Dukane Power Supply 403 573 02 User Manual

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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iQSeries,ꢀAutoꢀUser’sꢀManual  
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  
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  
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  
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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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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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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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