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iQ Series AL - Plus User`s Manual

1. Tagout Devices 13 Lockout Tagout Devices 13 Page 74 M Multiple Electronic Overload 4 N Navigating the Modes Advanced Settings 33 Deleting a Setup 36 Energy Mode 31 Hold 32 Selecting a Setup 36 Setup Maintenance 35 Changing the Current Setup 36 Time Mode 30 Notes Cautions and Warnings 3 O Operating Environment 58 Overload 51 P Pop up Fault Status Screens 53 Power Cords 17 Power Switch Circuit Breaker 23 Probe Configuration 40 Probe Overview 39 Theory of Operation 40 Probes and Probe Stacks 37 Booster 41 Booster Notes 48 Ultrasonic Horn 41 Process Controller Settings 29 Navigating the Modes 30 Select the Welding Mode 29 Pulse Width Modulation 4 Dukane Manual Part No 403 596 00 R Regulatory Agency Compliance 60 Regulatory Agency Compliance 60 CE Marking 60 FCC 60 IP International Protection Rating 60 Removing Replaceable Tips from a Horn 47 Removing the Mounting Stud from a Horn or Booster 47 Rocker style Power Switch Circuit Breaker 16 S Selecting a Setup 36 Separating the Horn from a Booster Booster from a Probe or Horn from a Probe 47 SETUP 23 Setup Maintenance 35 Specifications 55 AC Power Requirements 59 Generator Outline Drawing 57 Weights 58 Stack Assembly 42 Attaching a Replaceable Tip to a Horn 42 Attaching Horn to Booster Booster to Probe or Horn to Probe 44 Attaching Mounting Stud to Horn or Booster 43 Stack Disassembly 46 Removing Replaceable Tips from a Horn 47
2. Removing Mounting Stud from Horn or Booster 47 Separating Horn from Booster Booster from Probe or Horn from Probe 47 Starting a Weld Cycle 25 Start up Sequence 25 Stopping a Weld Cycle 25 System I O Connector Pinout 18 System LCD Display 24 System Overview 4 Dukane Manual Part No 403 596 00 Index T TIME 24 Trigger by Power 4 Troubleshooting 49 Generator Fault Does Not Reset 51 No Ultrasonic Output 51 Overload 51 Overtemperature 51 Pop up Fault Status Screens 53 System Power Diagnostic Procedures 51 Welding Problems 52 TUV Certification 4 U Ultrasonic Horn 41 User Information 3 Drawings and Tables 3 Notes Cautions and Warnings 3 Read the Manual First 3 W Welding Problems 52 Page 75 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 76 Dukane Manual Part No 403 596 00 Dukane 150 ISO CERTIFICATION Dukane chose to become ISO 9001 certified in order to demonstrate to our customers our continuing commitment to being a quality ven dor By passing its audit Dukane can assure you that we have in place a well defined and systematic approach to quality design manu facturing delivery and service This certificate reinforces Dukane s status as a quality vendor of technology and products To achieve ISO 9001 certification you must prove to one of the quality system registrar groups that you meet three requirements 1 Leadership 2 Inv
3. 403 596 00 Section 5 Process Control Settings iQ Information gt System Information Advanced Settings Figure 5 11 INFO Screen Dukane Corporation iQ AL Series 40kHz FP v1 08 MB v2 56 FPGA v7 Figure 5 11A System Information Example Screen Modified settings may affect operation of this unit Figure 5 12 Warning Screen NOTE Trigger by Power is only avail able when the weld mode is either Time or Energy Advanced Settings Free Run Freq 19900Hz Ramp Up Time 150mS Lock and Hold ONE OFF gt Trigger By Power OFF Press Enter To Accept Press Cancel To Abort Figure 5 13 Advanced Settings Screen Continued Page 33 iQ Series Ultrasonic Power Supply AL Plus User s Manual Continued from Previous Page Ramp Up Time This parameter increases the amplitude linearly in the programmed time period at the start of the weld from zero to the programmed amplitude level This brings the probe up to operating amplitude smoothly preventing shock stress Follow the on screen prompts to make setting adjustments Lock and Hold For an explanation of Frequency Lock and Hold please refer to Application Note 505 found on our website at http www dukane com us DL ApplData asp Follow the on screen prompts to make setting adjustments Trigger by Power For an explanation of Trigger by Power and the three settings that are connected with it please refer to Application Note 506 found on our web
4. Advanced Settings 33 Setup Maintenance ss ss Ee 35 Section 6 Probes and Probe Stacks 37 Section 7 Troubleshooting 49 Section 8 Specifications 55 Section 9 Contacting Dukane 61 Section 10 Appendices 65 Appendix A E Stop Circuitry Examples 67 Appendix B List of Figures 68 Appendix C List of Tables 69 EE 71 Dukane Manual Part No 403 596 00 Page v iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page vi Dukane Manual Part No 403 596 00 Section 1 Introduction Introduction General User Information 3 Read the Manual First AU 3 Notes Cautions and Warnings 3 Drawings and Tables 00 d System Overview 4 Key Features 4 Dukane Manual Part No 403 596 00 Page 1 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 2 Dukane Manual Part No 403 596 00 General User Information Read the 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 orga nized to allow you to learn how to safely operate this gen erator The examples given are chosen for their simplicity to illustrate basic operation concepts Notes Ca
5. Do not tighten the studs to these higher ratings as it may induce unnecessary stress in the assembly Page 45 iQ Series Ultrasonic Power Supply AL Plus User s Manual Stack Disassembly Stack disassembly is required when changing the booster or horn or for a thorough inspection of all stack components In mounted systems always remove the stack from its mounting to disassemble the stack components To establish a maintenance schedule inspect the mating surfaces after the first 200 00 hours of operation If they require cleaning halve the time between inspections If the surfaces do not require reconditioning then double the time between inspections Each system is different due to the large number of operational parameters and stress factors The assembly and disassembly procedures for a probe are shown in Figure 6 5 It makes no difference whether the horn is attached to the booster first or the booster is attached to the probe first ASSEMBLY lt Output End PROBE HOUSING PROBE A ASSEMBLY Mounting Stud Insert Into Horn First and Tighten to Torque Specs y Input End DISASSEMBLY Figure 6 5 Probe Assembly and Disassembly Page 46 Dukane Manual Part No 403 596 00 Separating the Horn from a Booster Booster from a Probe or Horn from a Probe On all transducers and horns with spanner wrench holes use only the correct size spanner wrench that came with your
6. Optional Ground the probe support This is a user supplied 14 Gauge wire Input Output Cable Attach the automation control cable from the user supplied automa tion equipment to the system HD 15 connector INPUTS OUTPUTS on the rear panel in Figure 3 3 Attach the high voltage coaxial cable from the probe to the ultrasound output connector in Figure 3 3 Connect the AC power cord to the generator IEC power inlet connector and plug the other end into an approved AC outlet O in Figure 3 3 Page 17 iQ Series Ultrasonic Power Supply AL Plus User s Manual System I O Connector Pinout Table 3 II lists the signal names and descriptions with more detailed descriptions listed on the next page Pin 2 3 EE IRCH WE Lo o 12 113 IN 15 BLUNHT Table 3 Il Generator Input Output Signals Pin 1 Enable Out This is a current limited voltage source output intended to connect to an E Stop circuit If an E Stop circuit is not used Pin must be jumpered to Pin 2 for ultrasound operation to be enabled Pin 2 Enable In The output from the E Stop circuit is connected to this pin when an E Stop circuit is used Otherwise this pin must be jumpered to Pin 1 for ultrasound operation to be enabled See Figure 4 1 in Appendix A for E Stop circuit wiring examples Pin 3 System Overload Status Output Pin 3 is an isolated digital NPN PNP status output that activates when an output overload
7. 4949 Service amp Parts 630 584 0796 Website The website has information about our products processes solutions and technical data Downloads are available for many kinds of literature Here is the address for the main website www dukane com us You can locate your local representative at www dukane com us sales intsales htm Dukane Manual Part No 403 596 00 Section 9 Contacting Dukane Page 63 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 64 Dukane Manual Part No 403 596 00 Appendices Appendix A E Stop Circuitry Examples 67 Appendix B List of Figures 68 Appendix C List of Tables 0 0 00 eee eee 69 Dukane Manual Part No 403 596 00 Page 65 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 66 Dukane Manual Part No 403 596 00 Appendices Appendix A E Stop Circuitry Examples Dedicated E Stop Switch Wiring Diagram System I O Connector iQ Auto Pin 1 Enable Out User supplied E stop switch Pin 2 Enable In Automation System Safety Circuit Wiring Diagram System I O Connector iQ Auto Pin 1 Relay contact block Enable Out Master Pin 2 control Enable In relay V User automation T control hardware Figure A 1 E Stop Circuitry Dukane Manual Part No 403 596 00 Page 67 iQ Se
8. 8 Grounding Contacts Typical Outlet Provided Cable 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 prop erly grounded three prong type Have a qualified electrician replace it fol lowing the National Electric Code and any local codes and ordinances that apply See Figures 2 1 and 2 2 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 Dukane Manual Part No 403 596 00 Lifting the Equipment How to Lift Safely Before lifting take a moment to think about what you re about to do Examine the object for sharp corners slippery spots or other potential hazards Know your limit and don t try to exceed it Ask for help if needed or if possible divide the load to make it lighter Know where you are going to set the item down and make sure it and your path are free of obstructions Then follow these steps Step 1 Step 2 Step 3 Step 4 Step 5 Stand close to the load with your feet sp
9. Freguency 40100 Power 4 W LCD Display Figure 4 1 Front Panel Power Switch Circuit Breaker The power switch circuit breaker has a rocker style actua tor 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 posi tion 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 Dukane Manual Part No 403 596 00 Section 4 Controls and Connections Power Switch 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 advanced settings System Information Identifies the current version of system software Advanced 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 Page 23 iQ Series Ultrasonic Power Supply AL Plus User s Manual Con
10. IGBT transistor current exceeded Peak Overload Caused by a severe frequency mis match Fault will reset when next weld cycle starts Resonant frequency not found or lost Generator Fault Check for a defective stack component Check for stack coupling to the fixture Fault will reset when next weld cycle starts Frequency Overload System Overtemperature fault detected Generator Fault Fault will reset when system cools down Over Temperature Generator Fault Internal communications error Turn generator power off and back on See Call Dukane service if the fault persists Table 7 Pop Up Fault Status Screens Dukane Manual Part No 403 596 00 Page 53 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 54 Dukane Manual Part No 403 596 00 Section 8 Specifications Specifications Generator Outline Drawing eee eee 57 Seg EEE NE Ee 58 Operating Environment EE 58 AC Power Requirements ss 0a 59 Regulatory Agency Compliance 60 Dukane Manual Part No 403 596 00 Page 55 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 56 Dukane Manual Part No 403 596 00 Section 8 Specifications 2 93 74 4 12 43 315 6 ALLOW 2 50mm FREE SPACE BEHIND GENERATOR FOR CABLE CONNECTIONS ALLOW 3 75mm ALLOW 2 50mm FREE SPACE 3 56 90 5 HA
11. 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 ultrasound U S is active 40 of IN CYCLE In Cycle power used EE Ta screen Power 225 W 2 i TT 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 Operate screen Weld Energy 301 J 1 IMT 40 of power delivered in previous weld Figure 4 1B Power Bar Graph Operate Dukane Manual Part No 403 596 00 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 Two Power up screens appear briefly Figure 4 3 and Figure 4 3A 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 3B 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 The generator is ready to start a
12. maintenance Failure to follow these instructions may result in the mating surfaces bonding and difficulty removing the tip from the horn 3 Thread the tip into the horn and tighten to the torque specifications below using an open end wrench of the correct size to fit the wrench flats of the tip This is illustrated in Figure 6 3 If necessary use a spanner wrench on horns with spanner wrench holes or an open end wrench on horns with wrench flats to keep the horn from turning in your hand A canvas strap wrench is permissible if it does not gouge or scratch the horn Replaceable Tips to Horn 3 8 x 24 tpi tip threads 5 16 x 24 tpi tip threads 1 4 x 28 tpi tip threads NOTE Do not apply any grease to the threads of the replaceable tip This may cause the tip to loosen from the horn resulting in inconsistent operation Figure 6 3 Replaceable Tip Installation NOTE Dukane Part No for the 20kHz span ner wrenches is 721 68 Dukane Part No for the 40kHz span ner wrenches is 721 44 Table 6 1 Tip Torque Unit Conversions Page 42 Dukane Manual Part No 403 596 00 Attaching the Mounting Stud to a Horn or a Booster 1 Inspect the stud for cracks or damaged threads Replace the stud if it is cracked or otherwise dam aged 2 Remove any foreign matter from the threaded stud and the mating hole 3 Thread the mounting stud into the input end of the hom or the input end ofthe booster and ti
13. system to provide sufficient torque to loosen a joint See Figure 6 6 Loosen ep EZ Sms Figure 6 6 Separating the Horn from the Booster On boosters and horns with wrench flats use only the correct size wrench to provide sufficient torque to loosen a joint when necessary Removing the Mounting Stud from a Horn or Booster Only use an Allen wrench of the correct size in the socket head s stud to remove the stud from the horn or booster Removing Replaceable Tips from a Horn Use an open end wrench of the correct size to fit the wrench flats of the detachable tip Use a spanner wrench on horns with spanner wrench holes or an open wrench on horns with wrench flats to provide an opposite force to keep the horn from turning in your hand Refer to Figure 6 7 for the correct tip removal procedure Dukane Manual Part No 403 596 00 Section 6 Probes and Probe Stacks NOTE Do not hold a booster by the mounting rings when removing the stud from the booster Use a spanner or open end wrench to provide opposite force and keep the hom or booster from tuming in your hand when loosening the stud Use a spanner wrench on horns and boosters with spanner wrench holes Use an open end wrench on horns and boosters with wrench flats Loosen Figure 6 7 Removing a Replaceable Tip from the Horn Page 47 iQ Series Ultrasonic Power Supply AL Plus User s Manual Booster Notes How to Tell the Booster Input End from
14. the Output 1 The depth of the threaded hole on the output end is always deeper than the threaded hole on the input end 2 On an amplifying booster gain gt 1 0 the larger diameter end is the input end On a reducing booster gain lt 1 0 the larger diameter end is the output end On a neutral acting booster the diameters are equal 3 The cap screws on the booster mounting rings are always inserted from the output end toward the input end How to Tell if the Booster Is Amplifying or Reducing Boosters have a die stamped number on their surface that indicates their gain or reduction If the number is greater than 1 0 e g 1 5 it is an amplifying booster If the number is less than 1 0 e g 0 6 it is a reducing or reverse booster A neutral booster has no gain and has 1 0 stamped on it A neutral or coupling booster is used to provide another probe stack clamping location for added stability Page 48 Dukane Manual Part No 403 596 00 Section 7 Troubleshooting Troubleshooting Dukane Manual Part No 403 596 00 No Ultrasonic Output ss aaa kaa 51 System Power Output Level 51 Welding PrODIEMS EE 52 Pop up Fault Status Screens 53 Page 49 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 50 Dukane Manual Part No 403 596 00 No Ultrasonic Output Probe Make sure that the probe cable is connected to t
15. weld cycle when the Ultrasound Activate Cycle Start Input Pin 12 is activated Stopping a Weld Cycle Normal Conditions The cycle stops when the programmed welding cycle ends if the generator is configured to weld by time or energy If it is configured to weld by automation the cycle ends when the Ultrasound Activate Cycle Start Input Pin 12 is deactivated Emergency Conditions Manual System Push the Power Switch to OFF See Figure 4 2 to stop the ultrasound signal This may be done under any conditions Automated System Customer supplied external controls provide the means to stop the cycle for an automated system An auxiliary cable connects these external controls to the iQ generator at the INPUTS OUTPUTS connector Dukane Manual Part No 403 596 00 Push OFF Section 4 Controls and Connections wg Push ON o Figure 4 2 Power Switch Software version MB FPGA version Current Setup iQ AL Series xxkHz WOOK Setup 1 VERE p Address http www dukane com Figure 4 3 Power up Screen 1 Trigger by Power available U S Patent 47475801 Figure 4 3A Power up Screen 2 Weld by Time Weld Time 0 000 S Weld Energy 0 J 1 HII Figure 4 3B Operate Screen After Power up Page 25 iQ Series Ultrasonic Power Supply AL Plus User s Manual LCD Display Overview There are two basic kinds of screen displays Operate screens and In Cycle screens An Operate screen tells
16. 3 3 isa DB 9M standard D subminiature nine circuit male typically used for RS 232 serial communications This serial port DTE connects to a serial port DCE on a computer via a standard 9 pin serial cable If the computer does not have a serial port you may use a USB to serial conversion cable This port is used for field updates to the generator firmware without removing the enclosure cover This port can also be used with a software application running on a Windows PC to modify the factory default system settings and hardware configurations Contact your local sales representative for software availability information and access to documentation that will allow you to make use of the configuration port features Page 19 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 20 Dukane Manual Part No 403 596 00 Section 4 Controls and Connections Controls Front Panel Overview 0 00000 revene 23 Start up Sequence 2 4 ET ENER EER ER RE EE aa RR KG 25 LED Display Overview EEN 26 Dukane Manual Part No 403 596 00 Page 21 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 22 Dukane Manual Part No 403 596 00 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 IN CYCLE
17. 3 596 00 Ultrasonic Horn The horn transfers the ultrasonic mechanical vibrations originating at the transducer in the probe housing to the plastic parts through direct physical contact The horn is precision machined and designed to vibrate at either 20kHz 30kHz 40kHz 50kHz or 70kHz The tuning is accomplished using electronic frequency measurement Inherent variations in material composition prevent tuning by dimensional machining alone There are many different horn profile styles depending upon the process requirements Factors which affect the horn design are the materials to be welded and the method of assembly Horns are usually constructed from aluminum hardened steel or titanium As the frequency increases vibration amplitude typically decreases but internal stress in the horn increases Higher frequencies are used for delicate parts that cannot handle a lot of amplitude Some factors to keep in mind for high frequency e g 40kHz ultrasonic welding versus low frequency e g 20kHz ultrasonic welding are listed here 1 Stress in the hom is higher at high frequencies 2 Wear on the horn is greater at high frequencies 3 Clean and flat mating surfaces between the horn booster and transducer are more critical at high frequencies Booster The function of a booster is to alter the gain i e output amplitude of the probe A booster is amplifying ifits gain is greater than one and reducing if its gain is less tha
18. C Power Requirements Ultrasonic Pressure Ultrasonic Pressure i Generator Models kHz Useful Beam 360 degrees Ultrasonic Pressure Operator s Position dB Ultrasonic Pressure 1 m from the Equipment dB Table SI iQ Generator Ultrasonic Pressure NOTE All measurements taken with Data Physics Dynamic 4 Channel Signal Analyzer with calibrated 377C01 Microphone and 426B02 Preamplifier Dukane Manual Part No 403 596 00 Page 59 iQ Series Ultrasonic Power Supply AL Plus User s Manual Regulatory Agency Compliance FCC The iQ generator complies with the following Federal Communications Commission regulations e The limits for FCC measurement procedure MP 5 Methods of Measurement of Radio Noise Emissions from ISM Equipment pursuant to FCC Title 47 Part 18 for Ultrasonic Equipment CE Marking This mark on your equipment certifies that it meets the requirements of the EU European Union concerning interference causing equipment regulations CE stands for Conformit Europe ne European Conformity The equipment complies with the following CE requirements e The EMC Directive 2004 108 EC for Heavy Industrial EN 61000 6 4 2001 EN 55011 2003 EN 61000 6 2 2005 EN61000 4 2 EN61000 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN61000 4 8 EN61000 4 11 e The Low Voltage Directive 2006 95 EC e The Machinery Directive 2006 42 EC EN 60204 2006 Safety of Machinery Electrical Equipment of Machin
19. IEC AC Power Cord Part Numbers ni Re AR ee ee ee Re AR ee 17 A Generator Input Output Signals ENNEN 18 6 I Tip Torque Unit Conversions ENEE 42 GI Stud Torque Unit Conversions ee RA RA RR AR Ee RR NANANA RE ee RR ee ee RR ee Re Re ee Re Re dee i 43 6 III Horn Booster Torque Unit Conversions aaa 45 7 1 Pop up Fault Status Screens n anan ann ee ee ee ee NANANA NAGANA ee ee ee ee ee ee ee ee 53 8 iO Generator Mel E 58 EBI AC Power Requirements era ee ee ee ee ee 59 8 IIl io Ultrasonic Pressure ciers ennan eean aE A EEA EEEE ERER ES ETE 59 Dukane Manual Part No 403 596 00 Page 69 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 70 Dukane Manual Part No 403 596 00 Index Index Dukane Manual Part No 403 596 00 Page 71 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 72 Dukane Manual Part No 403 596 00 Index A Advanced Settings 33 Agency Compliance IP International Protection Rating 60 AMP 24 Amplitude Adjustment 32 Appendices E Stop Circuitry Examples 67 List of Figures 68 List of Tables 69 Arrow Keys 24 Attaching the Horn to a Booster Booster to a Probe or Horn to a Probe 44 Attaching the Mounting Stud to a Horn or a Booster 43 Automation Controlled System 17 B Before Installation Lockout Tagout Devices 13 Booster 41 Booster Notes 48 C CANCEL 24 CE Certific
20. Intelligent Assembly Solutions IO Series ULTRASONIC POWER SUPPLY AL Plus AUTOMATED HAND PROBE PRESS User s Manual Dukane Part No 403 596 00 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 Em ISO 900 registered facilities IV www dukane com us iQ Series Ultrasonic Power Supply AL Plus User s Manual Copyright O 2014 Dukane Intelligent Assembly Solutions 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 Corporation Notice of Liability The information contained in this manual is distributed on an As is basis without warranty While ev ery precaution has been taken in the preparation of this manual Dukane Corporation shall not have any li ability 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 Specifications subject to change without notice This user s manual documents product features hardware and co
21. NDPROBE AND AUTOMATION CONNECTORS ON Figure 8 1 Generator Outline Drawing Page 57 Dukane Manual Part No 403 596 00 iQ Series Ultrasonic Power Supply AL Plus User s Manual Weights Me e Generator Only Generator Packing 17 7 71 Materials Table 8 1 iQ Generator Weights Operating Environment Operate the equipment within these guidelines Temperature 40 F to 100 F 5 C to 38 C Air Particulates Keep the equipment dry Minimize exposure to moisture dust dirt smoke and mold Humidity 5 to 95 non condensing 5 C to 30 C Nonoperating storage guidelines Temperature 4 F to 158 F 20 C to 70 C Air Particulates Keep the equipment dry Minimize exposure to moisture dust dirt smoke and mold Humidity 5 to 95 non condensing 0 C to 30 C Page 58 Dukane Manual Part No 403 596 00 Section 8 Specifications AC Power Requirements Overload i Operating Generator Power Input AC Power Requirements SE Frequency Model Number Rating Nominal AC Volt AC SE eng Watts 20kHz 20ALP060 1S 100 120 VAC 50 60 Hz Q 9 0 Amps 20kHz 20ALP060 2S 200 240 VAC 50 60 Hz Q 4 5 Amps 30kHz 30AL060 1S 100 120 VAC 50 60 Hz Q 9 0 Amps 600 15 0 Amps 30kHz 30AL060 2S 200 240 VAC 50 60 Hz Q 4 5 Amps 40kHz 40AL060 1S 100 120 VAC 50 60 Hz Q 9 0 Amps 40kHz 40AL060 2S 200 240 VAC 50 60 Hz Q 4 5 Amps Table 8 II A
22. Power Cord with Strain Relief O I 7 CONFIGURATION DUKANE CORP WARNING ST CHARLES IL 60174 A AN POWER LINE OUTLET MADE IN U S A MUST BE GROUNDED DISCONNECT LINE POWER U S PATENT 5 880 580 amp BEFORE REMOVING COVER OTHER PATENTS PENDING L IEC Connector Detail Figure 3 3 Generator Detail Rear View Page 100 120 Volt Model 16 G 200 240V Model Dukane Manual Part No 403 596 00 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 1 Continent of Use Power Cord Part Number North America 200 1541 240V 10A Europe 200 1542 240V 10A dia 200 1624 240V 10A Table 3 1 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 Dukane Manual Part No 403 596 00 Section 3 Installation Automation Controlled System Step I Step 2 Step 3 Step 4 Step 5 Ground the generator chassis using the supplied 14 Gauge wire and attach it to the grounding stud in Figure 3 3
23. Start Guide Complete the basic connections as shown below Step 1 Step 2 Step 3 Step 4 AC Line Input LO Input Output Connector Grounding Stud AC Power Cord Connection Connect the AC line For the 100 120V model plug the permanently attached power cord into a suitable receptacle For the 200 240V model attach the female end of the power cord to the generator s power inlet con nector Y in Figure 3 3 Attach the VO cable connector to the generator s input output connection O in Figure 3 3 Secure the connector to the system using the two jack screws attached to the connector hood Ground the generator chassis with the supplied 14 Gauge wire Attach one end to the grounding stud in Figure 3 2 Attach the other end to the near est grounded metal pipe or equal earth ground Attach the male end of the power cord to a suit able line receptacle Connector See Page 19 for information about the rear panel CONFIGURATION 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 4 below Push ON Push OFF Figure 3 4 Rocker style Power Switch Circuit Breaker
24. TUP and the display will look like Figure 5 19 4 Delete To delete the setup select Delete as shown in Figure 5 19 and press the ENTER key A pop up screen appears to ask you to confirm your choice Select YES or NO and press ENTER again Dukane Manual Part No 403 596 00 Section 5 Process Control Settings Setup Maintenance Delete Setup 1 EMPTY Figure 5 17 Setup Maintenance 1 Setup 1 Empty Load Defaults YES Figure 5 17A Pop up Load Defaults Setup Maintenance Delete Setup T 0 000 S E 0J TBP OFF Mode Automation A 100 H 0 0 S Figure 5 18 Setup Maintenance 2 Setup Maintenance Load Setup id Mode Automation T 00008 A 100 E OJ H 0 0 S TBP OFF Figure 5 19 Setup Maintenance 3 Continued Page 35 iQ Series Ultrasonic Power Supply AL Plus User s Manual Continued from Previous Page Setup Maintenance Changing the Current Setup Weld by Time Try using your navigation skills on this example ES 1 Follow instructions on Page 24 to set the mode to Press Enter To Accept Weld by Time Set the time to 1 520 seconds Piss CRS To Avai See Figure 5 20 Figure 5 20 Set Time 2 Press SETUP and you will notice that the time just set appears in the current setup The new time replaced whatever time was in the current setup It was changed or overwritten 3 To avoid having your current setup changed Press SETUP and with LOAD highlighted u
25. acks Ultrasonic Probe Overview 39 Theory of Operation emmemasesesssaesanacaneneconeo 40 Probe CONNQUuIANON sae ANAN 40 Ultrasonic Hon EN EE 41 PO EDE EE EK 41 Stack Assemblies GEE de EE shine 42 Attaching Replaceable Tips 42 Attaching Mounting Stud to Horn Booster 43 Attaching Horn to Boostetr ccssseeeeeeeeees 44 Attaching Booster to Probe 44 Attaching Horn to RE 44 Stack RI EE 46 ee ie 48 Dukane Manual Part No 403 596 00 Page 37 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 38 Dukane Manual Part No 403 596 00 Ultrasonic Probe Overview Operating Notes Compressed Air Fitting In continuous duty operation it is important to keep the probe cool with compressed air Use the probe s air fitting to connect the air source to the probe See Section 8 Specifications for more detail Dukane Manual Part No 403 596 00 Section 6 Probes and Probe Stacks NOTE Compressed air supply Make sure the air is clean oil free and dry Page 39 iQ Series Ultrasonic Power Supply A Plus User s Manual Theory of Operation Plastic welding is the most common application of ultrasonic assembly To perform ultrasonic plastic welding the vibrating tip is brought into contact with one of the work pieces Pressure is applied and ult
26. ake sure you have adequate ventilation whenever these plastics are processed Dukane Manual Part No 403 596 00 Section 2 Health and Safety WARNING Never operate the gen erator with the cover off This is an unsafe practice and may cause injury Page 7 iQ Series Ultrasonic Power Supply AL Plus 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 Con tinental European countries Refer to Figure 2 3 How ever if your application requires another type of power cord check with your equipment supplier and follow lo cal regulations concerning proper wiring and grounding Page
27. ation 4 CE Marking 60 Changing the Current Setup 36 Chassis Grounding Stud 15 Compressed Air Fitting 39 Connecting Cables Quick Start Guide 16 Control Keys 23 Controls Control Keys 23 AMP 24 Dukane Manual Part No 403 596 00 Index and Keys 24 Arrow Keys 24 CANCEL 24 ENERGY 24 ENTER 24 HOLD 24 INFO 23 SETUP 23 TIME 24 Front Panel Overview 23 Power Switch Circuit Breaker 23 System LCD Display 24 D Deleting a Setup 36 Digi Trac Tuning 4 Domestic Power Grounding 8 Drawings and Tables 3 Dukane 61 Contacting 63 Intelligent Assembly Solutions 63 www dukane com us 63 E Electrical Safety 8 Emergency Conditions 25 Automated System 25 Manual System 25 ENERGY 24 ENTER 24 F FCC 60 Page 73 iQ Series Ultrasonic Power Supply AL Plus User s Manual H Health and Safety Electrical Safety 8 Domestic Power Grounding 8 International Power Grounding 8 Lifting the Equipment 9 Plastics Health Notice 7 HOLD 24 I Industrial Line Power Source 4 INFO 23 Installation Automation Controlled System 17 Before Installation 13 Connecting Cables Quick Start Guide 16 Placement 15 Power Cords 17 RFI Grounding 15 System I O Connector Pinout 18 Unpacking 15 International Power Grounding 8 IP International Protection Rating 60 ISO 9001 Certification 4 K Key Features 4 L LCD Display 26 Lifting the Equipment 9 Linear Ramp Soft Start 4 Line Voltage Regulation 4 Load Regulation 4 Lockout
28. ay be used However it is likely to leave carbonaceous deposits on the surface and require more frequent joint maintenance Grease may be omitted if mylar washers are preferred on sys tems that require frequent changes Mylar is plastic and will creep under compression so mylar is not recom mended for systems that are not changed frequently Failure to follow these instructions may result in the mating surfaces bonding and difficulty removing the horn from the booster or the booster from the probe Page 44 NOTE Always remove a probe stack from the machine in which it is mounted before attaching or removing a horn a F Tightens Figure 6 4 Stack Assembly Procedure Continued Dukane Manual Part No 403 596 00 Section 6 Probes and Probe Stacks Continued from Previous Page 6 Thread the components together and tighten to the following torque specifications using only the correct size wrenches Use spanner wrenches on components with spanner wrench holes or an open end wrench on components with wrench flats See Figure 6 4 for the correct procedure Refer to Table 6 111 for torque unit conversions Be careful not to overtighten nib Frib om ve 2 i Table GI Horn Booster Torque Unit Conversions Dukane Manual Part No 403 596 00 NOTE Horn and booster torque specifications are higher than stud torque specs Be sure to tighten the horn or booster joints to the higher torque limits
29. cle The cycle starts and the ultrasonic signal U S activates when Ultrasound Activate Cycle Start Input Pin 12 is activated When the Ultrasound Activate Cycle Start Input Pin 12 is deactivated the ultrasonic signal stops and the cycle is complete unless there is a hold time programmed Time In TIME mode the operator sets a maximum time seconds that the ultrasonic signal will be active for each weld cycle The cycle starts when the Ultrasound Activate Cycle Start Input Pin 12 is activated The U S stops when the programmed time is reached Energy In ENERGY mode the operator sets a maximum energy Joules the generator will reach during the weld cycle 4 maximum weld time must be set when welding by energy If the energy level is not reached the preset for time will determine when the U S is deactivated When the preset energy level is reached the U S will be deactivated The cycle starts when the Ultrasound Activate Cycle Start Input Pin 12 is activated When the programmed energy is reached ultrasound stops Dukane Manual Part No 403 596 00 Section 5 Process Control Settings Page 29 iQ Series Ultrasonic Power Supply AL Plus User s Manual Navigating the Modes When the generator is first powered up the default operating mode is Automation and Automation Weld is shown at the top of the display as shown in Figure 5 1 Navigate to Time Mode 1 Follow the sequence shown in the figures to the right to
30. condition is tripped This output will be an open circuit if an output overload condition is not tripped This output will remain latched ON until the U S Activate input is switched OFF and then ON again Page 18 Pin 4 Ultrasound Active Status Output Pin 4 is an isolated digital NPN PNP status output that activates when the system is delivering ultrasonic power to the load attached to the ultrasound output connector This output will be an open circuit when the ultrasound output is off Pin 5 Any Fault Status Output Pin 5 is an isolated digital NPN PNP status output that activates whenever any fault condition is detected that inhibits ultrasound output and normal system operation This output will be an open circuit when no system fault conditions are active Pin 6 No Connection Pin 7 Isolated Status Output Common Pin 7 is electrically isolated from chassis ground This common line should be connected to the negative output of a user provided isolated 24VDC power supply for a PLC sourcing input card For a PLC Sinking input card this line is connected to the positive output of the isolated 24VDC power supply Continued Dukane Manual Part No 403 596 00 Section 3 Installation Continued from Previous Page Pin 8 System Ready Status Output This status output signal will activate only when the system is ready to activate ultrasound or begin a weld cycle Pin 8 is an isolated digital NPN PNP status output that ac
31. e 5 9A HOLD Time 2 Amplitude 100 Figure 5 10 Amplitude Dukane Manual Part No 403 596 00 System Information Advanced Settings When the INFO key is pressed the display looks like Figure 5 11 Using the keys move the pointer to indicate System Information or Advanced Settings Press ENTER to make the selection 1 System Information Manufacturer s information is shown including the manufacturer s name the name of the system and the software identification Figure 5 11A shows an example of this information 2 Advanced Settings After Advanced Settings is selected a warning screen is displayed as shown in Figure 5 12 Adjusting these settings may affect the operation of your unit Before you change a setting please check with Dukane personnel for their recommendations The warning screen is shown for a few seconds then the Advanced Settings screen appears See Figure 5 13 Adjustments can be made to Free Run Frequency Ramp Up Time Frequency Lock and Hold and Trigger By Power but note that Trigger by Power is only available when the weld mode is Time or Energy Free Run Frequency Free Run is the frequency at which the generator drives the ultrasound output pulses until a valid resonant frequency feedback signal is detected Typically this value should be below the operating frequency of the probe Follow the on screen prompts to make setting adjust ments Dukane Manual Part No
32. er s Manual Continued from Previous Page Lockout Tagout Procedure to use BEFORE making any internal adjustments to the generator 1 Push the generator s AC power switch breaker to the OFF position 2 Unplug the generator s electrical cord from its source 3 Authorized personnel apply a lockout tagout LOTO device to the plug end of the generator s electrical cord Using a typical clam shell type LOTO device 1 Open the clam shell 2 Place the electrical cord plug end inside the shell 3 Close the shell 4 Secure the shell with its lock and lock it 4 Wait a minimum of five minutes for the generator to discharge its electrical energy 5 After taking these steps make the necessary adjustments to the generator Assuming the generator is being put back into service Procedure to use AFTER making any internal adjustments to the generator 1 Authorized personnel remove the lockout tagout device from the plug end of the generator s electrical cord Using a typical clam shell type LOTO device 1 Unlock the protective shell 2 Open the shell exposing the electrical cord end 3 Remove the LOTO device and set it aside 2 Plug the generator s electrical cord into its AC power source 3 Push the generator s AC power switch breaker to the ON position Page 14 Dukane Manual Part No 403 596 00 Unpacking Carefully open your shipping container and make sure it contains the items shown on t
33. erance of about 10 See Figure 10 4 for a handy conversion graph Page 43 iQ Series Ultrasonic Power Supply AL Plus User s Manual Attaching the Horn to a Booster Booster to a Probe or Horn to a Probe 1 Inspect all surfaces to be joined for stress cracks chips or gouges Any of these irregularities will affect operation and could lead to further equipment damage Contact the Dukane Ultrasonic Tooling Department concerning a damaged booster 2 Ensure that the mating surfaces of the two components are clean and smooth These surfaces must make inti mate contact for the mechanical energy to pass from one component to the next Pitting or a buildup of old grease and dirt on a mating surface will interfere with the energy transfer and reduce the power delivered 3 Make sure that the stud in the horn or booster is tight See the preceding mounting stud assembly instructions for torque specifications 4 Remove any foreign matter from the threaded stud and mating hole 5 Apply an extremely thin layer of a high temperature high pressure silicon grease to the surface that mates with the horn The grease will allow both surfaces to intimately mate and become acoustically transparent which improves the energy transfer We recommend Dow Corning 4 or 111 as an alternate A small packet of Dow Corning 4 is supplied with the system If you cannot use a silicon based grease in your facility a petroleum based grease m
34. erican 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 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 TUV Certification TUV Rheinland certifies Dukane products comply with applicable UL Underwriters Laboratories and CSA Canadian Standards Association requirements Dukane Manual Part No 403 596 00 Section 2 Health and Safety Health and Safety General Considerations ss scans cx Seen E fa desk 7 Plastics Health Notice NNN CEA T Electrical Safety ae le EE d ENEE 8 Lifting the Equipment RE EE OE SEE 9 Dukane Manual Part No 403 596 00 Page 5 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 6 Dukane Manual Part No 403 596 00 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 know
35. es Part 1 General Requirements IP International Protection Rating The iQ generator has an IP rating from the IEC Interna tional Electrotechnical Commission The rating is IP2X in compliance with finger safe industry standards Page 60 UL The iQ generator complies with these standards Underwriters Laboratories UL 61010 1 2012 and National Standards of Canada CAN CSA C22 2 No 61010 1 12 2012 as verified by TUV Rheinland A T VRheinland Dukane Manual Part No 403 596 00 Section 9 Contacting Dukane Contacting Dukane Dukane Manual Part No 403 596 00 Page 61 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 62 Dukane Manual Part No 403 596 00 Contacting Dukane Identify Equipment When contacting Dukane about a service related problem be prepared to give the following information e Model number line voltage and serial number e Fault error indicators from the LCD display e Software version Press INFO With pointer at System Information press ENTER to get this data e Problem description and steps taken to resolve it Many problems can be solved over the telephone so it is best to call from a telephone located near the equipment Intelligent Assembly Solutions Mailing Address Dukane Ultrasonics 2900 Dukane Drive St Charles IL 60174 USA Phone 630 797 4900 E mail ussales dukane com Fax Main 630 797
36. ghten to the following torque specifications using an Allen wrench in the socket head of the mounting stud Table 6 II lists the torque specifications in units for both English and Metric systems of measure ments DO NOT hold the booster by the mounting rings when tightening stud The mounting rings have a shear pin which could snap under excessive torque Use a spanner wrench on horns with spanner wrench holes or an open end wrench on horns with wrench flats to keep the horn or booster from turning in your hand Table 6 ll Stud Torque Unit Conversions Always assemble the mounting studs that mate boosters transducers and horns to the input end of the horn or the input end of the booster first This is shown in Figure 6 5 NEVER thread a stud into the transducer or the output end of the booster first See Booster Notes in this section for correctly identifying the output end of a booster Dukane Manual Part No 403 596 00 Section 6 Probes and Probe Stacks NOTE Do not apply any grease to the stud threads or the tapped hole This may cause the stud to loosen If the stud wanders within the joint it can vibrate resulting in excessive heat In some cases this can melt the tooling material NOTE To convert inch lbs to ft lbs divide by 12 To convert inch Ibs to Nm divide by 8 852 To convert ft lbs to Nm multiply by 1 356 To convert Nm to ft lbs multiply by 0 7376 Torque specifications have a tol
37. gy level Press Cancel To Abort Figure 5 7 Energy Weld Mode 1 Weld By Energ Maximum Weld Time 1 000 S Figure 5 8 Energy Weld Mode 2 Page 31 iQ Series Ultrasonic Power Supply AL Plus User s Manual Hold HOLD is used more often with Time or Energy modes but it can be used with the Automation mode HOLD does not allow the automation program to begin a new cycle until HOLD is finished To set a HOLD period 1 Select the weld mode Automation Time Energy 2 Set the time and energy parameters as needed 3 Press the HOLD key The screen will appear as it does in Figure 5 9 4 Setthe time withthe keys A maximum of 5 0 seconds Figure 5 9A shows a setting for 2 0 seconds 5 Press the ENTER key to confirm your selection Amplitude Adjustment Amplitude refers to the movement of the hom at its workface The higher the amplitude setting the higher the power output level will be at a particular pressure level Amplitude settings are given as a percent of the horn s nominal amplitude in the range of 20 to 100 It is typical to leave the amplitude setting at 100 for maximum power output To adjust amplitude 1 Press the AMP key The screen will appear as in Figure 5 10 2 Set the amplitude level using the keys and the keys 3 Press ENTER to confirm your amplitude setting Page 32 Hold Time OFF S Figure 5 9 HOLD Time 1 Hold Time 2 0 S Figur
38. he generator connector PROBE and secured to the rear panel Also make sure the probe stack is properly assembled System Power Output Level Overload When an overload occurs it will automatically reset when the next ultrasound activation signal begins If the condition persists Turn the generator OFF and 1 Check the system Change the probe to one that is known to be good 2 Turn the generator ON and see if the fault condition has been corrected Overtemperature When the system overheats and the generator s internal temperature exceeds 85 C 185 F an overtemperature fault condition will trip When the system cools the system automatically resets the overtemperature fault Generator Fault Does Not Reset When a system fault condition does not automatically reset the generator needs servicing System Power Diagnostic Procedures The only fault indications available with these probe systems are the ones shown on the LCD display Dukane Manual Part No 403 596 00 Section 7 Troubleshooting NOTE The LCD screen displays a variety of pop up status changes as they oc cur Check Table 7 1 Pop up Fault Status Screens Page 53 NOTE When Latching Faults is enabled ENTER must be pressed to clear a fault Page 51 iQ Series Ultrasonic Power Supply AL Plus User s Manual Welding Problems Weak Welds Weak welds or underwelding is caused by insufficient energy being transmitted
39. he shipping documents Inspect all items and report any missing items or damage immediately Placement 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 REI 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 Dukane Manual Part No 403 596 00 Section 3 Installation 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 3 on the following page Page 15 iQ Series Ultrasonic Power Supply AL Plus User s Manual Connecting Cables Quick
40. ion Controlled System 2 2 0000 e eee eee 17 System I O Connector Pinout 18 Dukane Manual Part No 403 596 00 Page 11 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 12 Dukane Manual Part No 403 596 00 Before Installation As you plan for the installation of your generator please consider these important subjects as listed below e When to use lockout tagout devices e Lifting the generator safely See Section 2 Health and Safety Page 9 When to Use Lockout Tagout Devices Figure 3 1 Lockout Device In Open Position Unlocked The typical kind of LOTO device for this generator is a clam shell type device with lockout capability The LOTO device is placed over the plug end of the generator electrical cord This effectively prevents access to the energy isolation point See the example of one such device in the figure above The figure to the right shows the lockout device in the closed locked position Dukane Manual Part No 403 596 00 Section 3 Installation WARNING Electrical safety haz ards exist inside the generator chassis Be fore making any internal adjustments to the gen pg erator apply a lockout tagout LOTO device to N the generator chassis E WE O EE HE EE EE EE EE EE EE uu ma ma di Figure 3 2 Bottom Lockout Device In Closed Position Locked Continued Page 13 iQ Series Ultrasonic Power Supply AL Plus Us
41. jury or loss of life Condition Electrical Hearing or Practice Hazard Protection Page 3 iO Series Ultrasonic Power Supply AL Plus User s Manual System Overview Your iQ Series Ultrasonic Power Supply AL PIus an ultrasonic generator provides a versatile 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 are 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 also includes an RFI line filter that passes strict CE test specifications for global applications Key Features Trigger by Power is a Dukane patented feature that produces greater weld consistency by requiring that a sufficient amount of pressure force is applied to the part before the actual weld begins Trigger by Power is a cost effective alternative to trigger by force because it does not require additional expensive components such as a load cell amplifier board or cabling e Compact Generator is small and easily moved and this allows your table or work bench to accommodate more of the items needed for your process e 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 horn
42. n 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 man ufacturer Unauthorized modifications may cause injury to the operator and or equipment damage In addition unauthorized modifications will void the equipment war ranty Keep the Cover On Do not remove any equipment cov er unless specifically 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 8 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 M
43. n one A neutral or coupling booster is used to provide an additional clamping location for added probe stack stability A probe designed to be mounted in a fixture along with a booster and horn is shown in Figure 6 2 This is commonly referred to as a stack As indicated the components are secured with threaded studs Dukane Manual Part No 403 596 00 Section 6 Probes and Probe Stacks Probe Housing Booster Figure 6 2 Probe Booster and Horn Page 41 iQ Series Ultrasonic Power Supply AL Plus User s Manual Stack Assembly Attaching a Replaceable up to a Horn Inspect all horn and tip surfaces for stress cracks chips or gouges Any of these irregularities will affect operation and could lead to further equipment damage Contact the Dukane Ultrasonics Tooling Department concerning damaged horn components 2 Apply an extremely thin layer of a high temperature high pressure silicon grease to the back surface that mates with the horn The grease will allow both surfaces to intimately mate and become acoustically transparent which improves the energy transfer Do not apply any grease to the threads We recommend Dow Corning 4 or 111 as an alternate A small packet of Dow Corning 4 is supplied with the system If you cannot use a silicon based grease in your facil ity a petroleum based grease may be used However it is likely to leave carbonaceous deposits on the surface and require more frequent joint
44. navigate from Automation mode to Time mode In Automation mode press the TIME key Figure 5 2 2 The phrase Enter Changes Mode means when the ENTER key is pressed the mode will change So press the ENTER key and the Weld by Time screen seen in Figure 5 3 appears 3 Set the time Use the 4 and the keys to move the cursor and to set the digits for the weld time you want 4 Press the ENTER key to accept the time that has been set Figure 5 4 Press the CANCEL key if you decide not to set the time NOTE Navigating to Automation Mode Set Time or Energy depending on mode to OFF and press ENTER This will put you back in Automation mode Alternately Find an empty setup Press SETUP Press ENTER A pop up screen about defaults appears Setup 1Empty Load Defaults ves No Select YES to load the default operating mode which is Automation and you can weld using the Automation mode Page 30 Automation Weld Weld Time 0 000 S Weld Energy 0 J 2 MITT Figure 5 1 Automation Weld Mode Automation Weld Weld By Time OFF Enter Changes Mode Figure 5 2 Navigate to Time Mode Weld by Time Weld By Time Set the time OFF S Press Enter To Accept Press Cancel To Abort Figure 5 3 Time Weld Mode 1 Weld by Time Weld Time 0 500 S Press Enter To Accept Press Cancel To Abort Figure 5 4 Time Weld Mode 2 Dukane Manual Part No 403 596 00 Na
45. ntrols software available at the time this user s manual was published Printed in the United States of America Dukane Part Number 403 596 00 Dukane 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 7 475 801 and 8 052 816 Page ii Dukane Manual Part No 403 596 00 Revision History Revision Revision Number Summary Date 00 Original release 06 10 2014 Dukane Manual Part No 403 596 00 Page iii iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page iv Dukane Manual Part No 403 596 00 Contents Section 1 Introduction 1 Section 2 Health and Safety 5 Section 3 Installation 11 Before Installation 13 IDSC INGOs ots thaw keer EE 15 Placement a nn eke bed dS Soa dd da 15 RFI Grounding se roes ae EE pad 15 Connecting Cables 16 System VO Connector Pinout 18 Section 4 Controls 21 Front Panel Overview 055 23 Start up Sequence 25 LCD Display Overview 26 Section 5 Process Control Settings 27 Selecting the Weld Mode 29 Navigating the Modes 30 Hold seere 32 Amplitude Adjustment ER System Information
46. olvement 3 Quality in Line Organizations and Quality System Infrastructure The ISO 9001 standard establishes a minimum requirement for these requirements and starts transitioning the company from a traditional inspection oriented quality system to one based on partnership for continuous improve ment This concept is key in that Dukane no longer focuses on inspection but on individual processes Dukane s quality management system is based on the following three objectives 1 Customer oriented quality The aim is to improve customer satisfaction 2 Quality is determined by people The aim is to improve the internal organization and cooperation between staff members 3 Quality is a continuous improvement The aim is to continuously improve the internal organization and the competitive position ISO 9001 CERTIFIED Dukane products are manufactured in ISO registered facilities View the Dukane ISO certificate of compliance at Attp www dukane com ISORegistrationCertificate pdf Please refer to our website at www dukane com us sales intsales htm to locate your local representative iQ Series Ultrasonic Power Supply AL Plus User s Manual Part No 403 596 00 www dukane com us Printed in the United States of America Dukane Intelligent Assembly Solutions 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 FAX 630 797 4949
47. rasonic energy travels through the material generating frictional heat at the contact point of the two parts The frictional heat melts a molded ridge of plastic on one of the pieces and the molten material flows between the two surfaces When the vibration stops the material solidifies forming a permanent bond Probe Configuration A basic ultrasonic probe package consists of 1 Aprobe which houses the transducer to convert the elec trical energy supplied by the generator into mechanical vibrations 2 A horn to transfer the mechanical vibrations from the probe to the parts to be welded Optional components include special replaceable tips which can be threaded on to the tip of the horn and a booster to amplify the mechanical vibrations of the horn A basic probe system is shown in Figure 6 1 Normally a booster is not used with a probe as this increases the length and weight and reduces its versatility The optional threaded titanium tip can be used when the application calls for a staking profile or a pointed spot weld Replaceable tips are not commonly used in high volume production environments Page 40 Figure 6 1 Probe Horn and Tip For automated systems we recommend that you use a booster with the probe as shown in Figure 6 2 Read Dukane s Application Note 504 Ultrasonic Acoustic Stack Mounting Guidelines found on our website at http www dukane com us DL ApplData asp Dukane Manual Part No 40
48. read apart about shoulder width with one foot slightly in front of the other for balance Squat down bending at the knees not your waist Tuck your chin while keeping your back as vertical as possible Get a firm grasp of the object before be ginning the lift Begin slowly lifting with your LEGS by straightening them Never twist your body during this step Once the lift is complete keep the object as close to the body as possible As the load s center of gravity moves away from the body there is a dramatic increase in stress to the lumbar region of the back If you must turn while carrying the load turn using your feet not your torso To place the object below the level of your waist follow the same procedures in re verse order Remember keep your back as vertical as possible and bend at the knees Dukane Manual Part No 403 596 00 Section 2 Health and Safety NOTE Equipment weights are shown in Section 8 Specifications Table 8 1 Page 9 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 10 Dukane Manual Part No 403 596 00 Section 3 Installation Installation Before Installation cascas Sei EISE una e ga ak we 13 When to Use Lockout Tagout Devices 13 Unpacking ss ser se EE HE BEEK eee E Lp 15 Placement Ae E ee Sege 15 RFI Grounding ER 15 KEES DEE RE SE AE ED 16 Power COS EE rossi asd ce Se ds ud BAHAG GS 17 Automat
49. ries Ultrasonic Power Supply AL Plus User s Manual Appendix B List of Figures No Description Page 2 1 Example of 125 Volt Grounded 3 prong Plug and Receptacle ee ee ee 8 2 2 Example of 250 Volt Grounded 3 prong Plug and Receptacle ie ee ee 8 2 3 International 220 240V GUN Naa EE aaa EE GEE a 8 3 1 Lockout Device in Open Position Unlocked ee eie ee ee ER EE EE ee ee ee ee Ee 13 3 2 Bottom Lockout Device in Closed Position Locke 13 3 3 Generator Detail Rear Views 16 3 4 Rocker style Power Switch Circuit Breaker iese ese sees eek ARE Ee Ge ek Ke RE EE Se ee ee ee 16 4 1 Front Panel 23 AA Power Bar Graph Im TEE 24 4 1B Power Bar Graph Operate e iari ee ee ee ee ee ee 24 4 2 Power Gwitch aeee acaaaeaa aeee aeee aca a aca EEEE En EEEn n Ennen Ennn nnne 25 4 3 Power up Screen egene eege Se RE RE OE OR 25 4 3A Power up Screen 2 25 4 3B Operate Screen Appears After POWer UD iii ccsseeeeeeeaenaaacaanaaaa 25 4 4 Example of an Operate Screen aeee ee ee nn ee ee 26 4 5 Example ol an In Cycle STE passas EE ENG ER N AA a a 26 5 1 Manual Weld Modem aT ANAN ee 30 5 2 Navigate to Time MOdEs EER SE EKS ESE AA RR NE SE ERGE Re Ee RS EE at 30 5 3 Time Weld Mode SS SE SE EN GESE ga fado EN ed easier a a 30 5 4 Time Weld Mode 2 EE nana canes viens SE NE a adle la Res Ke id E a 30 5 5 Time Weld Mode EES EE GEES GA VR Sead Da UR AGU Lad Ma EE GR eN Di 31 5 6 Navigate to Energy Mode EES ed RS cas Ga ta
50. s with reduced power It also provides more power efficient 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 e Digi Trac Tuning tracks the resonant frequency of the acoustic stack horn booster transducer and ad justs 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 devia tion The available output power is maintained with any voltage input within the specified range This pro Page 4 vides consistent system performance regardless of line voltage fluctuations It also eliminates the need for bulky external constant voltage trans formers 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 Am
51. se the keys to select an empty setup Press ENTER Then make the Time and or Energy entries Nothing will be overwritten because your entries were made Setup Maintenance in an empty setup Delete S ATE Mode Automation 4 Confirm that your setup has been saved in memory T pad S A100 by going back to SETUP Your new setup should AE H 0 0 S appear as it does in Figure 5 22 Figure 5 21 New Setup Saved Selecting a Setup To select a setup previously loaded 1 Press SETUP 2 With Load highlighted use the keys to select the number of the setup you want 3 Press ENTER NOTE The power supply program always has one default setup as shown below 4 The Operate screen will display this setup selection as anumber in the display s lower left hand corner Deleting a Setup This can be overwritten but can not be To delete a setup previously stored deleted 1 Press SETUP Fo Setup Maintenance 2 With Delete highlighted use the T keys to select Delete the number of the setup you want Setup H Mode Manual r Gs 3 Press ENTER and a pop up screen will ask you to TBP OFF gt confirm your selection Make your choice and press Figure 5 22 Default Setup Screen ENTER 4 Check that the setup is deleted Press SETUP and the Setup Maintenance screen will show EMPTY for the setup you just deleted Page 36 Dukane Manual Part No 403 596 00 Section 6 Probes and Probe Stacks Probes and Probe St
52. site at http www dukane com us DL ApplData asp When Trigger by Power is selected three additional settings screens are presented Trigger Amplitude e Trigger Power and Trigger Timeout See Figures 5 14 5 15 and 5 16 for previews of these screens Page 34 Trigger By Power Amplitude Figure 5 14 Trigger Amplitude Trigger By Power Watts Figure 5 15 Trigger Watts Trigger By Power Timeout Figure 5 16 Trigger Timeout Dukane Manual Part No 403 596 00 Setup Maintenance Introduction The screens available in Setup Maintenance allow the operator to Load Store or Delete generator weld setups As many as eight 8 setups can be loaded and stored for your convenience Navigating 1 Whenthe SETUP key is pressed for the first time the display looks like Figure 5 17 This screen indicates that Setup 1 is Empty Because there is not yet any data available this setup has nothing in it and is empty You will see that Load is highlighted Press ENTER 2 Load Load means to put data into the generator s memory or to program a setup A pop up screen asks if defaults should be loaded for Setup 1 See Figure 5 17A Select NO and the display will change to an Operate screen Select YES and Automation Weld shows at the top of the Operate screen that will display next The setup number appears in the lower left corner of the screen Refer to Figure 4 4 3 After selecting YES press SE
53. the operator what happened in the last weld cycle Weld Mode Automation Time or Energy Data from Automation Weld last weld a Weld Time 0 500 S cycle Weld Energy 18 J 2 DU Setup number Figure 4 4 Example of an Operate Screen An In Cycle screen activates when the ultrasound signal has been activated Stack Frequency IN CYCLE Frequency 40087 Hz Power 40 W Status Indication 2 BOA Power Draw Power Bar Graph Figure 4 5 Example of an In Cycle Screen Page 26 Dukane Manual Part No 403 596 00 Section 5 Process Control Settings Process Control Settings Select the Welding Mode 0 00 29 Navigating the Modes 00 cee eee ees 30 HOL Gre 32 Amplitude Adjustment aaaea 32 System Information Advanced Settings 39 Setup Maintenance Ae e EN NN reka addere deena ken 35 Dukane Manual Part No 403 596 00 Page 27 iQ Series Ultrasonic Power Supply AL Plus User s Manual This page intentionally left blank Page 28 Dukane Manual Part No 403 596 00 Process Controller Settings This section of the manual helps the reader become familiar with the operating modes and illustrates some typical programming steps There are three welding modes available These correspond to the three ways in which the welder can be used Automation Time and Energy Select the Welding Mode Automation In AUTOMATION mode the PLC controls the weld cy
54. tinued from Previous Page Control Keys 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 method of welding Set the weld time seconds ENERGY Use this key to select energy as the 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 automation program 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 ENTER Press the ENTER key to select a menu item and move to the next level of the menu Think of it as a forward key When pressed it also confirms and stores a selection in memory It is also used to reset a latched condition 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 retum to the previous screen Think of itas a back key Press this key when you do not want to store the selection in memory Page 24 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
55. tivates when a weld processing cycle is completed and the welding process control system is ready to start the next welding cycle This output will be an open circuit when the welding process controller determines that the next welding cycle cannot be started This includes system faults or E Stop active but not a process fault like Overload Pin9 No Connection Pin 10 No Connection Pin 11 Fault Reset Input Pin 11 is an isolated input control signal that will reset any output faults when it is activated It can be used by the automation control system to simplify PLC programming Pin 12 U S Activate Cycle Start Input Pin 12 is used to activate the generator ultrasound output Activating this isolated control input will switch the ultrasound output ON and deactivating this signal will switch ultrasound OFF Pin 13 Isolated Input Common Electrically connected to Pin 5 on MPC I O connector if MPC Interface option is installed Pin 13 is electrically isolated from chassis ground Using sourcing PNP output drivers this common line would be connected to the automation system power supply common Using sinking NPN output drivers this common line would be connected to the automation system positive supply output See Figure A 1 in Appendix A for E Stop circuit wiring examples Pin 14 No Connection Pin 15 No Connection Dukane Manual Part No 403 596 00 Configuration Port Connector This connector in Figure
56. to the part You can increase the weld pressure increase the weld duration Time or Energy or change to a higher gain booster to increase the amplitude to increase the energy delivered to the weld Inconsistent Welds Variations in plastic due to filler materials and moisture absorption may lead to inconsistent welds Fillers can be especially troublesome if they are not uniformly distributed the content is too high or it contains too much or poor quality regrind or degraded plastic Try welding by energy This eliminates many inconsistencies There should be no unusual or loud noise from the acoustic stack If there is disassemble the stack and reassemble Exchange the probe with another unit to see if the problem disappears If not exchange the generator with another unit to try and isolate the problem The horn amplitude may not be uniform if it has been machined altered or damaged All of these will change the resonant frequency of the horn You can have the horn analyzed Page 52 Dukane Manual Part No 403 596 00 Section 7 Troubleshooting Pop up Fault Status Screens Generator Fault Status Screens Automation Mode Status Text Displayed System Status or Fault Explanation Generator Fault An Average Overload fault tripped Output power exceeded rated wattage Average Overload Lower the welding pressure or amplitude Fault will reset when next weld cycle starts Fault A Peak Overload fault tripped Peak
57. utions 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 have important information that if ignored could have increasingly se vere outcomes 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 is sue or an operator protection issue Drawings and Tables The figures and tables are identified by the section num ber followed by a sequence number The sequence num ber 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 LH JI 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 Dukane Manual Part No 403 596 00 Section 1 Introduction NOTE Note statements provide additional information or highlight procedures WARNING ms Warning statements point out conditions or practices that could re KG sult in personal in
58. vigate to Energy Mode 1 Follow the sequence shown in the figures to the right to navigate from Time mode to Energy mode In Time mode Figure 5 5 press the ENERGY key and the screen as shown in Figure 5 6 appears The phrase Enter Changes Mode means when the ENTER key is pressed the mode will change So press the ENTER key and the Weld by Energy screen seen in Figure 5 6A appears Use the and the cursor and to set the digits for the energy you want keys to move the See Figure 5 7 Press the ENTER key to accept the energy that has been set Press the CANCEL key if you decide not to set the energy If you set the energy level a maximum weld time needs to be set also Set a time that is reasonable for your application The factory default for this time is 30 seconds also the maximum The time can not be set below 0 001 second Use the and the and to set the digits for the time you want keys to move the cursor See Figure 5 8 Dukane Manual Part No 403 596 00 Section 5 Process Control Settings Weld by Time Weld Time 0 500 S Weld Energy 00 J 2 DITT Figure 5 5 Time Weld Mode Weld By Time Weld By Energy OFF Enter Changes Mode Figure 5 6 Navigate to Energy Mode 1 Figure 5 6A Navigate to Energy Mode 2 Weld By Enero Weld Energy OFF J Press Enter To Accept Press Cancel To Abort Weld By Enero Weld Energy 27 J Press Enter To Accept Set ener
59. y as SS AA 31 5 6A Navigate to Energy EE 31 5 7 Energy Weld Mode E 31 5 8 Energy Weld Mode RE RR ERE ET 31 5 9 HOLD TIMES WE 32 DOA HOLD Time iii 32 5 10 une UE 32 5 11 INFO SCRCGN EE AA 33 5 11A System Information Example Screen 33 5 12 Warning S ed RR AL TER IN ERA RD eer ee eer 33 5 13 Advanced Settings Screen EE 33 Continued Page 68 Dukane Manual Part No 403 596 00 Appendices Continued from Previous Page Appendix B List of Figures No Description Page 5 14 Trigger Tell 34 5 15 Tngger WANG sys act oases ORE ER E 34 5 16 Tigger TE ER RE en ende 34 5 17 Setup Maintenance 7 35 5 17A Pop up Load Defaults 2snnnnnnnnnnnnrnnnrnnnrnnnrnnnrnnnrnnnrnnnrnnrnnnrrnnrrnnrrnnrrnnrsnnrrnrsrnessnessnenn 35 5 18 Setup Maintenance 2 35 5 19 Setup Maintenance WE 35 5 20 Set ln 36 5 21 New Setup SAVE sas ss eke aaa AE DEK ek NA Re BEL Ek BR Ge EG kV ee ke AR WK 36 5 22 Default Setup Screen EE 36 6 1 Probe Horn and DoE ER ER EE 40 6 2 Probe Boosterand HOM BE 41 6 3 Replaceable Tip Installation ee ee AA ee ee 42 6 4 Stack Assembly Procedure sessie ba ER Re ee Ahaha EE AE RR ie ASE ED GR A4 6 5 Probe Assembly and Disassembly iis SES RE EER aaa 46 6 6 separating the Horn from the Booster ummmmmmmnmmminesueevivve evnet 47 6 7 Removing a Replaceable Tip From the Home 47 8 1 Generator Outline Drawing is eae eae ieee avid Ane aaa 57 Appendix C List of Tables No Description Page 3 l Standard

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