximum of 500 mA.
Table 3-II lists the signal names.
Pin Signal Name
0V Output Common
1 End of Weld Alarm
2 Any Fault Alarm
3 Bad Part
Table 3-II System OUTPUTS Connector Signals
NOTE
All outupt signals are non-isolated and
sink current to chassis ground when
activated.
Pin 0V (Output Common)
Pin 0V is connected to chassis ground.
Pin 1 (End of Weld Alarm)
Non-isolated NPN output that sinks current at the End of
Weld cycle. It activates when ultrasound switches off, or
at the end of a preset Hold period. The signal lasts for one
second, then deactivates.
Pin 2 (Any Fault Alarm)
Pin 2 is a non-isolated digital NPN status output that sinks
current to chassis ground if any fault condition is sensed.
This output is active until the start of the next cycle or
until ENTER is pressed if in non-latching fault mode.
In latching fault mode the user must press ENTER to clear
this output.
If a hardware fault like Over Temperature or a power fault
occurs, Any Fault is active until the fault is cleared in nonlatching fault mode. In latching fault mode, the user must
press ENTER to clear this output. However if the fault
persists, pressing ENTER has no effect.
Pin 3 (Bad Part)
Pin 3 is a non-isolated digital NPN status output that sinks
current to chassis ground if a Bad Part is detected. This
output is active until the start of the next cycle or until
ENTER is pressed if in a non-latching fault mode. It is
active until ENTER is pressed if in a latching fault mode.
Refer to Figure 9-1, OUTPUTS Interface Example, Page 65.
Page 14
NOTE
Dukane Manual Part No. 403-577-01
Section 4 – Controls and Connections
SECTION 4
Controls
Front Panel Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Start-Up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LCD Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
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Dukane Manual Part No. 403-577-01
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.
Section 4 – Controls and Connections
Power
Switch
LCD Display
Figure 4-1 Front Panel
Power Switch/Circuit Breaker
The power switch/circuit breaker has a rocker-style actuator switch that will activate or deactivate the AC power
to the system. The power ON position is marked with the
internationally recognized I symbol, the power OFF position is marked with the 0 symbol. This power switch also
integrates an appropriately sized over-current protection
circuit breaker function in the generator.
If an over-current condition trips the circuit breaker, it will
automatically switch to the OFF position. If the overload
current that caused the circuit breaker to trip is due to a
transient condition, the circuit breaker can be reset by
switching the actuator back to the ON position.
CAUTION
If when resetting the circuit
breaker afer it has tripped, it
immediately trips again, there
is likely an internal system
malfunction, and the generator
will need service. Do NOT repeatedly try to reset the circuit
breaker. If it trips, this will only
cause more damage to the
generator.
Control Keys
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 - Identies 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.
Continued
Dukane Manual Part No. 403-577-01
Page 17
iQ Series, Ultrasonic Hand Held Systems User’s Manual
IN CYCLE
Frequency: 40087 Hz
Power: 225 W
# 2
Weld by Time
Weld Time 1.500 S
Weld Energy 24 J
# 1
Control Keys
Continued
AMP
Set the ultrasound amplitude output level in the range of
20 to 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).
HOLD
Hold is a time period beginning after the weld portion
of the cycle is complete. The operator holds the probe in
place applying pressure to the weld, and an audible alarm
indicates that the Hold time is nished. Hold can be set to
a maximum of 5.0 seconds.
System LCD Display
This high resolution, multi-line display provides a clear
graphic interface to the operate and in-cycle screens
needed to monitor and program the system.
Power Bar Graph
The Power Bar Graph appears at the bottom of the
LCD display. It 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 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).
40% of
power used
Figure 4-1A Power Bar Graph - In Cycle
In Cycle
screen
ENTER
Press the ENTER key to select a menu item, and move to
the next level of the menu. Think of it as a “forward” key.
When pressed, it also conrms 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.
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 4-1B Power Bar Graph - Operate
CAUTION
Make sure the stack is properly assembled before it is
connected to the system. The
horn should never come in
direct contact with a metal xture or anvil when ultrasound
is activated.
Page 18
Dukane Manual Part No. 403-577-01
Section 4 – Controls and Connections
DUKANE
iQ Hand Probe Setup #1
xxxxxxxxx
xxxxxxx
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Weld by Time
Weld Time 0.000 S
Weld Energy 0 J
# 1
Start-up Sequence
After all connections have been completed.
1. Push the Power Switch to ON (Figure 4-2).
The generator performs a self-diagnostics sequence.
2. The Power-up screen appears briey - Figure 4-3.
3. The next screen is an Operate screen ready for a
new weld to be done. The display shows:
The setup used for the last weld, and zeros for any
weld parameters.
See Figure 4-3A.
Push OFF
Software
version
MB FPGA
version
Push ON
Figure 4-2 Power Switch
Current
Setup
Website
Address
Figure 4-3 Power-up Screen
Figure 4-3A Operate Screen Appears 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. Apply the probe tip to the components to be
ultrasonically joined, and press the hand probe’s
trigger switch to activate ultrasound.
4. After meeting the weld parameters (and with the Hold
time set to zero) - in either Manual, Time or Energy
modes - an internal alarm beeps once after the weld
setting is met, or after the trigger switch is released.
Depending on optional customer OUTPUTS
connections - System Outputs, Page 14 - external
audible or visual alerts can be activated as well.
5. Release the probe’s activation switch (trigger), and
if appropriate, apply pressure while an optional Hold
time elapses. The generator signals when that period
is over by sounding an audible alert.
Stopping a Weld Cycle
1. Release the hand probe’s activation switch (trigger)
to abort a weld cycle and stop ultrasound.
2. In addition, press the generator’s Power Switch/
Circuit Breaker to the OFF position to power down
the generator.
NOTE
The system will not beep as described
here if the Audible Alarm is OFF.
See Hardware Settings, Page 27 to learn
how to turn the Alarm ON or OFF.
The user can release the activation switch during the
Hold time, but there will not be an audible beep until
the preset Hold time ends.
Dukane Manual Part No. 403-577-01
Page 19
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