Dukane iQ Series User manual

ISO 9001:2000
Products are manufactured in ISO
registered facilities.
Intelligent Assembly Solutions
www.dukcorp.com/us
Dukane Part No. 403–577-00
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

Page ii
User’s Manual
Dukane Manual Part No. 403-577-00
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
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, with-
out 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.

Page iii
Dukane Manual Part No. 403-577-00
Revision History
Revision Revision
Number Summary Date
- 00 Original release. 08/01/2008

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User’s Manual
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Page v
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
RFIGrounding ......................12
Connecting Cables . . . . . . . . . . . . . . . . . . . 13
Section4-Controls.........................15
Front Panel Overview . . . . . . . . . . . . . . . . . 17
Start-up Sequence . . . . . . . . . . . . . . . . . . . 19
DisplayOverview.....................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 - Specications ....................49
Section 9 - Outputs Interface. . . . . . . . . . . . . . . . . . 57
Section 10 - Contacting Dukane . . . . . . . . . . . . . . . 61
Appendices ...............................61
ListofFigures.......................67
ListofTables........................68

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User’s Manual
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Page 1
Section 1 – Introduction
Dukane Manual Part No. 403-577-00
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

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User’s Manual
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Page 3
Section 1 – Introduction
Dukane Manual Part No. 403-577-00
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
Throughout this manual we use NOTES to provide in-
formation that is important for the successful applica-
tion 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 in-
creasing levels of important information. These state-
ments help you to identify and avoid hazards and rec-
ognize 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 identied by the section num-
ber 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 ex-
ample, 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 Electrical
Hazard
Hearing
Protection
CAUTION
Caution statements
identify conditions or
practices that could result
in damage to the equip-
ment or other property.
WARNING
Warning statements
point out conditions or
practices that could re-
sult in personal injury or
loss of life.
NOTE
Note statements provide additional
information or highlight procedures.
 

Page 4
User’s Manual
Dukane Manual Part No. 403-577-00
System Overview
Two basic components make up your iQ Series Ultra-
sonic Hand Held System - an ultrasonic generator, and
a hand probe.
Generator
The generator is specically designed for ultrasonic appli-
cations using hand held probes. Using the available system
control inputs and outputs, the generator provides a versa-
tile stand-alone workstation.
This product’s rugged internal circuitry ensures a continu-
ous resonant frequency lock at the start of each weld.
Standard to this line of generators is time and energy con-
trol. 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
specications 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
efciently change the output amplitude. This makes
it possible to start large horns with reduced power. It
also provides more power efcient switch-mode gen-
erator 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.
Digi-Trac Tuning tracks the resonant frequency of the
acoustic stack (horn, booster, transducer) and adjusts
•
•
•
•
the generator output frequency to match it. This
is done for every weld cycle and eliminates the
need to manually tune the generator.
Line Voltage Regulation automatically maintains
constant amplitude regardless of line voltage de-
viation. The available output power is maintained
with any voltage input within the specied range.
This provides consistent system performance re-
gardless of line voltage uctuations. It also elimi-
nates the need for bulky, external constant–volt-
age transformers.
Load Regulation provides constant amplitude
automatically regardless of power draw. The ul-
trasonic output amplitude level is held to within
±1% to provide weld process consistency and re-
duced 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 sys-
tems are optionally available to operate on the
120VAC line voltage level.
Multiple Electronic Overload protec-
tion circuits prevent instantaneous com-
ponent failure in the event of extreme out-
put overload conditions and rated overload
power limit is based on the actual true RMS
power output level.
CE Certication means that the system meets
the required European standards to be sold and
used in Europe.
ISO 9001 Certication means that this system
has been manufactured to high quality standards
and assures you of manufacturing excellence.
•
•
•
•
•
•

Page 5
Section 2 – Health & Safety
Dukane Manual Part No. 403-577-00
SECTION 2
Health and Safety
GeneralConsiderations.............................. 7
PlasticsHealthNotice................................ 7
ElectricalSafety.................................... 8

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User’s Manual
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Page 7
Section 2 – Health & Safety
Dukane Manual Part No. 403-577-00
General Considerations
Please observe these health and safety recommendations for
safe, efcient, 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 Modications - Do not modify your
system in any way unless authorized to do so by the man-
ufacturer. Unauthorized modications may cause injury
to the operator and/or equipment damage. In addition,
unauthorized modications will void the equipment war-
ranty.
Keep the Cover On - Do not remove any equipment cov-
er unless specically directed to do so by the manufactur-
er. 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 ap-
plicable 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. Depart-
ment 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.
CAUTION
Parts being joined ultrason-
ically sometimes vibrate at
audible frequencies. Wear
ear protection to reduce
annoying or uncomfort-
able sounds. In addition,
sound absorbing materi-
als, enclosures or sound
deectors may be installed
to reduce the noise level.
IMPORTANT
Never operate the gen-
erator with the cover off.
This is an unsafe prac-
tice and may cause injury.


Page 8
User’s Manual
Dukane Manual Part No. 403-577-00
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.
International Power Grounding
The power cable normally provided for international use
is compatible with the power outlet used in many Conti-
nental 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 reg-
ulations concerning proper wiring and grounding.
Figure 2–3 International 220/240V Grounding
Grounding Contacts
Typical Outlet
Provided Cable
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
CAUTION
If there is any question about
the grounding of your recep-
tacle, 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 exten-
sion cord with this product.
CAUTION
If you have a two-prong elec-
trical receptacle, we strongly
recommend that you replace
it with a properly grounded
three-prong type. Have a
qualied electrician replace
it following the National Elec-
tric Code and any local codes
and ordinances that apply.
See Figures 2–1 and 2–2.


Figure 2–1 Example of 125 Volt,
Grounded, 3-Prong Plug and Receptacle
Approved 2 pole, 3 wire grounding receptacle
HUBBELL No. HBL 5262 or equivalent
NEMA Configuration 5–15R or 5–20R

Page 9
Section 3 – Installation
Dukane Manual Part No. 403-577-00
SECTION 3
Installation
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Placing..........................................11
RFIGrounding....................................11
ConnnectingCables............................... 12
SystemOutputsConnector.............................14

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Page 11
Section 3 – Installation
Dukane Manual Part No. 403-577-00
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 conguration
(illustrated below). Do not
DAISYCHAIN the grounds.

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.
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.
CAUTION
If you have any questions
about the grounding of your
equipment and/or the electri-
cal box, contact a qualified
electrician.


Page 12
User’s Manual
Dukane Manual Part No. 403-577-00
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 (200/240
V only) to the generator’s power inlet connector
-Ain 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. - Bin
Figure 3-1. Secure the connector to the system us-
ing 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 suit-
able line receptacle.
Optional Connections - See the next page for information
about the rear panel OUTPUTS connector.
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 pow-
ered ON whenever the AC line power is
live and the switch is in the ON position as
shown in Figure 3-2 below.
HAND PROBE
OUTPUTS
HAND PROBE
OUTPUTS
REAR VIEW
200/24O VOLT MODEL
REAR VIEW
100/12O VOLT MODEL
Figure 3-1 Generator Detail - Rear Views
Figure 3-2 Rocker-style Power Switch/Circuit Breaker
Push ON
Push OFF
C
A
B
Power Cord Strain Relief
Optional
Connections
C

Page 13
Section 3 – Installation
Dukane Manual Part No. 403-577-00
Table 3-I Standard IEC AC Power Cord Part Numbers
Continent of Use Power Cord
Part Number
Power
North America 200 - 1541 240V, 10A
Europe 200 - 1542 240 V, 10A
Power Cords
200/240 Volt Systems
The IEC AC power inlet connector mounted on the rear
panel requires a properly congured 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 specied use. See Table 3-I.
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.

Page 14
User’s Manual
Dukane Manual Part No. 403-577-00
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
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 non-
latching 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.
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 customer-
supplied. 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.
NOTE
All outupt signals are non-isolated and
sink current to chassis ground when
activated.
NOTE
Refer to Figure 9-1, OUTPUTS Inter-
face Example, Page 59 .