Dukane Welding System iQ Series User Manual
Intelligent Assembly Solutions  
iQ Series  
ULTRASONIC HAND HELD SYSTEMS  
HP  
AUTOMATED HAND PROBE  
PRESS  
User’s Manual  
Dukane Part No. 403–577–01  
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive St. • Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797-4949  
Products are manufactured in ISO  
registered facilities.  
www.dukane.com/us  
ISO 9001:2000  
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Revision History  
Revision  
Number  
Revision  
Summary  
Date  
- 00  
- 01  
Original release.  
08/01/2008  
11/12/2009  
Add 20kHz and 30kHz models.  
Update Pop-up Fault Status Screens.  
Add Trigger by Power feature.  
Add Options section.  
DukaneꢀManualꢀPartꢀNo.ꢀ403-577-00  
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Contents  
Section 1- Introduction                                               1  
Section 2- Health and Safety                                      5  
Section 3- Installation                                                 9  
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
Placing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . 11  
Connecting Cables . . . . . . . . . . . . . . . . . . . . .12  
System Outputs (Optional Connections). . . . .14  
Section 4 - Controls                                                   15  
Front Panel Overview . . . . . . . . . . . . . . . . . . .17  
Start-up Sequence . . . . . . . . . . . . . . . . . . . . .19  
LCD Display Overview . . . . . . . . . . . . . . . . . .20  
Section 5 - Process Control Settings                       24  
Selecting the Weld Mode . . . . . . . . . . . . . . . .23  
Navigating Through the Modes . . . . . . . . . 24-25  
Hold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26  
Amplitude Adjustment . . . . . . . . . . . . . . . . . . .26  
System Information, Hardware Settings,  
Advanced Settings . . . . . . . . . . . . . . . . . . .27  
Setup Maintenance . . . . . . . . . . . . . . . . . . . . .30  
Section 6 - Probes and Probe Stacks                      33  
Section 7 - Troubleshooting                                     45  
Section 8 - Options                                                    51  
Section 9 - Specifications                                         55  
Section 10 - Outputs Interface                                  63  
Section 11 - Contacting Dukane                               67  
Appendices                                                               71  
List of Figures . . . . . . . . . . . . . . . . . . . . . . .73  
List of Tables . . . . . . . . . . . . . . . . . . . . . . . .74  
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Section 1 – Introduction  
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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Section 1 – Introduction  
General User Information  
Read This Manual First  
Before operating your ultrasonic system, read this User’s  
Manual to become familiar with the equipment. This will  
ensure correct and safe operation. The manual is 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.  
NOTE  
Note statements provide additional  
information or highlight procedures.  
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.  
CAUTION  
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.  
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.  
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. –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  
Hearing  
Protection  
Electrical  
Hazard  
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iQSeries, UltrasonicꢀHandꢀHeldꢀSystemsꢀUser’sꢀManual  
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.  
System Overview  
Your iQ Series UltrasonicꢀHandꢀHeldꢀSystemꢀhas two  
basic components:ꢀ an ultrasonic generator, and a hand  
probe.  
•
LineVoltageRegulationautomaticallymaintains  
constant amplitude regardless of line voltage de-  
viation. The available output power is maintained  
with any voltage input within the specified range.  
This provides consistent system performance re-  
gardless of line voltage fluctuations. It also elimi-  
nates the need for bulky, external constant–volt-  
age transformers.  
Generator  
The generator is specifically 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.  
•
•
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.  
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 flexibility.  
The generator’s compact size and its integrated hand grip  
make it easy to carry.  
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.  
It also includes an RFI line filter that passes strict CE test  
specifications for global applications.  
Hand Probes  
The probes are perfect for manual spot welding, staking,  
cutting and inserting applications. Both the HP and PG  
(pistol grip) models include hangers so that when a probe  
is not needed it can be hung on a counterbalanced hook.  
Fittings for air-cooling are also standard on all probes.  
•
•
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.  
Key Features  
•
Compact Generator means this component is easy to  
move, and there will be more space for other necessities  
on the table or work bench.  
Trigger by Power produces greater weld consis-  
tency by requiring that a sufficient amont of pres-  
sure/force is applied to the part before the actual  
weld begins.  
•
Pulse Width Modulation incorporates patented  
circuitry giving the power supply the ability to  
efficiently change the output amplitude. This makes  
it possible to start large horns with reduced power. It  
also provides more power efficient switch-mode gen-  
erator operation and increased reliability.  
•
•
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.  
•
•
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  
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Section 2 – Health & Safety  
SECTION 2  
Health and Safety  
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
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Section 2 – Health & Safety  
General Considerations  
IMPORTANT  
Please observe these health and safety recommendations for  
safe, efficient, and injury-free operation of your equipment.  
In this manual, the term system refers to a complete group  
of components associated with the welding of plastic or  
metal parts, also known as an ultrasonic assembly system.  
A typical system consists of a generator and/or ultrasonic  
process controller, start and stop switches, power controls,  
connecting cables, and the probe assembly which includes  
the transducer, booster, horn and replaceable horn tip.  
Never operate the gen-  
erator with the cover off.  
This is an unsafe prac-  
tice and may cause injury.  
CAUTION  
Proper Installation - Operate system components only  
after they are properly installed and checked.  
Parts being joined ultrasoni-  
cally sometimes vibrate at  
audible frequencies. Wear ear  
protection to reduce annoying  
or uncomfortable sounds. In  
addition, sound absorbing  
materials, enclosures or sound  
deflectors may be installed  
to reduce the noise level.  
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 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.  
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iQSeries, UltrasonicꢀHandꢀHeldꢀSystemsꢀUser’sꢀManual  
Electrical Safety  
Domestic Power Grounding  
Grounding Contacts  
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.  
Typical Outlet  
Provided Cable  
Figure 2–3 International 220/240V Grounding  
CAUTION  
If you have a two-prong elec-  
trical receptacle, we strongly  
recommend that you replace  
it with a properly grounded  
Approved 2 pole, 3 wire grounding receptacle  
HUBBELL No. HBL 5262 or equivalent  
three-prong type. Have a  
qualified electrician replace  
it following the National Elec-  
tricCodeandanylocalcodes  
and ordinances that apply.  
NEMA Configuration 5–15R or 5–20R  
Figure 2–1 Example of 125 Volt,  
Grounded, 3-Prong Plug and Receptacle  
See Figures 2–1 and 2–2.  
CAUTION  
If there is any question about  
the grounding of your recep-  
tacle, have it checked by  
Approved 2 pole, 3 wire grounding receptacle  
HUBBELL No. HBL 5662 or equivalent  
NEMA Configuration 6–15R or 6–20R  
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.  
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 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.  
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Section 3 – Installation  
SECTION 3  
Installation  
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11  
Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11  
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11  
Connnecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
System Outputs Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14  
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Section 3 – Installation  
Unpacking  
CAUTION  
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.  
To minimize electri-  
cal noise and eliminate  
ground currents, ground  
the chassis as shown.  
Use a STAR configuration  
(illustrated below). Do not  
DAISYCHAINthegrounds.  
Placing  
Make certain generator placement and cable routing do  
not interfere with normal operation. Maintain easy access  
to your equipment.  
Chassis Grounding  
Fixed Probe Mount  
or 2nd Chassis  
Stud  
Grounding Stud  
#14 Gauge  
Stranded or  
Solid Wire  
The operator should have unobstructed access to cables  
and wiring.  
Recommended protective  
earth ground connection  
wire color: green or green  
with yellow stripe.  
3rd Chassis  
Grounding  
Stud  
RFI Grounding  
Earth  
Ground  
Proper grounding for the generator chassis is essential  
for the effective suppression of electrical noise or  
RFI (Radio Frequency Interference). Every ultrasonic  
generator contains a RFI filter that blocks noise on the  
AC power line from entering the system control circuitry.  
This filter also prevents ultrasonic frequency noise from  
being fed back into the AC power line. For the RFI filter  
to operate effectively, it is necessary to correctly ground  
the system.  
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.  
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  
If you have any questions  
about the grounding of your  
equipment and/or the electri-  
cal box, contact a qualified  
electrician.  
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iQSeries, UltrasonicꢀHandꢀHeldꢀSystemsꢀUser’sꢀManual  
Connecting Cables - Quick  
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  
Start Guide  
Complete the basic connections as shown below:  
•AC Line Input  
• HAND PROBE Connector  
• Grounding Stud  
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.  
•AC Power Cord Connection  
Step 1. Attach the female end of the power cord  
(200/240V only) to the generator’s power inlet  
connector - A in Figure 3-1.  
(The 100/120V model’s power cord is permanently  
attached to the unit.)  
Push ON  
Step 2. Attach the hand probe’s cable connector to the  
generator’s HAND PROBE connection. - B in  
Figure 3-1. Secure the connector to the system us-  
ing the two jack screws attached to the connector  
hood.  
Push OFF  
Figure 3-2 Rocker-style Power Switch/Circuit Breaker  
Step 3. Ground the generator chassis with a user–supplied  
14-Gauge wire. Attach one end to the grounding  
stud - C in Figure 3-1. Attach the other end to the  
nearest grounded metal pipe or equal earth ground.  
Step 4. Attach the male end of the power cord to a suit-  
able line receptacle.  
Optional Connections - See Page 14 for information  
about the rear panel OUTPUTS connector.  
Power Cord Strain Relief  
B
HAND PROBE  
OUTPUTS  
HAND PROBE  
A
C
OUTPUTS  
C
Optional  
Connections  
REAR VIEW  
100/12O VOLT MODEL  
REAR VIEW  
200/24O VOLT MODEL  
Figure 3-1 Generator Detail - Rear Views  
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Section 3 – Installation  
Power Cords  
200/240 Volt Systems  
The IEC AC power inlet connector mounted on the rear  
panel requires a properly configured IEC compliant power  
cord.  
The 200/240 AC power cords supplied with the  
generators are matched to the ultrasonic output power  
rating and the continent of specified use. See Table 3-I.  
Continent of Use  
Power Cord  
Part Number  
Power  
North America  
Europe  
200 - 1541  
200 - 1542  
200 - 1624  
240V, 10A  
240V, 10A  
240V, 10A  
India  
Table 3-I Standard IEC AC Power Cord Part Numbers  
100/120 Volt Systems (North America or Japan)  
The power cord (including strain relief) supplied with the  
100/120 AC systems is permanently attached to the rear  
of the generator. Units with this power cord are for use in  
North America or Japan.  
HAND PROBE Connector  
Ultrasound Output  
The ultrasound output connector used with this generator  
is integrated into a D-Sub style connector. This connector  
provides superior shielding of electrical noise. The output  
connector mates with a fully shielded ultrasound cable  
that is secured to the generator with two simple, reliable  
thumbscrews.  
The ultrasonic output from this connector (that drives the  
attached ultrasonic load) is a very high AC voltage. At  
high power levels there is high current, and the cable must  
be securely attached to the hand probe for safe operation.  
Only use original equipment ultrasound cables for safe  
and reliable system operation.  
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iQSeries, UltrasonicꢀHandꢀHeldꢀSystemsꢀUser’sꢀManual  
System Outputs  
(Optional Connections)  
NOTE  
All outupt signals are non-isolated and  
sink current to chassis ground when  
activated.  
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 and can activate an attached load  
up to a maximum of 500 mA.  
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.  
Table 3-II lists the signal names.  
Pin  
0V  
1
Signal Name  
Output Common  
Pin 2 (Any Fault Alarm)  
End of Weld Alarm  
Any Fault Alarm  
Bad Part  
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.  
2
3
Table 3-II System OUTPUTS Connector Signals  
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.  
NOTE  
Refer to Figure 9-1, OUTPUTS Inter-  
face Example, Page 65.  
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Section 4 – Controls and Connections  
SECTION 4  
Controls  
Front Panel Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
Start-Up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
LCD Display Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
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Section 4 – Controls and Connections  
Front Panel Overview  
This section gives an overview of the front panel functions:  
powering the generator on/off; monitoring the process with  
the display; and, programming with the control keys.  
Power  
Switch  
LCD Display  
Control Keys  
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.  
Control Keys  
The control keys shown in Figure 4-1 and described  
below, are used to display information, and to program  
the generator.  
INFO  
Press this key to get system information or to modify the  
hardware settings.  
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.  
System Information - Identifies the current  
version of system software.  
Hardware Settings - Select features that can be  
turned on or off including theAudibleAlarm or Fault  
Latching options.  
CAUTION  
If when resetting the circuit  
breaker afer it has tripped, it  
immediately trips again, there  
SETUP  
Use the SETUP key to Load, Store, or Delete as many as  
eight setups.  
is likely an internal system  
malfunction, and the generator  
will need service. Do NOT re-  
peatedly try to reset the circuit  
breaker. If it trips, this will only  
cause more damage to the  
generator.  
ꢀꢀContinued  
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Continued  
System LCD Display  
Control Keys  
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.  
AMP  
Set the ultrasound amplitude output level in the range of  
20 to 100%.  
Power Bar Graph  
Typically amplitude is set to 100%.  
The Power Bar Graph appears at the bottom of the  
LCD display. It contains 20 segments that represent the  
generator’s range of power from 0% at the far left of  
the bar graph to 100% of power at the far right. Each  
segment equals 5% of the total.  
TIME  
Use this key to select time as the primary method of  
welding. Set the weld time (seconds).  
ENERGY  
In the example below, 40% of the available power is used  
during the weld cycle. The display shows an In Cycle  
screen (while U/S is active).  
Use this key to select energy as the primary method of  
welding. Set the weld energy (joules).  
HOLD  
40% of  
power used  
IN CYCLE  
Hold is a time period beginning after the weld portion  
of the cycle is complete. The operator holds the probe in  
place applying pressure to the weld, and an audible alarm  
indicates that the Hold time is finished. Hold can be set to  
a maximum of 5.0 seconds.  
In Cycle  
screen  
Frequency: 40087 Hz  
Power:  
225 W  
#2  
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).  
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.  
Weld by Time  
Operate  
Weld Time 1.500 S  
Weld Energy 24 J  
screen  
Arrow Keys  
Press the right and left arrow keys to move the cursor to  
#1  
the right or left.  
40% of power delivered in previous weld  
Figure 4-1B Power Bar Graph - Operate  
+ and - Keys  
Press these keys to increase or decrease the value of a  
selected digit.  
CAUTION  
Make sure the stack is prop-  
erly assembled before it is  
connected to the system. The  
CANCEL  
Press CANCEL to return to the previous screen. Think of  
it as a “back” key. Press this key when you do not want to  
store the selection in memory.  
horn should never come in  
direct contact with a metal fix-  
ture or anvil when ultrasound  
is activated.  
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Section 4 – Controls and Connections  
Start-up Sequence  
Push ON  
After all connections have been completed.  
Push OFF  
1. Push the Power Switch to ON (Figure 4-2).  
The generator performs a self-diagnostics sequence.  
Figure 4-2 Power Switch  
Current  
Setup  
2. The Power-up screen appears briefly - Figure 4-3.  
DUKANE  
Software  
version  
iQ Hand Probe  
xxxxxxxxx  
xxxxxxx  
Setup #1  
Website  
Address  
http://www.dukcorp.com  
MB FPGA  
version  
3. The next screen is an Operate screen ready for a  
new weld to be done. The display shows:  
Figure 4-3 Power-up Screen  
The setup used for the last weld, and zeros for any  
weld parameters.  
Weld by Time  
Weld Time 0.000 S  
Weld Energy 0 J  
See Figure 4-3A.  
#1  
Figure 4-3A Operate Screen Appears After  
Power-up  
Starting a Weld Cycle  
Stopping a Weld Cycle  
1. If the generator is not powered, press its Power  
1. Release the hand probe’s activation switch (trigger)  
to abort a weld cycle and stop ultrasound.  
Switch/Circuit Breaker to the ON position.  
2. Select the setup you want to use, if appropriate.  
2. In addition, press the generator’s Power Switch/  
Circuit Breaker to the OFF position to power down  
the generator.  
3. Apply the probe tip to the components to be  
ultrasonically joined, and press the hand probe’s  
trigger switch to activate ultrasound.  
4. After meeting the weld parameters (and with the Hold  
time set to zero) - in either Manual, Time or Energy  
modes - an internal alarm beeps once after the weld  
setting is met, or after the trigger switch is released.  
NOTE  
The system will not beep as described  
here if the Audible Alarm is OFF.  
Depending on optional customer OUTPUTS  
connections - System Outputs, Page 14 - external  
audible or visual alerts can be activated as well.  
SeeHardware Settings, Page27to learn  
how to turn the Alarm ON or OFF.  
5. Release the probe’s activation switch (trigger), and  
if appropriate, apply pressure while an optional Hold  
time elapses. The generator signals when that period  
is over by sounding an audible alert.  
The user can release the activation switch during the  
Hold time, but there will not be an audible beep until  
the preset Hold time ends.  
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LCD Display Overview  
There are two basic kinds of screen displays:  
Operate screens, and In Cycle screens.  
An Operate screen tells the operator  
what happened in the last weld cycle.  
Weld Mode -  
Manual, Time, or  
Energy  
Data from  
last weld  
cycle.  
Manual Weld  
Weld Time 0.500 S  
Weld Energy 18 J  
#2  
*
Setup  
number.  
Asterisk indicates setup  
is modified but not  
stored in memory.  
Figure 4-4 Example of an Operate Screen  
An In Cycle screen activates when the probe activation  
switch (trigger) is pressed.  
Status Indication  
Stack Frequency  
IN CYCLE  
Frequency: 40087 Hz  
Power:  
25 W  
#2  
Power Draw  
Power Bar Graph %  
Figure 4-5 Example of an In Cycle Screen  
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Section 5 - Process Control Settings  
SECTION 5  
Process Control Settings  
Select the Welding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
Navigating Through the Modes . . . . . . . . . . . . . . . . . . . . .24-25  
Hold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26  
Amplitude Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26  
System Information, Hardware Settings, Advanced Settings. 27  
Setup Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
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Section 5 - Process Control Settings  
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: Manual, Time, and Energy.  
Select the Welding Mode  
Manual - In MANUAL mode the operator controls  
the weld cycle. The cycle starts when the operator presses  
the hand probe’s trigger switch, and the ultrasonic signal  
(U/S) activates. When the trigger switch is released,  
the ultrasonic signal stops, and the cycle is complete.  
(Manual mode is the default selection.)  
NOTE  
With one exception, U/S is acti-  
vated anytime the probe’s trigger  
switch trigger is pressed regard-  
less of operating mode, or what is  
displayed on the LCD screen.  
The EXCEPTION - When a fault  
has occurred in Latching Fault  
Mode. In that case ENTER must  
be pressed to clear the fault be-  
fore U/S can be activated.  
Time - In TIME mode the operator sets a maximum  
time (seconds) the ultrasonic signal will be active for  
each weld cycle. The cycle starts when the hand probe’s  
trigger switch is activated, and the U/S activates. The  
U/S stops when the programmed time is reached. The  
trigger switch must be held activated for the entire  
welding cycle. Then it is released so that a new weld  
cycle can begin.  
Energy - In ENERGY mode the operator sets a  
maximum energy (Joules) the generator will reach  
during the weld cycle. [A 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 hand probe’s trigger switch is pressed, and U/S is  
activated. When the programmed energy is reached, U/S  
stops. The trigger switch must be held activated for the  
entire welding cycle. Then it is released so that a new  
weld cycle can begin.  
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Navigating Through the Modes  
When the generator is first powered up, the default  
operating mode is Manual, and Manual Weld is shown  
at the top of the display as shown in Figure 5-1.  
Manual Weld  
Weld Time 0.000 S  
Weld Energy 0 J  
#2  
Navigate to Time Mode  
Figure 5-1 Manual Weld Mode  
1. Follow the sequence shown in the figures to the right  
to navigate from Manual mode to Time mode.  
In Manual mode, press the TIME key (Figure 5-2).  
TIME key  
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.  
Manual Weld  
Weld By Time  
OFF  
Enter Changes Mode  
3. Set the time.  
Figure 5-2 Navigate to Time Mode  
Use the  
and the  
keys to move the cursor  
+ -  
and to set the digits for the weld time you want.  
ENTER key  
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.  
Weld by Time  
Weld By Time  
OFF  
Set the time.  
S
Press Enter To Accept  
Press Cancel To Abort  
NOTE  
Navigating to Manual Mode  
Figure 5-3 Time Weld Mode - 1  
Set Time or Energy (depending on mode) to  
OFF, and press ENTER.  
This will put you back in Manual mode.  
Weld by Time  
Alternately:  
Find an empty setup. Press SETUP.  
Press ENTER.  
Weld Time  
ENTER key  
0.500 S  
Press Enter To Accept  
Press Cancel To Abort  
A pop-up screen about defaults appears.  
Figure 5-4 Time Weld Mode - 2  
Setup #1Empty  
Load Defaults?  
YES NO  
Select YES to load the default operating mode  
which is Manual, and you can weld using the  
Manual mode.  
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Section 5 - Process Control Settings  
Navigate to Energy Mode  
1. Follow the sequence shown in the figures to the right  
to navigate from Time mode to Energy mode.  
Weld by Time  
Weld Time 0.500 S  
Weld Energy 00 J  
#2  
Figure 5-5 Time Weld Mode  
ENERGY  
key  
Weld By Time  
Weld By Energy  
OFF  
In Time mode (Figure 5-5), press the ENERGY key,  
and the screen as shown in Figure 5-6 appears.  
Enter Changes Mode  
Figure 5-6 Navigate to Energy Mode - 1  
ENTER key  
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 Energy screen  
seen in Figure 5-6A appears.  
Weld By Energy  
Weld Energy  
OFF J  
Press Enter To Accept  
Press Cancel To Abort  
Figure 5-6A Navigate to Energy Mode - 2  
3. Use the  
and the  
keys to move the  
+ -  
Weld By Energy  
cursor and to set the digits for the energy you want.  
See Figure 5-7.  
Weld Energy  
Set energy  
27 J  
level.  
Press Enter To Accept  
Press Cancel To Abort  
4. Press the ENTER key to accept the energy that has  
been set. Press the CANCEL key if you decide not to  
set the energy.  
Figure 5-7 Energy Weld Mode - 1  
5. 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).]  
Weld By Energy  
Maximum Weld Time  
ENTER key  
1.000 S  
The time can not be set below 0.001 second.  
Use the  
and the  
keys to move the cursor  
+ -  
Figure 5-8 Energy Weld Mode - 2  
and to set the digits for the time you want.  
See Figure 5-8.  
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Hold  
NOTE  
HOLD is used more often with Time or Energy modes,  
but it can be used with the Manual mode. It is a period of  
time that can be set to follow release of the probe’s trigger  
switch.  
The generator’s end of HOLD signal  
will only be heard if the audible alarm  
is ON.  
The Audible Alarm can be set ON or  
OFF. See Hardware Settings on the  
next page.  
During HOLD the operator typically applies pressure to  
the part being welded. Next, the operator hears an audible  
alarm that serves as a reminder that HOLD has finished,  
and the probe can be lifted.  
HOLD does not allow the operator to begin a new cycle  
until HOLD is finished.  
To set a HOLD period:  
1. Select the weld mode (Manual, Time, Energy).  
Hold Time  
2. Set the time and energy parameters as needed.  
OFF S  
3. Press the HOLD key. The screen will appear as it  
does in Figure 5-9.  
Figure 5-9 HOLDTime - 1  
4. Set the time with the  
keys.  
+ -  
(A maximum of 5.0 seconds.)  
Hold Time  
Figure 5-9A shows a setting for 2.0 seconds.  
5. Press the ENTER key to confirm your selection.  
2.0 S  
Figure 5-9A HOLDTime - 2  
Amplitude Adjustment  
Amplitude refers to the movement of the horn 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:  
Amplitude  
1. Press the AMP key. The screen will appear as in  
Figure 5-10.  
100 %  
2. Set the amplitude level using the  
keys and the  
keys.  
+ -  
Figure 5-10 Amplitude  
3. Press ENTER to confirm your amplitude setting.  
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Section 5 - Process Control Settings  
System Information,  
iQ Information  
> System Information  
Hardware Settings  
Advanced Settings  
Hardware Settings, Advanced  
Settings  
When the INFO key is pressed the display looks like  
Figure 5-11:  
Figure 5-11 INFO Screen  
Using the  
keys, move the pointer to indicate:  
+ -  
System Information, Hardware Settings, or  
Advanced Settings  
Dukane Corporation  
iQ 20kHz Hand Probe  
FP v1.07 MB v2.56  
FPGA v6  
Press ENTER to make the selection.  
1. System Information  
Manufacturer’s information is shown including the  
manufacturer’s name, the name of the system (iQ 20kHz  
Hand Probe) and the software identification.  
Figure 5-11A System Information Example Screen  
Figure 5-11A shows an example of this information.  
Hardware Settings  
2. Hardware Settings  
> Audible Alarm  
ON OFF  
ON OFF  
Latching Faults  
Figure 5-12 gives a view of the Hardware Settings  
screen.  
Press Enter To Accept  
Press Cancel To Abort  
Figure 5-12 Hardware Settings Screen  
Audible Alarms - With the pointer as shown in Figure  
5-12, the operator can turn the audible alarms on or  
off. Use the  
keys to move from ON to OFF.  
The current selection is highlighted.  
NOTE  
Latching Faults - Latching faults can be turned on  
or off.  
ChangesinHardwareSettingstake  
place after ENTER is pressed.  
If Latching Faults is on, and a fault occurs, the alarm  
sounds twice (beep, beep) indicating the generator  
is latched and it will not weld again until the fault is  
corrected.  
Pressing ENTER clears the fault, and the next cycle  
can begin.  
If Latching Faults is off, and a fault occurs, the audible  
alarm (beep, beep) will be heard, but welding can  
continue.  
Continued  
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3. Advanced Settings  
Continued  
Warning  
Modified settings  
may affect operation  
of this unit!  
AfterAdvanced Settings is selected, a warning screen  
is displayed as shown in Figure 5-13.  
Adjusting these settings may affect the operation of  
your unit. Before you change a setting, please check  
with Dukane personnel for their recommendations.  
Figure 5-13 Warning Screen  
The warning screen is shown for a few seconds, then,  
the Advanced Settings screen appears.  
NOTE  
See Figure 5-14.  
Trigger by Power is only avail-  
able when the weld mode is  
either Time or Energy.  
Adjustments can be made to: Free Run Frequency;  
Ramp Up Time; Frequency Lock and Hold; and, Trig-  
ger By Power, but note that Trigger by Power is only  
available when the weld mode is time or energy.  
Free Run Frequency  
Advanced Settings  
Free run is the frequency at which the generator  
drives the ultrasound ouput pulses until a valid  
feedback signal is detected. Typically this value  
should be below the operating frequency of the  
probe.  
19900Hz  
150mS  
ON OFF  
Free Run Freq  
Ramp Up Time  
Lock and Hold  
> Trigger By Power  
Press Enter To Accept  
Press Cancel To Abort  
ON OFF  
Follow the on screen prompts to make setting  
adjustments.  
Figure 5-14 Advanced Settings Screen  
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.  
Continued  
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Section 5 - Process Control Settings  
Advanced Settings  
Trigger by Power  
Continued  
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 website at:  
http://www.dukane.com/us/DL_ApplData.asp  
When Trigger by Power is selected, three additional  
settings screens are presented:  
Trigger By Power  
Amplitude  
•
•
•
Trigger Amplitude;  
Trigger Power; and,  
Trigger Timeout  
40 %  
_
Figure 5-15 Trigger Amplitude  
See Figures 5-15, 5-16, and 5-17 for previews of these  
screens  
Trigger By Power  
Watts  
80 W  
_
Figure 5-16 Trigger Watts  
Trigger By Power  
Timeout  
1.100 S  
_
Figure 5-17 Trigger Timeout  
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Setup Maintenance  
Setup Maintenance  
Introduction  
Delete  
Store  
Load  
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.  
Setup # 1  
EMPTY  
Figure 5-18 Setup Maintenance - 1  
Navigating  
1. When the SETUP key is pressed for the first time, the  
display looks like Figure 5-18. 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.  
Setup #1 Empty  
Load Defaults?  
NO  
YES  
Figure 5-18A Pop-up Load Defaults?  
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 5-18A.  
Setup Maintenance  
Delete  
Store  
Load  
Select NO, and the display will change to an Operate  
screen.  
Setup # 1  
T: 0.000 S  
E: 0 J  
Mode: Manual  
A: 100%  
H: 0.0 S  
Select YES, and Manual 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.  
Figure 5-19 Setup Maintenance - 2  
Setup Maintenance  
3. After selecting YES, press SETUP, and the display  
will look like Figure 5-19.  
Delete  
Store  
Load  
Setup # 1  
T: 0.000 S  
E: 0 J  
Mode: Manual  
A: 100%  
H: 0.0 S  
4. Store - (Store means to save the setup data.)  
Tap the right arrow key once to highlight Store.  
See Figure 5-20.  
Figure 5-20 Setup Maintenance - 3  
Overwrite  
Setup #1?  
5. Press ENTER, and a pop-up screen as shown in  
Figure 5-21 appears.  
NO  
YES  
6. Select YES if you want to overwrite (replace)  
whatever is in the setup, and select NO if you do not  
want to change anything for that setup.  
Figure 5-21 Pop-up Overwrite Setup?  
Press the ENTER key to save your selection.  
Setup Maintenance  
7. Delete -To delete the setup, select Delete as shown  
in Figure 5-22, and press the ENTER key. A pop-up  
screen appears to ask you to confirm your choice.  
Store  
Delete  
Load  
Setup # 1  
T: 0.000 S  
E: 0 J  
Mode: Manual  
A: 100%  
H: 0.0 S  
Select YES or NO, and press ENTER again.  
Figure 5-22 Setup Maintenance - 4  
Continued  
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Section 5 - Process Control Settings  
Setup Maintenance  
Continued  
Weld by Time  
Saving the Current Setup  
Weld Time  
Try using your navigation skills on this example:  
1. Follow instructions on Page 24 to set the mode to  
Weld by Time. Set the time to 1.520 seconds.  
1.520 S  
Press Enter To Accept  
Press Cancel To Abort  
Figure 5-23 Save Current Setup  
See Figure 5-23.  
2. Press SETUP and then press the  
key until you  
+
Setup Maintenance  
get an Empty Setup Maintenance screen.  
Delete  
Store  
Load  
See Figure 5-24.  
Setup # 1  
EMPTY  
3. Use the right arrow key to select Store, and then  
press ENTER. You will be returned to the Operate  
screen.  
Figure 5-24 Store in Setup Maintenance  
Setup Maintenance  
4. Confirm that your setup has been stored in memory  
by going back to SETUP. Your new setup should  
appear, just as it does in Figure 5-25.  
Delete  
Store  
Load  
Setup # 1  
T: 1.520 S  
E: 0 J  
Mode: Manual  
A: 100%  
H: 0.0 S  
Selecting a Setup  
To select a setup previously stored:  
Figure 5-25 New Setup Stored  
1. Press SETUP.  
2. With Load highlighted, use the  
keys to select  
+ -  
the number of the setup you want.  
3. Press ENTER.  
4. The Operate screen will display this selection as a  
number in the lower left hand corner.  
Deleting a Setup  
To delete a setup previously stored:  
1. Press SETUP.  
2. With Delete highlighted, use the  
keys to select  
+ -  
the number of the setup you want.  
3. Press ENTER, and a pop-up screen will ask you to  
confirm your selection. Make your choice, and press  
ENTER.  
4. Check that the setup is deleted. Press SETUP, and the  
Setup Maintenance screen will show EMPTY for the  
setup you just deleted.  
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Section 6 – Probes and Probe Stacks  
SECTION 6  
Probes and Probe Stacks  
Ultrasonic Probe Overview...........................35  
Theory of Operation............................................36  
Probe Configuration............................................36  
Ultrasonic Horn ...................................................37  
Booster................................................................37  
Stack Assembly............................................38  
Installing Replaceable Tips .................................38  
Mounting Stud to Horn/Booster...........................39  
Horn to Booster...................................................40  
Booster to Probe.................................................40  
Horn to Probe......................................................40  
Stack Disassembly .......................................42  
Booster Notes...............................................44  
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Section 6 – Probes and Probe Stacks  
Ultrasonic Probe  
Overview  
CAUTION  
The ultrasonic cable car-  
ries high electrical current  
when in operation. Do not  
nick or cut this cable. If  
cut, there would be a high  
potential for electric shock!  
The two types of probes used with the iQ Hand Held  
Systems are shown in Figure 6-1 below.  
Operating Notes  
Compressed Air Fitting - In continuous duty  
operation, it is important to keep the probe cool with  
compressed air. Use the air fitting to connect the air source  
to the probe.  
NOTE  
Compressed air supply: Make sure  
the air is clean, oil-free, and dry.  
See Section 7, Specifications for more detail.  
41PG40 & 41PG40S  
Models  
Hanger  
Compressed Air Fitting  
Strain Relief  
U/S Cable  
Typical Horn Less Tip  
Trigger  
Rear View  
Pistol-style Grip  
Models  
41HP40 & 41HP40S  
Trigger Actuator  
Compressed Air Fitting  
Hanger  
Strain Relief  
U/S Cable  
Hand Grip  
Typical Horn Less Tip  
Rear View  
Figure 6-1 Typical Hand Held Probes  
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iQSeries, UltrasonicꢀHandꢀHeldꢀSystemsꢀUser’sꢀManual  
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 ultrasonic  
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.  
CAUTION  
Never use the hand probe if  
the cable insulating jacket is  
cut or damaged in any way.  
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 hand–held probe system is shown in Figure 6-2.  
The hand probe is easily identified by its trigger actuator  
and permanently attached cable. Normally a booster is not  
used with a hand 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.  
Hand  
Probe  
Standard  
Horn  
Custom  
Horn  
Tip  
Figure 6–2 Hand Probe, Horn and Tip  
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Section 6 – Probes and Probe Stacks  
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 horn is higher at high frequencies.  
Probe  
Housing  
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 if its gain  
is greater than one and reducing if its gain is less than 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 6–3. This is commonly referred to  
as a stack. As indicated, the components are secured with  
threaded studs.  
Booster  
Horn  
Figure 6–3 Probe, Booster and Horn  
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NOTE  
Stack Assembly  
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.  
Attaching a Replaceable  
Tip to a Horn  
1. 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.  
CAUTION  
NEVER clamp the horn  
in a vise. The resulting  
scratches or gouges in the  
surface are stress risers  
which may result in cracks.  
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 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 6-4. 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.  
Tighten  
Figure 6–4 Replaceable Tip Installation  
Replaceable Tips to Horn  
NOTE  
inch-lb ft-lb N-m  
Size  
40.7 1/2” x 20 tpi tip threads  
38 3/8” x 24 tpi tip threads  
Dukane Part No. for the 20kHz span-  
ner wrenches is 721–68.  
360  
336  
300  
240  
30  
28  
25  
20  
33.9 5/16” x 24 tpi tip threads  
27.1 1/4” x 28 tpi tip threads  
Dukane Part No. for the 40kHz span-  
ner wrenches is 721–44.  
Table 6-I Tip Torque Unit Conversions  
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Section 6 – Probes and Probe Stacks  
Attaching the Mounting  
Stud to a Horn or a  
Booster  
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, re-  
sulting in excessive heat. In some cases,  
this can melt the tooling material.  
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  
horn or the input* end of the booster and tighten 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.  
in-lb  
ft-Lb  
N-m  
Size  
12-18  
12-18  
12-18  
1 - 1.5 1.4 - 2 1/2” x 20 tpi studs  
1 - 1.5 1.4 - 2 3/8” X 20 tpi studs  
1 - 1.5 1.4 - 2 8 mm studs  
NOTE  
To convert inch-lbs to ft-lbs, divide by 12.  
To convert inch-lbs 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.  
Table 6-II Stud Torque Unit Conversions  
*
Always assemble the mounting studs that mate  
Torque specifications have a tolerance of  
about ± 10%.  
boosters, transducers and horns to the input end of  
the horn or the input end of the booster first. This is  
shown in Figure 6-6.  
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.  
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Attaching The Horn to  
a Booster, Booster to a  
Probe, or Horn to a Probe  
NOTE  
Always remove a probe stack from the  
machine in which it is mounted before  
attaching or removing a horn.  
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.  
CAUTION  
Never leave a horn or booster  
assembly hand tight. Torque  
it to the proper specifications  
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.  
before proceeding. If the as-  
sembly is installed without  
being properly torqued down,  
the assembly may vibrate  
severely, damaging the mat-  
ing surfaces and causing  
the generator to overload.  
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 may 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 system 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.  
Tighten  
Figure 6–5 Stack Assembly Procedure  
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Section 6 – Probes and Probe Stacks  
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 6–5 for the  
correct procedure. Refer to Table 6-III for torque unit  
conversions. Be careful not to overtighten.  
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.  
Do not tighten the studs to these higher  
ratings as it may induce unnecessary  
stress in the assembly.  
In-lb Ft-lb N-m  
kHz  
540  
420  
216  
216  
45  
61 15 kHz stack  
35 47.5 20 kHz stack  
18 24.4 30 kHz stack  
18 24.4 40 kHz stack  
Table 6-III Horn/Booster Torque Unit Conversions  
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Stack Disassembly  
CAUTION  
Stackdisassemblyisrequiredwhenchangingtheboosteror  
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.  
Never hold a probe by the  
housing when tightening or  
loosening an adjoining com-  
ponent. The probe housing  
has anti–rotation devices  
to keep the transducer  
aligned. These could shear  
under excessive torque.  
To establish a maintenance schedule, inspect the mating  
surfaces after the first 200–400 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 hand probe  
are shown in Figure 6–6. It makes no difference whether  
the horn is attached to the booster first, or the booster is  
attached to the probe first.  
ASSEMBLY  
HAND  
PROBE  
HOUSING  
HAND  
Output End  
PROBE  
HOUSING  
HAND  
PROBE  
ASSEMBLY  
Spanner  
Wrench  
Holes  
Mounting Stud  
(Insert Into Horn  
First and Tighten  
to Torque Specs)  
Input End  
HORN  
HORN  
DISASSEMBLY  
Figure 6–6 Hand Probe Assembly and Disassembly  
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Section 6 – Probes and Probe Stacks  
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 system to provide sufficient torque to loosen a joint.  
See Figure 6–7.  
Loosen  
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 horn or booster from turning in  
your hand when loosening the stud. Use  
a spanner wrench onhorns and boosters  
with spanner wrench holes. Use an open  
end wrench on horns and boosters with  
wrench flats.  
Figure 6–7 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.  
Loosen  
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 6–8 for the  
correct tip removal procedure.  
Figure 6–8 Removing a Replaceable Tip from the  
Horn  
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Booster Notes  
How to Tell the Booster  
Input End from 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 > 1.0), the larger  
diameter end is the input end. On a reducing booster  
(gain < 1.0) the larger diameter end is the output end.  
On a neutral acting booster the diameters are equal.  
CAUTION  
NEVER install a booster  
upside down to change  
an amplifying system to  
a reducing system. The  
boosters are dimensionally  
asymmetric. They are tuned  
from input to output to act  
like an acoustic lens. Re-  
versing them will not give the  
expected results and may  
causedamagetothesystem.  
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.  
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Section 7 – Troubleshooting  
SECTION 7  
Troubleshooting  
No Ultrasonic Output.....................................47  
System Power Output Level.........................47  
Welding Problems.........................................48  
Pop-up Fault Status Screens.................. 49-50  
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Section 7 – Troubleshooting  
No Ultrasonic Output  
Probe  
Make sure that the hand probe cable is connected to the  
generator connector (HAND PROBE) and secured to  
the rear panel. Also, make sure the hand probe stack is  
properly assembled.  
System Power Output Level  
NOTE  
Overload  
The LCD screen displays a vari-  
ety of pop-up status changes as  
they occur. Check Tables 7-I and  
7-II - Pop-up Fault Status Screens  
- Pages 49- 50.  
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 hand 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.  
NOTE  
When Latching Faults is enabled,  
ENTER must be pressed to clear  
a 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.  
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Welding Problems  
Weak Welds  
Weak welds, or underwelding, is caused by insufficient  
energy being transmitted 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.  
NOTE  
Primary factors in achieving consis-  
tent, quality welds - especially when  
using hand held probes - are the skill  
and training of the operator.  
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.  
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Section 7 – Troubleshooting  
Pop-up Fault Status Screens  
Generator Fault Status Screens - Manual Mode  
Status Text Displayed  
System Status or Fault Explanation  
An Average Overload fault tripped.  
Generator Fault  
Output power exceeded rated wattage.  
Lower the welding pressure or amplitude.  
Fault will reset when next weld cycle starts.  
Average Overload  
A Positive Peak Overload fault tripped.  
Peak IGBT transistor current exceeded.  
Caused by a severe frequency mis-match.  
Fault will reset when next weld cycle starts.  
Generator Fault  
Peak Overload  
Resonant frequency lock not found, or lost.  
Check for a defective stack component.  
Check for stack coupling to the fixture.  
Fault will reset when next weld cycle starts.  
Generator Fault  
Frequency Lock Lost  
System Overtemperature fault detected.  
Fault will reset when system cools down.  
Generator Fault  
Over Temperature  
Internal communications error.  
Turn generator power off and back on.  
Call Dukane service if the fault persists.  
Generator Fault  
Cycle Power  
Table 7- I Pop-Up Fault Status Screens - Manual Mode  
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Process Fault Status Screens - Time and Energy Modes  
Status Text Displayed  
System Status or Fault Explanation  
Latch On Fault ENABLED Latch On Fault DISABLED  
Process Fault  
Process Fault  
Set Weld  
Time Not Reached  
Enter Clears Fault  
Set Weld  
SetꢀWeldꢀTimeꢀNotꢀReached, or  
Time Not Reached  
SetꢀWeldꢀEnergyꢀNotꢀReached - appears if the  
weld ends before the set time or energy is reached  
(respectively) due to operator error, or  
Process Fault  
Process Fault  
Set Weld  
Energy Not Reached  
Enter Clears Fault  
Set Weld  
Energy Not Reached  
because the weld was intentionally aborted.  
Process Fault  
Process Fault  
Peak Overload  
Time Not Reached  
Enter Clears Fault  
Average Overload  
Time Not Reached  
PeakꢀOverload,ꢀAverageꢀOverload,ꢀFrequencyꢀLockꢀ  
Lost,ꢀInputꢀUndervoltage,ꢀorꢀOverꢀTemperature is  
displayed in place of SetꢀWeldꢀTimeꢀnotꢀReached,  
or SetꢀWeldꢀEnergyꢀnotꢀReached, if the weld ends  
before the set time or energy is reached due to a  
process or generator fault.  
Process Fault  
Over Temperature  
Energy Not Reached  
Process Fault  
Frequency Lock Lost  
Energy Not Reached  
Enter Clears Fault  
Process Fault  
Input Undervoltage  
Energy Not Reached  
Enter Clears Fault  
Table 7-II Pop-Up Fault Status Screens - Time and Energy Modes  
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Section 8 – Options  
SECTION 8  
Options  
iQ Hand Probe Buzzer Kit .............................53  
iQ Hand Probe Foot Switch Kit.....................53  
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Section 8 – Options  
iQ Hand Probe Options  
Buzzer Kit (Part No. 438-971)  
In some noisy environments the built-in buzzer can not  
easily be heard. This buzzer kit is designed for those  
conditions, and it suits the customer that prefers not to  
provide their own buzzer (using the status outputs of the  
generator).  
The kit adds a 100dB buzzer inside the generator.  
Foot Switch Kit (Part No. 438-976)  
This kit allows the customer to add their own external  
foot switch to replace the trigger on the hand probe.  
An external breakout box with cabling is supplied. The  
box connects to the generator and to the hand probe.  
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Section 9 – Specifications  
SECTION 9  
Specifications  
Generator Outline Drawing. . . . . . . . . . . . . . . . . . . . . . . . . . . 57  
Probes Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58  
Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59  
Operating Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59  
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60  
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . 61  
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Section 9 – Specifications  
ALLOW 5" (125 mm) BEHIND UNIT  
FOR CABLE CONNECTIONS  
12.41  
[315.2]  
10.00  
[254]  
3.95  
[100.3]  
3.51  
[89.2]  
IN  
[mm]  
Figure 9-1 Generator Outline Drawing  
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B
C
A
2.59 in  
(66 mm)  
1.25 in (32 mm)  
Diameter  
Air fitting for cooling  
.25 in O.D. tubing  
Soft grip handle  
Standard single connector for  
iQ generator  
A
B
Air fitting for cooling  
.25 in O.D. tubing  
C
1.25 in (31.75 mm)  
Diameter  
D
Standard cable  
9 ft (3 m)  
1.20 in  
(30 mm)  
Soft grip handle  
Standard single connector for  
iQ generator  
A
B
C
Body  
Length  
in (mm)  
D
Probe  
Weight  
System  
Model  
Number  
Probe  
Part  
Number  
Probe  
Cable  
Length  
Generator  
Model Number  
Diameter  
Length  
w/Strain Relief  
in (mm)  
Handle  
Length  
in (mm)  
lb (kg)  
in (mm)  
HP 2.61-P  
HP 2.61-H  
HP 2.62-P  
HP 2.62-H  
HP 3.61-H  
HP 3.62-H  
HP 4.61-P  
HP 4.61-H  
HP 4.62-P  
HP 4.62-H  
20HP060-1E  
20HP060-1E  
20HP060-2E  
20HP060-2E  
30HP060-1E  
30HP060-2E  
40HP060-1E  
40HP060-1E  
40HP060-2E  
40HP060-2E  
41PG20S 1.80 (.82)  
41HP20S 1.60 (.73)  
41PG20S 1.80 (.82)  
41HP20S 1.60 (.73)  
8.75 (222)  
10.00 (254)  
8.75 (222)  
10.00 (254)  
5.10 (130) 5.38 (137)  
5.02 (129)  
5.10 (130) 5.38 (137)  
5.02 (129)  
1.90 (48)  
41HP30S  
1.40 (.64)  
41HP30S  
9.00 (229)  
5.10 (130)  
9 ft (3 m)  
41PG40S 1.65 (.75) 2.10 (53)  
41HP40S 1.35 (.61) 1.90 (48)  
41PG40S 1.65 (.75) 2.10 (53)  
41HP40S 1.35 (.61) 1.90 (48)  
5.02 (129) 5.38 (137)  
4.80 (122)  
7.75 (197)  
5.02 (129) 5.38 (137)  
4.80 (122)  
Figure 9-2 Probes Outline Drawings and Dimensions  
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Section 9 – Specifications  
Weights  
Generator:  
12 pounds (5.44 kg)  
Probes:  
Please see the table on the previous page.  
Add 5 pounds (2.27 kg) to unit weight for packing materials.  
Shipping:  
Operating Environment  
Operate the equipment within these guidelines:  
Temperature:  
Air Particulates: Keep the equipment dry.  
Minimize exposure to moisture, dust, dirt, smoke  
40°F to 100°F (+5°C to +38°C)  
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  
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AC Power Requirements  
Overload  
Power  
Rating  
System  
Model  
Number  
North America/  
Japan  
AC Outlet Rating  
Operating  
Frequency  
Generator  
Model Number Part Number  
Probe  
Input AC Power Requirements  
Nominal AC Volt  
(Watts)  
20kHz  
20kHz  
20kHz  
20kHz  
30kHz  
30kHz  
40kHz  
40kHz  
40kHz  
40kHz  
HP 2.61-P  
HP 2.61-H  
HP 2.62-P  
HP 2.62-H  
HP 3.61-H  
HP 3.62-H  
HP 4.61-P  
HP 4.61-H  
HP 4.62-P  
HP 4.62-H  
20HP060-1E  
20HP060-1E  
20HP060-2E  
20HP060-2E  
30HP060-1E  
30HP060-2E  
40HP060-1E  
40HP060-1E  
40HP060-2E  
40HP060-2E  
41PG20S  
41HP20S  
41PG20S  
41HP20S  
41HP30S  
41HP30S  
41PG40S  
41HP40S  
41PG40S  
41HP40S  
100-120 VAC, 50/60 Hz @ 9.0 Amps  
100-120 VAC, 50/60 Hz @ 9.0 Amps  
200-240 VAC, 50/60 Hz @ 4.5 Amps  
200-240 VAC, 50/60 Hz @ 4.5 Amps  
100-120 VAC, 50/60 Hz @ 9.0 Amps  
200-240 VAC, 50/60 Hz @ 4.5 Amps  
100-120 VAC, 50/60 Hz @ 9.0 Amps  
100-120 VAC, 50/60 Hz @ 9.0 Amps  
200-240 VAC, 50/60 Hz @ 4.5 Amps  
200-240 VAC, 50/60 Hz @ 4.5 Amps  
600  
15.0 Amps  
Table 9-I AC Power Requirements  
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Section 9 – Specifications  
Regulatory Agency  
Compliance  
FCC  
CAUTION  
The generator complies with the following Federal  
Communications Commission regulations.  
DO NOT make any  
modifications to the  
generator or associated  
cables as the changes  
may result in violating  
one or more regulations  
under which this equip-  
ment is manufactured.  
•
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 Conformité Europeéne (European Conformity). The  
generator complies with the following CE requirements.  
•
T h e E M C D i r e c t i v e 2 0 0 4 / 1 0 8 / E C  
for Heavy Industrial —  
EN 61000-6-4: 2001  
EN 55011: 2003  
EN 61000-6-2: 2001  
EN61000–4–2  
EN61000–4–3  
EN61000–4–4  
EN61000–4–5  
EN61000–4–6  
EN61000–4–8  
EN61000–4–11  
•
•
The Low Voltage Directive 2006/95/EC.  
The Machine Directive 98/37/EC.  
EN 60204-1: 2006  
Safety of Machinery - Electrical Equip-  
ment of Machines Part 1: Specification  
for General Requirements.  
Effective 12/29/09:  
The Machinery Directive 2006/42/EC.  
EN 60204: 2006  
Safety of Machinery - Electrical Equipment  
of Machines Part 1: General Requirements.  
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Section 10 – I/O Interface  
SECTION 10  
Outputs Interface  
Outputs Connection Example. . . . . . . . . . . . . . . . . . . . . . . . . 65  
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Section 10 – I/O Interface  
iQ Hand Probe Generator  
Rear Panel Detail  
HAND PROBE  
OUTPUTS  
0V  
1
2
3
Provided by Customer  
Power Supply  
NOTE  
0V  
(Output  
Common)  
is  
connected  
to  
Chassis  
Ground  
(Earth).  
+ 30 VDC Maximum  
To OUTPUTS:  
1, 2, or 3  
+ 24 V  
0V  
X 1  
X 2  
Status  
+
_
Indicator or  
Audible  
Alarm  
(333mA  
maximum)  
Figure 10-1 OUTPUTS Connection Example  
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Section 11 – Contacting Dukane  
SECTION 11  
Contacting Dukane  
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Section 11 – Contacting Dukane  
Contacting Dukane  
Identify Equipment  
When contacting Dukane about a service–related problem,  
be prepared to give the following information:  
• Model number, line voltage and serial number  
• Fault/error indicators from the LCD display  
• Software version (Press INFO. With pointer at System  
Information, press ENTER to get this data.)  
• 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  
(630) 797–4949  
Fax:  
Main  
Service & 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  
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Appendices  
APPENDICES  
List of Figures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73  
List of Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74  
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Appendices  
List of Figures  
No.  
Description  
Page  
2-1  
2-2  
2-3  
Example of 125 Volt, Grounded, 3-prong Plug and Receptacle......................................8  
Example of 250 Volt, Grounded, 3-prong Plug and Receptacle......................................8  
International 220/240V Grounding ..................................................................................8  
3-1  
3-2  
Generator Detail - Rear Views.......................................................................................12  
Rocker-style Power Switch/Circuit Breaker...................................................................12  
4-1  
Front Panel....................................................................................................................17  
Power Bar Graph - In Cycle ..........................................................................................18  
Power Bar Graph - Operate ..........................................................................................18  
Power Switch.................................................................................................................19  
Power-up Screen...........................................................................................................19  
Operate Screen Appears After Power-up......................................................................19  
Example of an Operate Screen.....................................................................................20  
Example of an In Cycle Screen.....................................................................................20  
4-1A  
4-1B  
4-2  
4-3  
4-3A  
4-4  
4-5  
5-1  
Manual Weld Mode........................................................................................................24  
Navigate to Time Mode .................................................................................................24  
Time Weld Mode - 1 ......................................................................................................24  
Time Weld Mode - 2 ......................................................................................................24  
Time Weld Mode ...........................................................................................................25  
Navigate to Energy Mode -1..........................................................................................25  
Navigate to Energy Mode -2..........................................................................................25  
Energy Weld Mode - 1...................................................................................................25  
Energy Weld Mode - 2...................................................................................................25  
HOLD Time - 1 ..............................................................................................................26  
HOLD Time - 2 ..............................................................................................................26  
Amplitude ......................................................................................................................26  
INFO Screen .................................................................................................................27  
5-2  
5-3  
5-4  
5-5  
5-6  
5-6A  
5-7  
5-8  
5-9  
5-9A  
5-10  
5-11  
5-11A System Information Example Screen............................................................................27  
5-12  
5-13  
5-14  
5-15  
5-16  
5-17  
Hardware Settings Screen ............................................................................................27  
Warning Screen.............................................................................................................28  
Advanced Settings Screen............................................................................................28  
Trigger Amplitude ..........................................................................................................29  
Trigger Watts.................................................................................................................29  
Trigger Timeout .............................................................................................................29  
Pageꢀ 73  
DukaneꢀManualꢀPartꢀNo.ꢀ403-574-01  
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iQSeries, UltrasonicꢀHandꢀHeldꢀSystemsꢀUser’sꢀManual  
List of Figures continued  
5-18  
Setup Maintenance - 1 ..................................................................................................30  
5-18A Pop-up Load Defaults?..................................................................................................30  
5-19  
5-20  
5-21  
5-22  
5-23  
5-24  
5-25  
Setup Maintenance - 2 ..................................................................................................30  
Setup Maintenance - 3 ..................................................................................................30  
Pop-up Overwrite Setup?..............................................................................................30  
Setup Maintenance 4 ....................................................................................................30  
Save Curent Setup .......................................................................................................31  
Store in Setup Maintenance .........................................................................................31  
New Setup Stored ........................................................................................................31  
6-1  
6-2  
6-3  
6-4  
6-5  
6-6  
6-7  
6-8  
Typical Hand Held Probes.............................................................................................35  
Hand Probe, Horn and Tip.............................................................................................36  
Probe, Booster and Horn...............................................................................................37  
Replaceable Tip Installation ..........................................................................................38  
Stack Assembly Procedure ...........................................................................................40  
Hand Probe Assembly and Disassembly ......................................................................40  
Separating the Horn from the Booster...........................................................................43  
Removing a Replaceable Tip From the Horn ................................................................43  
9-1  
9-2  
Generator Outline Drawing............................................................................................57  
Probes Outline Drawings and Dimensions....................................................................58  
10-1  
OUTPUTS Interface Example .......................................................................................65  
List of Tables  
No.  
Description  
Page  
3-I  
Standard IEC AC Power Cord Part Numbers .................................................................13  
System OUTPUTS Connector Signals ...........................................................................14  
3-II  
6-I  
Tip Torque Unit Conversions...........................................................................................38  
Stud Torque Unit Conversions ........................................................................................39  
Horn/Booster Torque Unit Conversions...........................................................................41  
6-II  
6-III  
7-I  
Pop-up Fault Status Screens - Manual Mode.................................................................49  
Pop-up Fault Status Screens - Time and Energy Modes................................................50  
7-II  
9-I  
AC Power Requirements ................................................................................................60  
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ꢀ
DukaneꢀManualꢀPartꢀNo.ꢀ403-574-01  
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Dukane ISO  
ISO CERTIFICATION  
Dukane chose to become ISO 9001:2000 certi-  
fied in order to demonstrate to our customers  
our continuing commitment to being a quality  
vendor. 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.  
The ISO 9001:2000 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  
improvement. This concept is key in that Du-  
kane 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.  
To achieve ISO 9001:2000 certification, you  
must prove to one of the quality system regis-  
trar groups that you meet three requirements:  
1. Leadership  
2. Involvement  
3. Quality in Line Organizations and Quality  
System Infrastructure.  
ISO 9001:2000  
C E R T I F I E D  
Dukane products are manufactured in ISO  
registered facilities  
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Please refer to our website at:  
www dukane com/us/sales/intsales htm  
to locate your local representative.  
iQ Series, Ultrasonic Hand Held Systems User's Manual  
Part No. 403–577–01  
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  
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