Dukane iQ Series user manual General Considerations, Plastics Health Notice

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Section 2 – Health & Safety

General Considerations

Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your equipment. In this manual, the term system refers to a complete group of components associated with the welding of plastic or metal parts, also 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 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.

Never operate the gen- erator with the cover off. This is an unsafe prac- tice and may cause injury.IMPORTANT

CAUTION

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.

Dukane Manual Part No. 403-577-01

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Contents User’s Manual Copyright Revision Revision HistorySummary Date This page intentionally left blank Contents This page intentionally left blank Introduction SectionThis page intentionally left blank Read This Manual First General User InformationDrawings and Tables System Overview Key FeaturesGenerator Hand ProbesHealth and Safety This page intentionally left blank Plastics Health Notice General ConsiderationsDomestic Power Grounding Electrical SafetyInternational Power Grounding Unpacking Placing RFI Grounding Connnecting Cables InstallationThis page intentionally left blank Placing UnpackingRFI Grounding AC Power Inlet Connecting Cables Quick Start Guide200/240 Volt Systems Power CordsUltrasound Output Pin 2 Any Fault Alarm Pin 1 End of Weld AlarmSystem Outputs Optional Connections Pin 0V Output CommonControls This page intentionally left blank Front Panel Overview Power Switch/Circuit BreakerControl Keys Arrow Keys Power Bar Graph+ and Keys System LCD DisplayStarting a Weld Cycle Start-up SequenceStopping a Weld Cycle Manual Weld LCD Display OverviewSetup Maintenance Process Control SettingsThis page intentionally left blank Select the Welding Mode Process Controller SettingsNavigating to Manual Mode Navigate to Time ModeNavigating Through the Modes Time keyKey Navigate to Energy ModeHold Amplitude AdjustmentHardware Settings System Information Hardware Settings, AdvancedSystem Information Free Run Frequency Advanced Settings40 % Introduction Setup MaintenanceNavigating Selecting a Setup Saving the Current SetupDeleting a Setup This page intentionally left blank Probes and Probe Stacks This page intentionally left blank Operating Notes Ultrasonic Probe OverviewCompressed Air Fitting In continuous duty Theory of Operation Ultrasonic Horn Attaching a Replaceable Tip to a Horn Stack AssemblyAttaching the Mounting Stud to a Horn or a Booster 5Stack Assembly Procedure In-lb Ft-lb KHz Stack Disassembly Removing the Mounting Stud from a Horn or Booster Booster Notes How to Tell the Booster Input End from the OutputTroubleshooting This page intentionally left blank No Ultrasonic Output System Power Output LevelWeak Welds Welding ProblemsInconsistent Welds Generator Fault Status Screens Manual Mode Pop-up Fault Status ScreensProcess Fault Status Screens Time and Energy Modes Options This page intentionally left blank IQ Hand Probe Options Foot Switch Kit Part NoBuzzer Kit Part No This page intentionally left blank Specifications This page intentionally left blank 1Generator Outline Drawing 2Probes Outline Drawings and Dimensions Operating Environment WeightsAC Power Requirements CE Marking Regulatory Agency ComplianceThis page intentionally left blank Outputs Interface This page intentionally left blank IQ Hand Probe Generator Rear Panel Detail This page intentionally left blank Contacting Dukane This page intentionally left blank Contacting Dukane Intelligent Assembly SolutionsIdentify Equipment This page intentionally left blank Appendices This page intentionally left blank Front Panel List of FiguresDescription List of TablesDukane ISO Part No - 577- 01