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Frequently Asked Questions

Ultrasonic Assembly Equipment Repair


Application or Tooling Problems

I'm experiencing difficulties with my ultrasonic horn, fixture, or application, should I call a repair technician?

Usually not. Our repair technicians’ expertise is the repair of the electrical and mechanical system components. Questions concerning tooling are best referred to the Tooling Department;  Application questions are best handled by the Applications Lab. Of course, if you are unsure if your problem is equipment, tooling, or application related, feel free to contact our Technical Support Team and we’ll gladly resolve it any way we can.

  • Ultrasonic Tooling:  
  • Application:  
  • Technical Support:  

Ultrasonic Generator Overloading

What should I look for when my generator overloads in both CYCLE and TEST?

Check your stack components (i.e., transducer - booster - horn) for clean, tight connections at all mating surfaces. Remove the horn and test for overload. If the generator continues to overload, remove the booster and test again. If available, try using a spare transducer and test again. If the generator overload continues, contact a Dukane Service Technician.


Thruster won't descend

Why won't my thruster head go down?

Try the following procedure:

  1. Make sure the digital timer or Ultra-Com is set for the mode (Manual or Auto) you are using.
  2. Verify the In-Cycle command. In an Ultra-Com system, the display will read "In Cycle". With a digital timer system, the OPERATE light on the timer board flashes. (Please see the User Manual that came with your system for more detailed information.)
  3. Check cable connections. Verify that the thruster has safety activation switches connected to the activation switch port: J8 on an Ultra generator; J202 on a Millennium Dynamic Process Controller (DPC). Make sure cable connectors and pins are straight and in place.   NOTE: Never unplug cables from any device unless its power is OFF. Serious equipment damage may occur otherwise.
  4. Ensure the thruster has an adequate air supply providing at 80-110 psi max. of clean, dry air.
  5. Check for a clogged air filter.

Digital Timer Error Codes

The Dukane Model #43A175 Digital Weld Timer monitors the assembly process. When it detects a condition that is out of the programmed operating range, the timer displays an error code. The following error codes may appear in the Weld Display area when using a Dukane assembly system equipped with a digital weld timer. To clear an error and continue operation, perform the solution listed after each error description.

Error Description
Code Solution
E0 Weld time greater than upper limit Unlatched:
Press any key or start next cycle.
E1 Weld time lower than lower limit Latched, Manual Initiation:
Press any key.
E2 Weld time equals programmed weld time Latched, Auto Initiation:
Press any key or start next cycle.
E16 Trigger active at cycle initiation.
Deactivate trigger.
E17 End of Weld active at cycle initiation.
Deactivate End of Weld or Ground Detect.
E18 Auto In signal HIGH at end of cycle.
Change Auto In signal to LOW.
E19 Trigger lost within 100ms of cycle initiation.
Press any key or start next cycle.
E20 Trigger lost while sonics applied.
Press any key or start next cycle.
E21 Auto In signal detected in Manual mode.
Change to Auto mode. (Programmed for cycle activation switch)  
Go to L11 and change "set status" to 1.
E22 SS1 or SS2 active in Auto mode.
Change to Manual mode. Go to L11 and change "set status" to 0.
E32 System Error. RAM test has failed.
System will not operate. Contact service technician.