Dukane iQ Series Ultrasonic Power Supply - Auto-Plus MPC Manual

Dukane iQ Series Ultrasonic Power Supply - Auto-Plus MPC Manual
iQ Series
ULTRASONIC GENERATOR/POWER SUPPLY
Auto-Plus MPC
AUTOMATED HAND PROBE
PRESS
User’s Manual
Dukane Part No. 403 - 608 - 00
Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 - 4900
Dukane products are manufactured in
ISO registered facilities
www.dukane.com
iQ Series, Auto-Plus MPC User’s Manual
Copyright © 2019
Dukane
2900 Dukane Drive
St. Charles, IL 60174 USA
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 Dukane.
Notice of Liability:
The information contained in this manual is distributed on an “As is” basis, without warranty. While
every precaution has been taken in the preparation of this manual, Dukane shall not have any liability to
any person or entity with respect to any liability, loss, or damage caused or alleged to be caused directly
or indirectly by the instructions contained in this manual, or by the hardware products described herein.
Specifications subject to change without notice.
This user’s manual documents product features, hardware, and controls software available at the
time this user's manual was published.
Printed in the United States of America.
Dukane Part Number: 403-608-00
Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents:
(* = Inactive)
3,780,926 * 4,131,505* 4,277,710* 5,798,599 5,880,580 6,984,921 7,225,965 7,475,801,
7,819,158 and, 8,052,816
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Dukane Manual Part No. 403-608-00
Revision History
Revision
Number
- 00 Revision
Summary
Date
Original release.
June 13, 2019
Dukane Manual Part No. 403-608-00
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Dukane Manual Part No. 403-608-00
Contents
Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 2- Health and Safety . . . . . . . . . . . . . . . . . . . 7
Section 3- Installation . . . . . . . . . . . . . . . . . . . . . . . 13
Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Section 4 - System Operation . . . . . . . . . . . . . . . . 19
iQ Auto-Plus System Operational Test . . . . . . . . . . . . . . . . . . . . . . . 22
LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Section 5 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Distance Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Section 6 - Automation Interface . . . . . . . . . . . . . . . 31
E-Stop Wiring and Automation System Safety Circuit . . . . . . . . . . . 33
iQLinQ™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Section 7 - Contacting Dukane . . . . . . . . . . . . . . . . . 35
Section 8 - Specifications . . . . . . . . . . . . . . . . . . . . . 39
Generator Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Weight, Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Interpreting the Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Section 9 - Appendices . . . . . . . . . . . . . . . . . . . . . . . 47
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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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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Dukane Manual Part No. 403-608-00
Section 1 – Introduction
General User Information
Read This Manual First
Before operating your ultrasonic system, 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 equipment.
The examples given are chosen for their simplicity to illustrate basic operation concepts.
This manual provides information to set up, operate, and
interface this generator/power supply.
Particular models are listed in Section 7 - Specifications.
Notes, Cautions and Warnings
NOTE
Note statements provide additional
information or highlight procedures.
Throughout this manual we use NOTES to provide information that is important for the successful application and
understanding of the product. A NOTE block is shown to
the right.
CAUTION
Caution statements
identify conditions or
practices that could result
in damage to the equipment or other property.
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 increasing levels of important information. These statements help
you to identify and avoid hazards and recognize 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 a operator protection issue.
WARNING
Warning statements
point out conditions or
practices that could result in personal injury or
loss of life.
Drawings and Tables
The figures and tables are identified by the section number followed by a sequence number. The sequence number begins with one in each section. The figures and
tables are numbered separately. The figures use Arabic
sequence numbers (e.g. –1, –2, –3) while the tables use
Roman sequence numerals (e.g. –I, –II, –III). As an example, Figure 3–2 would be the second illustration in section three while Table 3–II would be the second table in
section three.
Dukane Manual Part No. 403-608-00
Condition
or Practice
Electrical
Safety Issue
Hearing
Protection
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iQ Series, Auto-Plus MPC User’s Manual
Generator Overview
This generator is designed for ultrasonic applications controlled by a Programmable Logic Controller (PLC). Using one of the supported industrial protocols see iQLinQ™
section pg. 34, the generator can easily be integrated into a
wide variety of automated systems.
tion. 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. The ultrasonic
output amplitude level is held to within ±1% to provide weld process consistency and reduced weld cycle
times.
•
Universal AC Power Source means that standard
systems will operate worldwide at all industrial high
line voltage levels, whether it is 100-200VAC @60Hz
in Japan, 240VAC @50Hz in Europe or 100-240VAC
@60Hz in the United States. There are no internal
transformer taps to change for worldwide operation.
•
Amplitude Adjustment Control allows the peak -topeak excursion of the horn at its workface to be adjusted between 20% and 100% of the horn’s nominal
amplitude.
•
Multiple Electronic Overload protection circuits
prevent instantaneous component failure in the event
of extreme output overload conditions and rated overload power limit is based on the actual true RMS
power output level.
•
Integrated MPC allows sequencing up to eight ultrasonic probes. Each probe is independently controlled
and monitored allowing different process settings and
indepedent suspect or bad part alarms for each weld
point.
•
Optional Weld by Distance Feature to monitor up to
eight analog 0-10 VDC encoders (requires customer
supplied encoders).
•
CE Certification means that the system meets the
required European standards to be sold and used in
Europe.
•
ISO Certified means that this system has been manufactured to high quality standards and assures you of
manufacturing excellence.
•
TUV Certification - TÜV Rheinland certifies Dukane
products comply with applicable UL (Underwriters
Laboratories) and CSA (Canadian Standards Association) requirements.
The generator has a variety of status LED indicators, and
built-in USB and EtherNet connectors.
The iQ Auto-Plus MPC combines an iQ Auto-Plus generator and Dukane’s patented Multi-Probe Controller in a
single unit. This allows the generator to power multiple
probes selected by an automated control system.
This product’s rugged internal ultrasonic generator circuitry ensures a continuous resonant frequency lock at
the start of each weld. Users can modify generator performance to meet a wide variety of ultrasonic processing
requirements if needed.
The generator’s compact size allows multiple units to be
placed into an industrial equipment cabinet, and the generator 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.
Key Generator Features
•
Compact Enclosure Size requires a small footprint for
either vertical or horizontal mounting into your equipment cabinet.
•
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 generator operation and increased reliability.
•
Linear Ramp Soft Start circuitry allows the acoustic stack to ramp up to operating amplitude smoothly,
minimizing the startup surges and abnormal stress to
the stack and generator.
•
Automatic Tuning tracks the resonant frequency of
the acoustic stack (horn, booster, transducer) and adjusts the generator output frequency to match it. This
is done for every weld cycle and eliminates the need
to manually tune the generator.
•
Line Voltage Regulation automatically maintains
constant amplitude regardless of line voltage devia-
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Dukane Manual Part No. 403-608-00
Section 1 – Introduction
Thermal Considerations
The thermal design of this generator is for applications
that require 100% of rated power at no more than a 50%
duty cycle.
Dukane Manual Part No. 403-608-00
NOTE
Add transducer cooling as necessary to keep
front mass temperature to 110°F or less.
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Dukane Manual Part No. 403-608-00
Section 2 – Health and Safety
SECTION 2
Health and Safety
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Plastics Health Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Power Grounding Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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Dukane Manual Part No. 403-608-00
Section 2 – Health and Safety
General Considerations
Please observe these health and safety recommendations for safe, efficient, and injury-free operation of your
equipment.
Proper Installation - Operate system components only
after they are properly installed.
No Unauthorized Modifications - Do not modify your
system in any way unless authorized to do so by Dukane.
Unauthorized modifications could cause equipment damage and/or injury to the operator. In addition, unauthorized
modifications will void equipment warranty.
Keep the Cover On - Do not remove any equipment
cover unless directed to do so by Dukane. The generator produces hazardous electrical voltages which could
cause injury.
Grounded Electrical Power - Operate this equipment
only with a grounded electrical connection.
See Electrical Safety for grounding instructions, Page 10.
Comply with Regulations - You may be required to add
accessories to bring the system into compliance with
applicable regulations (OSHA in the USA) for machine
guarding and noise exposure.
Use Eye Protection - Wear ANSI approved safety impact
goggles.
Acoustic Stack Hazard - When an acoustic stack (transducer, booster, horn and tip) is energized by the ultrasound
signal, it presents a potential hazard. Stay clear of an
energized stack.
System E-STOP (abort) Switch - Install a system ESTOP (abort) switch at each operator station when ultrasonic plastic assembly equipment is used with automatic
material handling equipment in an automated system.
Foot Switch - Do not use a foot switch. Using a foot
switch in place of the optical touch finger switches (operate switches) violates OSHA regulations. Do not install
a foot switch.
NOTE
These recommendations apply to the
welding system. System in this manual
refers to a complete group of components
associated with the welding of parts, also
known as an ultrasonic assembly system.
A typical iQ Series System consists of the
iQ generator, a press with thruster, switches, controls, cables, transducer, booster,
horn, and fixture, and iQ Explorer II software.
WARNING
Any fixture manufactured
by a third party must comply with all OSHA and ANSI
requirements. All fixtures must
be guarded as necessary.
Dukane does not assume any
responsibility or liability for
fixtures manufactured by the
customer or any third party
manufacturer.
WARNING
Never operate the generator with the cover off. This
is an unsafe practice and
may cause injury.
CAUTION
At some time you may be asked
to remove equipment covers
by the Dukane Service Dept.
personnel. Before doing so,
disconnect the unit electrically from the incoming line AC power. If the unit is a press/
thruster, lock the Air Lockout Valve, located
on the rear panel, in its closed position.
Continued
Dukane Manual Part No. 403-608-00
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iQ Series, Auto-Plus MPC User’s Manual
Continued from Previous Page
General Considerations
System Electrical Cabling - Electrical power must be
off when connecting or disconnecting electrical cables.
Do Not Wear Loose Clothing or Jewelry - They can
become caught in moving parts.
Stay Alert - Watch what you are doing at all times. Use
common sense. Do not operate the equipment when you
are tired or distracted from the job at hand.
Do Not Operate the Equipment - Your judgement or
reflexes could be impaired while taking prescription medications. If so, do not operate the equipment. Be familiar
with warning labels and recommended activity restrictions
that accompany your prescription medications. If you have
any doubt, do not operate the equipment.
CAUTION
Parts being joined ultrasonically will at times vibrate at
audible frequencies. Wear ear
protectors to reduce annoying or uncomfortable sounds.
In addition, ultrasound baffles, sound enclosures, or materials that absorb sound
may be located to surround the system.
Plastics Health Notice
Certain plastic materials, when being processed, may
emit fumes and/or gases that may be hazardous to the
operator’s health. Proper ventilation of the work station
should be provided where such materials are processed.
Inquiries should be made to the U.S. Department of Labor
concerning OSHA regulations for a particular plastic prior
to processing with Dukane ultrasonic equipment.
Electrical Safety
The iQ Series generator provides the operating power
and power returns. Make sure the generator is grounded
properly.
In addition to the safety considerations, proper grounding
is essential for the effective suppression of RFI (Radio
Frequency Interference). Every generator contains a RFI
filter which blocks noise on the AC power line from entering the generator control circuitry. This filter also prevents
ultrasonic RFI from being fed back into the AC power line.
Always connect the included ground wire from the PE
ground of the generator to the nearest grounded metal pipe
or equivalent earth ground by means of a ground clamp.
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CAUTION
When making cable connections to system equipment
or disconnecting cables
from system equipment,
make sure electrical power to the system
is turned off, and AC power cords are
removed from their receptacles. After the
cables have been securely connected
and the connections and cable routing
checked a final time, the power may be
restored.
Dukane Manual Part No. 403-608-00
Section 2 – Health and Safety
Electrical Safety
Power Grounding Connection
Figure 2-1 illustrates how the AC line is connected to the
iQ Auto Plus generator.
iQ Auto Plus Power
Inlet
L
CAUTION
If there is any question
about grounding of your
equipment and/or its
electrical power source,
contact a qualified electrician.
N
CAUTION
Pluggable AC
Line Connector
Figure 2–1
Terminal
L
N
AC Line Connection
Wire Color
North America
Europe
Black
Lt. Brown
(Ground)
Green
Green w/yellow
stripe
(Neutral)
White
Lt. Blue
(Live)
Table 2-I
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) AC line connector.
Conventional Wire Color Code
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Dukane Manual Part No. 403-608-00
Section 3 – Installation
SECTION 3
Installation
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Chassis Grounding Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Basic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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14Dukane Manual Part No. 403-608-00
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.
NOTE
For equipment weights see Page 42, in
Section 8, Specifications.
Placement
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. See Figure 3-1, below. 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.
NOTE
Heat Dissipation - Provide enough air
flow for heat dissipation. For best heat dissipation, mount the generator vertically.
Mounting
Bracket
Figure 3-1
Generator Mounting Bracket
Placement in a Seismic Region
If the iQ generator is to be used in an active seismic region,
secure the unit by rack-mounting it or by securing the unit
to a benchtop.
Refer to Dukane’s website for more information about
installation in a seismic zone. See Application Note 511 http://www.dukane.com/us/DL_ApplData.asp
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iQ Series, Auto-Plus MPC 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.
The ground connection should comply with all of the requirements specified by the National Electrical code and
any other local codes or ordinances that are applicable.
Chassis Grounding Stud
Proper grounding for the generator chassis is essential for
the effective suppression of electrical noise or RFI (Radio 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 mandatory.
Additionally, the included grounding wire must be connected 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.
See Connecting Cables on the next page.
CAUTION
To minimize electrical noise
and eliminate ground currents, ground the chassis as
shown. Use a STAR configuration (shown below).Do not
DAISY CHAIN the grounds.
Chassis Grounding
Stud
Protective earth ground
connection wire color:
green or green with yellow
stripe.
Fixed Probe Mount
or 2nd Chassis
Grounding Stud
#14 Gauge
Stranded or
Solid Wire
Earth
Ground
3rd Chassis
Grounding
Stud
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 interference (RFI) that is common in an industrial
environment. Stud location is shown in
Figure 3-2 on the following page.
CAUTION
If you have any questions
about the grounding of your
equipment and/or the electrical box, contact a qualified
electrician.
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16Dukane Manual Part No. 403-608-00
Section 3 – Installation
Connecting Cables
NOTE
Basic Connections
Complete these basic connections for the standard configuration as shown below:
• AC Line Input
• iQLinQ™
• Ultrasound Outputs
• Grounding
Details about the various system connectors and their pin
assignments are covered in the next section.
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
3–4. (See Figure 2-1 also.)
2. Connect the appropriate cable from the PLC to the
Ethernet/IP Modbus - B in Figure 3-2, or ANYBUS
module port for iQLinQ™ control of the generator.
3. Attach high–voltage coaxial ultrasound cables (from
the ultrasonic probes) , the ultrasound output connectors - C in Figure 3-2.
4. Connect the included ground wire from the grounding
stud, D in Figure 3-2, to earth ground.
5. Connect the included E-STOP terminal block to a switch
or jumper the two connections together ( E in Figure
3-2). Plug the terminal block into the E-Stop port.
Connecting Cables
Two-piece pluggable terminal block connectors are used for the the AC Power Inlet
connections.
This type of connector allows the wiring to
be attached to the spring loaded terminal
connector, which plugs into the mating connector on the iQ Auto system front panel.
In the event a field replacement unit is
required, the terminal connectors with the
wires can be easily detached and then
plugged into the replacement unit.
AC Power Inlet
NOTE
Line voltage required for the generator is
100-240VAC at 50/60 Hz and 15 Amps
Maximum.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.
C
E
U/S Connectors
E-STOP
See NOTE on
Page 18.
A
Power Inlet
Figure 3-2
D
B
Grounding Stud Ethernet/IP Modbus port
Generator Front View
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iQ Series, Auto-Plus MPC User’s Manual
NOTE
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 electrical 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 ultrasonic output from this connector (that drives the attached
ultrasonic load) is a very high AC voltage (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.
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18Dukane Manual Part No. 403-608-00
Section 4 –System Operation
SECTION 4
System Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
iQ Auto-Plus System Operational Test . . . . . . . . . . . . . . . . . . 22
LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
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Dukane Manual Part No. 403-608-00
Section 4 –System Operation
Introduction
The ultrasonic iQ Auto-Plus generator/power supply,
is specifically designed to meet the machine builder’s
requirements. This unit is automation ready and has the
capability of controlling up to 8 probes.
The generator’s USB, Ethernet, and optional ANYBUS
ports extend communication and control functions
depending on the specifications of a particular generator
model.
This section deals primarily with basic operational testing
and troubleshooting.
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iQ Series, Auto-Plus MPC User’s Manual
iQ Auto-Plus System
Operational Test
1. Verify that the standard system installation is complete
and all cables are connected.
Refer to installation instructions included in Section 3,
if needed.
2. After completing Step 1, activate line power to the iQ
Auto-Plus system.
PROBE
STATUS LED
Normal Condition:
STATUS LED
GREEN - The POWER and STATUS LEDs on the
iQ Auto-Plus panel should both light up GREEN.
The system is now ready to operate.
Troubleshooting Abnormal iQ Auto-Plus
System Conditions
POWER LED
RED - If this LED lights up RED, check line
voltage level.
GRAY - If this LED is a gray color (not lit),
check line input.
3. After completing Step 2, test ultrasound output by
using iQLinQ™ or iQ Commander™
Normal Condition:
The system is operating properly when power is
delivered to the attached stack.
4. Check the operational Status LED
POWER LED
Figure 4-1
Generator POWER LED Detail
An Overload Fault latches until the next time U/S
is activated.
Any Fault status activates when any fault is detected by the system. It latches until the start of the next
cycle, unless it is activated due to Overtemperature or
Power Not OK fault.
Five fault conditions are monitored by the iQ
Auto-Plus system for Any Fault:
• Average Overload
(Automatically resets on next cycle)
• Peak Overload
(Resets same as Average Overload)
• Overtemperature
(Automatically resets on cool-down)
• Power Not OK
(AC line voltage under minimum voltage)
• Frequency Overload
(Automatically resets on next cycle)
• Over Voltage Overload
(Automatically resets on next cycle)
Continued
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Dukane Manual Part No. 403-608-00
Section 4 –System Operation
5. Check MPC Channels
Check that all MPC channels can be selected and
activated. The automation control system activates
input selection bits.
Select a channel: PROBE SELECTION STATUS
indicator illuminates GREEN when it is the selected
channel.
Activate ultrasound: Activate the iQ Auto-Plus ultrasound output. The PROBE SELECTION STATUS
indicator on the selected channel should switch to
RED (from GREEN).
The probe on the selected channel should deliver
ultrasonic power.
Repeat this test for all MPC channels.
Dukane Manual Part No. 403-608-00
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iQ Series, Auto-Plus MPC User’s Manual
LED Indication
There are seven LEDs on the iQ Auto-Plus generator:
- POWER (1)
- ETHERNET (2)
- MOD (1)
- NET (1)
- STATUS (1)
- PROBE SELECTION (2, 4, 6, or 8)
Figure 4-2 shows LED location, and Table 4-I shows
their indications.
PROBE SELECTION
(STATUS LED)
ETHERNET
MOD
STATUS
NET
POWER
Figure 4-2
Page
LED Locations
24
Dukane Manual Part No. 403-608-00
Section 4 –System Operation
LED
COLOR
Gray
POWER
Green - Steady
Red - Steady
INDICATION
Off - No power.
Power on.
Voltage problem. Check line voltage level.
ETHERNET
Left - Speed Indicator
Amber - Steady
On - Operating as a Gigabit connection (1000 Mbps)
Green - Steady
On - Operating as a 100-MBPs connection.
Off
Right - Activity Indicator
MOD
Yellow - Blinking
Off
STATUS
No activity.
Unrecoverable Fault
Red - Blinking
Minor Fault
Green - Steady
Device Operational
Green - Blinking
Standby
Off - No power.
Red - Steady
Duplicate IP (Not Supported)
Red - Blinking
Connection Time Out
Green - Steady
Connection
Green - Blinking
No Connection
Green - Steady
Ready
Yellow - Steady
E-STOP Active
Orange - Steady
In Cycle
Red - Steady
Average Overload
Red - Blinking
Peak Overload
Orange - Blinking
Blue - Steady
Light Blue - Steady
Yellow - Blinking
PROBE STATUS
Gray
Green
Red
Table 4-I
There is activity.
Red - Steady
Gray
NET
Operating as a 10-Mbps connection.
Voltage Overload
Overload - Frequency Failed
Overload - Frequency Lost
Power Fault
OFF - Not Selected
ON - Selected
Selected and Ultrasound Active
LED Colors and Indication
Dukane Manual Part No. 403-608-00
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Dukane Manual Part No. 403-608-00
Section 5 – Options
SECTION 5
Options
Heat Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Distance Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Dukane Manual Part No. 403-608-00
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28
Section 5 – Options
Heat Sink
The thermal design of 600 watt generators is for
applications that require a power of 600 watts or less at
duty cycles less than 50%.
For applications that require higher duty cycles, an optional
cooling package is available. The Dukane Part Number for
the package is 438-1020.
The cooling package is standard on 1200 watt models and
includes a heat sink that mounts to the generator as shown
in Figure 5-1 below.
CAUTION
Operate the iQ Auto-Plus
generator in the vertical position as shown in Figure
5-1. This allows for optimal
air circulation enabling the
heat sink to be most effective.
Air Flow
When operating an iQ Auto-Plus MPC generator with the
optional heat sink, do so with the generator in the vertical
position as shown in Figure 5-1. Air flow is enhanced, and
the heat sink’s efficiency is maximized.
Heat Sink
Figure 5-1
Generator with Heat Sink Option
Dukane Manual Part No. 403-608-00
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iQ Series, Auto-Plus MPC User’s Manual
Distance Option
The weld by distance feature can monitor up to eight
analog 0-10 VDC encoders. A maximum of one customer
supplied encoder for each MPC channel. See https://
documents.dukane.com/AppNote/AN528.pdf for more
information.
Page
Dukane Manual Part No. 403-608-00
30
Section 6 – Automation Interface
SECTION 6
Automation Interface
E-STOP Switch Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Automation System Safety Circuit . . . . . . . . . . . . . . . . . . . . . . . 33
TM
iQLinQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Dukane Manual Part No. 403-608-00
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32
Section 6 – Automation Interface
Dedicated E-Stop Switch Wiring Diagram
iQ Auto-Plus MPC
E-STOP Connector
(Pin 1)
Enable Out
User supplied
E-stop switch
(Pin 2)
Enable In
Automation System Safety Circuit Wiring Diagram
iQ Auto-Plus MPC
E-STOP Connector
(Pin 1)
Enable Out
(Pin 2)
Enable In
Relay contact block
Master
control
relay
User automation
control hardware
Figure 6-1
E-STOP Wiring and Automation System Safety Circuit
Dukane Manual Part No. 403-608-00
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33
iQ Series, Auto-Plus MPC User’s Manual
™
iQLinQ™ communication options allow automated
systems to monitor and change settings in iQ generators.
These options provide machine builders the ability to
integrate the generator into an electrical cabinet and to use
the machine’s HMI to program or monitor weld settings.
All iQ Auto-Plus MPC generator includes iQLinQ™
EtherNet/IP and Modbus TCP/IP communication protocol
support. Using one of these protocols avoids adding
expensive analog cards into PLC racks. iQLinQ™ is
available for PROFIBUS, PowerLink, Profinet, EtherCAT,
and CC-Link with the optional ANYBUS module.
iQLinQ Demos are available to provide complete ladder
logic and HMI screens that can be dropped into Allen
Bradley (RSLogix 5000; Studio 5000 Logix Designer;
Factory View Studio ME) Siemens (TIA Portal) and B&R
(Automation Studio) PLC projects.
Contact your local Dukane representative for more
information about the iQLinQ™ options.
™
Control Parameters Available via iQLinQ™
1. All parameters that are configured via iQLinQ™.
2. Real time data which includes welder state (ultrasound
active or not), frequency, power, amplitude, and position.
3. Weld cycle data from previous weld which includes:
• Cycle Count
• Good, Bad, and Suspect Part information
• Process Limit setting exceeded or not reached if Bad
or Suspect Part checking is enabled
• Weld Time
• Weld Energy
• Peak Power
• Weld Distance
• Weld End Position
iQ LinQ™
For information on how to control and/or monitor specific parameters, iQ Generator iQLinQ™ Communication and Control
documentation is available.
The iQLinQ™ allows the iQ generator to connect to an
industrial network.
Signing a non-disclosure agreement is required to obtain this
documentation.
Control Parameters available via iQLinQ™
1. Set weld method to Time, Energy, Peak Power, Distance, and/or Position. Set associated values in seconds,
joules, watts, or millimeters/inches.
2. Set Amplitude, Ramp Up Time, and Ramp Down Time.
3. Enable and set Trigger by Power or Trigger By Position
parameters.
4. Enable and set Hold time.
5. Enable and set Afterburst delay and duration.
6. Enable checking for Suspect Parts. Set maximum and
minimum values for Time, Power Energy, Distance,
and/or position.
7. Enable checking for Bad Parts. Set maximum and
minimum values for Time, Power, Energy, Distance,
and/or Position.
8. Configure advanced hardware settings including Frequency Tracking, Free Run Frequency, Frequency Lock
and Hold, and Frequency limits.
Page
34
Dukane Manual Part No. 403-608-00
Section 7 – Contacting Dukane
SECTION 7
Contacting Dukane
Dukane Manual Part No. 403-608-00
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Dukane Manual Part No. 403-608-00
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.
Mailing Address:
Dukane
2900 Dukane Drive
St. Charles, IL 60174 USA
Phone:
(630) 797–4900
E-mail:
[email protected]
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:
www.dukane.com
You can locate your local representative at:
www.dukane.com/contact-us/
Dukane Manual Part No. 403-608-00
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Dukane Manual Part No. 403-608-00
Section 8 – Specifications
SECTION 8
Specifications
Generator Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Interpreting the Model Number . . . . . . . . . . . . . . . . . . . . . . . . 44
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . 45
Dukane Manual Part No. 403-608-00
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Dukane Manual Part No. 403-608-00
Section 8 – Specifications
OPTIONAL
BOTTOM
HEAT SINK
AND MOUNTING
FEET
PICTORIAL VIEW:
SCALE 2 / 3
.85
[22]
ALLOW 3.00" [76]
FOR CABLE
CONNECTOR
.88
[22]
9.12
[232]
9.25
[235]
LOWER
MOUNTING
BRACKETS
4.15
[105]
11.25
[286]
10.61
[269]
10.38
[264]
9.50
[241]
10.73
[273]
11.25
[286]
9.85
[250]
9.50
[241]
ANYBUS CONNECTION
ETHERNET
USB 2.0
.75
[19]
4.50
[114]
.69
[18]
6.00
[152]
.89
[22]
7.38
[187]
MAXIMUM (8) PROBES
2.00
[51]
BOTTOM REAR
MOUNTING BRACKET
2.00
[51]
DISTANCE CONNECTOR
1.78
[45]
POWER INLET
100-240 VAC
1.78
[45]
BASE MOUNTING
BRACKETS (2)
41
Page
Dukane Manual Part No. 403-608-00
TOP REAR
MOUNTING BRACKET
5.11
[130]
.72
[18]
Generator Outline Drawing
Figure 8-1
iQ Series, Auto-Plus MPC User’s Manual
Weight
Standard Model:
16 pounds (7.26 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.
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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Dukane Manual Part No. 403-608-00
Section 8 – Specifications
AC Power Requirements
Operating
Frequency
Generator
Model Number
Overload Power
Ratings (Watts)
Input AC Power Requirements
Nominal AC Volt
@ Maximum RMS Current
20kHz
20AM060-UF-CX-XX
600
100-240V 50/60 Hz @ 15 Amps Max
20kHz
20AM120-2F-CX-XX
1200
200-240V 50/60 Hz @ 15 Amps Max
30kHz
30AM060-UF-CX-XX
600
100-240V 50/60 Hz @ 15 Amps Max
30kHz
30AM120-2F-CX-XX
1200
200-240V 50/60 Hz @ 15 Amps Max
35kHz
35AM060-UF-CX-XX
600
100-240V 50/60 Hz @ 15 Amps Max
35kHz
35AM120-2F-CX-XX
1200
200-240V 50/60 Hz @ 15 Amps Max
40kHz
40AM060-UF-CX-XX
600
100-240V 50/60 Hz @ 15 Amps Max
50kHz
50AM040-UF-CX-XX
400
100-240V 50/60 Hz @ 15 Amps Max
Table 8-I
AC Power Requirements
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iQ Series, Auto-Plus MPC User’s Manual
Interpreting the Model Number
3 0
Nominal U/S Frequency
20 = 20 kHz
30 = 30 kHz
35 = 35 kHz
40 = 40 kHz
50 = 50 KHz
AM
2
F
System Process Control
Probe System Options
F = Auto Plus w/iQLinQ™ Advanced communication Support
AC Line Input
2 = 200-240 for 1200W
U = 100-240V for 600 W
120 = 1200 Watts
060 = 600 Watts
040 = 400 Watts
Power Level
1 2 0
C1 = iQLinQ™ PROFIBUS Interface Module
C2 = iQLinQ™ Ethernet/IP Interface
C3 = iQLinQ™ PROFINET Interface Module
C4 = iQLinQ™ CC-Link Interface Module
C5 = iQLinQ™ POWERLINK Interface Module
C6 = iQLinQ™ EtherCAT Interface Module
C7 = iQLinQ™ Modbus TCP Interface
Options Slot #1
C 5
iQ Integrated MPC Probe Generator Model Number Codes
Chassis Style – Power Switch Configuration
AM = Auto Series With integrated MPC Panel Mount Chassis (Non-Automotive)
ST = Auto Series With integrated MPC Panel Mount Chassis (Automotive)
Example System Number shown above:
30AM120-2F-C5-02
System Assembly Detailed Description:
30kHz 1,200 Watt System operates on a 200-240V AC Line with a POWERLINK communications module and two point MPC installed.
1200W is only available in 30K and 35K units and 400W is only available in 50K models.
0 2
Number of Probes
Without Distance
02 = 2 Probes
04 = 4 Probes
06 = 6 Probes
08 = 8 Probes
With Distance
D2 = 2 Probes
D4 = 4 Probes
D6 = 6 Probes
D8 = 8 Probes
44
Dukane Manual Part No. 403-608-00
Page
Interpreting the Model Number
Figure 8-2
Section 8 – Specifications
Regulatory Agency Compliance
FCC
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.
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
equipment complies with the following CE requirements.
• The EMC Directive 2004/108/EC
for Heavy Industrial —
EN 61000-6-4: 2001
EN 55011: 2003
EN 61000-6-2: 2005
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.
UL
The iQ generator complies with these standards:
Underwriters Laboratories:
UL 1012: 2010
UL 61010-1:2012, and
National Standards of Canada:
CAN/CSA C22.2 No. 61010-1-12:2012
as verified by TÜV Rheinland.
• The Machinery Directive 2006/42/EC.
EN 60204: 2006
Safety of Machinery - Electrical Equipment of
Machines Part 1: General Requirements.
IP Rating
The iQ generator has an IP (International Protection)
rating from the IEC (International Electrotechnical
Commission).
The rating is IP2X, in compliance with finger-safe
industry standards.
Dukane Manual Part No. 403-608-00
CAUTION
DO NOT make any modifications to the generator
or associated cables as
the changes may result
in violating one or more
regulations under which
this equipment is manufactured.
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Section 9 – Appendices
SECTION 9
Appendices
Appendix A, List of Figures . . . . . . . . . . . . . . . . . . . . 49
Appendix B, List of Tables . . . . . . . . . . . . . . . . . . . . . 50
Dukane Manual Part No. 403-608-00
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Dukane Manual Part No. 403-608-00
Section 9 – Appendices
Appendix A
No.
Description
List of Figures
Page
2-1
AC Line Connection.......................................................................................................11
3-1
Generator Mounting Bracket..........................................................................................15
3-2
Generator Front View.....................................................................................................17
4-1
Generator POWER LED Detail......................................................................................22
4-2
LED Locations................................................................................................................24
5-1
Generator with Heat Sink Option....................................................................................29
6-1
E-STOP Wiring and Automation System Safety Circuit..................................................33
8-1
Generator Outline Drawing.............................................................................................41
8-2
Interpreting the Model Number.......................................................................................44
Dukane Manual Part No. 403-608-00
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iQ Series, Auto-Plus MPC User’s Manual
Appendix B
List of Tables
No.
Description
2-I
Conventional Wire Color Code........................................................................................11
4-I
LED Colors and Indication...............................................................................................25
8-I
AC Power Requirements.................................................................................................43
Page
Page
50
Dukane Manual Part No. 403-608-00
Index
Index
Dukane Manual Part No. 403-608-00
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Dukane Manual Part No. 403-608-00
Index
Index
G
General User Information 3
Drawings and Tables 3
A
Agency Compliance 45
CE Marking 45
Notes, Cautions and Warnings 3
Read This Manual First 3
Generator
Features 4
FCC 45
Overview 4
IP (International Protection) Rating 45
Thermal Considerations 5
Appendices 47
Appendix A - List of Figures 49
Appendix B - List of Tables 50
Automation Interface 31
H
Health and Safety
Electrical Safety 10
C
General Considerations 9
Plastics Health Notice 10
Chassis Grounding Stud 16
Connecting Cables 17
D
Dukane
Email 37
Phone 37
Service and Parts 37
www.dukane.com 37
E
Electrical Safety
Power Grounding Connection 11
F
FCC 45
Recommendations 9
Heat Sink 29
I
Installation
Connecting Cables 17
Placement 15
Placement in a Seismic Region 15
Power Grounding 16
Unpacking 15
Interpreting the Model Number 44
IP (International Protection) Rating 45
iQLinQ™ 34
N
Notes, Cautions and Warnings 3
Dukane Manual Part No. 403-608-00
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53
iQ Series, Auto-Plus MPC User’s Manual
O
Options
Distance Option 30
Heat Sink 29
R
Regulatory Agency Compliance 45
S
Specifications
AC Power Requirements 43
Interpreting the Model Number 44
Operating Environment 42
Weight 42
System Operation
Introduction 21
iQ Auto-Plus System Operational Test 22
LED Indication 24
T
Thermal Considerations 5
Page
54
Dukane Manual Part No. 403-608-00
Dukane ISO
ISO CERTIFICATION
Dukane chose to become ISO 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.
To achieve ISO certification, you must prove
to one of the quality system registrar groups
that you meet three requirements:
1. Leadership
2. Involvement
3. Quality in Line Organizations and Quality System Infrastructure.
The ISO standards establish 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 Dukane 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.
Dukane products are
manufactured in ISO
registered facilities
View the Dukane ISO certificate of
compliance at: https://documents.dukane.com/Certifications/ISO-Cert.pdf
Please refer to our website at:
www.dukane.com/contact-us/
to locate your local representative.
iQ Series, Ultrasonic Generator/Power Supply
Auto-Plus MPC User's Manual
Part No. 403-608-00
www.dukane.com
Printed in the United States of America
Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900
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