Dukane iQ Series Contents

Page v

Dukane Manual Part No. 403-577-00

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 - Specications ....................55

Section 10 - Outputs Interface. . . . . . . . . . . . . . . . . 63

Section 11 - Contacting Dukane . . . . . . . . . . . . . . . 67

Appendices ...............................71

List of Figures .......................73

List of Tables ........................74

Contents

Main iQ Copyright 2009 Revision History Page Contents Page SECTION 1 Introduction Page General User Information Read This Manual First Notes, Cautions and Warnings Drawings and Tables WARNING System Overview Generator Hand Probes Key Features Page Page General Considerations Plastics Health Notice IMPORTANT Electrical Safety Domestic Power Grounding International Power Grounding SECTION 3 Installation Page Unpacking Placing RFI Grounding Chassis Grounding Stud Connecting Cables - Quick Start Guide AC Power Inlet Power Cords 200/240 Volt Systems 100/120 V olt Systems HAND PROBE Connector Ultrasound Output System Outputs (Optional Connections) All outupt signals are non-isolated and sink current to chassis ground when activated. Refer to Figure 9-1, OUTPUTS Inter- face Example, Page 65. Page Page Front Panel Overview Control Keys INFO System Information - Hardware Settings - Control Keys AMP TIME ENERGY HOLD Start-up Sequence DUKANE Starting a Weld Cycle Stopping a Weld Cycle LCD Display Overview Operate screens, and In Cycle screens. IN CYCLE * SECTION 5 Process Control Settings Page Process Controller Settings Select the Welding Mode Manual T ime Energy Navigating Through the Modes Navigate to Time Mode Navigate to Energy Mode ENERGY key ENTER key Weld by Time Weld Time 0.500 S ENTER key Set energy level. Weld by Time Weld Time 0.500 S Hold Amplitude Adjustment + - Hold Time Amplitude System Information, Hardware Settings, Advanced Settings Continued iQ Information Hardware Settings Changes in Hardware Settings take place after ENTER is pressed. Warning Modified settings may affect operation of this unit! > Setup Maintenance Introduction Navigating Overwrite Setup #1? YES Setup #1 Empty Load Defaults? YES Setup Maintenance Saving the Current Setup Selecting a Setup Deleting a Setup Page SECTION 6 Probes and Probe Stacks Page Page 35 Section 6 Probes and Probe Stacks Figure 6-1 Typical Hand Held Probes Ultrasonic Probe Overview The two types of probes used with the iQ Hand Held Systems are shown in Figure 6-1 below. Operating Notes Compressed Air Fitting Compressed air supply: Make sure the air is clean, oil-free, and dry. Theory of Operation Probe Conguration Standard Horn Hand Probe Tip Ultrasonic Horn Booster Probe Housing Booster Horn Stack Assembly Attaching a Replaceable Tip to a Horn Attaching the Mounting Stud to a Horn or a Booster Attaching The Horn to a Booster, Booster to a Probe, or Horn to a Probe Page A D Stack Disassembly Page Booster Notes How to Tell the Booster Input End from the Output How to Tell if the Booster Is Amplifying or Reducing Page Page No Ultrasonic Output Probe System Power Output Level Overload Overtemperature Welding Problems Weak Welds Inconsistent Welds Generator Fault Status Screens - Manual Mode Pop-up Fault Status Screens Continued Process Fault Status Screens - Time and Energy Modes Page Page iQ Hand Probe Options Buzzer Kit Foot Switch Kit Page Page Page Page Page 58 iQ Series, UltrasonicHandHeldSystemsUsersManual A Figure 9-2 Probes Outline Drawings and Dimensions B C A B C D Operating Environment Weights Page 60 iQ Series, UltrasonicHandHeldSystemsUsersManual Table 9- I AC Power Requirements AC Power Requirements Regulatory Agency Compliance FCC CE Marking Page Page Page iQ Hand Probe Generator Rear Panel Detail X 1 X 2 + _ Page Page Page Contacting Dukane Identify Equipment Intelligent Assembly Solutions Mailing Address Phone: Fax: Page Page Page List of Figures List of Tables List of Figures Dukane ISO ISO CERTIFICATION CERTIFIED ISO 9001:2000