Dukane iQ Series User manual

www.dukane.com
Dukane Part No. 403-601-00
iQ Series
ULTRASONIC WELDER
i220 Servo
User’s Manual
Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL [phone]
Dukane products are manufactured in ISO
registered facilities

Dukane Manual Part No. 403-601-00
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i220 Servo Ultrasonic Welder User’s Manual
Copyright © 2019 Dukane
2900 Dukane Drive
St. Charles, IL 60174 USA
Notice of Rights:
All rights reserved. No part of this manual including the
interior design, cover design and icons may be reproduced,
transmitted or utilized in any form or by any means, electronic,
mechanical, photocopying, recording, or by any information
storage and retrieval system, without written permission from
Dukane.
Notice of Liability:
The information contained is this manual is distributed on an
“As is” basis, without warranty. While every precaution has
been taken in the preparation of this manual, Dukane shall
not have any liability to any person or entity with respect to
any liability, loss, or damaged caused or alleged to be caused
directly or indirectly by the instructions contained in this
manual, or by the hardware and software products described
herein.
Printed in the United States of America.
Dukane Part Number: 403-601-00
Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents:
3,772,538 3,780,926 3,825,481 3,832,019 4,131,505 4,208,001
4,277,710 5,798,599 5,880,580 6,984,921 7,225,965 7,475,801
7,819,158 8,052,816 8,245,748 8,720,516 8,721,817 9,144,937

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Revision History
Revision Revision
Number Summary Date
- 00 Original Release June 26, 2019

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Section 1 - Introduction ............................................1
Section 2 - Safety Considerations ...........................7
Section 3 - Unpacking and Setup...........................13
Section 4 - Display and Controls ...........................21
Section 5 - Acoustic Stack and Fixture .................27
Section 6 - Screen Menus.......................................41
Section 7 - Machine Operation...............................61
Section 8 - System Operational Test .....................81
Section 9 - Operation In Automation .....................89
Section 10 - Specications.....................................97
Section 11 - Maintenance......................................105
Section 12 - Troubleshooting ............................... 113
Section 13 - Contacting Dukane...........................133
Index .......................................................................137
Dukane i220 Servo Ultrasonic Welder
Contents

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Page 1
Important User Information ..........................3
Read This Manual First ....................................3
Notes and Tips...........................................3
Caution and Warnings .....................................3
Drawings and Tables ......................................3
i220 Servo Ultrasonic Welder Overview ................4
Key i220 Servo Features ............................5
SECTION 1
Introduction

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Section 1 - Introduction
NOTE
NOTE statements provide additional
information or highlight procedures.
WARNING
WARNING statements
point out conditions or
practices that could result
in personal injury or loss
of life.
CAUTION
CAUTION statements identify
conditions or practices that
could result in damage to the
equipment or other property.
Important User Information
Read This Manual First
Before operating the i220 Servo Ultrasonic Welder,
read this User’s Manual to become familiar with the
system. This will ensure correct and safe operation.
The manual is organized to allow you to learn how
to safely operate this system. The examples given are
chosen for their simplicity to illustrate basic setup
procedures.
Notes and Tips
Throughout this manual we use NOTES to provide
information that is important for the successful
application and understanding of the system. A NOTE
block is shown to the right.
Cautions and Warnings
In addition, we use special notices to make you aware
of safety considerations. These are the CAUTION and
WARNING blocks as shown here. They represent
increasing levels of important information. These
statements help you to identify and avoid hazards and
recognize the consequences. Different symbols also
accompany the CAUTION and WARNING blocks
to indicate whether the notice pertains to a general
condition or practice, an electrical safety issue, a hot
surface issue, or other condition.
Drawings and Tables
The gures and tables are identied by the section
number followed by a sequence number. The
sequence number 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. Electrical
Hazard
Condition
Or Practice
Hot Surface

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i220 Servo Ultrasonic Welder User’s Manual
i220 Servo Ultrasonic
Welder Overview
The iQ Series i220 Integrated Servo Driven Ultrasonic
Welder with patented Melt-Match® technology is a self-
contained unit with iQ Series Generator/Power Supply
housed within the press. In a smaller footprint, the i220
Servo provides the efciency and reliability of a 100%
digitally controlled, multi-core iQ Series power supply
with the precision of an advanced servo press. Like all
other iQ Series Servo Ultrasonic Welders from Dukane,
the i220 Servo welder also delivers unprecedented
repeatability, accuracy and reliability to the ultrasonic
bonding process.
All models have a 5-inch stroke, and a xture throat
depth of 8.5-inches. All models have a vertical
maximum travel speed of 4.5 inches per second, and a
maximum weld force of 550 pounds. Additionally all
current models operate at a 2400-watt power level. See
table 1-I for a list of model numbers.

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Section 1 - Introduction
Key i220 Servo
Features
The i220 Servo system provides the following major
features:
• Repeatable and accurate servo motion control
• Integrated Melt-Match® technology
• Dynamic Velocity Melt Initiation (DVMI™)
• Programmable stack velocity and location control
• Integrable into automated assembly systems

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Health and Safety Tips ..............................9
Plastics Health Notice ....................................10
Operate Switches .......................................10
General Safety..........................................10
Electrical Safety ..................................11
AC Power Receptical.....................................11
Grounding .............................................11
SECTION 2
Safety Considerations

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Section 2 - Safety Considerations
WARNING
Never operate the i220
Servo with the protective
sheet metal covers
removed. This is an unsafe
practice and can result in
injury or loss of life.
WARNING
Molten plastic or hot
particulate may be ejected
during the welding process
on some applications. Use
of gloves and arm coverings
is recommended.
WARNING
Press the Emergency-Stop
(E-Stop) switch or turn
welder power off when
installing and removing
tools.
WARNING
Always wear a face shield
when operating the i220
Servo.
WARNING
Welded parts may be hot.
Health and Safety Tips
Please observe these health and safety recommendations
for safe, efcient, and injury-free operation of your
welder.
Proper Installation - Do not operate the i220 Servo
until after the electrical system is properly installed.
No Unauthorized Modications - Do not modify your
i220 Servo in any way unless authorized to do so by
Dukane. Unauthorized modications may cause injury
to the operator and/or equipment damage. In addition,
unauthorized modications will void the equipment
warranty.
Keep the Sheet Metal Intact - Do not remove any of
the protective sheet metal welder covers. The servo
motors and drives have exposed electrical terminals
which could cause injury or death if touched.
Grounded Electrical Power - Operate this equipment
only with a properly grounded electrical connection.
Refer to the NEMA Type 6–20R wiring diagram in
Figure 2-1 and receptacle photo in Figure 3–5. If there
is any question about the grounding of your AC power,
have it checked by a qualied electrician.
Comply with Regulations - You may be required to
add accessories to bring the system into compliance
with applicable OSHA (Occupational Safety and Health
Administration) regulations for machine guarding and
noise exposure.
Ear Protection - Parts joined ultrasonically may vibrate
at audible frequencies. Wear ear protectors to reduce
annoying or uncomfortable sounds. Ultrasound pressure
level could exceed 110dB.
Operate Safely – Keep your hands and body away
from the acoustic stack during operation. Always wear
a face shield when operating the ultrasonic welder. Be
aware that loose clothing or jewelry can become caught
in moving parts. Always press the Emergency-Stop
(E-Stop) switch or turn welder power off when installing
and removing tools. Do not operate the welder if under
the inuence of alcohol or drugs. Read the warning
labels on prescriptions to determine if your judgement or
reexes are impaired while taking drugs. If there is any
doubt, do not operate the machine.

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i220 Servo Ultrasonic Welder User’s Manual
WARNING
Always turn off AC power
at the power switch,
unplug the power cord,
and wait at least 5 minutes
before removing covers
or servicing the welder.
Failure to remove AC
power and to wait for the
servo drives to discharge
are unsafe practices and
can result in injury or loss
of life.
WARNING
Power line outlet MUST be
grounded.
Plastics Health Notice
Before using any Dukane 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, some
of them may emit fumes and/or vapors that could be
hazardous (e.g. PVC – Polyvinyl Chloride can emit
chlorine gas under certain processing conditions). Make
sure you use proper ventilation whenever these plastics
are processed.
Operate Switches
The dual nger operate switches comply with OSHA
safety regulations. Using a foot switch in place of the
dual nger run switches violates OSHA regulations.
General Safety
Before performing any maintenance or service on the
i220 Servo, locks and tags should be applied to all energy
isolating switches. Anything that might restore energy to
the welder must be locked out.
You may be required to add accessories to bring the
system into compliance with applicable regulations for
operator safety. In the United Sates, these regulations
are administered by OSHA.

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Section 2 - Safety Considerations
Electrical Safety
AC Power Receptacle
The power cord used on the i220 Servo Ultrasonic Welder
has a two–blade, grounding type plug designed for 240
VAC at 20 Amps. It is designed to be plugged into a 240
VAC, 20 Amp NEMA type 6–20R receptacle as shown
in Figure 2–1. Do not alter the plug or receptacle in any
way.
Grounding
It is important for operator safety that the receptacle
grounding wire be installed properly and securely
attached to an effectively grounded rod. The function
of the ground wire is to keep the i220 Servo Ultrasonic
Welder base and housing at earth potential. In the event
of a short circuit from one of the AC lines to the case, the
circuit breaker will open, protecting the equipment and
operator. If there is any question about the grounding
of your AC power, have it checked by a qualied
electrician.
Grounding studs are also provided, one on the back of
the base (see Figure 2-2) and one on the back of the
welder housing (see Figure 2-3). An 14 AWG* wire
should be connected between these two studs and an
effectively grounded metal pipe. This will minimize
any external electrical interference from leaking into the
i220 Servo Ultrasonic Welder control circuitry. This will
not compromise the safety of the power ground.
* 14 AWG wire has a diameter of .064 inch (1.63 mm)
Figure 2-1 240VAC–20A Receptacle Wiring
Figure 2-2 Ground on base
Figure 2-3 Ground on welder
Grounding Stud
Grounding Stud
GND
G
240V

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SECTION 3
Unpacking and Setup
Unpacking Welder ................................15
Packing List .....................................15
Work Area .......................................15
Securing to Work Bench ...........................16
Bench Capacity .........................................16
Leveling ...............................................16
Mounting Holes .........................................16
Acoustic Stack & Base.............................17
AC Power........................................18
Head Height Adjustment ...........................19
Welder/Base Cable Connection .....................20

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