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Press System Overview
An iQ Series Ultrasonic Press System ES consists of
these components: the iQ generator, press (with thruster,
switches, controls, cables, transducer, booster, horn, and
xture) and iQ Explorer software. The software allows
the operator to control the system either remotely or at the
press location.
The iQ Series ES generator has rugged internal ultrasonic
circuitry and ensures a continuous resonant frequency lock
at the start of each weld.
The generator’s compact size allows multiple units to be
placed into an industrial equipment cabinet. This genera-
tor will operate at the same international line voltage input
specications as the other generators of this product fam-
ily (unless the 120V option is installed). It also includes an
RFI line lter that passes FCC and strict CE test specica-
tions for global applications.
Key Generator Features
• Digital Control of all power supply functions, includ-
ing digital frequency synthesis, and parameters allows
for unique congurations and allows for future up-
grades.
• Process Parameters such as frequency, amplitude
and power are all updated at a 0.5 ms rate.
• Pulse Width Modulation incorporates patented
circuitry giving the power supply the ability to
efciently change the output amplitude. This makes
it possible to start large horns with reduced power. It
also provides more power-efcient switch-mode gen-
erator operation and increased reliability.
• Linear Ramp Soft-Start circuitry allows the acoustic
stack to be brought to operating amplitude smoothly,
minimizing 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 specied range. This
provides consistent system performance regardless of
line voltage uctuations. It also eliminates the need
for bulky, external constant–voltage transformers.
• Load Regulation provides constant ultrasound
amplitude automatically regardless of power draw.
The ultrasonic output amplitude level is held to
within ±1% to provide weld process consistency
and reduced weld cycle times.
• High Line Voltage Power Supply means that
standard systems will operate worldwide at the lo-
cal high line voltage level, 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.
• Low Line Voltage Power Supply - This optional
120V power supply is designed for North Ameri-
can applications.
• Flow Through Cooling Tunnel with a matched
high–performance heatsink and thermostatically
controlled fan reduces thermal gradients and in-
creases component life.
• AC Power Inrush protection reduces electri-
cal stress on the internal components by protect-
ing them from AC power startup transient current
surges.
• Multiple Electronic Overload protection circuits
prevent instantaneous component failure in the
event of extreme output overload conditions. The
overload power limit is based on the actual true RMS
power output level.
• Process Limits include: distance, time only, time
and energy, and peak power. These programmable
limits provide the means to adapt to a wide variety
of welding applications.
• Rear Panel Expansion Slot is available to allow
for custom congurations for OEM and cost effec-
tive solutions.
• RS232SerialCongurationPortis used for eld
software upgrades, troubleshooting and advanced
hardware setup with optional PC-based congura-
tor.
• CECertication means that the system meets the
required European standards to be sold and used in
Europe (high line voltage models only).
• ISO9001Certication means that this system has
been manufactured to high quality standards and
assures you of manufacturing excellence.
Page 4
iQ Series Ultrasonic Generator/Power Supply ES User’s Manual
Dukane Manual Part No. 403-575-00