Intelligent Assembly Solutions iQ 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 ISO 9001:2008 Products are manufactured in ISO registered facilities. www.dukane.
iQ Series, Auto User’s Manual Copyright © 2010 Notice of Rights: All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical, photocopying, recording, or by any information storage and retrieval system, without written permission from the manufacturer. Notice of Liability: The information contained is this manual is distributed on an “As is” basis, without warranty.
Revision History Revision Number - 00 - 01 - 02 Revision Summary Date Original release. 10/09/2007 20kHz and 30kHz models added. System I/O Connector signals modified. Amplitude control added. 08/27/2009 I/O Connector Pin 9 signal scale revised. 12/15/2010 Miscellaneous spelling errors corrected. Fig 5-1 and 5-2 dimensions edited.
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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 . . . . . . . . . . . . . . . .
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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. . .
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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. Notes, Cautions and Warnings NOTE Note statements provide additional information or highlight procedures.
iQ Series, Auto User’s Manual Generator Overview • Line Voltage Regulation automatically maintains constant amplitude regardless of line voltage deviation. The available output power is maintained with any voltage input within the specified range. This provides consistent system performance regardless of line voltage fluctuations. It also eliminates the need for bulky, external constant–voltage transformers. • Load Regulation provides constant amplitude automatically regardless of power draw.
Section 2 – Health & Safety Thermal Considerations 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. 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 438962.
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section 2 – Health & Safety General Considerations 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.
iQ Series, Auto User’s Manual Electrical Safety Power Grounding Connection Figure 2-1 illustrates how the AC line is connected. iQ Auto Power Inlet CAUTION If there is any question about grounding of your equipment and/or its electrical power source, contact a qualified electrician. L N CAUTION Pluggable AC Line Connector Figure 2–1 AC Line Connection Terminal L N Wire Color North America Europe Black Lt. Brown (Ground) Green Green w/yellow stripe (Neutral) White Lt.
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: Step 1.
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Section 3 – Installation SECTION 3 Installation Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Placing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Chassis Grounding Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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.
iQ Series, Auto User’s Manual Power Grounding For safety, the iQ Auto chassis must be properly grounded. The power line ground connection is located on the center screw terminal on the AC Power Inlet pluggable screw terminal connector. 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.
Section 3 – Installation Connecting Cables NOTE Standard Model Configuration Connecting Cables Complete three basic connections for the standard configuration as shown below: Two-piece pluggable terminal block connectors 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 connector, which plugs into the mating connector on the iQ Auto system front panel.
iQ Series, Auto User’s Manual 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.
Section 3 – Installation Pin 1 (Enable 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 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.
iQ Series, Auto User’s Manual Optional Multi- Probe Control (MPC) Interface Model Details about the various system connectors and their pin assignments are covered in the next section. The iQ Auto MPC model includes an optional MPC Interface circuit board that powers and controls an external MPC multi- probe control module.
Section 3 – Installation MPC I/O Connector Pinout The MPC I/O connector is a two-piece pluggable terminal block connector. Table 3-II lists the signal names and descriptions, with more detailed descriptions listed below.
iQ Series, Auto User’s Manual MPC Probe Control 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. The table below shows how the setup bit inputs correspond to the probes.
Section 3 – Installation MPC Module Installation Guide Cut Outs For panel mounted modules: MPC modules are designed for assembly systems where one ultrasonic generator is sequenced to as many as 16 ultrasonic probes. 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. Use Figure 3-3 below to determine the size of the cut needed for your equipment panel.
iQ Series, Auto User’s Manual Connecting Cables Front Connections For stand-alone modules and securely installed panel mounted modules: Refer to Figure 3-5 below. Complete these connections. 1. Probe Cable(s) - Beginning with PROBE 1, connect one end of the cable (See Table 3-IV below.) to the U/S connector on the MPC’s front panel - D in 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.
Section 3 – Installation MPC Module Status LEDs E System Status F The front panel SYSTEM STATUS LED lights up GREEN when the system is powered and ready in Figure 3-6. E 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.
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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 Dukane Manual Part No.
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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 Section 3, if needed. Refer to Section 6 - Automation Interface -for information 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.
iQ Series, Auto User’s Manual Continued from previoius page 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) Troubleshooting Abnormal iQ Auto System Conditions RED - If the POWER STATUS LED lights up RED, check line voltage level. GRAY - If the POWER STATUS LED is a gray color (not lit), check line input.
Section 4 –System Operation Continued from previoius page Options for U/S Activation Connections: • Optionally monitor the U/S Active status output on I/O connector Pin 4. This NPN status output signal will activate when U/S is ON. • 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. Step 4. Other options the operator can check: • Fault Status output signals Step 5.
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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 Dukane Manual Part No.
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ALLOW 3.00" [76.2 mm] FOR CABLE CONNECTOR Dukane Manual Part No. 403-573-02 3.35 [85.09] IN [ mm ] 4.50 [114.3] .75 [19.05] 2.00 [50.8] BASE MOUNTING BRACKETS(2) 3.47 [88.14] TOP REAR MOUNTING BRACKET 9.75 [247.65] OAL POWER INLET POWER STATUS GROUNDING STUD 10.76 [273.30] SYSTEM I/O MPC I/O CONTROL CONNECTOR 9.38 [238.3] 10.73 [272.54] 10.61 [269.49] 11.25 [285.75] 100% 2.00 [50.8] U/S CONNECTOR All mounting holes are 0.219 inch diameter for M5 or #10 screws.
Page ALLOW 3.00" [76.2 mm] FOR CABLE CONNECTOR OPTIONAL HEAT SINK KIT - 438-962 2.05 [52.1] 0.38 [9.7] 2.00 [50.8] .75 [19.05] 3.35 [85.09] BASE MOUNTING BRACKETS (2) IN [ mm ] 3.47 [88.14] TOP REAR MOUNTING BRACKET 9.75 [247.7] OAL 9.02 [229] 1.20 [30.5] 4.50 [114.3 1.21 [30.7] POWER INLET 10.76 [273.30] SYSTEM I/O 9.38 [238.3] 10.73 [272.54] CONNECTOR CONTROL 6.00 [152.4] 20% 100% 1.44 [36.6] 7.38 [187.5] 0.91 [23.1] 2.00 [50.8] U/S CONNECTOR NOTE: ALL MOUNTING HOLES ARE .
Section 5 – Specifications Weight Standard Model: 7 pounds (3.18 kg) Model with MPC Option : 8 pounds (3.63 kg) Shipping: Add 5 pounds (2.3 kg) to unit weight for packing materials. Operating Environment Operate the generator within these guidelines: Temperature: 40°F to 100°F (+5°C to +38°C) Air Particulates: Keep the equipment dry. Minimize exposure to moisture, dust, dirt, smoke and mold.
iQ Series, Auto User’s Manual AC Power Requirements Operating Frequency Generator Model Number Overload Power Ratings (Watts) Input AC Power Requirements Nominal AC Volt @ Maximum RMS Current 20kHz 20AT060-1X-XX 600 100-120V 50/60 Hz @ 15 Amps 20kHz 20AT060-2X-XX 600 200-240V 50/60 Hz @ 6.3 Amps 30kHz 30AT060-1X-XX 600 100-120V 50/60 Hz @ 15 Amps 30kHz 30AT060-2X-XX 600 200-240V 50/60 Hz @ 6.
Section 5 – Specifications Regulatory Agency Compliance FCC CAUTION The generator complies with the following Federal Communications Commission regulations. • 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.
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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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Section 6 – Automation Interface PNP (Sourcing) Type Input Circuit System I/O Connector iQ Auto Ground +DC (Pin 13) Input Common (Pin 12) U/S Activate (Pin 11) Fault Reset (same as above) Input Voltage Range DC 24V ± 10% Input Current 10mA(typ) @ DC 24V input Figure 6-1 PNP Type Input Circuit Dukane Manual Part No.
iQ Series, Auto User’s Manual NPN (Sinking) Type Input Circuit System I/O Connector iQ Auto Ground +DC (Pin 13) Input Common (Pin 12) U/S Activate (Pin 11) Fault Reset (same as above) Input Voltage Range DC 24V ±10% Input Current 10mA(typ) @ DC 24V input Figure 6-2 NPN Type Input Circuit Page 44 Dukane Manual Part No.
Section 6 – Automation Interface NPN Type Output Circuit System I/O Connector iQ Auto Ground Gate Drive (same as above) Overload (Pin 3) L U/S Status (Pin 4) L (same as above) Any Fault (Pin 5) (same as above) Power OK (Pin 6) +DC Output Common (Pin 7) Rated Output Voltage DC 24V ± 10% Maximum Output Current 500mA/1 Output Output Driver N Channel Power MOSFET Figure 6-3 NPN Type Output Circuit Dukane Manual Part No.
iQ Series, Auto User’s Manual 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 iQ Auto System I/O Connector (Pin 1) Enable Out (Pin 2) Enable In Relay contact block Master control relay User automation control hardware Figure 6-4 E-Stop Circuitry Page 46 Dukane Manual Part No.
Section 7 – Contacting Dukane SECTION 7 Contacting Dukane Dukane Manual Part No.
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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.
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Dukane ISO ISO CERTIFICATION Dukane chose to become ISO 9001:2008 certified 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, manufacturing, delivery and service. This certificate reinforces Dukane's status as a quality vendor of technology and products.
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 www.dukane.com/us Printed in the United States of America Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St.
