Dukane iQ Series Ultrasonic Power Supply AL-E User manual

Products are manufactured in ISO

registered facilities.

www.dukane.com/us

Dukane Part No. 403 – 607 – 00

iQ Series

ULTRASONIC POWER SUPPLY

AL-E

Users Manual

Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797-4949

AUTOMATED HAND PROBE PRESS

Applicable System Models:

20AL060-1H 35AL060-1H

20AL060-2H 35AL060-2H

30AL060-1H 40AL060-1H

30AL060-2H 40AL060-2H

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iQ Series, Ultrasonic Power Supply AL - E Users Manual

Dukane Manual Part No. 403-607-00

Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents:

3,772,538 3,780,926 3,825,481 3,832,019 4,131,505 4,208,001

4,277,710 5,798,599 5,880,580 6,984,921 7,225,965 7,475,801

7,819,158 8,052,816 8,245,748 8,720,516 8,721,817 9,144,937

2900 Dukane Drive

St. Charles, IL 60174 USA

Notice of Rights:

design, cover design and icons may be reproduced, transmitted

or utilized in any form or by any means, electronic, mechanical,

photocopying, recording, or by any information storage and

retrieval system, without written permission from Dukane.

Notice of Liability:

The information contained is this manual is distributed on an

“As is” basis, without warranty. While every precaution has

been taken in the preparation of this manual, Dukane shall not

have any liability to any person or entity with respect to any

liability, loss, or damaged caused or alleged to be caused directly

or indirectly by the instructions contained in this manual, or by

the hardware and software products described herein.

Printed in the United States of America.

Dukane Part Number: 403-607-00

Page iii

Dukane Manual Part No. 403-607-00

Revision History

Revision Revision

Number Summary Date

- 00 Original release. August 30th, 2017

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iQ Series, Ultrasonic Power Supply AL - E Users Manual

Dukane Manual Part No. 403-607-00

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Page v

Dukane Manual Part No. 403-607-00

Contents

Section 1- Introduction .......................1

Section 2- Health and Safety ...................5

Section 3- Installation ........................9

Before Installation ...........................11

Unpacking .................................13

Placement .................................13

RFI Grounding .............................13

Connecting Cables ..........................14

Section 4 - Controls .........................19

Controls Overview ..........................21

Start-up Sequence ..........................23

LCD Display Overview .......................24

Section 5 - Process Control Settings ...........25

Selecting the Weld Mode .....................27

Navigating the Modes ........................28

Hold .....................................30

Amplitude Adjustment ........................30

Trigger by Power ...........................31

System Information, Advanced Settings ..........32

Setup Maintenance ..........................34

Section 6 - Probes and Probe Stacks...........37

Section 7 - Troubleshooting ..................49

Section 8 - Specifications ....................57

Section 9 - Contacting Dukane ................63

Section 10 - Appendices .....................67

Appendix A - E-Stop Circuitry Examples .........69

Appendix B - List of Figures ...................70

Appendix C - List of Tables ....................71

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iQ Series, Ultrasonic Power Supply AL - E Users Manual

Dukane Manual Part No. 403-607-00

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Page 1

Section 1 – Introduction

Dukane Manual Part No. 403-607-00

SECTION 1

Introduction

Important 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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iQ Series, Ultrasonic Power Supply AL - E Users Manual

Dukane Manual Part No. 403-607-00

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Page 3

Section 1 – Introduction

Dukane Manual Part No. 403-607-00

NOTE

NOTE statements provide additional

information or highlight procedures.

CAUTION

CAUTION statements identify

conditions or practices that

could result in damage to the

equipment or other property.

WARNING

WARNING statements point

out conditions or practices

that could result in personal

injury or loss of life.

Condition

or Practice

Electrical

Hazard

Read This Manual First

Before operating the iQ Series Ultrasonic Power Supply

AL- E, read this User’s Manual to become familiar with the

system. This will ensure correct and safe operation. The

manual is organized to allow you to learn how to safely

operate this system. The examples given are chosen for

their simplicity to illustrate basic setup procedures.

Notes and Tips

Throughout this manual we use NOTES to provide

information that is important for the successful application

and understanding of the system. A NOTE block is shown

to the right.

Cautions and Warnings

In addition, we use special notices to make you aware

of safety considerations. These are the CAUTION

and WARNING blocks as shown here. They represent

increasing levels of important information. These

statements help you to identify and avoid hazards and

recognize the consequences. Different symbols also

accompany the CAUTION and WARNING blocks to

indicate whether the notice pertains to a general condition

or practice, an electrical safety issue, a hand protection

issue or other condition.

Drawings and Tables

The gures and tables are identied by the section number

followed by a sequence number. The sequence number

begins with one in each section. The gures and tables

are numbered separately. The gures use Arabic sequence

numbers (e.g. –1, –2, –3) while the tables use roman

sequence numerals (e.g. –I, –II, –III). As an example,

Figure 3–2 would be the second illustration in section

three while Table 3–II would be the second table in section

three.

Important User Information

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iQ Series, Ultrasonic Power Supply AL - E Users Manual

Dukane Manual Part No. 403-607-00

System Overview

Your iQ Series Ultrasonic Power Supply AL-E, an ul-

trasonic generator, provides a versatile stand-alone work-

station.

This product’s rugged internal circuitry ensures a continu-

ous resonant frequency lock at the start of each weld.

Standard to this line of generators are time and energy

control. The brightly lit display is easy to read. The menu

structure makes programming simple, and the one-touch

hot keys give the operator even more exibility.

The generator also includes an RFI line lter that passes

strict CE test specications for global applications.

Key Features

• Trigger by Power is a Dukane patented feature that

produces greater weld consistency by requiring that

a sufcient amount of pressure/force is applied to the

part before the actual weld begins. Trigger by Power is

a cost effective alternative to trigger by force because

it does not require additional, expensive components

such as a load cell, amplier board or cabling.

• Compact Generator is small and easily moved, and

this allows your table or work bench to accommodate

more of the items needed for your process.

• Pulse Width Modulation incorporates patented

circuitry giving the power supply the ability to

efciently change the output amplitude. This makes

it possible to start large horns with reduced power. It

also provides more power efcient switch-mode gen-

erator operation and increased reliability.

• Linear Ramp Soft Start circuitry allows the acous-

tic stack to ramp up to operating amplitude smoothly,

minimizing the start-up surges and abnormal stress to

the stack and generator.

• Digi-Trac Tuning tracks the resonant frequency of

the acoustic stack (horn, booster, transducer) and ad-

justs the generator output frequency to match it. This

is done for every weld cycle and eliminates the need

to manually tune the generator.

• Line Voltage Regulation automatically maintains

constant amplitude regardless of line voltage devia-

tion. The available output power is maintained with

any voltage input within the specied range. This pro-

vides consistent system performance regardless

of line voltage uctuations. It also eliminates the

need for bulky, external constant–voltage trans-

formers.

• Load Regulation provides constant amplitude

automatically regardless of power draw. The ul-

trasonic output amplitude level is held to within

±1% to provide weld process consistency and re-

duced weld cycle times.

• Industrial Line–Power Source means that

standard systems will operate worldwide at all

industrial high line voltage levels, whether it is

200VAC @60Hz in Japan, 240VAC @50Hz in

Europe or 208VAC @60Hz in the United States.

There are no internal transformer taps to change

for worldwide operation. North American sys-

tems are optionally available to operate on the

120VAC line voltage level.

• Multiple Electronic Overload protec-

tion circuits prevent instantaneous com-

ponent failure in the event of extreme out-

put overload conditions, and rated overload

power limit is based on the actual true RMS

power output level.

• CE Certication means that the system meets

the required European standards to be sold and

used in Europe.

• ISO 9001 : 2008 Certication means that this

system has been manufactured to high quality

standards and assures you of manufacturing ex-

cellence.

• TUV Certication - TÜV Rheinland certies

Dukane products comply with applicable UL

(Underwriters Laboratories) and CSA (Canadian

Standards Association) requirements.

Page 5

Section 2 – Health and Safety

Dukane Manual Part No. 403-607-00

SECTION 2

Health and Safety

General Considerations .............................. 7

Plastics Health Notice ................................7

Electrical Safety .................................... 8

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iQ Series, Ultrasonic Power Supply AL - E Users Manual

Dukane Manual Part No. 403-607-00

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Page 7

Section 2 – Health and Safety

Dukane Manual Part No. 403-607-00

General Considerations

Please observe these health and safety recommendations for

safe, efcient, and injury-free operation of your equipment.

In this manual, the term system refers to a complete group

of components associated with the welding of plastic or

metal parts, also known as an ultrasonic assembly system.

A typical system consists of a generator and/or ultrasonic

process controller, start and stop switches, power controls,

connecting cables, and the probe assembly which includes

the transducer, booster, horn and replaceable horn tip.

Proper Installation - Operate system components only

after they are properly installed and checked.

No Unauthorized Modications - Do not modify your

system in any way unless authorized to do so by the man-

ufacturer. Unauthorized modications may cause injury

to the operator and/or equipment damage. In addition,

unauthorized modications will void the equipment war-

ranty.

Keep the Cover On - Do not remove any equipment cov-

er unless specically directed to do so by the manufactur-

er. The generator produces hazardous electrical voltages

which could cause injury.

Grounded Electrical Power - Operate this equipment

only with a properly grounded electrical connection.

(See Page 8 for grounding information.)

Comply with Regulations - You may be required to add

accessories to bring the system into compliance with ap-

plicable OSHA regulations for noise exposure.

Plastics Health Notice

Before using any ultrasonic welding system, be sure you

are familiar with OSHA regulations from the U.S. Depart-

ment of Labor about the particular type of plastic(s) you

are using.

When plastic materials are being processed, they may emit

fumes and/or gases that could be hazardous. Make sure

you have adequate ventilation whenever these plastics are

processed.

WARNING

Never operate the generator

with the cover off. This is

an unsafe practice and may

cause injury.

CAUTION

Parts being joined ultrasonically

sometimes vibrate at audible

frequencies. Wear ear

protection to reduce annoying

or uncomfortable sounds. In

addition, ultrasound baffles,

sound enclosures or materials

that absorb sound may be

located to surround the

system. Ultrasound pressure

level could exceed 110dB.

Page 8

iQ Series, Ultrasonic Power Supply AL - E Users Manual

Dukane Manual Part No. 403-607-00

Electrical Safety

Domestic Power Grounding

For safety, the power cords used on this product have a

three-wire, grounding-type power cord. Figures 2-1 and

2-2 illustrate the appropriate electrical outlet to use with

the power cords included with 100-120 volt and 200-240

volt systems respectively. This information applies to

systems shipped to North America or Japan.

International Power Grounding

The power cable normally provided for international use

is compatible with the power outlet used in many Con-

tinental European countries. Refer to Figure 2–3. How-

ever, if your application requires another type of power

cord, check with your equipment supplier, and follow lo-

cal regulations concerning proper wiring and grounding.

Figure 2–3 International 220/240V Grounding

Grounding Contacts

Typical Outlet

Provided Cable

Approved 2 pole, 3 wire grounding receptacle

HUBBELL No. HBL 5662 or equivalent

NEMA Conﬁguration 6–15R or 6–20R

Figure 2–2 Example of 240 Volt,

Grounded, 3-Prong Receptacle

Figure 2–1 Example of 120 Volt,

Grounded, 3-Prong Plug and Receptacle

Approved 2 pole, 3 wire grounding receptacle

HUBBELL No. HBL 5262 or equivalent

NEMA Conﬁguration 5–15R or 5–20R

CAUTION

If you have a two-prong

electrical receptacle, we strongly

recommend that you replace

it with a properly grounded

three-prong type. Have a

qualied electrician replace it

following the National Electric

Code and any local codes

and ordinances that apply.

See Figures 2–1 and

2–2 for suggested parts.

CAUTION

If there is any question about the

grounding of your receptacle,

have it checked by a qualied

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 extension

cord with this product.

Page 9

Section 3 – Installation

Dukane Manual Part No. 403-607-00

SECTION 3

Installation

Before Installation ................................. 11

When to Use Lockout/Tagout Devices .................. 11

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

RFI Grounding .................................... 13

Connecting Cables ................................. 14

Power Cords .....................................15

Automation Controlled System. . . . . . . . . . . . . . . . . . . . . . . . 15

System I/O Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . 16

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iQ Series, Ultrasonic Power Supply AL - E Users Manual

Dukane Manual Part No. 403-607-00

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Page 11

Section 3 – Installation

Dukane Manual Part No. 403-607-00

Before Installation

As you plan for the installation of your generator, please

consider these importants subjects as listed below:

• When to use lockout / tagout devices

When to Use Lockout /

Tagout Devices

The typical kind of LOTO device for this generator is a

clam shell type device (with lockout capability). The LOTO

device is placed over the plug end of the generator electri-

cal cord. This effectively prevents access to the energy

isolation point. See the example of one such device in the

gure above.

The gure to the right shows the lockout device in the

closed, locked position.

Figure 3-1 Lockout Device In Open Position,

Unlocked

Figure 3-2 Bottom Lockout Device In

Closed Position, Locked

Continued

WARNING

Electrical safety hazards

exist inside the generator

chassis. Before making any

internal adjustments to the

generator, apply a lockout/

tagout (LOTO) device to the

generator chassis.

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iQ Series, Ultrasonic Power Supply AL - E Users Manual

Dukane Manual Part No. 403-607-00

Continued from Previous Page

Assuming the generator is being put back into

service. . .

Procedure to use AFTER making any internal

adjustments to the generator:

1. Authorized personnel remove the lockout/tagout

device from the plug end of the generator's

electrical cord. Using a typical clam shell type

LOTO device:

1) Unlock the protective shell.

2) Open the shell, exposing the electrical

cord end.

3) Remove the LOTO device, and set it

aside.

2. Plug the generator's electrical cord into its AC

power source.

3. Push the generator's AC power switch/breaker to

the ON position.

Lockout/Tagout

Procedure to use BEFORE making any internal

adjustments to the generator:

1. Push the generator’s AC power switch/

breaker to the OFF position.

2. Unplug the generator’s electrical cord from

its source.

3. Authorized personnel apply a lockout/

tagout (LOTO) device to the plug end of the

generator’s electrical cord. Using a typical

clam shell type LOTO device:

1) Open the clam shell.

2) Place the electrical cord plug end

inside the shell.

3) Close the shell.

4) Secure the shell with its lock, and

lock it.

4. Wait a minimum of ve minutes for the

generator to discharge its electrical energy.

5. After taking these steps, make the necessary

adjustments to the generator.

Page 13

Section 3 – Installation

Dukane Manual Part No. 403-607-00

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.

Placement

Make certain generator placement and cable routing do

not interfere with normal operation. Maintain easy access

to your equipment. The operator should have unobstructed

access to cables and wiring.

RFI Grounding

Proper grounding for the generator chassis is essential for

the effective suppression of electrical noise or RFI (Radio

Frequency Interference). Every ultrasonic generator

contains a RFI lter that blocks noise on the AC power

line from entering the system control circuitry. This lter

also prevents ultrasonic frequency noise from being fed

back into the AC power line. For the RFI lter to operate

effectively, it is necessary to correctly ground the system.

Connect a grounding wire from the grounding stud

connection (see Figure 3-1) to the nearest grounded metal

pipe or equivalent earth ground.

See Connecting Cables on the next page.

CAUTION

To minimize electrical noise

and eliminate ground currents,

ground the chassis as shown.

Use a STAR configuration

(illustrated below). Do not

DAISY CHAIN the grounds.

Earth

Ground

#14 Gauge

Stranded or

Solid Wire

Fixed Probe Mount

or 2nd Chassis

Grounding Stud

3rd Chassis

Grounding

Stud

Chassis Grounding

Stud

Recommended protective

earth ground connection

wire color: green or green

with yellow stripe.

CAUTION

If you have any questions about

the grounding of your equipment

and/or the electrical box,

contact a qualied electrician.

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 an industrial environ-

ment. Stud location is shown in Figure 3-3

on the following page.

Page 14

iQ Series, Ultrasonic Power Supply AL - E Users Manual

Dukane Manual Part No. 403-607-00

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. Connect the AC line. For the 100/120V model,

plug the permanently attached power cord into a

suitable receptacle.

For the 200/240V model, attach the female end of

the power cord to the generator’s power inlet con-

nector - A in Figure 3-3.

Step 2. Attach the I/O cable connector to the generator’s

input/output connection. - B in Figure 3-3.

Secure the connector to the system using the two

jack screws attached to the connector hood.

Step 3. Ground the generator chassis with the supplied 14-

Gauge wire. Attach one end to the grounding stud

- C in Figure 3-2. Attach the other end to the near-

est grounded metal pipe or equal earth ground.

Step 4. Attach the male end of the power cord to a suit-

able line receptacle.

Connector - See Page 19 for information about the rear

panel CONFIGURATION connector E.

Figure 3-3a Generator Detail - Rear View

(100/120 Volt Model)

Figure 3-4 Rocker-style Power Switch/Circuit Breaker

Push ON

Push OFF

Figure 3-3b Generator Detail - Rear View

(200/240 Volt Model)

NOTE

AC Power Inlet

Depending on your generator model, line

voltage required for the generator is either

100-120 VAC at 50/60 Hertz or

200-240 VAC at 50/60 Hertz.

The unit has a power switch, and is pow-

ered ON whenever the AC line power is

live and the switch is in the ON position as

shown in Figure 3-4 below.

C

A

B

Power Cord with Strain Relief

E

D

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