Dukane AiM iQ Series Owner'S Manual Download Page 1

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Dukane Part No. 403-610-02

Series

AUTOMATION IN MIND

ULTRASONIC POWER SUPPLY

AiM

™

Color Front Panel

Dukane IAS • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900

Dukane products are manufactured in

ISO registered facilities

www.dukane.com

AUTOMATED HAND PROBE

PRESS

Summary of Contents for AiM iQ Series

Page 1: ...OMATION IN MIND ULTRASONIC POWER SUPPLY AiM Color Front Panel Dukane IAS 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 Dukane products are manufactured in ISO registered facilities www dukane com AUTOMATED HAND PROBE PRESS ...

Page 2: ...ansmitted 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 liabil...

Page 3: ... 9 Added No Cords pictures on Pg 10 Added DC Power Information page on Pg 10 Added 380 480V AC Line Wiring Information page on Pg 11 Added Descriptions to J5 Pins 14 and 15 on Pg 20 Added MPC E note and link to Pg 38 Added additional outline drawings on Pgs 53 55 Revised AC Power Requirements table on Pg 54 Revised Model Number chart on Pg 55 Revised Regulatory Agency Compliance on Pg 56 02 Added ...

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Page 5: ...ew 17 AC Power Inlet Panel 17 System Inputs Outputs Connector 18 Ultrasound Output Connector 23 Ethernet IP Port Connector 24 USB Port Connector 24 iQ CommanderTM 25 Section 4 Standard System Status and Controls 27 Front Panel Controls 29 Screen Basics 32 Multi Point Control MPC Interface 38 iQLinQTM 40 System Verification Tests 41 Section 5 Contacting Dukane 45 Section 6 Specifications 49 Generat...

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Page 7: ...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 Short Circuit Current Rating 6 ...

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Page 9: ...nts 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 per tains to a condition or practice an electrical safety issue or a operator protection issue Drawings and Tables The figures and tables are identified by the section num ber followed by a sequence number The sequence...

Page 10: ...ized by the ultrasound signal it presents a potential hazard Stay clear of an energized stack System E STOP Abort Switch Install a system E STOP abort switch at each operator station when ultra sonic plastic assembly equipment is used with automatic material handling equipment in an automated system NOTE These recommendations apply to the weld ing system System in this manual refers to a complete ...

Page 11: ...h 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 theAC power line from enter ing the gen...

Page 12: ...e 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 If there is any question about the grounding of your recep tacle have it checked by a qualified electrician Do not cut off the power cord ground ing prong or alter the pl...

Page 13: ...0 02 SECTION 2 Installation Connecting Cables 9 AC Power 9 DC Power 10 Wiring Information for 380 480 VAC 3 Phase Lines 11 Automation Controlled Probe System 12 RFI Groundings 13 Proper Handling of Cable Slack 13 Coil Extra Slack 13 Avoid Excessive Bending 13 ...

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Page 15: ...00W use permanently at tached power cords Table 2 I Standard IEC AC Power Cord Part Numbers Continent of Use Power Cord Part Number Power North America 200 1109 120V 15A 200 1110 240V 15A Continental Europe 200 1111 240V 16A The power cord is equipped with a three prong ground ed type plug for your safety Whenever a two slot re ceptacle is encountered we strongly recommend that it is replaced with...

Page 16: ... The cable is then inserted into the connector and the cap is screwed back onto the connector to secure the cable firmly Leave enough cable on the back side of the cable connector to insert the cable wires into the AC input terminals shown in Figure 2 4 380 480 VAC 3 Phase Line Wiring Information is found on Page 11 DC Power Some generators such as 3 phase 480 VAC versions have a separate 24 VDC 3...

Page 17: ...the Dukane website at https documents dukane com AppNote AN524 pdf Wiring from a 3 Phase Circuit WYE 3 Phase 380 480 Volt connections should be wired as shown below Figure 2 6 Wiring a 3 Phase 380 480 Volt Circuit WYE Wiring from a 3 Phase Circuit Delta 3 Phase 380 480 Volt connections should be wired as shown below Figure 2 7 Wiring a 3 Phase 380 480 Volt Circuit Delta ...

Page 18: ...obe 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 8 4 Attach the high voltage coaxial cable from the probe to the ultrasound output connector J1 C in Figure 2 8 5 Connect the AC power cord to the generator I...

Page 19: ...ing 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 ground ing stud PE connection to the nearest grounded metal pipe or equivalent earth ground and secure it with a ground clamp See Figure 2 8 on Pa...

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Page 21: ...l Layout Overview 17 AC Power Inlet Panel 17 Chassis Grounding Stud 17 IEC AC Power Inlet Connector 18 Power Switch Circuit Breaker 18 System Inputs Outputs Connector 18 System Inputs Outputs Signal Descriptions 19 Ultrasound Output Connector 23 EtherNet IP Port Connector 24 USB Port Connector 24 iQ CommanderTM 25 ...

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Page 23: ...rd AC power inlet panel is described in this section Figure 3 1 Generator Bottom Panel G ETHERNET IP MODBUS TCP IP F USB E ULTRASOUND A AC POWER ENTRY C PE B AC BREAKER H MPC I ANYBUS OPTIONS SLOT D SYSTEM I O A IEC Power Inlet Connector Attaches to an IEC stylepower cord B Power Switch Circuit Breaker Used to switch sys tem power ON and OFF C Chassis Grounding Stud Chassis connection for a protec...

Page 24: ... diagrams of example applications The SYSTEM INPUTS OUTPUTS connector J5 as shown in Figure 3 2 is a HD 26F high density D sub miniature 26 circuit female connector Table 3 I on page 22 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 IEC AC Po...

Page 25: ...ble input that defaults to 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 a programmable input that defaults to an input control signal that when en...

Page 26: ...d conditions have been detected Pin 13 Isolated Ultrasound Common Pin 13 is the common connection for Pin 12 Ultrasound Activation Cycle Start Input Pin 13 is electrically iso lated 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 isola...

Page 27: ...tput 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 deter mines that the next welding cycle cannot be started This includes system faults or E STOP active but not a process fault like Overload Pin 25 MPC Ready Status Output Pin 25 is a pr...

Page 28: ...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 IS...

Page 29: ...superior shield ing 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 highAC voltage At high power levels this can exceed 4...

Page 30: ...ls Refer to section 4 for additional iQLinQ information USB Port Connector J3 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 Fig...

Page 31: ...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 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 6 ...

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Page 33: ...reen Basics 32 Making Selections 32 Interpreting On Screen Arrows 32 System Power Output Level 33 Setup Identification 34 Alarms 37 Multi Point Control MPC Interface 38 iQLinQ 40 Control Parameters Available via iQLinQ 40 Parameters that can be obtained via iQLinQ 40 System Verification Tests 41 Preliminary Setup 41 Testing the Generator 41 System Test 42 Probe Operation 43 Stopping the Ultrasound...

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Page 35: ...screen basics are introduced Making selections Interpreting on screen arrows Taking a look at setup identification NOTE Do not touch the display Touch only the keys that are on the front panel Cleaning If the display is dirty clean it by first putting a mild cleaning solution on a clean soft cloth Then gently wipe the cloth over the screen System Operating Mode Keys 3 Navigation Keys 4 ENTER Key C...

Page 36: ...e air This provides reference information throughout the life cycle of each stack This information can be used for comparison when troubleshooting wear and mating surface fatigue The Test History feature has the option of saving the test results for future reference If the displayed power is significantly higher than normal make sure the stack is properly assembled and not damaged OFFLINE After AC...

Page 37: ...gation keys or to scroll through menu lists Also use the keys to move to different levels of the list ENTER Key Press ENTER to confirm and store a selection in memory Example After entering a time value press ENTER CANCEL Key Press the CANCEL key to stop editing a value without saving changes to the value or to leave secondary menu screens INFO Key Press the INFO key and the menu shown to the righ...

Page 38: ...rpreting On Screen Arrows Arrows pointing up and down give visual cues that more text is available in the direction the arrow points An example is shown below in Figure 4 7 For this screen the and up or down navigation keys are used to move in the direction of the on screen arrow Screen Basics Figure 4 7 Arrows Indicate Direction of More Text Figure 4 6 Making Selections Cursor shows selected digi...

Page 39: ...raph is lit and the generator is operating at 100 power At 50 amplitude the entire graph is lit and the generator is operating at 50 power If the amplitude setting is lowered the graph rescales automatically according to the revised amplitude Example With a 1200W generator at 50 amplitude if the whole graph is lit that represents 600W System Power Output Level Bar Graph Figure 4 8 Display Detail P...

Page 40: ...icates a good part yellow a suspect part and blue a bad part PLC CONNECTION PLC indicates if a PLC is con nected Green means a PLC is connected to the genera tor Otherwise PLC is gray AMPLITUDE CONTROL R indicates how the ampli tude is controlled If it is gray the generator controls the amplitude green means amplitude is controlled by the analog input and if OTF is displayed a PLC controls amplitu...

Page 41: ...rk administrator if you do not know whether to enable or disable DHCP 2 IP ADDRESS This Internet Protocol address is a number unique to a piece of equipment acting as an identifier when the equipment is connected to a network This field is editable when DHCP is disabled You may need to contact your network administrator if you do not know what address to use 3 NETWORK MASK defines the subset of th...

Page 42: ...rt No 403 610 02 Continued from Previous Page Restore Factory Defaults Restore Factory Defaults Deletes all setups and restores all parameters to factory defaults An intermediate display allows for confirmation When confirmed factory defaults are restored Figure 4 11 Miscellaneous Sub menu Items ...

Page 43: ...d output U108 Average Overload Fault The output power has exceeded the rated power of the generator model U110 Power not OK Fault There is a problem with the AC line voltage U111 Over Temperature Fault Generator has exceeded its safe operating temperature limit U112 Frequency Overload Fault 3 There was excessive operating frequency drift due to heating of the stack The operating frequency is far a...

Page 44: ... 4 I on Page 32 for further information MPC INTERFACE Attach one end of the MPC Inter face cable Dukane 200 1408 XX to the MPC con nector 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 Continued MPC INTERFACE CONNECTOR Figure 4 2 J2 MPC Interface Connector NOTE The MPC Interface cable is a separate line ...

Page 45: ...or The ultrasound output connector used with all standard generators is a high voltage 5000V coaxial style SHV BNC connector This connector provides superior shield ing 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 mechani...

Page 46: ...ated values in seconds joules watts or millimeters inches 2 SetAmplitude 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 max...

Page 47: ...ode key B The display shows OFFLINE in the upper right hand corner and the screen background will change to yel low b Press the TEST key C The ultrasound should not activate and the Alarm ID 308 will be displayed c Press the ONLINE key D The display shows ONLINE in the upper right hand corner and the screen background will change back to white d Press the TEST key C Ultrasound should acti vate and...

Page 48: ...sation in your hand This is normal There should not be any loud or unusual noise 4 Navigate to the Real Time Data screen 5 Press and hold the TEST key A in Figure 4 18 6 The first segment LED of the SYSTEM POWER OUTPUT LEVEL bar graph B in Figure 4 19 turns red The probe will operate as long as the TEST key is pressed 7 When the TEST key is released the SYSTEM POW ER OUTPUT LEVEL bar graph turns o...

Page 49: ... welding cycle 3 Hand Probe The programmed welding time or energy will be processed and then the ultrasound will be shut off Automation System The programmed weld time energy peak power or distance will be processed and then the ultrasound will shut off NOTE Neither a hand probe or an automa tion system can trigger the generator to produce an ultrasound output if the generator is OFFLINE Press the...

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Page 51: ...Page 45 Section 5 Contacting Dukane Dukane Manual Part No 403 610 02 SECTION 5 Contacting Dukane ...

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Page 53: ... 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 E mail ussales dukane com Fax Main 630 797 4949 Service Parts 630 584 0796 Website The website has information about our products...

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Page 55: ...on 6 Specifications Dukane Manual Part No 403 610 02 SECTION 6 Specifications Generator Drawings 51 Operating Environment 56 AC Power Requirements 57 Interpreting the Model Number 58 Regulatory Agency Compliance 59 ...

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Page 57: ...7 4 11 23 285 3 4 00 101 5 5 59 142 0 5 21 132 3 SYSTEM I O OPTIONS SLOT MPC EtherNet IP Modbus USB AC BREAKER AC POWER ENTRY ULTRASOUND DISPLAY ALLOW MIN 5 INCHES 125 MM FOR COOLING ALLOW MIN 5 INCHES 125 MM FOR COOLING ALLOW MIN 6 INCHES 150 MM FOR CABLE CLEARANCE PE Figure 6 1 Horizontal 2600 watts and below Generator Drawing ...

Page 58: ...SLOTS AC POWER ENTRY AC BREAKER CONNECTIONS ALLOW MIN 5 INCHES 125 MM FOR COOLING ALLOW MIN 5 INCHES 125 MM FOR COOLING ULTRASOUND UNIT WEIGHT 27 lb 12 kg ALLOW MIN 6 INCHES 150 MM FOR CABLE CLEARANCE PE 4 05 102 8 10 58 268 7 1 17 29 7 53 13 3 5 21 132 3 USB EtherNet IP Modbus MPC OPTIONS SLOT SYSTEM I O KEYPAD DISPLAY Figure 6 2 Vertical 2600 watts and below Generator Drawing ...

Page 59: ...Page 53 Section 6 Specifications Dukane Manual Part No 403 610 02 Figure 6 3 Horizontal Vertical 3600 watt Single Phase Generator Drawing 400 2561 ...

Page 60: ...Page 54 iQ Series AiM Automation in Mind Ultrasonic Power Supply User s Manual Dukane Manual Part No 403 610 02 Figure 6 4 Vertical 3600 and 5000 watt Single Phase Generator Drawing 400 2514 ...

Page 61: ...Page 55 Section 6 Specifications Dukane Manual Part No 403 610 02 Figure 6 5 Horizontal Vertical 5000 watt Single Phase Generator Drawing 400 2558 ...

Page 62: ...re 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 63: ...0A or 30A 1300 3 0 20kHz 20XX500 2R XX 5000 200 240V 50 60 Hz 26 Amps 30A 1100 5 0 20kHz 20XX120 UR XX 1200 100 240V 50 60 Hz 15 Amp 15A 1300 1 0 20kHz 20XX180 2R XX 1800 200 240V 50 60 Hz 10 Amps 15A 1300 1 5 20kHz 20XX260 2R XX 2600 200 240V 50 60 Hz 15 Amps 15A 1300 2 2 25kHz 25XX120 UR XX 1200 100 240V 50 60 Hz 15 Amps 15A 1000 1 3 25kHz 25XX200 2R XX 2000 200 240V 50 60 Hz 11 Amps 15A 1000 2 ...

Page 64: ...Page 58 iQ Series AiM Automation in Mind Ultrasonic Power Supply User s Manual Dukane Manual Part No 403 610 02 Figure 6 3 Interpreting the Model Number ...

Page 65: ... Europeéne European Conformity The equipment complies with the following CE requirements T h e E M C D i r e c t i v e 2 0 1 4 3 0 E U 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 The Machinery Directive 2006 42 EC EN 60204 Safety of Machinery Electrical Equipment of...

Page 66: ...tablish a minimum re quirement for these requirements and starts transitioning the company from a traditional inspection oriented quality system to one based on partnership for continuous improve ment This concept is key in that Dukane no longer focuses on inspection but on indi vidual processes Dukane s quality management system is based on the following three objectives 1 Customer oriented quali...

Page 67: ...ica www dukane com Please refer to our website at www dukane com contact us to locate your local representative Part No 403 610 01 Dukane IAS 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 iQ Series AiM Color Front Panel ...

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