Dukane iQ Series, Ultrasonic Hand Held System iQ Series User Manual

4.93 Mb

Intelligent Assembly Solutions

iQ Series




User’s Manual

Dukane Part No. 403 – 577– 01

Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 7974900 • FAX (630) 7974949

ISO 9001:2000

Products are manufactured in ISO


registered facilities.

iQSeries, 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










- 00

Original release.


- 01

Add 20kHz and 30kHz models.



Update Pop-up Fault Status Screens.



Add Trigger by Power feature.



Add Options section.


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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

- Specifications . . . . .

. .

. . . . . . . . . . . . . 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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Section 1 – Introduction



General User Information . . . . . . .

. .

. .


. 3

Read The Manual First. . . . . . . . .

. .

. .




Notes, Cautions and Warnings. . . . . .

. .

. .




Drawings and Tables. . . . . . . . .

. .

. .

. .


. 3

System Overview.






Key Features .






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Dukane Manual Part No. 403-577-01

Section 1 – Introduction

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 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.


Note statements provide additional information or highlight procedures.


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 statements point out conditions or practices that could result in personal injury or loss of life.




or Practice



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iQSeries, 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.


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 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 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 the generator output frequency to match it. This is done for every weld cycle and eliminates the need to manually tune the generator.

LineVoltage 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–volt- age 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











in the

event of extreme out-

put overload conditions, and rated overload power limit is based on the actual true RMS power output level.

Trigger by Power produces greater weld consistency by requiring that a sufficient amont of pressure/force is applied to the part before the actual weld begins.

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.


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Section 2 – Health & Safety


Health and Safety

General Considerations . . . . . . . . . . . . . . . 7

Plastics Health Notice . . . . . . . . . . . . . . . . 7

Electrical Safety . . . . . . . . . . . . . . . . . . 8

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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, 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.

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.

Never operate the generator with the cover off.

This is an unsafe practice and may cause injury.IMPORTANT


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.

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iQSeries, Ultrasonic Hand Held Systems 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 2- 2 illustrate the appropriate electrical outlet to use with the power cords included with 100-120 volt and 200-240 volt systems respectively. This information applies to systems shipped to North America or Japan.

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

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.

Grounding Contacts

Typical Outlet

Provided Cable

Figure 2–3 International 220/240V Grounding


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.


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.


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Section 3 – Installation



Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. .11

Placing . . . . . . . . . . . . . . . . . . . .


RFI Grounding . . . . . . . . . . . . . . . . .


Connnecting Cables . . . . . . . . . . . . . . .


System Outputs Connector . . . . . . . . . . . . .

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Section 3 – Installation


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.


Make certain generator placement and cable routing do not interfere with normal operation. Maintain easy access to your equipment.

The operator should have unobstructed access to cables and wiring.

RFI Grounding

Proper grounding for the generator chassis is essential for the effective suppression of electrical noise or RFI (Radio Frequency Interference). Every ultrasonic generator contains a RFI filter that blocks noise on the

AC power line from entering the system control circuitry.

This filter also prevents ultrasonic frequency noise from being fed back into the AC power line. For the RFI filter to operate effectively, it is necessary to correctly ground the system.

Connect a grounding wire from the grounding stud connection (see Figure 3-1) to the nearest grounded metal pipe or equivalent earth ground.

See Connecting Cables on the next page.


To minimize electri - cal noise and eliminate ground currents, ground the chassis as shown.

Use a STAR configuration

(illustrated below). Do not DAISY CHAIN the grounds.

Chassis Grounding


Recommended protective earth ground connection wire color: green or green with yellow stripe.



Fixed Probe Mount

or 2nd Chassis

Grounding Stud

#14 Gauge

Stranded or

Solid Wire

3rd Chassis Grounding Stud


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.


If you have any questions about the grounding of your equipment and/or the electrical box, contact a qualified electrician.

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iQSeries, Ultrasonic Hand Held Systems User’s Manual

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 - Cin Figure 3-1. Attach the other end to the nearest grounded metal pipe or equal earth ground.

Step 4. Attach the male end of the power cord to a suitable line receptacle.

Optional Connections - See Page 14 for information about the rear panel OUTPUTS connector.


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

Power Cord Strain Relief





















Figure 3-1 Generator Detail - Rear Views

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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





North America

200 - 1541

240V, 10A





200 - 1542

240V, 10A





200 - 1624

240V, 10A




Table 3- I Standard IEC AC Power Cord Part Numbers

100/120 Volt Systems (North America or Japan)

The power cord (including strain relief) supplied with the 100/120 AC systems is permanently attached to the rear of the generator. Units with this power cord are for use in North America or Japan.

HAND PROBE Connector

Ultrasound Output

The ultrasound output connector used with this generator is integrated into a D-Sub style connector. This connector provides superior shielding of electrical noise. The output connector mates with a fully shielded ultrasound cable that is secured to the generator with two simple, reliable thumbscrews.

The ultrasonic output from this connector (that drives the attached ultrasonic load) is a very high AC voltage.  At high power levels there is high current, and the cable must be securely attached to the hand probe for safe operation. Only use original equipment ultrasound cables for safe and reliable system operation.

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iQSeries, 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.


Signal Name




Output Common

1End of Weld Alarm

2Any Fault Alarm

3Bad Part

Table 3-II System OUTPUTS Connector Signals


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.

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Section 4 – Controls and Connections



Front Panel Overview . . . . . . . . . . . . . . .


Start-Up Sequence . . . . . . . . . . . . . . . .


LCD Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


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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.

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.


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.


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.


Use the SETUP key to Load, Store, or Delete as many as eight setups.


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iQSeries, Ultrasonic Hand Held Systems User’s Manual

Control Keys



Set the ultrasound amplitude output level in the range of 20 to 100%.

Typically amplitude is set to 100%.


Use this key to select time as the primary method of welding. Set the weld time (seconds).


Use this key to select energy as the primary method of welding. Set the weld energy (joules).


Hold is a time period beginning after the weld portion of the cycle is complete. The operator holds the probe in place applying pressure to the weld, and an audible alarm indicates that the Hold time is finished. Hold can be set to a maximum of 5.0 seconds.


Press the ENTER key to select a menu item, and move to the next level of the menu. Think of it as a “forward” key.

When pressed, it also confirms and stores a selection in memory. It is also used to reset a latched condition.

Arrow Keys

Press the right and left arrow keys to move the cursor to the right or left.

+ and - Keys

Press these keys to increase or decrease the value of a selected digit.


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.

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


In Cycle

power used

Frequency: 40087 Hz




225 W




Figure 4-1A Power Bar Graph - In Cycle

In the example below, 40% of the generator power was the maximum (peak) power delivered in the previous weld. The display shows an Operate screen (while U/S is inactive).

Weld by Time


Weld Time 1.500 S


Weld Energy 24 J



40% of power delivered in previous weld

Figure 4-1B Power Bar Graph - Operate


Make sure the stack is properly assembled before it is connected to the system. The horn should never come in directcontactwithametalfixture or anvil when ultrasound is activated.

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Section 4 – Controls and Connections

Start-up Sequence

After all connections have been completed.

1.Push the Power Switch to ON (Figure 4-2).

The generator performs a self-diagnostics sequence.

2.The Power-up screen appears briefly - 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.

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.

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.

Push ON

Push OFF


Figure 4-2 Power Switch









iQ Hand Probe Setup #1













Figure 4-3 Power-up Screen




Weld by Time

Weld Time 0.000 S

Weld Energy 0 J


Figure 4-3A Operate Screen Appears After


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.


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.

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