Intelligent Assembly Solutions
Series
ULTRASONIC GENERATOR/POWER SUPPLY
Auto
AUTOMATED
HAND PROBE
PRESS
User’s Manual
Dukane Part No. 403-573-02
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797
-
4900 • FAX (630) 797 4949
-
Products are manufactured in ISO
registered facilities.
ISO 9001:2008
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Revision History
Revision
Number
Revision
Summary
Date
- 00
- 01
Original release.
10/09/2007
08/27/2009
20kHz and 30kHz models added.
System I/O Connector signals modified.
Amplitude control added.
- 02
I/O Connector Pin 9 signal scale revised.
Miscellaneous spelling errors corrected.
Fig 5-1 and 5-2 dimensions edited.
12/15/2010
Fault conditions modified:
Negative Peak Overload eliminated;
Positive Peak Overload changed to Peak Overload;
Frequency Lock Lost changed to Frequency Overload.
Copyright page modified: Specifications subject to change statement added,
and Patent 7,819,158 B2 added.
Updated Dukane ISO certification statement to 2008.
How to Lift Safely information added to Section 2, Health and Safety.
International Protection Rating added to Section 5, Specifications.
DukaneꢀManualꢀPartꢀNo.ꢀ403-573-02
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Contents
Section 1- Introduction 1
General User Information . . . . . . . . . . . . . . . 3
Generator Overview . . . . . . . . . . . . . . . . . . . 4
Key Generator Features . . . . . . . . . . . . . . . . 4
Thermal Considerations . . . . . . . . . . . . . . . . 5
Section 2- Health and Safety 7
General Considerations. . . . . . . . . . . . . . . . .9
Plastics Health Notice . . . . . . . . . . . . . . . . . .9
Electrical Safety. . . . . . . . . . . . . . . . . . . . . .10
How to Lift Safely . . . . . . . . . . . . . . . . . . . . 11
Section 3- Installation 13
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . .15
Placing. . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Power Grounding . . . . . . . . . . . . . . . . . . . .16
Chassis Grounding Stud . . . . . . . . . . . . . . .16
Connecting Cables . . . . . . . . . . . . . . . . 17-19
MPC Module Installation Guide. . . . . . . 20-25
Section 4 - System Operation 27
Standard iQ Auto System Test. . . . . . . . . . .29
iQ Auto System with MPC Test . . . . . . . . . .30
Section 5 - Specifications 33
Section 6 - Automation Interface 41
Input/Output Connection Examples. . . . 43-44
E-Stop Circuitry Connection Examples . . . .46
Section 7 - Contacting Dukane 47
DukaneꢀManualꢀPartꢀNo.ꢀ403-573-02
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Section 1 – Introduction
SECTION 1
Introduction
General User Information . . . . . . . . . . . . . . . . . . 3
Read The Manual First . . . . . . . . . . . . . . . . . . . . . .3
Notes, Cautions and Warnings. . . . . . . . . . . . . . . . . .3
Drawings and Tables . . . . . . . . . . . . . . . . . . . . . . .3
Generator Overview . . . . . . . . . . . . . . . . . . . . . 4
Key Generator Features. . . . . . . . . . . . . . . . . . . 4
Thermal Considerations . . . . . . . . . . . . . . . . . . . 5
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Section 1 – Introduction
General User Information
Read This Manual First
Before operating your ultrasonic generator, read this
User’s Manual to become familiar with the equipment.
This will ensure correct and safe operation. The manual
is organized to allow you to learn how to safely operate
this generator. The examples given are chosen for their
simplicity to illustrate basic operation concepts.
NOTE
Note statements provide additional
information or highlight procedures.
Notes, Cautions and Warnings
Throughout this manual we use NOTES to provide in-
formation that is important for the successful applica-
tion and understanding of the product. A NOTE block is
shown to the right.
CAUTION
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 in-
creasing levels of important information. These state-
ments help you to identify and avoid hazards and rec-
ognize the consequences. One of three different symbols
also accompany the CAUTION and WARNING blocks
to indicate whether the notice pertains to a condition or
practice, an electrical safety issue or an operator protec-
tion issue.
Caution statements
identify conditions or
practices that could result
in damage to the equip-
ment or other property.
WARNING
Warning statements
point out conditions or
practices that could re-
sult in personal injury or
loss of life.
Drawings and Tables
The figures and tables are identified by the section num-
ber followed by a sequence number. The sequence num-
ber begins with 1 in each section. The figures and tables
are numbered separately. The figures useArabic sequence
numbers (e.g. –1, –2, –3) while the tables use roman se-
quence numerals (e.g. –I, –II, –III). As an example, Fig-
ure 3–2 would be the second illustration in section three
while Table 3–II would be the second table in section
three.
Condition
or Practice
Hearing
Protection
Electrical
Hazard
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•
LineVoltageRegulationautomaticallymaintains
constant amplitude regardless of line voltage de-
viation. The available output power is maintained
with any voltage input within the specified range.
This provides consistent system performance re-
gardless of line voltage fluctuations. It also elimi-
nates the need for bulky, external constant–volt-
age transformers.
Generator Overview
This generator is designed for ultrasonic applications con-
trolled by a Programmable Logic Controller (PLC). Us-
ing the available system control inputs and outputs, the
generator can easily be integrated into a wide variety of
automated systems.
The generator design accepts several control input signals,
provides system output signals, has a power status LED
indicator, and an amplitude adjustment control.
•
•
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.
An optional Multi-Probe Control (MPC) interface module
allows the generator to power multiple probes selected by
an automated control system.
This product’s rugged internal ultrasonic generator cir-
cuitry ensures a continuous resonant frequency lock at the
start of each weld. Ultrasonic settings for the drive signal,
phase delay angle, starting frequency and soft–start ramp
parameters can be customized at the factory. (Contact your
local Dukane sales representative for more information.)
Users can modify generator performance to meet a wide
variety of ultrasonic processing requirements if needed.
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.
The generator’s compact size allows multiple units to be
placed into an industrial equipment cabinet, and the gen-
erator will operate at the same international line voltage
input specifications as the other generators of this product
family. It also includes an RFI line filter that passes strict
CE test specifications for global applications.
NOTE
120VAC is also available for these
countries: United States of Amer-
ica, Canada, Mexico and Japan.
•
•
Amplitude Adjustment Control allows the peak
-to-peak excursion of the horn at its workface to
be adjusted between 20% and 100% of the horn’s
nominal amplitude.
Key Generator Features
•
Compact Enclosure Size requires a small footprint for
either vertical or horizontal mounting into your equip-
ment cabinet.
Multiple
Electronic
Overload
protec-
•
Pulse Width Modulation incorporates patented
circuitry giving the power supply the ability to
efficiently change the output amplitude. This makes
it possible to start large horns with reduced power. It
also provides more power efficient switch-mode gen-
erator operation and increased reliability.
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 Certification means that the system meets
the required European standards to be sold and
used in Europe.
•
•
Linear Ramp Soft Start circuitry allows the acous-
tic stack to ramp up to operating amplitude smoothly,
minimizing the startup surges and abnormal stress to
the stack and generator.
ISO 9001 Certification means that this system
has been manufactured to high quality standards
and assures you of manufacturing excellence.
Automatic 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.
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Section 2 – Health & Safety
Figure 1-1 shows the thermal capability of the generator
with and without the cooling package. For further
information about the cooling package, contact your local
Dukane sales representative.
Thermal Considerations
The thermal design of this generator is for applications that
require 600 watts or less of power at less than a 50% duty
cycle. For applications that require higher duty cycles, an
optional cooling package is available, Part Number 438-
962. The cooling package includes a heat sink that mounts
to the rear of the generator (Refer to Figure 5-2).
NOTE
Add transducer cooling as necessary to keep
front mass temperature to 100°F or less.
Standard Generators
Duty Cycle
100%
75%
65%
60%
55%
50%
Power
(Watts)
100
200
300
400
500
600
Generators with Optional Heatsink
Duty Cycle
100%
75%
65%
60%
55%
50%
Power
(Watts)
100
200
300
400
500
600
Figure 1–1 Thermal and Power Considerations for iQ Auto Generators
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Section 2 – Health & Safety
SECTION 2
Health and Safety
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power Grounding Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
How to Lift Safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Section 2 – Health & Safety
General Considerations
CAUTION
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.
Never operate the gen-
erator with the cover off.
This is an unsafe prac-
tice and may cause injury.
CAUTION
Proper Installation - Operate system components only
after they are properly installed and checked.
Parts being joined ultrason-
ically sometimes vibrate at
audible frequencies. Wear
ear protection to reduce
annoying or uncomfort-
able sounds. In addition,
sound absorbing materi-
als, enclosures or sound
deflectors may be installed
to reduce the noise level.
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 16 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 machine guarding and
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.
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Electrical Safety
Power Grounding Connection
CAUTION
If there is any question
about grounding of your
equipment and/or its elec-
trical power source, con-
tact a qualified electrician.
Figure 2-1 illustrates how the AC line is connected.
iQ Auto Power Inlet
N
CAUTION
For safe system operation: To
avoid the risk of fire, electrical
shock, serious injury or death,
the power line safety ground
must be securely connected
to the center terminal on the
(pluggable)AClineconnector.
Pluggable AC
Line Connector
Figure 2–1 AC Line Connection
Wire Color
Terminal
North America
Europe
L
(Live)
(Ground)
(Neutral)
Black
Lt. Brown
Green w/yellow
stripe
Green
White
N
Lt. Blue
Table 2-I Conventional Wire Color Code
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Section 2 – Health & Safety
How to Lift Safely
•
Before lifting, take a moment to think about what
you’re about to do.
•
Examine the object for sharp corners, slippery spots
or other potential hazards. Know your limit and don’t
try to exceed it.
•
•
Ask for help if needed, or if possible, divide the load
to make it lighter.
Know where you are going to set the item down, and
make sure it and your path are free of obstructions.
Then follow these steps:
CAUTION
Take care in lifting the
equipment. We recom-
mend using a mechanical
lift device to assist.
Step 1. Stand close to the load with your feet
spread apart about shoulder width, with
one foot slightly in front of the other for
balance.
Step 2. Squat down bending at the knees (not your
waist). Tuck your chin while keeping your
back as vertical as possible.
Step 3. Get a firm grasp of the object before be-
ginning the lift. Begin slowly lifting with
your LEGS by straightening them. Never
twist your body during this step.
Step 4. Once the lift is complete, keep the object
as close to the body as possible. As the
load’s center of gravity moves away from
the body, there is a dramatic increase in
stress to the lumbar region of the back.
Step 5. If you must turn while carrying the load,
turn using your feet-not your torso. To
place the object below the level of your
waist, follow the same procedures in re-
verse order. Remember, keep your back
as vertical as possible and bend at the
knees.
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Section 3 – Installation
SECTION 3
Installation
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chassis Grounding Stud. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Standard Model Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . 17
System I/O Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Optional MPC Interface Model. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
MPC I/O Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
MPC Probe Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
MPC Installation Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
MPC Module Status LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
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Section 3 – Installation
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.
Placing
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.
Two sets of removable mounting brackets are attached
to the generator. (Refer to Figure 5-1, Generator Outline
Drawing.) Use them to securely mount the unit vertically
or horizontally in your equipment cabinet.
If the generator is installed inside an enclosure with a
door, be sure there is adequate clearance for the system
cables with the door closed.
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Power Grounding
CAUTION
For safety, the iQ Auto chassis must be properly ground-
ed. The power line ground connection is located on the
center screw terminal on the AC Power Inlet pluggable
screw terminal connector.
To minimize electrical noise
and eliminate ground cur-
rents, ground the chassis as
shown. Use a STAR configu-
ration (shown below).Do not
DAISY CHAIN the grounds.
This system ground connection must be attached to an
earth ground potential at the electrical box that supplies
power to the enclosure or cabinet in which the iQ Auto
system is installed.
The ground connection should comply with all of the re-
quirements specified by the National Electrical code and
any other local codes or ordinances that are applicable.
Chassis Grounding
Fixed Probe Mount
or 2nd Chassis
Stud
Grounding Stud
#14 Gauge
Stranded or
Solid Wire
Protective earth ground
connection wire color:
green or green with yellow
stripe.
Chassis Grounding Stud
Proper grounding for the generator chassis is essential for
the effective suppression of electrical noise or RFI (Ra-
dio Frequency Interference). Every ultrasonic generator
contains a RFI filter that blocks noise on the AC power
line from entering the system control circuitry. This filter
also prevents ultrasonic frequency noise from being fed
back into the AC power line. For the RFI filter to operate
effectively, it is necessary to correctly ground the system.
The power line ground previously mentioned is manda-
tory.
3rd Chassis
Grounding
Stud
Earth
Ground
NOTE
Chassis Grounding Stud
The chassis grounding stud is used to
attach a protective earth ground to the
generator. This helps suppress electrical
interference or radio frequency interfer-
ence (RFI) that is common in an industrial
environment. Stud location is shown in
Figure 3-1 on the following page.
Additionally, the included grounding wire must be con-
nected from the grounding stud connection (see Figure 3-
1) to the nearest grounded metal pipe or equivalent earth
ground.
This will improve the chassis ground connection and may
be needed in noisy industrial environments.
CAUTION
If you have any questions
about the grounding of your
equipment and/or the electri-
cal box, contact a qualified
electrician.
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Section 3 – Installation
Connecting Cables
NOTE
Connecting Cables
Standard Model Configuration
Complete three basic connections for the standard con-
figuration as shown below:
Two-piece pluggable terminal block connec-
tors are used for the System I/O connections
and the AC Power Inlet connections.
This type of connector allows the wiring to
be attached to the screw terminal connec-
tor, which plugs into the mating connector
on the iQ Auto system front panel.
In the event a field replacement unit is re-
quired, the screw terminal connectors with
the wires can be easily detached and then
plugged into the replacement unit.
•AC Line Input
• System Control Inputs/Status Outputs
• Ultrasound Output
• Grounding
Details about the various system connectors and their pin
assignments are covered in the next section.
Step 1. Wire the AC line connector, and attach it to the
generator’s power inlet connector, matching the
power source line, ground, and neutral with the
generator’s line, ground, and neutral connector
pins - A in Figure 3–1. (See Figure 2-1 also.)
NOTE
AC Power Inlet
Step 2. Wire the user-supplied automation system control
inputs/status outputs to the CONTROL CON-
NECTOR, and attach it to the system I/O port -
B in Figure 3-1.
Line voltage required for the generator is
200-240 VAC at 50/60 Hertz and 6.3Amps,
or 100-120VAC at 50/60 Hz and 15 Amps.
The unit does not include a power switch,
and is powered ON whenever the AC line
power is live.
The unit can be switched ON/OFF with a
user-supplied AC circuit breaker wired to
the AC power inlet connection.
Step 3. Attach a high–voltage coaxial ultrasound cable
(from the ultrasonic probe) to J1, the ultrasound
output connector - C in Figure 3-1.
Step 4. Connect the included ground wire from the ground-
ing stud, D in Figure 3-1, to earth ground.
10.76
[273.30]
LOWER REAR
MOUNTING BRACKET
TOP REAR
9.38
MOUNTING BRACKET
[238.25]
AMPLITUDE
ꢂ
GROUNDING STUD
100%
20%
3.47
[88.14]
2.00
[50.8]
2.00
[50.8]
U/S
3.35
[85.09]
POWER
STATUS (LED)
IN
[ mm ]
SYSTEM I/O
.75
[19.05]
ꢁ
U/S CONNECTOR
See NOTE on
Page 22
AMPLITUDE
ADJUSTMENT
CONTROL
ꢃ
CONTROL
CONNECTOR
ꢀ
POWER INLET
BASE MOUNTING
BRACKETS(2)
Figure 3-1 Generator Front View - Standard Model
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System I/O Connector Pinout
The SYSTEM I/O connector is a two-piece pluggable
terminal block connector.
Table 3-I lists the signal names and descriptions, with
more detailed descriptions listed on the next page.
Pin
1
Signal Name
Enable Out (+22V Current Limited)
2
Enable In (Jumper to Pin1, without an E-Stop switch)
Overload Out (system overload status output)
U/S Status Out
3
4
5
Any Fault Out
6
Power OK Out
7
Output Common (chassis ground - non-isolated)
Spare Status Out (programmable status output)
Analog Power Out + (1mV = 1 Watt)
Analog Power Out - (analog monitor signal common, non-isolated)
8
9
10
11
12
13
Fault Reset Input
U/S Active Input
Input Common (electrically isolated from chassis ground)
Table 3-I System I/O Connector Signals
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Section 3 – Installation
Pin 1 (Enable Out)
Pin 8 (Spare Status Out)
This is a current limited voltage source output intended
to connect to an E-Stop circuit. If an E-Stop circuit is
not used, Pin 1 must be jumpered to Pin 2 for ultrasound
operation to be enabled.
Pin 8 is not functional with the standard factory
configuration.
Pin 9 (Analog Power Out +)
Pin 9 is a analog output signal proportional to the true
RMS ultrasound power output level. This signal is
scaled so 1mV = 1 Watt.
Pin 2 (Enable In)
The output from the E-Stop circuit is connected to this
pin when an E-Stop circuit is used. Otherwise, this pin
must be jumpered to Pin 1 for ultrasound operation to
be enabled. See Figure 6-4 for E-Stop circuit wiring
examples.
Pin 10 (Analog Power Out -)
Pin 10 is a signal ground (non-isolated chassis ground)
for the Analog Power output signal on Pin 9.
Pin 11 (Fault Reset Input)
Pin 11 is an isolated input control signal that will reset
any output faults when it is activated. It can be used
by the automation control system to simplify PLC
programming.
Pin 3 (Overload Out)
Pin 3 is a non-isolated digital NPN status output that
activates when an output overload condition is tripped.
This output will be an open circuit if an output overload
condition is not tripped. This output will remain latched
ON until the U/S Activate input is switched OFF and
then ON again.
Pin 12 (U/S Activate Input)
Pin 12 is used to activate the generator ultrasound
output.Activating this isolated control input will switch
the ultrasound output ON, and deactivating this signal
will switch ultrasound OFF.
Pin 4 (Ultrasound Active Status Output)
Pin 4 is a non-isolated digital NPN status output that
activates when the system is delivering ultrasonic power
to the load attached to the ultrasound output connector.
This output will be an open circuit when the ultrasound
output is off.
Pin 13 (Input Common)
[Electrically connected to Pin 5 on MPC I/O connector
if MPC Interface option is installed.]
Pin 13 is electrically isolated from chassis ground.
Using sourcing (PNP) output drivers, this common line
would be connected to the automation system power
supply common. Using sinking (NPN) output drivers,
this common line would be connected to the automation
system positive supply output. Refer to Section 6 for
wiring examples to connect these input signals.
Pin 5 (Any Fault Out)
Pin 5 is a non-isolated digital NPN status output that
activates whenever any fault condition is detected that
inhibits ultrasound output and normal system operation.
This output will be an open circuit when no system fault
conditions are active.
Pin 6 (Power OK Out)
Pin 6 is a non-isolated digital NPN status output that
activates when no fault conditions are detected by any of
the power fault detection circuits included in the system.
This output will be an open circuit when any power
related fault condition is detected.
Pin 7 (Output Common)
Pin 7 is connected to chassis ground. The non-isolated
NPN status output signals can drive isolated PNP inputs
on the automation control system. Refer to Section 6 for
wiring examples to connect output signals.
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Details about the various system connectors and their
pin assignments are covered in the next section.
Optional Multi-Probe Control
(MPC) Interface Model
The iQ Auto MPC model includes an optional MPC
Interface circuit board that powers and controls an external
MPC multi-probe control module. This external module,
(that can be ordered with a minimum of two probe controls
up to a maximum of 16 probe controls), must be purchased
in addition to generator Model 40AT060-2N-MO (iQ Auto
with MPC option) for a fully functional MPC system.
The connections needed for the MPC Interface board are
described below. Connections required for the external
MPC module are also described below.
Step 5. MPC I/O - Wire the MPC control/input signals
and status output signals terminal block to the
user-supplied automation control system - E
in Figure 3-2.
Step 6. MPC INTERFACE-Attach one end of the MPC
Interface cable (Dukane # 200-1408-XX) to the
MPC Interface connector on the iQ Auto panel
-F in Figure 3-2. Connect the other end of the
cable to the MPC INTERFACE connector on
the right rear of the MPC module.
Optional MPC Interface Connections
Complete the same basic connections used for the stan-
dard iQ Auto configuration as previously described.
NOTE
The MPC Interface cable is a separate line
item on the iQ Auto system order. The -XX
at the end of the cable number specifies
cable length. This will vary depending on
your MPC installation.
•AC Line Input
• System Control Inputs/Status Outputs
• Ultrasound Output
• Grounding (optional)
In addition to completing Steps 1-4 of the basic con-
nections as previously described, complete Steps 5 and
6 to wire the MPC Control Inputs/Status Outputs as
described below.
NOTE
Amplitude adjustment will affect ALL
MPC points.
AMPLITUDE
ADJUSTMENT
AMPLITUDE
CONTROL
GROUNDING STUD
100%
20%
ꢀ
MPC INTERFACE
U/S
MPC I/O
POWER
STATUS (LED)
ꢁ
SYSTEM I/O
U/S CONNECTOR
See NOTE
on Page 22
OPTIONAL MPC
CONNECTORS
CONTROL
CONNECTOR
POWER INLET
Figure 3-2 Generator Front View - Optional MPC Model
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Section 3 – Installation
Pin 5 (Input Common) [Electrically connected to
Pin 13 on System I/O connector.]
MPC I/O Connector Pinout
The MPC I/O connector is a two-piece pluggable termi-
nal block connector.
Pin 5 is electrically isolated from chassis ground. Using
sourcing (PNP) output drivers, this common line would
be connected to the automation system ground potential.
Using sinking (NPN) output drivers, this common line
would be connected to the automation system positive
supply voltage output. Refer to Section 6 for wiring
examples to connect input signals.
Table 3-II lists the signal names and descriptions, with
more detailed descriptions listed below.
Pin
1
Signal Name
Setup Bit 0 Input
2
Setup Bit 1 Input
Setup Bit 2 Input
Setup Bit 3 Input
Input Common
Pin 6 (MPC Ready Out)
3
Pin 6 is a non-isolated digital NPN status output that
activates when the MPC control is ready to accept
changes on the probe selection control bits and ready to
start the next MPC welding cycle. This output will be an
open circuit when the MPC system is not ready to accept
changes to control input signals, and it is able to switch a
sourcing PNP input ON or OFF.
4
5
6
MPC Ready Out
Output Common
7
Table 3-II MPC I/O Connector Signals
Any changes will be ignored until this status output signal
activates to the ready state. This status output signal will
also be open (MPC NOT READY) if a fault condition
is detected inside the MPC system. If this status output
will not activate, check for a RED fault status indication
(SYSTEM STATUS LED) on the front panel of the MPC
module.
Pin 1 (Setup Bit 0 Input)
Setup Bit 0 is the least significant bit used to select differ-
ent probe channels when a Multi-Probe Control (MPC)
Interface is used. This MPC control bit is used on all
MPC systems.
Pin 2 (Setup Bit 1 Input)
Setup Bit 1 is the second least significant bit used to se-
lect different probe channels when a MPC Interface is
used. This MPC control bit is used on MPC systems with
three or more channels.
Pin 7 (Output Common)
Pin 7 is connected to chassis ground. The non-isolated
NPN status output signal can drive an isolated PNP input
on the automation control system.
Pin 3 (Setup Bit 2 Input)
Setup Bit 2 is the third least significant bit used to select
different probe channels when a MPC Interface is used.
This MPC control bit is used on MPC systems with five
or more channels.
Refer to Section 6 for wiring examples to connect output
signals.
Pin 4 (Setup Bit 3 Input)
Setup Bit 3 is the second most significant bit used to se-
lect different probe channels when a MPC Interface is
used. This MPC control bit is used on MPC systems with
nine or more channels.
NOTE
The Input Common Pins: Pin 13 of the
System I/O connector and Pin 5 on the
MPC I/O connector are both electrically
isolated from chassis ground, but they
are connected together. Both of these
signals must be connected to the same
voltage potential, either automation
system ground or the automation sys-
tem positive supply voltage.
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MPC Probe Control
NOTE
When the optional MPC Interface and MPC I/O
connectors are used, the generator has the capability of
controlling as many as sixteen compatible probes. One
probe can be turned on at a time while the sequence
of probe activation is determined by the user’s
automation.
Ultrasound Output Connector
The ultrasound output connector
used with all standard generators is
a high voltage (5000V) coaxial style
SHV-BNC connector. This connector
provides superior shielding of electri-
cal noise, compared to other types
of connectors. The ultrasound output
connector mates with fully shielded
coaxial ultrasound cables that are
secured with a simple and reliable
quarter-turn bayonet style attachment
mechanism.
The table below shows how the setup bit inputs
correspond to the probes.
MPC
Probe
Selected
3
2
1
0
Off Off Off Off
Off Off Off On
Off Off On Off
Off Off On On
Off On Off Off
Off On Off On
Off On On Off
Off On On On
On Off Off Off
On Off Off On
On Off On Off
On Off On On
On On Off Off
On On Off On
On On On Off
On On On On
1
2
3
The ultrasonic output from this con-
nector (that drives the attached
ultrasonic load) is a very highAC volt-
age (1200VAC). At high power levels
this can exceed 2 amps of current and
must be securely terminated via the
ultrasound cable for safe operation.
Use original equipment ultrasound
cables for safe and reliable system
operation. Improperly assembled
ultrasound cables can result in high
voltage arcing and will destroy the
ultrasound connectors.
4
5
6
7
8
9
10
11
12
13
14
15
16
Table 3-III MPC Setup Bit Inputs
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Section 3 – Installation
Cut Outs
MPC Module Installation
For panel mounted modules:
Guide
MPC modules are designed for assembly systems where
one ultrasonic generator is sequenced to as many as 16
ultrasonic probes.
Use Figure 3-3 below to determine the size of the cut
needed for your equipment panel.
Make the appropriate cut, and install the MPC module
securing the mounting flange to the equipment panel
before continuing with the cable connections.
The MPC module is typically supplied as a stand-alone
bench-top unit, or as a component that can be mounted in
a through-panel configuration.
No special installation is needed for a stand-alone MPC
module that can be put on a bench top or a shelf.
Use the following installation recommendations for a
panel mounted MPC module.
0.25
[06.35]
C
C/2
(6 PLCS)
D
A
MODEL
"A"
"B"
"C"
6.75
"D"
7.12
[181 mm]
1.75
[45 mm]
2.25
[57.2 mm]
MPC0404
[171.5 mm]
10.88
[277 mm]
1.75
[45 mm]
10.50
[266.7 mm]
2.25
[57.2 mm]
MPC0808
MPC1616
18.25
[464 mm]
1.75
[45 mm]
18.00
[457.2 mm]
2.25
[57.2 mm]
Figure 3-3 MPC Module Cutout Guide
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Front Connections
Refer to Figure 3-5 below. Complete these connections.
Connecting Cables
For stand-alone modules and securely installed panel
1. Probe Cable(s) - Beginning with PROBE 1, connect
mounted modules:
one end of the cable (See Table 3-IV below.) to the U/S
connector on the MPC’s front panel - Din Figure 3-5.
Connect the other end of the cable to the corresponding
probe for your specific welding application.
Rear Connections
Refer to Figure 3-4 below. Complete these connections.
1. Earth ground - Connect one end of a user-supplied
14-Gauge ground wire to the ground connection at
2. Repeat Step 1 for each of the remaining probes (in
sequence: 2, 3, 4, etc.) in your system.
the rear of the MPC - A in Figure 3-4. Connect the
other end of the wire to an earth ground potential at
the electrical box that supplies power to the equipment
(or to the equipment enclosure into which your system
is installed).
2. U/S (ultrasonic) cable (Dukane P/N 200-479-XX -
Order the correct cable length for your installation.)
- Connect one end of the cable to the left rear U/S
connector of the MPC module- B in Figure 3-4. The
other end of the cable connects to J1 of the ultrasonic
generator.
D
Figure 3-5 MPC Module Front Connectors
3. MPC Interface cable (Dukane P/N 200-1408-XX -
Order the correct cable length for your installation.)
- Connect one end of the cable to the right rear MPC
Interface connector- C in Figure 3-4. The other end
of the cable connects to the MPC INTERFACE con-
nector on the ultrasonic generator.
B
A
C
Figure 3-4 MPC Module Rear Connectors
System Frequency
Probe P/N
Cable P/N : MPC to Probe
20kHz
30kHz
40kHz
41Q20RE or 41Q20RS
41A60E or 41A60S
41A40
200-479-XXM
200-479-XXM
200-615-XXM
XX = length in meters
Table 3-IV Probe Cables
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Section 3 – Installation
MPC Module Status LEDs
E
F
System Status
The front panel SYSTEM STATUS LED lights up
GREEN when the system is powered and ready - E
in Figure 3-6.
If this LED is lit with a YELLOW/ORANGE color, a
recoverable fault condition has tripped. This indicates
that the system is operational, but a fault condition has
occurred preventing normal operation. Examples of this
type of fault would be a generator overload that will
automatically reset when the next weld cycle begins,
or the automation control system is selecting a channel
that doesn’t exist - trying to select channel 10 for an 8
channel system, for instance.
Figure 3-6 MPC Module Status LED’s
If this LED lights up RED, a hardware fault has been
sensed, and the unit should be returned to Dukane for
servicing.
NOTE
Refer to Section 4, System Opera-
tion, for more information.
Probe Selection Status
The PROBE SELECTION STATUS LED - F in
Figure 3-6 - lights up GREEN indicating it is the
selected probe.
A probe’s LED turns to RED (from GREEN) when
ultrasonic power is activated.
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Section 4 –System Operation
SECTION 4
System Operation
Standard iQ Auto System Operational Test . . . . . . . . . . . . . . 29
iQ Auto System with MPC Operational Test . . . . . . . . . . . . . . 30
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Section 4 –System Operation
Standard iQ Auto System
Operational Test
Step 1. Verify that the standard system installation is
complete and all cables are connected.
Refer to installation instructions included in Sec-
tion 3, if needed.
Refer to Section 6 -Automation Interface -for in-
formation on wiring system controls, if needed.
Step 2. After completing Step 1, activate line power to
the standard iQ Auto system.
Normal Condition:
GREEN - The POWER STATUS LED on the iQ
Auto panel should light up GREEN.
POWER STATUS LED
The system is now ready to operate.
Figure 4-1 Generator POWER STATUS LED Detail
Troubleshooting Abnormal iQ Auto System
Conditions
Options for U/S Activation Connections:
Optionally, monitor the U/S Active status output on
I/O connector Pin 4.
RED - If the POWER STATUS LED lights up
RED, check line voltage level.
This NPN status output signal will activate when U/S
is ON.
GRAY - If the POWER STATUS LED is a
gray color (not lit), check line input.
Step 4. Other Options the Operator can Check:
• Fault Status output signals
Fault Status output signals are available for:
Overload (Pin 3), or
Optional System Status Output to Monitor:
Optionally the Power OK status output can be
monitored on I/O connector Pin 6.
Any Fault (Pin 5).
This NPN status output signal will activate when
power is OK.
These NPN status outputs will activate when there is
a fault:
Step 3. After completing Step 2, test ultrasound output
by activating I/O connector Pin 12.
An Overload Fault latches until the next time U/S
is activated, or Fault Reset Input is activated..
Normal Condition:
Any Fault status activates when any fault is de-
tected by the system. It latches until the start of the
next cycle, or Fault Reset Input is activated.
The system is operating properly when power is
delivered to the attached stack.
Ultrasound Activation Connections:
Usually an automated control system is wired to
this control input.
Continued
Optionally - A manual switch could be wired to
this control input.
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iQSeries,ꢀAutoꢀUser’sꢀManual
Continued from previoius page
Troubleshooting Abnormal iQ Auto Sys-
tem Conditions
Five fault conditions are monitored by the iQ
Auto system for Any Fault:
RED - If the POWER STATUS LED lights
up RED, check line voltage level.
• Average Overload
(Automatically resets on next cycle, or until an
activation of Fault Reset Input)
GRAY - If the POWER STATUS LED is a
gray color (not lit), check line input.
• Peak Overload
(Resets same as Average Overload)
Troubleshooting Abnormal MPC Module
Conditions
• Overtemperature
(Automatically resets on cool-down)
MPC Module SYSTEM STATUS LED is
ORANGE/YELLOW (resettable fault):
• Power Not OK
(AC line voltage under 180VAC)
•Check for an iQAuto overload on the previous
welding cycle.
• Check for an invalid channel selection input
control code - selection code is greater than the
number of installed channels.
• Frequency Overload
(Automatically resets on next cycle, or until an
activation of Fault Reset Input)
MPC SYSTEM STATUS LED is RED (non-recov-
erable fault.
iQ Auto System with MPC
Check for POWER OK fault on the iQ Auto Sys-
tem.
Operational Test
Step 1. Verify that the system installation (with the MPC
option) is completed and all cables are connect-
ed.
• Resolve any iQ Auto power problem first.
• There could be a circuit failure in the MPC
module. If a circuit failure is discovered, return
the MPC Module to Dukane for service.
Refer to the iQ Auto installation instructions in
Section 3, if needed.
Refer to Section 6 - Automation Interface - for in-
formation on wiring system controls, if needed.
Step 3. After completing Step 2, test ultrasound output
by activating I/O Connector Pin 12.
Step 2. After completing Step 1, activate line power to the
Normal Condition:
standard iQ Auto system.
The system is operating properly when power is
delivered to the attached stack.
Normal Condition:
The POWER STATUS LED on the iQ Auto front
panel should light up GREEN.
Ultrasound Activation Connections:
The MPC module SYSTEM STATUS LED should
light up GREEN.
Usually an automated control system is wired
to this control input.
The system is ready to operate when both status LEDs
light up GREEN.
Optionally - A manual switch could be wired
to this control input.
Continued
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Section 4 –System Operation
Step 5. Check MPC Channels
Continued from previoius page
Check that all MPC channels can be selected and
activated. The automation control system activates
input selection bits.
Options for U/S Activation Connections:
• Optionally monitor the U/S Active status output on
I/O connector Pin 4.
Select a channel: PROBE SELECTION STATUS
indicator illuminates GREEN when it is the selected
channel.
This NPN status output signal will activate
when U/S is ON.
Activate ultrasound:Activate the iQAuto ultrasound
output on I/O connector Pin 12. The PROBE SE-
LECTION STATUS indicator on the selected channel
should switch to RED (from GREEN).
• Optionally monitor the MPC Ready status output
on MPC I/O connector Pin 6.
This NPN status output signal will activate
when the MPC is ready.
The probe on the selected channel should deliver
ultrasonic power.
Step 4. Other options the operator can check:
• Fault Status output signals
Repeat this test for all MPC channels.
Fault Status output signals are available for Overload
(Pin 3) or Any Fault (Pin 5).
These NPN status outputs will activate when a
fault occurs:
An Overload Fault latches until the next time
U/S is activated, or the Fault Reset Input is ac-
tivated.
Any Fault status activates when any fault is
detected by the system. The output will latch
until U/S is activated or the Fault Reset Input is
activated.
Five fault conditions are monitored by the iQ Auto
system for Any Fault:
• Average Overload
(Automatically resets on next cycle, or until an
activation of Fault Reset Input)
• Peak Overload
(Resets same as Average Overload)
• Overtemperature
(Automatically resets on cool-down)
• Power Not OK
(AC line voltage under 180VAC)
• Frequency Overload
(Automatically resets on next cycle, or until an
activation of Fault Reset Input)
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Section 5 – Specifications
SECTION 5
Specifications
Generator Outline Drawings. . . . . . . . . . . . . . . . . . . . . . . .35-36
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Operating Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . 39
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Section 5 – Specifications
Figure 5-1 Generator Outline Drawing
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iQSeries,ꢀAutoꢀUser’sꢀManual
Figure 5-2 Generator with Optional Heat Sink Outline Drawing
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Section 5 – Specifications
Weight
Standard Model:
7 pounds (3.18 kg)
8 pounds (3.63 kg)
Model with MPC Option :
Shipping:
Add 5 pounds (2.3 kg) to unit weight for packing materials.
Operating Environment
Operate the generator within these guidelines:
Temperature:
Air Particulates: Keep the equipment dry.
Minimize exposure to moisture, dust, dirt, smoke
40°F to 100°F (+5°C to +38°C)
and mold.
Humidity:
5% to 95% non–condensing @ +5°C to +30°C
Nonoperating storage guidelines:
Temperature:
-4°F to 158°F (-20°C to +70°C)
Air Particulates: Keep the equipment dry.
Minimize exposure to moisture, dust, dirt, smoke
and mold.
Humidity:
5% to 95% non–condensing @ 0°C to +30°C
DukaneꢀManualꢀPartꢀNo.ꢀ403-573-02
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iQSeries,ꢀAutoꢀUser’sꢀManual
AC Power Requirements
Overload
Input AC Power Requirements
Nominal AC Volt
@ Maximum RMS Current
North America/
Japan AC Outlet
Rating
Operating
Frequency
Generator
Power Ratings
(Watts)
Model Number
20kHz
20kHz
30kHz
30kHz
40kHz
40kHz
20AT060-1X-XX
20AT060-2X-XX
30AT060-1X-XX
30AT060-2X-XX
40AT060-1X-XX
40AT060-2X-XX
600
600
600
600
600
600
100-120V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 6.3 Amps
100-120V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 6.3 Amps
100-120V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 6.3 Amps
15 Amps
Table 5-I AC Power Requirements
NOTE
Standard iQ Auto model = XXAT060-XN
iQ Auto with MPC model = XXAT060-XN-M0
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Section 5 – Specifications
Regulatory Agency
Compliance
FCC
CAUTION
The generator complies with the following Federal
Communications Commission regulations.
DONOTmakeanymodi-
ficationstothegenerator
or associated cables as
the changes may result
in violating one or more
regulations under which this
equipment is manufactured.
•
The limits for FCC measurement procedure MP-5,
“Methods of Measurement of Radio Noise Emissions
from ISM Equipment”, pursuant to FCC Title 47 Part
18 for Ultrasonic Equipment.
CE Marking
This mark on your equipment certifies that it meets the
requirements of the EU (European Union) concerning
interference causing equipment regulations. CE stands
for Conformité Europeéne (European Conformity). The
generator complies with the following CE requirements.
•
T h e E M C D i r e c t i v e 2 0 0 4 / 1 0 8 / E C
for Heavy Industrial —
EN 61000-6-4: 2001
EN 55011: 2003
EN 61000-6-2: 2001
EN61000–4–2
EN61000–4–3
EN61000–4–4
EN61000–4–5
EN61000–4–6
EN61000–4–8
EN61000–4–11
•
•
The Low Voltage Directive 2006/95/EC.
The Machinery Directive 2006/42/EC.
EN 60204: 2006
Safety of Machinery - Electrical Equipment of
Machines Part 1: General Requirements.
IP (International Protection)
Rating
The iQ generator has an IP rating from the IEC
(International Electrotechnical Commission).
The rating is IP2X, in compliance with finger-safe
industry standards.
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Section 6 – Automation Interface
SECTION 6
Automation Interface
Input/Output Connection Examples . . . . . . . . . . . . . . . . . . . 43
PNP (Sourcing) Type Input Circuit. . . . . . . . . . . . . . . . . . . . . . . . 43
NPN (Sinking) Type Input Circuit. . . . . . . . . . . . . . . . . . . . . . . . . 44
NPN Type Output Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
E-Stop Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
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Section 6 – Automation Interface
PNP (Sourcing) Type Input Circuit
System I/O Connector
iQ Auto
+DC
Ground
(Pin 13)
Input Common
(Pin 12)
U/S Activate
(Pin 11)
Fault Reset
(same as above)
±
Input Voltage Range
Input Current
DC 24V 10%
10mA(typ) @ DC 24V input
Figure 6-1 PNP Type Input Circuit
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iQSeries,ꢀAutoꢀUser’sꢀManual
NPN (Sinking) Type Input Circuit
System I/O Connector
iQ Auto
+DC
Ground
(Pin 13)
Input Common
(Pin 12)
U/S Activate
(Pin 11)
Fault Reset
(same as above)
Input Voltage Range
Input Current
DC 24V 10%
±
10mA(typ) @ DC 24V input
Figure 6-2 NPN Type Input Circuit
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Section 6 – Automation Interface
NPN Type Output Circuit
System I/O Connector
iQ Auto
Ground
+DC
Gate Drive
Overload
(Pin 3)
L
L
U/S Status
(Pin 4)
(same as above)
Any Fault
(Pin 5)
(same as above)
(same as above)
Power OK
(Pin 6)
Output Common
(Pin 7)
±
Rated Output Voltage
Maximum Output Current
Output Driver
DC 24V 10%
500mA/1 Output
N Channel Power MOSFET
Figure 6-3 NPN Type Output Circuit
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iQSeries,ꢀAutoꢀUser’sꢀManual
Dedicated E-Stop Switch Wiring Diagram
System I/O Connector
iQ Auto
(Pin 1)
Enable Out
User supplied
E-stop switch
(Pin 2)
Enable In
Automation System Safety Circuit Wiring Diagram
System I/O Connector
iQ Auto
(Pin 1)
Enable Out
Relay contact block
Master
control
relay
(Pin 2)
Enable In
User automation
control hardware
Figure 6-4 E-Stop Circuitry
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Section 7 – Contacting Dukane
SECTION 7
Contacting Dukane
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Section 7 – Contacting Dukane
Contacting Dukane
Identify Equipment
When contacting Dukane about a service–related problem,
be prepared to give the following information:
• Model number, line voltage and serial number.
• Fault status.
• Problem description and steps taken to resolve it.
Many problems can be solved over the telephone, so it is
best to call from a telephone located near the equipment.
Intelligent Assembly Solutions
Mailing Address: Dukane Ultrasonics
2900 Dukane Drive
St. Charles, IL 60174 USA
Phone:
E-mail:
(630) 797–4900
Fax:
Main
(630) 797–4949
Service & Parts (630) 584–0796
Website
The website has information about our products, processes,
solutions, and technical data. Downloads are available for
many kinds of literature.
Here is the address for the main website:
You can locate your local representative at:
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Dukane ISO
ISO CERTIFICATION
Dukane chose to become ISO 9001:2008 certi-
fied in order to demonstrate to our customers
our continuing commitment to being a quality
vendor. By passing its audit, Dukane can assure
you that we have in place a well–defined and
systematic approach to quality design, manu-
facturing, delivery and service. This certificate
reinforces Dukane's status as a quality vendor
of technology and products.
The ISO 9001:2008 standard establishes a
minimum requirement for these requirements
and starts transitioning the company from a
traditional inspection–oriented quality system
to one based on partnership for continuous
improvement. This concept is key in that Du-
kane no longer focuses on inspection, but on
individual processes.
Dukane's quality management system is based
on the following three objectives:
1. Customer oriented quality. The aim is to
improve customer satisfaction.
2. Quality is determined by people. The aim
is to improve the internal organization and
cooperation between staff members.
3. Quality is a continuous improvement.
The aim is to continuously improve the
internal organization and the competitive
position.
To achieve ISO 9001:2008 certification, you
must prove to one of the quality system regis-
trar groups that you meet three requirements:
1. Leadership
2. Involvement
3. Quality in Line Organizations and Quality
System Infrastructure.
ISO 9001:2008
C E R T I F I E D
Dukane products are manufactured in ISO
registered facilities.
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Please refer to our website at:
www dukane com/us/sales/intsales htm
to locate your local representative.
iQ Series, Ultrasonic Generator/Power Supply
Auto User's Manual
Part No. 403-573-02
Printed in the United States of America
Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797-4900 • FAX (630) 797-4949
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