Dukane iQ Series Ultrasonic Power Supply - Aim - Blank Front Panel Manual

Dukane iQ Series Ultrasonic Power Supply - Aim - Blank Front Panel Manual
iQ Series
AUTOMATION IN MIND
ULTRASONIC POWER SUPPLY
AiM™
AUTOMATED
HAND PROBE
PRESS
Dukane Part No. 403-611-00
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 AiM™ Automation in Mind, Ultrasonic Power Supply 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: 403-611-00
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
Page
ii
Dukane Manual Part Number 403-611-00
Revision History
Revision
Number
- 00 .
Revision
Summary
Original release.
Date
March 28, 2019
Dukane Manual Part Number 403-611-00
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Dukane Manual Part Number 403-611-00
Contents
Section 1 - Introduction, Health and Safety . . . . . . . . . . . 1
General User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plastics Health Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
4
5
5
Section 2 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Proper Handling of Cable Slack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Section 3 - Standard Connections . . . . . . . . . . . . . . . . . . 13
Bottom Panel Layout Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Power Inlet Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Inputs/Outputs Connector . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ultrasound Output Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ethernet/IP Port Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
USB Port Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
16
16
21
22
23
Section 4 - Standard System Status and Controls���������25
Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Multi-Point (MPC) Inteface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
iQLinQ™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Section 5 - Contacting Dukane . . . . . . . . . . . . . . . . . . . . . 33
Section 6 - Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 37
Generator Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Interpreting the Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dukane Manual Part Number 403-611-00
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40
41
42
43
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Dukane Manual Part Number 403-611-00
Section 1 – Introduction, Health and Safety
SECTION 1
Introduction
Health and Safety
General User Information . . . . . . . . . . . . . . . . . . . . . 3
Read the Manual First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Drawings and Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Considerations . . . . . . . . . . . . . . . . . . . . . . 4
Plastics Health Notice . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Domestic Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
International Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Dukane Manual Part Number 403-611-00
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Dukane Manual Part Number 403-611-00
Section 1 – Introduction, Health and Safety
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.
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 have important
information that, if ignored, could have increasingly severe outcomes. 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 3 while Table 3- II
would be the second table in Section 3.
Dukane Manual Part Number 403-611-00
Condition
or Practice
Electrical
Hazard
Hearing
Protection
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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
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 5.
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.
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.
Typical of the iQ Series AiMTM system
consists of the iQ generator, cables, transducer, booster, horn, and fixture.
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.
Continued
Page
Page 44
DukaneManual
ManualPart
PartNumber
Number403-611-00
403-611-00
Dukane
Section 1 – Introduction, Health and Safety
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 generator 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. Ultrasound
pressure level could exceed 110dB.
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
WARNING
Keep head, hands, limbs and
body at least six inches (152
mm) away from an operating
press/thruster. A vibrating,
descending horn can cause burns and/or
crushing injuries.
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.
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.
Continued
Dukane Manual Part Number 403-611-00
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iQ Series Aim™Automation in Mind, Ultrasonic Power Supply User’s Manual
Continued from Previous Page
Electrical Safety
Domestic Power Grounding
For safety, the power cords used on this product have a
three-wire, grounding-type power cord. Figure 1-1 illustrates the appropriate electrical outlet to use with the
power cord that is included with systems shipped to North
America.
Approved 2 pole, 3 wire grounding
receptacle HUBBELL No. 5652 or
equivalent to NEMA 6–15R or 6–20R
Figure 1–1 Example of 220/240 Volt, Grounded, 3-Prong Receptacle
International Power Grounding
The power cable normally provided for international use is
compatible with the power outlet used in many Continental European countries (Refer to Figure 1–2). However,
if your application requires another type of power cord,
check with your equipment supplier, and follow local regulations concerning proper wiring and grounding.
Grounding Contacts
CAUTION
If you have a two-prong
electrical receptacle, we
strongly recommend that
you replace it with a properly grounded three-prong type. Have
a qualified electrician replace it following the National Electric Code and
any local codes and ordinances
that apply. See Figures 1-1 and 1-2.
CAUTION
If there is any question
about the grounding of your
receptacle, have it checked
by a qualified electrician.
Do not cut off the power cord grounding prong, or alter the plug in any
way. If an extension cord is needed,
use a three-wire cord that is in good
condition. The cord should have
an adequate power rating to do the
job safely. It must be plugged into a
grounded receptacle. Do not use a twowire extension cord with this product.
Typical Outlet
Provided Cable
Figure 1-2 International 220/240V Grounding
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Dukane Manual Part Number 403-611-00
Section 2 – Installation
SECTION 2
Installation
Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Automation Controlled Probe System . . . . . . . . . . . . . . . . . . . . . . . . 10
RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Proper Handling of Cable Slack . . . . . . . . . . . . . . . . 11
Dukane Manual Part Number 403-611-00
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Dukane Manual Part Number 403-611-00
Section 2 – Installation
Connecting Cables
(Quick Start Guide)
Details about the various system connectors and their pin
assignments are covered in Section 3.
The connections are the same for both the vertical and
horizontal generator configurations. However, the panel
location of the connectors differs between the two chassis
styles.
AC Power
Detached Cords
The AC line cords supplied with the standard generators
are matched to the ultrasonic output power rating and the
continent of specified use. See Table 2-I.
Continent of Use
North America
Continental Europe
Table 2 - I
Power Cord
Part Number
Power
200-1109
120V, 15A
200 - 1110
240V, 15A
200 - 1111
240V, 16A
CAUTION
The power cord is equipped
with a three-prong,
grounded-type plug for
your safety. Whenever
a two-slot receptacle is encountered, we strongly recommend that
it is replaced with a properly
grounded three-lead receptacle.
Have a qualified electrician do the
replacement in accordance with the
National Electrical Code and local
codes and ordinances. DO NOT
cut off the power cord grounding
prong or alter the plug in any way.
Standard IEC AC Power Cord Part Numbers
Attached Cords
240 Volt Single Phase Systems - High power generators with power ratings above 2600W use permanently attached power cords.
No Cords
Three-Phase Systems - High power Three-Phase generators do not include an AC Line Cord and must be directly
wired.
Dukane Manual Part Number 403-611-00
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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Continued from Previous Page
AC BREAKER
SYSTEM I/O
B
OPTIONS SLOT
MPC
A PE
EtherNet/IP Modbus TCP/IP
USB
D AC POWER ENTRY
ULTRASOUND
C
Figure 2-1 Generator - Bottom View (Vertical Panel
Mount Chassis)
Automation Controlled Probe
System
1. Ground the generator chassis using the supplied
14-Gauge wire, and attach it to the grounding stud:
A in Figure 2-1.
2. Recommended – Ground the probe support. This is a
user–supplied 14-Gauge wire. This is required if the
probe support does not have a good earth ground
through the machine.
3. Input Cable/Output Cable - Attach the automation
control cable from the user–supplied automation
equipment to the system input HD-26 connector, J5
on the I/O panel: B in Figure 2-1.
4. Attach the high voltage coaxial cable from the probe
to the ultrasound output connector J1:
C in Figure 2-1.
5. Connect the AC power cord to the generator IEC
power inlet connector, and plug the other end into
an approved AC outlet:
D in Figure 2-1.
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Dukane Manual Part Number 403-611-00
Section 2 – Installation
RFI Grounding
In addition to the safety considerations previously mentioned, proper grounding at the generator power cord is
essential for the effective suppression of electrical noise
or RFI (Radio Frequency Interference). Every ultrasonic
generator contains a RFI filter which 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. In order for the RFI
filter to operate properly, it is necessary to correctly ground
the system. Run a grounding wire from the grounding stud
connection to the nearest grounded metal pipe or equivalent earth ground, and secure it with a ground clamp.
CAUTION
To minimize electrical
noise and eliminate
ground currents, ground
the chassis as shown.
Use a STAR configuration
(illustrated below). Do not
DAISY CHAIN the grounds.
Chassis Grounding
Lug
See Figure 2-1 on Page 10.
Proper Handling of Cable Slack
Coil Extra Slack
Earth
Ground
Fixed Probe Mount
or 2nd Chassis
Grounding Lug
#14 Gauge
Stranded or
Solid Wire
3rd Chassis
Grounding
Lug
When taking up slack in cables, the extra length should
be coiled up as shown in Figure 2-2 rather than folded as
shown in Figure 2-3.
Figure 2-2
Cable Slack Take-up - Correct
Avoid Excessive Bending
Avoid excessive tension and bends on cables. Cables
should be routed so that there are no abrupt bends in the
cables, especially near their connectors.
Dukane Manual Part Number 403-611-00
Figure 2-3
Cable Slack Take-up - Incorrect
NOTE
Cables shown in the two figures directly
above are representative samples. If
cables have slack, coil them rather than
fold them.
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Dukane Manual Part Number 403-611-00
Section 3 – Standard Connections
SECTION 3
Standard Connections
Bottom Panel Layout Overview . . . . . . . . . . . . . . . 15
AC Power Inlet Panel . . . . . . . . . . . . . . . . . . . . . . . . 16
IEC AC Power Inlet Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Power Switch/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Chassis Grounding Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
System Inputs/Outputs Connector . . . . . . . . . . . . 16
System Inputs/Outputs Signal Descriptions . . . . . . . . . . . . . . . . . . . . 17
Ultrasound Output Connector . . . . . . . . . . . . . . . . 21
EtherNet/IP Port Connector . . . . . . . . . . . . . . . . . . 22
USB Port Connector . . . . . . . . . . . . . . . . . . . . . . . . 23
Dukane Manual Part Number 403-611-00
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Dukane Manual Part Number 403-611-00
Section 3 – Standard Connections
Bottom Panel Layout Overview
This section provides an overview of the generator rear
panel layout, which includes panel areas dedicated to various standard system functions and options that are available. Figure 3 - 1 illustrates the panel layout.
B AC BREAKER
SYSTEM I/O
D
OPTIONS SLOT
C PE
MPC
E
I
H
EtherNet/IP Modbus TCP/IP G
USB F
A AC POWER ENTRY
ULTRASOUND
E
Figure 3 - 1 Generator Bottom Panel
E
A
Ultrasound Output Connector – Coaxial high voltage
connection to ultrasonic stack.
B
Configuration Port Connector – Digital control port to
modify system parameters.
IEC Power Inlet Connector – Attaches to an IEC style
power cord.
Power Switch – Circuit Breaker – Used to switch
system power ON and OFF.
C
Chassis Grounding Stud – Chassis connection for a
protective earth ground.
D
System Input/Output Connector – Connections for
system control input signals and system status output signals.
Dukane Manual Part Number 403-611-00
F
G
Ethernet/IP Connector – Provides for communication
between the iQ generator and an automation network.
H
Multi-Point Control Connector - Used to connect an
MPC module.
I
An option module can be installed here.
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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
AC Power Inlet Panel
The standard AC power inlet panel is described in this section.
IEC AC Power Inlet Connector
The IEC AC power inlet connector mounted on the system
AC power inlet panel requires a properly configured IEC
compliant power cord, which enables worldwide system
operation by simply changing the power cord.
This system includes a 16/20 amp rated IEC inlet connector. Single phase 3600W/5000W systems include a nondetachable power cord.
An appropriately rated power cord must be securely attached to the welding system’s IEC inlet connector. If the
correct power cord configuration is not included with the
system for the local AC power outlet at your location, an
appropriate IEC power cord should be available from a local electrical parts supplier.
Chassis Grounding Stud
The chassis grounding stud is used to attach a protective earth ground to the generator. This will aid in the
suppression of electrical interference or radio frequency
interference (RFI) that is common in an industrial environment. The chassis ground stud is C in Figure 3-2.
Proper system grounding is discussed in Section 2.
C
Figure 3 - 2 IEC AC Power Inlet Connector
Power Switch/Circuit Breaker
The power switch/circuit breaker has a rocker type actuator switch that will activate or deactivate the AC power
to the system. The power ON position is marked with the
internationally recognized I symbol, the power OFF position is marked with the 0 symbol. This power switch also
integrates an appropriately sized over-current protection
circuit breaker function in the generator.
If an over-current condition trips the circuit breaker, it will
automatically switch to the OFF position. If the overload
current that caused the circuit breaker to trip is due to a
transient condition, the circuit breaker can be reset by
switching the actuator back to the ON position. If when
resetting the circuit breaker after it has tripped, it immediately trips again, there is likely an internal system malfunction, and the generator will require service.
Do not repeatedly try to reset the circuit breaker. If it trips,
this will only cause more damage to the generator.
System Inputs/Outputs Connector
The SYSTEM INPUTS/OUTPUTS connector mounted
on the system I/O panel includes connections for all of
the basic system control input and output signals that
will typically be associated with an automated control
system. The cable attached to this connector includes
all of the available system control signals, which will
be controlled by an output card or output port on the
automation controller.
The user can determine which signals to use for each
particular welding application, but there must be at least
two connections to this connector or the generator will
always be in an E-STOP condition. All of the I/O signals
on this connector are electrically isolated (signals are
NOT referenced to chassis ground). Inputs are activated
when there is a 24VDC difference between the input pin
and the Input Common pin. The electrically isolated I/O
signals can be activated/monitored from an automation
controller with either sinking (NPN) or sourcing (PNP)
I/O depending upon how the isolated common connection is terminated. All inputs sink or source 10mA of
current from a 24VDC power supply. The total output
current cannot exceed 500mA when using the +22VDC
generator output (pin 1). If an external supply is used the
maximum current for each output is 400mA.
Continued
Page
16
Dukane Manual Part Number 403-611-00
Section 3 – Standard Connections
Continued from Previous Page
Note that a simple switch closure (relay contact) connected to a control input can not activate the input without
adding an external power supply to power the input. Adding jumper connections to pins available on the System
Inputs connector, can configure switch closure inputs to
operate referenced to generator chassis ground (non-isolated), without adding a separate power supply, if desired.
Refer to Application Note AN525 found on the Dukane
website at:
https://documents.dukane.com/AppNote/AN525.pdf
for detailed wiring diagrams of example applications.
The SYSTEM INPUTS/OUTPUTS connector is a HD26F (high density D-subminiature 26 circuit female) connector. Table 3 - I lists the signal names and descriptions,
with detailed descriptions below. The wire color coding
for the system input cable is listed in Table 3 - I, to assist
with custom automation system wiring and assembly.
System Inputs/Outputs Signal
Descriptions
Figure 3 - 3 System I/O Panel (standard panel shown)
Pin 1 (+22V)
This pin can supply +22VDC at up to 500mA to power
the user’s automation controls.
Pin 2 (Power Gnd)
Pin 2 is the 22VDC return and is tied to the system chassis ground.
Pin 3 (E-STOP Output)
Refer to AN525 for E-STOP wiring.
Pin 4 (E-STOP Input)
Refer to AN525 for E-STOP wiring.
Pin 5 (Remote Setup Selection Bit 0 Input)
Pin 5 is the Remote Setup Selection Bit 0, which is the
least significant bit used to select different welding setups
with an automation control system. This input is also used
to select different channels when a Multi-Point Controller
(MPC) module is connected to J2.
Pin 6 (Remote Setup Selection Bit 1 Input)
Pin 6 is the Remote Setup Selection Bit 1, which is the
second least significant bit used to select different welding setups with an automation control system. This input
is also used to select different channels when a MultiPoint Controller (MPC) module is connected to J2.
Continued
Dukane Manual Part Number 403-611-00
Page
17
iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Continued from Previous Page
Pin 7 (Remote Setup Selection Bit 2 Input)
Pin 7 is the Remote Setup Selection Bit 2, which is the
third least significant bit used to select different welding
setups with an automation control system. This input is
also used to select different channels when a Multi-Point
Controller (MPC) module is connected to J2.
Pin 8 (Remote Setup Selection Bit 3 Input)
Pin 8 is the Remote Setup Selection Bit 3, which is the
most significant bit used to select different welding setups
with an automation control system. This input is also used
to select a different channels when a Multi-Point Controller (MPC) module is connected to J2.
Pin 9 (Automation Cycle Stop Input)
Pin 9 is an input control signal that when enabled, can
be used by the automation control system as a redundant
signal to shut the ultrasound output off.
Pin 10 (Front Panel Lockout Input)
Pin 10 is not applicable since this model doesn’t have a
user interface.
Pin 11 (Isolated Input Common)
Pin 11 is electrically isolated from chassis ground. Using
isolated sourcing (PNP) output drivers, this common line
would be connected to isolated ground potential. Using
isolated sinking (NPN) output drivers, this common line
would be connected to the isolated positive supply voltage
output. For correct operation of inputs it is critical that
this pin is connected to either isolated ground or positive
supply (See AN525 for more information).
Pin 12 (Ultrasound Activation/ Cycle Start
Input)
Pin 12 is used to activate the generator ultrasound output.
Activation of this control input will switch the ultrasound
output ON, and deactivating this signal will switch
ultrasound OFF. This input signal will also function as
a cycle start input, where the ultrasound activation and
timing are completely under the control of the process
controller. Depending on the welding process controller
setup, this input signal could be activated momentarily to
start a welding cycle.
Pin 13 (Isolated Ultrasound Common)
Pin 13 is the common connection for Pin 12 (Ultrasound
Activation/Cycle Start Input). Pin 13 is electrically isolated
from chassis ground. Using isolated sourcing (PNP)
Page
18
output drivers, this common line would be connected to
isolated ground potential. Using isolated sinking (NPN)
output drivers, this common line would be connected to
the isolated positive supply voltage output. For correct
operation of the Ultrasound Activation/Cycle Start input
it is critical that this pin is connected to either isolated
ground or positive supply.
Pin 14 (Analog Input (0-10VDC))
Pin 15 (Analog Input (0-10VDC))
Pin 16 (Analog Ground)
Pin 16 is the signal common (ground) connection for all
of the analog signals (on Pins 14, 15, 17, and 18). This
signal common pin is connected to system chassis ground
and is not isolated from the generator chassis. This is
an analog signal ground connection. Do not connect
anything to this ground connection, except the wiring to
the inputs/outputs of the analog devices.
Pin 17 (Analog Power Output (0-10VDC))
Pin 17 is an analog output signal used to monitor the
power output from the welding system. The scaling on
this output signal is as shown below:
1 Watt = 0.001 VDC (1mV per Watt)
Example: • 20kHz system measures 0.525 VDC on
Power Monitor Output = 525 W
Pin 18 (Analog Amplitude Output (0-10VDC))
Pin 18 is an analog output signal used to monitor the
system amplitude setting. The scaling on this output
signal is 100% amplitude = 10.0 VDC, or 0.1 VDC per
1% amplitude. Using this monitor output, the control
system can verify that the amplitude is set to the expected
programmed amplitude level.
Pin 19 (Ultrasound Status Output)
Pin 19 is a digital 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 20 (Any Fault Status Output)
Pin 20 is a digital output that activates whenever any fault
condition is detected that terminates/inhibits ultrasound
output and normal system operation. This output will
be an open circuit when no system fault conditions are
Continued
Dukane Manual Part Number 403-611-00
Section 3 – Standard Connections
Continued from Previous Page
Fault output remains active until cleared by the System
Latch Reset input or by the start of the next weld cycle.
Generator faults that will activate the Any Fault output:
• Overload (Average, Peak, Frequency, Over Voltage)
• Over Temperature Fault
• System Power Fault
Pin 21 (Overload Status Output)
Pin 21 is a digital output that activates whenever any
overload condition is tripped. Activation of the overload
status output signal could be caused by an Average, Peak
Frequency, or Over Voltage overload condition. After the
overload status output activates, it will remain active until
cleared by the System Latch Reset input or by the start of
the next weld cycle. This output will be an open circuit
when no overload conditions have been detected.
Pin 22 (Bad Part Status Output)
Pin 22 is a digital status output that activates, either
momentarily or until the start of the next welding cycle,
when the welding parameters recorded during the previous
welding cycle are outside of the programmed bad part
limits. This output will be an open circuit when a bad part
has not been detected.
Pin 25 (MPC Ready Status Output)
This status output signal will activate only when an MPC
module is connected to the generator. Pin 25 is a digital
status output that activates when the MPC controller is
ready to start the next MPC welding cycle. This output
will be an open circuit when the MPC system is not
ready to start an MPC weld cycle. Any changes to the
probe selection control bits will not be acted on until the
completion of the current weld cycle. This status output
signal will also be open (MPC NOT READY) if a fault
condition is detected inside the MPC module. If this
status output will not activate, check for a red fault status
indication, the SYSTEM STATUS LED, on the front of
the MPC module.
Pin 26 (Isolated Output Common)
Pin 26 is electrically isolated from chassis ground.
For isolated sourcing (PNP) inputs, this common line
would be connected to isolated ground potential. Using
isolated sinking (NPN) output drivers, this commmon
line would be connected to the isolated positive supply
voltage output.
Pin 23 (Good Part Status Output)
Pin 23 is a digital status output that activates, either
momentarily or until the start of the next welding cycle,
when the welding parameters recorded during the previous
welding cycle do not exceed the programmed suspect or
bad part limits. This output will be an open circuit after a
welding cycle when either a suspect or bad part has been
detected.
Pin 24 (Ready Status Output)
This status output signal will activate only when the
system is ready to activate ultrasound or begin a weld
cycle. Pin 24 is a digital status output that activates when
a weld processing cycle is completed and the welding
process control system is ready to start the next welding
cycle. This output will be an open circuit when the welding
process controller determines that the next welding cycle
cannot be started. This includes system faults or E-STOP
active, but not a process fault like Overload.
Dukane Manual Part Number 403-611-00
Page
19
iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Pin
Color
J5-1
BLK/RED
+22V CURRENT LIMITED POWER SUPPLY (500mA MAX)
J5-2
RED/BLK
+22V RETURN (iQ CHASSIS GROUND)
J5-3
BLK/WHT
E-STOP OUTPUT
J5-4
WHT/BLK
E-STOP INPUT
J5-5
BLK/GRN
REMOTE SETUP SELECTION BIT 0 INPUT
J5-6
GRN/BLK
REMOTE SETUP SELECTION BIT 1 INPUT
J5-7
BLK/BLU
REMOTE SETUP SELECTION BIT 2 INPUT
J5-8
BLU/BLK
REMOTE SETUP SELECTION BIT 3 INPUT
J5-9
BLK/YEL
AUTOMATION CYCLE STOP INPUT
J5-10
YEL/BLK
FRONT PANEL LOCKOUT INPUT
J5-11
BLK/BRN
ISOLATED INPUT COMMON
J5-12
BRN/BLK
ULTRASOUND ACTIVATION/CYCLE START INPUT
J5-13
BLK/ORN
ISOLATED ULTRASOUND COMMON
J5-14
ORN/BLK
ANALOG DISTANCE INPUT (0-10VDC)
J5-15
RED/WHT
ANALOG AMPLITUDE INPUT (0-10VDC)
J5-16
WHT/RED
ANALOG GROUND
J5-17
RED/GRN
ANALOG POWER OUTPUT (0-10VDC)
J5-18
GRN/RED
ANALOG AMPLITUDE OUTPUT (0-10VDC)
J5-19
RED/BLU
ULTRASOUND STATUS OUTPUT
J5-20
BLU/RED
ANY FAULT STATUS OUTPUT
J5-21
RED/YEL
OVERLOAD STATUS OUTPUT
J5-22
YEL/RED
BAD PART STATUS OUTPUT
J5-23
RED/BRN
GOOD PART STATUS OUTPUT
J5-24
BRN/RED
READY STATUS OUTPUT
J5-25
RED/ORN
MPC READY STATUS OUTPUT
J5-26
ORN/RED
ISOLATED OUTPUT COMMON
Table 3-I
Description
System Input/Output Connector Signals
Note: The descriptions shown are for the default I/O settings. Almost all Inputs are programmable to other input functions
and all outputs to other output functions. The exception is the ULTRASOUND ACTIVATION / CYCLE START INPUT
which cannot be programmed to another function.
Page
20
Dukane Manual Part Number 403-611-00
Section 3 – Standard Connections
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.
Figure 3-4 Ultrasound Output Connector
CAUTION
The ultrasonic output from
this connector (that drives
the attached ultrasonic load)
is a very high AC voltage. At
high power levels this can exceed 2
amperes 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.
Do not use your generator if there is any
evidence of arcing (black carbon deposits) on either the ultrasound output
connector or the ultrasound cable connectors.
Dukane Manual Part Number 403-611-00
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21
iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
EtherNet/IP Port Connector
The EtherNet/IP or Modbus TCP/IP connector allows the
iQ generator to connect to an EtherNet/IP or Modbus TCP/
IP network.
ETHERNET/IP MODBUS TCP/IP
NOTE
Refer to Section 4, Pg. 31, for more
information.
Page
22
Figure 3-5 J9 Ethernet/IP or Modbus TCP/IP
Port Connector
Dukane Manual Part Number 403-611-00
Section 3 – Standard Connections
USB Port Connector
Connect a Windows PC to this port using the included
USB cable in order to use Dukane’s PC interface tool, iQ
CommanderTM. This tool works with all iQ AiMTM power
supplies and allows the user to easily perform field firmware
updates, product setup, parameter configuration and system
diagnostics along with other functions.
USB PORT CONNECTOR
To install iQ CommanderTM
1. Download the installation file from (http://update.
dukane.com/) and save to the desired location on the
PC.
2. Double-click on the installation file.
3. Once prompted, click on “Next >” on the “Welcome to
the InstallShield Wizard for iQ Commander” page. The
executable will start the installation process.
4. When the progress bar is nearly full, a new window
will appear asking to install the FTDI CDM Drivers.
This window may appear behind the iQ CommanderTM
installation window. If the FTDI CDM Driver window
is not visible, move the iQ CommanderTM installation
window to the side to see the FTDI CDM Drivers
installation window.
5. On the FTDI CDM Drivers installation window,
click on “Extract”, “Next >”, accept the agreement,
“Next >”, and then “Finish” to install the first set of
FTDI drivers.
6. Another window will pop up asking to install another
set of FTDI CDM Drivers. Repeat step 5 to install the
second set of drivers.
7. Once the drivers are installed, Click on “Finish” to
complete the process. The user can connect a USB
cable from the PC to the AiM generator and start the
program.
Figure 3-6 J3 USB Port Connector
Operations that can be done via iQ CommanderTM
1. Update the iQ AiM generator firmware.
2. Test the ultrasonic stack.
3. Scan an ultrasonic stack to determine the optimal Free
Run Frequency.
4. Weld a part.
5. Select a probe when an MPC module is connected.
Dukane Manual Part Number 403-611-00
Page
23
iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Control parameters available via iQ
CommanderTM
1. Set weld method to Time, Energy, Peak Power, Distance,
or Position and the associated value in seconds, joules,
watts, or millimeters.
2. Configure custom I/O.
3. Set Amplitude, Ramp Up Time, and Ramp Down Time.
4. Enable and set Trigger by Power parameters.
5. Enable and set Hold Time.
6. Enable and set Afterburst delay and duration.
7. Enable checking for Suspect Parts. Set maximum and
minimum values for Time, Power, Energy, Distance,
and/or Position.
8. Enable checking for Bad Parts. Set maximum and
minimum values for Time, Power, Energy, Distance
and/or Position.
9. Configure advanced hardware settings including, Free
Run Frequency, Frequency Tracking, Frequency Lock
and Hold, and Frequency Limits.
Parameters that can be obtained via iQ
CommanderTM
1. All parameters that are configured via iQ CommanderTM.
2. Real time data which includes welder state (ultrasound
active or not), frequency, power, position, and
amplitude.
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 Position.
Page
24
Dukane Manual Part Number 403-611-00
Section 4 – Standard System Status and Controls
SECTION 4
Standard System Status
and Controls
Status LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Multi-Point (MPC) Interface . . . . . . . . . . . . . . . . . . . 29
iQLinQ™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Control Parameters Available via iQLinQ™ . . . . . . . . . . . . . . . . . . . . 31
Control Parameters Available via Ethernet/IP . . . . . . . . . . . . . . . . . . 31
Dukane Manual Part Number 403-611-00
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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
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Page
26
Dukane Manual Part Number 403-611-00
Section 4 – Standard System Status and Controls
Status LED
The Status LED provide operating status for system
power, the system operating mode and system output
status as described below:
Status LED
STEADY GREEN = Generator is Ready to weld
BLINKING GREEN = Generator is Not Ready but
there isn’t a fault. This can occur during power
up while the DC BUS is charging or if an MPC
module is connected and it isn’t ready.
ORANGE = In cycle or ultrasound active.
STEADY YELLOW = Indicates the unit is E-Stopped
BLINKING YELLOW = This could indicate an
incorrect AC line voltage connected to the
generator. To operate, the generator needs AC
line voltage to be within this range: For “a 240V”
model a minimum 190 VAC; maximum 265 VAC.
For a “U” model a minimum 90VAC; maximum
265VAC. If this range is not maintained, a line
voltage fault will inhibit system operation, and
the Status LED will blink yellow. If the AC
Line voltage is within the valid range, and the
fault cannot be cleared by cycling power to the
generator, it should be returned for service.
STEADY RED = Average Overload Fault. The
output power has exceeded the rated power
of the generator model. This fault inhibits the
ultrasound output when it occurs, but will
automatically reset when the next ultrasound
activation signal begins.
BLINKING RED = Peak Overload Fault. The generators output current has exceeded it’s safe operating
level and has terminated the ultrasound output.
Will automatically reset when the next ultrasound
activation signal begins.
STEADY BLUE = Frequency Overload Fault 1. The
generator was unable to find the stacks frequency
by twice the time of the Ramp Up setting. This
fault inhibits the ultrasound output when it occurs, but will automatically reset when the next
ultrasoun activation signal begins.
Continued
Dukane Manual Part Number 403-611-00
Page
27
iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Continued from Previous Page
BLINKING BLUE = Frequency Overload Fault
3. There was excessive operating frequency
drift due to heating of the stack. The operating
frequency is “far” away from the Free Running
Frequency. This fault inhibits the ultrasound
output when it occurs, but will automatically
reset when the next ultrasound activation signal
begins.
STEADY PURPLE = Invalid Auto in. This can occur
if the ultrasound activate or cycle start input is
held after a cycle has finished or if a cycle start
signal has too much bounce.
BLINKING PURPLE = Cycle Start Reject. This
occurs when the ultrasound activate or cycle
start are given when a setup is invalid. (example:
Weld Time set to 0.000s) or the generator is not
ready.
Status LED
BLINKING PURPLE TO GREEN = Invalid MPC
Probe selection. This occurs when an invalid
probe is selected on an MPC (example: Probe
5 is selected on a 4-Probe MPC). This fault will
force the generator out of ready.]
STEADY WHITE = Indicates an Over Temperature Fault has occured. If an over temperature
condition is the cause of the fault, the fault
condition will automatically reset when the
system cools.
BLINKING YELLOW TO RED = Hardware Fault.
When this fault occurs the generator needs to be
sent to Dukane for repair.
Some system fault conditions will reset automatically. Most other system fault conditions will not
reset. In those cases the generator needs servicing.
Page
28
Figure 4-1 Status LED
NOTE
A welding cycle cannot be started when the
generator is in E-Stop because this blocks
the ultrasound output.
Dukane Manual Part Number 403-611-00
Section 4 – Standard System Status and Controls
Multi- Point Control (MPC)
Interface
The MPC Interface connector powers and controls an
external MPC 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 a basic generator for a fully functional MPC
system.
Connections required for the external MPC module are
described below.
In addition to completing these first four steps, complete the two steps below to wire the MPC Control
Inputs/Status Outputs as described.
Details about the various system connectors and their
pin assignments are covered below.
•
MPC I/O - MPC control/input signals and status
output signals are carried in the I/O cable that should
already be connected - See Table 4-II (Page 30)
•
MPC INTERFACE - Attach one end of the MPC
Interface cable (Dukane # 200-1408-XX) to the
MPC connector on the iQ generator panel in Figure
4-2. Connect the other end of the cable to the MPC
INTERFACE connector on the right rear of the MPC
module.
MPC Interface Connections
Complete the steps for the basic connections as described
on Pages 10-11. These involve:
• Grounding
• Ultrasound Output
• System Control Status Inputs/Outputs
• AC Line Input
NOTE
The MPC Interface cable is a separate line
item on the iQ generator system order. The
-XX at the end of the cable number specifies
cable length. This will vary depending on
your MPC installation.
AC BREAKER
SYSTEM I/O
OPTIONS SLOT
MPC
PE
See NOTE on the
MPC cable above.
EtherNet/IP Modbus TCP/IP
USB
AC POWER ENTRY
ULTRASOUND
Figure 4-2 Generator Bottom View (Vertical Panel Mount Chassis)
Continued
Dukane Manual Part Number 403-611-00
Page
29
iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Continued from Previous Page
MPC I/O Connections
Signal names and Pin numbers and the connectors related to the MPC option are shown in the table below.
See the pages referred to in the table for more information about the signals.
Pin
Signal Name
Connector
5
Setup Bit 0 Input
6
Setup Bit 1 Input
7
Setup Bit 2 Input
8
Setup Bit 3 Input
25
MPC Ready Out
J5 (Pages 17 -19)
J5 (Page 17 - 19)
Table 4 - I MPC I/O Connector Signals
NOTE
MPC Probe Control
When the optional MPC module and MPC I/O 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.
MPC I/O
3
2
1
0
Probe
Selected
Off
Off
Off
Off
1
Off
Off
Off
On
2
Off
Off
On
Off
3
Off
Off
On
On
4
Off
On
Off
Off
5
Off
On
Off
On
6
Off
On
On
Off
7
Off
On
On
On
8
On
Off
Off
Off
9
On
Off
Off
On
10
On
Off
On
Off
11
On
Off
On
On
12
On
On
Off
Off
13
On
On
Off
On
14
On
On
On
Off
15
On
On
On
On
16
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. 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.
Table 4 - II MPC Setup Bit Inputs
Page
30
Dukane Manual Part Number 403-611-00
Section 4 – Standard System Status and Controls
™
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 Dukane iQ AiM™ generators include 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 Ethernet/IP
1. All parameters that are configured via EtherNet/IP.
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
The iQLinQ™ allows the iQ generator to connect to an
industrial network.
Signing a non-disclosure agreement is required to obtain this
documentation.
**OPTIONAL ANYBUS MODULE
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.
ETHERNET/IP MODBUS TCP/IP
iQ LinQ™
For information on how to control and/or monitor specific parameters, iQ Generator iQLinQ™ Communication and Control
documentation is available.
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.
Figure 4-3
NS:
7. Enable checking for Bad Parts. Set maximum and
minimum values for Time, Power, Energy, Distance,
and/or Position.
EtherNet/IP™ Communications Module
8. Configure advanced hardware settings including Frequency Tracking, Free Run Frequency, Frequency Lock
and Hold, and Frequency limits.
Dukane Manual Part Number 403-611-00
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Dukane Manual Part Number 403-611-00
Section 5 - Contacting Dukane
SECTION 5
Contacting Dukane
Dukane Manual Part Number 403-611-00
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Dukane Manual Part Number 403-611-00
Section 5 - 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/error indicators from the Status LED and/or iQ
Commander.
• Software version (Displayed in the “MAIN” tab in iQ
Commander.
•
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 2900 Dukane Drive
St. Charles, IL 60174 USA
Phone:
(630) 797–4900
Fax:
Main
(630) 797–4949
Service & Parts
(630) 584–0796
E-mail:
[email protected]
Website
The website has information about our products,
processes, solutions, and technical data. Downloads are
available for many kinds of literature. This is our main
web address:
www.dukane.com
You can locate your local representative at:
www.dukane.com/contact-us/
Dukane Manual Part Number 403-611-00
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Dukane Manual Part Number 403-611-00
Section 6 - Specifications
SECTION 6
Specifications
Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Operating Environment . . . . . . . . . . . . . . . . . . . . . . 40
AC Power Requirements . . . . . . . . . . . . . . . . . . . . . 41
Interpreting the Model Number . . . . . . . . . . . . . . . 42
Regulatory Agency Compliance . . . . . . . . . . . . . . 43
Dukane Manual Part Number 403-611-00
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Dukane Manual Part Number 403-611-00
Section 6 - Specifications
10.58
[268.7]
CONNECTIONS:
4.05
[102.8]
17.00
[431.7]
USB
1.17
[29.7]
18.50
[469.9]
EtherNet/IP Modbus TCP/IP
MPC
OPTIONS SLOT
SYSTEM I/O
ALLOW MIN. 6 INCHES [150 MM]
FOR CABLE CLEARANCE
ULTRASOUND
2.88
[73.0]
3.98
[101.1]
5.21
[132.3]
4X
.22 [ 5.6] SLOTS
.53
[13.3]
18.00
[457.2]
STATUS
LED
UNIT WEIGHT: 27 lb. [12 kg]
39
Page
Dukane Manual Part Number 403-611-00
ALLOW MIN.
5 INCHES
[125 MM]
FOR COOLING
ALLOW MIN.
5 INCHES
[125 MM]
FOR COOLING
AC BREAKER
PE
AC POWER ENTRY
Figure 6-1 Vertical 2600 watt and below Generator Drawing
iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Operating Environment
Operate the generator within these guidelines:
Temperature:
40°F to 100°F (+4°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
Storage guidelines (generator is not operating):
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
Page
40
Dukane Manual Part Number 403-611-00
Section 6 - Specifications
AC Power Requirements
35kHz
35kHz
30kHz
30kHz
25kHz
25kHz
20kHz
20kHz
20kHz
20kHz
20kHz
15kHz
15kHz
Operating
Frequency
40HB060-UP-XX
35HB120-UP-XX
35HB120-UP-XX
30HB120-UP-XX
30HB090-UP-XX
25HB120-UP-XX
25HB200-2P-XX
20HB500-4P-XX
20HB360-4P-XX
20HB260-2P-XX
20HB180-2P-XX
20HB120-UP-XX
15HB500-4P-XX
15HB360-4P-XX
Generator
Model Number
900
600
1200
900
1200
900
1200
2000
5000
3600
2600
1800
1200
5000
3600
Overload
Power
Ratings
100-240V 50/60 Hz @ 15 Amps
100-240V 50/60 Hz @ 15 Amps
100-240V 50/60 Hz @ 15 Amps
100-240V 50/60 Hz @ 15 Amps
100-240V 50/60 Hz @15 Amps
100-240V 50/60 Hz @ 15 Amps
100-240V 50/60 Hz @ 15 Amps
100-240V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 15 Amps
380-480V 50/60 Hz @ 15 Amps*
380-480V 50/60 Hz @ 10 Amps*
200-240V 50/60 Hz @ 15 Amps
200-240V 50/60 Hz @ 12 Amps
100-240V 50/60 Hz @ 15 Amps
380-480V 50/60 Hz @ 15 Amps*
380-480V 50/60 Hz @ 10 Amps*
Input AC Power Requirements
Nominal AC Volt
@ Maximum RMS Current
(3 Phase)
30 Amps
(3 Phase)
30 Amps
North America/
Japan
AC Outlet Rating
(Nominal)
5A
(Nominal)
5A
15 Amps
1.5 - 3 A
0.75 - 2.5 A
1300 VAC
700 - 1300 VAC
(Nominal)
(Nominal)
(Nominal)
(Nominal)
Output
Voltage
(Max)
40kHz
40HB090-UP-XX
1200
Table 6- II
Generator AC Power Requirements
NOTES:
An X used above in the Model Numbers is a “wildcard” character meaning any valid
character code combination.
Maximum line current requirement is specified at the minimum nominal AC line voltage
and the rated power level.
**If the input line voltage is less than 100V, the output current will exceed 15 Amps.
Do not operate machine at
voltages lower than 100V.
Current will exceed rating
causing a shock hazard.
WARNING
* For 480 VAC generators, the 24V power supply that connected to power source (24V) shall be listed or labeled with 3rd party
North America marking (UL, CSA, TUV, etc.).
(Watts)
40kHz
40HB120-UP-XX
15 Amps
40kHz
Generator
The AC line voltage and current needed depend on whichever generator has been chosen for your system. See the table below.
41
Output
Current
(Max)
Page
Dukane Manual Part Number 403-611-00
iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
20
Nominal U/S Frequency
15 = 15kHz
20 = 20kHz
25 = 20kHz
30 = 30kHz
35 = 35kHz
40 = 40kHz
HB
Chassis Style
P-
Interpreting the Model Number
2
System Process Control
C3
Options Slot Board
Probe Status Options
P = AiM™ Blank Front Panel w/ iQLinQ™
AC Line Input
120 Power Level
200 = 20000 Watts
360 = 3600 Watts
260 = 2600 Watts
180 = 1800 Watts
120 = 1200 Watts
090 = 900 Watts
060 = 600 Watts
HB = Horizontal Bench Chassis
VB = Vertical Panel Mount Chassis
4 = 480V Three-Phase Extended Chassis
U = 100-240V Universal voltage input for
1200W and below only
2 = 200-240V for 1800, 2000, 2600
Blank = Ethernet/IP or Modbus TCP/IP
C1 = iQLinQ™ PROFIBUS INTERFACE Module
C3 = iQLinQ™ PROFINET INTERFACE Module
C4 = iQLinQ™ CC-LINK INTERFACE Module
C5 = iQLinQ™ POWERLINK INTERFACE Module
C6 = iQLinQ™ EtherCAT INTERFACE Module
Dukane Manual Part Number 403-611-00
42
Page
The example model number shown here is
20HB120-2P-C3
This means:
A 20kHz generator, rated for 1,200 watts,
horizontal bench, operating on a 200-240 VAC
line, with an ANYBUS PROFINET module in the
options slot.
Figure 6-2 Interpreting the Model Number
Section 6 - 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 2014/30/EU
for Heavy Industrial —
EN 61000-6-4
EN 55011
EN 61000-6-2
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 2014/35/EU.
UL
The iQ generator complies with these standards:
Underwriters Laboratories:
UL 61010-1, and
National Standards of Canada:
CAN/CSA C22.2 No. 61010-1-12
as verified by TÜV Rheinland.
• The Machinery Directive 2006/42/EC.
EN 60204: Safety of Machinery - Electrical
Equipment of Machines Part 1: General Requirements.
•
EN ISO 12100: Safety of Machinery - General principles of design, risk assessment, and risk reduction.
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 Number 403-611-00
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.
Page
43
iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
This page intentionally left blank
Page
44
Dukane Manual Part Number 403-611-00
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.
www.dukane.com
iQ Series, AiM™
Part No. 403-611-00
Printed in the United States of America
Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 - 4900
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