Manuale d’uso / di manutenzione del prodotto ISO 9001:2008 del fabbricante Dukane
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ISO 9001:2008 Products are manufactured in ISO registered facilities. Intelligent Assembly Solutions www .dukane.com/us Dukane Part No. 403 – 583– 00 iQ Series UL TRASONIC PO WER SUP P L Y AL User’ s Manual Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St.
Page ii iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Printed in the United States of America. Part Number: 403–583–00 This ultrasonic equipment is manufactured under one or more of the following U.
Page iii Dukane Manual Part No. 403-583-00 R e vis ion His tor y Revision Revision Number Summary Date - 00 Original release. 1 1/02/2010.
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Page v Dukane Manual Part No. 403-583-00 Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . 1 Section 2- Health and Safety . . . . . . . . . . . . . . . . . . . 5 Section 3- Installation . . . . . . . . . . . . .
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Page 1 Section 1 – Intr oduction Dukane Manual Part No. 403-583-00 SECTION 1 Intr oduction General User Information . . . . . . . . . . . . . . . . . . 3 Read the Manual First . . . . . . . . . . . . . . . . . . . . . . 3 Notes, Cautions and W arnings .
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Page 3 Section 1 – Intr oduction Dukane Manual Part No. 403-583-00 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.
Page 4 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 System Overview Y our iQ Series Ultrasonic Power Supply A L, an ultra- sonic generator , provides a versatile stand-alone worksta- tion.
Page 5 Section 2 – Health and Safety Dukane Manual Part No. 403-583-00 SECTION 2 Health and Saf ety G e n e r a l C o n s i d e r a t i o n s .............................. 7 P l a s t i c s H e a l t h N o t i c e .......................
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Page 7 Section 2 – Health and Safety Dukane Manual Part No. 403-583-00 General Considerations Ple ase obse rve thes e hea lth and safe ty recom men dat ion s for saf e, ef cie nt, and in jur y-f ree ope rat ion of you r e qui pme nt.
Page 8 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Electrical Safety Domestic Power Grounding For safety , the power cords used on this product have a three-wire, grounding-type power cord.
Page 9 Section 3 – Installation Dukane Manual Part No. 403-583-00 St ep 1. Stand close to the load with your feet spread apart about shoulder width, with one foot slightly in front of the other for balance. Step 2. Squa t down bend ing at the knees (not your waist).
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Page 1 1 Section 3 – Installation Dukane Manual Part No. 403-583-00 SECTION 3 Installa tion B e f o r e I n s t a l l a t i o n ................................ 1 3 When to Use Lockout/T agout Devices . . . . . . . . . . . . . . . . . . .
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Page 13 Section 3 – Installation Dukane Manual Part No. 403-583-00 Bef ore Ins t al latio n As y ou p lan for the ins tall atio n of yo ur g ener ato r , please consider these important s.
Page 14 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Lockout/T agout Procedur e to use BEFORE making any internal adjustments to the generator: 1. Push the generator's AC power switch/ breaker to the OFF position.
Page 15 Section 3 – Installation Dukane Manual Part No. 403-583-00 Unpacking Carefully open your shipping container , and make sure it contains the items shown on the shipping documents. Inspect all items, and report any missing items or damage immediately .
Page 16 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Connecting Cables - Quick Start Guide Complete the basic connections as shown below: • AC Line Input • I/O (Input/Output) Connector • Grounding Stud • AC Power Cord Connection Step 1.
Page 17 Section 3 – Installation Dukane Manual Part No. 403-583-00 Power Cords 200/240 V olt Systems The IEC AC power inlet connector mounted on the rear panel requires a properly congured IEC compliant power cord.
Page 18 iQ Series , Ultrasonic Power Supply AL User’s Manual Dukane Manual Part No. 403-583-00 Pin Color Description 1 BLK Enable Out 2 WHT E.
Page 19 Section 4 – Contr ols and Connections Dukane Manual Part No. 403-583-00 Pin 7 (Status Output Common) Pin 7 is connected to chassis ground. The non-isolated NPN status output signals can drive isolated PNP inputs on the automation control system.
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Page 21 Section 4 – Contr ols and Connections Dukane Manual Part No. 403-583-00 F r o n t P a n e l O v e r v i e w ............................... 2 3 Start-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 LCD Display Overview .
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Page 23 Section 4 – Contr ols and Connections Dukane Manual Part No. 403-583-00 40100 Figure 4-1 Front Panel F ro nt P ane l Ov er vie w 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.
Page 24 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 CAUTION Make sure the stack is prop- erly assembled before it is con nect ed to the sys tem.
Page 25 Section 4 – Contr ols and Connections Dukane Manual Part No. 403-583-00 Star t - up Seq uen ce After all connections have been completed. 1. Push the Power Switch to ON (Figure 4-2). The generator performs a self-diagnostics sequence.
Page 26 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 L CD Dis pla y O v er vie w There are two basic kinds of screen displays: Operate screens, and In Cycle screens.
Page 27 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-583-00 SECTION 5 Pr ocess Contr ol Settings Select the W elding Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 N a v i g a t i n g t h e M o d e s ...
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Page 29 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-583-00 P rocess C ontro ller Settings This section of the manual helps the reader become familiar with the operating modes, and illustrates some typical programming steps.
Page 30 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Navigating the Modes When the generator is rst powered up, the default operating mode is Automation, and Automation W eld is shown at the top of the display as shown in Figure 5-1.
Page 31 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-583-00 Navigate to Energy Mode 1. Follow the sequence shown in the gures to the right to navigate from T ime mode to Energy mode. In T ime mode (Figure 5-5), press the ENERGY key , and the screen as shown in Figure 5-6 appears.
Page 32 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Hold HOLD is used more often with T ime or Ener gy modes, but it can be used with the Automation mode.
Page 33 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-583-00 System Information, Advanced Settings When the INFO key is pressed the display looks like Figure 5-1 1: Using the keys, move the pointer to indicate: System Information , or Advanced Settings Press ENTER to make the selection.
Page 34 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Continued 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.
Page 35 Section 5 - Pr ocess Control Settings Dukane Manual Part No. 403-583-00 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.
Page 36 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Setup Maintenance C ontinued Changing the Current Setup T ry using your navigation skills on this example: 1.
Page 37 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 SECTION 6 Pr obes and Pr obe Stac ks Ultrasonic Probe Overview ...........................39 Theory of Operation ............................................ 40 Probe Conguration .
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Page 39 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 U lt ras on ic P robe Ov er vie w Operating Notes Compressed Air Fitting - In continuous duty operation, it is important to keep the probe cool with compressed air .
Page 40 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Theory of Operation Plastic welding is the most common application of ultrasonic assembly .
Page 41 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 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.
Page 42 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Stack Assembly Attaching a Replaceable T ip to a Horn 1. Insp ect all ho rn an d t ip sur fac es fo r s tre ss cra cks , chips, or gouges.
Page 43 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 At tac hin g the Mou nt ing St ud to a Ho rn or a Bo ost er 1. Inspect the stud for cracks or damaged threads. Replace the stud if it is cracked or otherwise dam- aged.
Page 44 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 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.
Page 45 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 6. Thread the components together and tighten to the following torque specications using only the correct size wrenches. Use spanner wrenches on components with spanner wrench holes or an open end wrench on components with wrench ats.
Page 46 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 HORN HORN PROBE ASSEMBL Y PROBE HOUSING .
Page 47 Section 6 – Pr obes and Probe Stacks Dukane Manual Part No. 403-583-00 Se par ati ng 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 sufcient torque to loosen a joint.
Page 48 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Booster Notes How to T ell 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.
Section 7 – T r oubleshooting Page 49 Dukane Manual Part No. 403-583-00 SECTION 7 T r oubleshooting No Ultrasonic Output ..................................... 51 System Power Output Level .........................51 W elding Problems ....
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Section 7 – T r oubleshooting Page 51 Dukane Manual Part No. 403-583-00 No Ultrasonic Output Probe Make sure that the probe cable is connected to the generator connector (PROBE) and secured to the rear panel. Also, make sure the probe stack is properly assembled.
Page 52 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 W elding Problems W eak Welds W eak welds, or underwelding, is caused by insufcient energy being transmitted to the part.
Section 7 – T r oubleshooting Page 53 Dukane Manual Part No. 403-583-00 Generator Fault Status Screens - Automation Mode Status T ext Displayed System Status or Fault Explanation An Average Overload fault tripped. Output power exceeded rated wattage.
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Section 8 – Specications Page 55 Dukane Manual Part No. 403-583-00 SECTION 8 Specica tions Generator Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 W e i g h t s .......................................... 5 8 O p e r a t i n g E n v i r o n m e n t .
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Section 8 – Specications Page 57 Dukane Manual Part No. 403-583-00 Figure 8-1 Generator Outline Drawing 12.41 [315.2] 10.00 [254] 3.95 [100.
Page 58 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 Operatin g En vir onment Operate the equipment within these guidelines: T emperature : 40 °F to 100° F ( +5°C to +38 °C) Air Particulates : Keep the equipment dry .
Section 8 – Specications Page 59 Dukane Manual Part No. 403-583-00 AC Power Requirements Operating Frequency Generator Model Number Overload Power Rating (W atts) Input AC Power Requirements Nominal AC V olt North America/ Japan AC Outlet Rating 20kHz 20ALP060-1E 600 100-120 V AC, 50/60 Hz @ 9.
Page 60 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 R egu lat or y Age nc y Com pli ance FCC The generator complies with the following Federal Communications Commission regulations.
Section 9 – Contacting Dukane Page 61 Dukane Manual Part No. 403-583-00 SECTION 9 Contacting Dukane.
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Section 9 – Contacting Dukane Page 63 Dukane Manual Part No. 403-583-00 Co ntactin g Duk ane Identify Equipment When contacting Dukane about a service–related problem, be prepared to gi.
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Page 65 Appendices Dukane Manual Part No. 403-583-00 APPENDICES Appendix A - E-Stop Circuitry Examples . . . . . . . . . . . . . . . . 67 Appendix B - List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . 68 Appendix C - List of T ables .
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Page 67 Appendices Dukane Manual Part No. 403-583-00 Figure A-1 E-Stop Circuitry iQ Auto Enable Out Enable In Dedicated E-Stop Switch Wiring Diagram System I/O Connector (Pin 1) (Pin 2) Use.
Page 68 iQ Series , Ultrasonic Hand Held Systems User ’s Manual Dukane Manual Part No. 403-583-00 List of Figures 2-1 Example of 125 V olt, Grounded, 3-prong Plug and Receptacle ...........
Page 69 Appendices Dukane Manual Part No. 403-583-00 No. Description Page 2-I iQ Generator W eights ........................................................................................................9 3-I Standard IEC AC Power Cord Part Numbers .
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Dukane ISO ISO CER TIFICA TION Duka ne chos e to beco me ISO 9001:2 008 certi- fied in order to demonstrate to our customers our continuing commitment to being a quality ve ndo r .
Par t No. 403 – 58 3 – 00 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • F AX (630) 797- 4949 iQ Series , Ultrasonic Power Supply AL User's Manual Printed in the United States of America www .
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Dukane ISO 9001:2008 è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Dukane ISO 9001:2008 - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Dukane ISO 9001:2008 imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Dukane ISO 9001:2008 ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Dukane ISO 9001:2008, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Dukane ISO 9001:2008.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Dukane ISO 9001:2008. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Dukane ISO 9001:2008 insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
