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Section 2 – Health and Safety

Dukane Manual Part No. 403-591-01

SECTION 2

Health and Safety

General Considerations .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 9
Plastics Health Notice   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 10
Electrical Safety   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  . 10

Power Grounding Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Summary of Contents for iQ Auto-Plus 20AT060-U Series

Page 1: ...591 01 Dukane 2900 Dukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 Dukane products are manufactured in ISO registered facilities iQ Series ULTRASONIC GENERATOR POWER SUPPLY Auto Plus User s Manual AUTOMATED PRESS HAND PROBE ...

Page 2: ...ed 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 o...

Page 3: ...tions Temperature note was 100 F on Pg 5 Changed sound caution note on Pg 10 Added MPC E note and link to pg 20 Revised Table 4 I on Pg 32 Added distance and ANYBUS options on Pg 36 Removed Computer Interface section on Pg 36 Added new iQLinQ Protocols on Pg 44 Removed all iQLinQ RS 232 Interface Option and information for S Model on Pg 44 Added iQ Commander download and installation instructions ...

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Page 5: ... 15 Power Grounding 16 Chassis Grounding Stud 16 Connecting Cables 17 MPC Module Installation Guide 22 Section 4 System Operation 25 Introduction 27 iQ Auto Plus System Operational Test 28 iQ Auto Plus System with MPC Module Operational Test 29 LED Indication 31 Section 5 Options 33 Heat Sink 35 Distance Option 36 ANYBUS Option 36 Section 6 Automation Interface 37 Input Output Connection Examples ...

Page 6: ...tion 8 Specifications 51 Generator Outline Drawing 53 Weight Operating Environment 54 AC Power Requirements 55 Interpreting the Model Number 56 iQ Auto to iQ Auto Plus Inputs Outputs Comparison 57 Regulatory Agency Compliance 58 Section 9 Appendices 59 Appendix A List of Figures 60 Appendix B List of Tables 61 Index 62 ...

Page 7: ... Dukane Manual Part No 403 591 01 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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Page 9: ...ions Notes Cautions and Warnings Throughout this manual we use NOTES to provide infor mation that is important for the successful application and understanding of the product A NOTE block is shown to the right 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 increas ing levels of important informatio...

Page 10: ...ator Automatic Tuning tracks the resonant frequency of the acoustic stack horn booster transducer and ad justs the generator output frequency to match it This is done for every weld cycle and eliminates the need to manually tune the generator Line Voltage Regulation automatically maintains constant amplitude regardless of line voltage devia tion The available output power is maintained with any vo...

Page 11: ...t No 403 591 01 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 NOTE Add transducer cooling as necessary to keep front mass temperature to 110 F or less ...

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Page 13: ...Page 7 Section 2 Health and Safety Dukane Manual Part No 403 591 01 SECTION 2 Health and Safety General Considerations 9 Plastics Health Notice 10 Electrical Safety 10 Power Grounding Connection 11 ...

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Page 15: ...ectrical 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 A...

Page 16: ...or 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 f...

Page 17: ...ellow stripe N Neutral White Lt Blue Table 2 I Conventional Wire Color Code L N iQ Auto Plus Power Inlet Pluggable AC Line Connector 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 CAUTION If there is any question about grounding of your equ...

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Page 19: ...ON 3 Installation Unpacking 15 Placement 15 Power Grounding 16 Chassis Grounding Stud 16 Connecting Cables 17 Basic Connections 17 P1 System I O Connector Pinout 18 Multi Probe Control MPC 20 MPC Module Installation Guide 22 Connecting Cables 23 MPC Module Status LEDs 24 ...

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Page 21: ...eat dis sipation mount the generator vertically as shown in Figure 5 1 on page 35 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 Placement Make certain generator placement and cable routing do not interfere with normal operation Maintain easy access to your equ...

Page 22: ...to operate effectively it is necessary to correctly ground the system The power line ground previously mentioned is manda tory Additionally the included grounding wire must be con nected from the grounding PE stud connection see Fig ure 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 environment...

Page 23: ...ble from the ultrasonic probe to J1 the ultrasound output con nector C in Figure 3 2 4 Connect the included ground wire from the grounding stud D in Figure 3 4 to earth ground Figure 3 2 Generator Front View NOTE AC Power Inlet 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 suppliedAC circuit breaker wired t...

Page 24: ...ise this pin must be jumpered to Pin 1 for ultrasound operation to be enabled See Figure 6 5 for E STOP circuit wiring examples Pin 3 Overload Out Pin 3 is an isolated digital NPN PNP status output that activates when an output overload condition is tripped This output will be an open circuit if an output overload condition is not tripped This output will remain latched ON until the U S Activate i...

Page 25: ...rd least significant bit used to select different probe channels when a MPC Interface is used This MPC control bit is used on MPC systems with five or more channels Pin 11 Remote Setup 3 Input Pin 11 represents Setup Bit 3 This is the second most significant bit used to select different probe channels when a MPC Interface is used This MPC control bit is used on MPC systems with nine or more channe...

Page 26: ... be connected See Table 3 II on Page 21 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 NOTE The MPC Interface cable is a separate line item on the iQ generator system order The XX at ...

Page 27: ...asound 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 mechanism The ultr...

Page 28: ... shelf Use the following installation recommendations for a panel mounted MPC module A C C 2 D 0 25 06 35 6 PLCS MPC0404 7 12 1 75 6 75 2 25 181 mm MODEL A B C D 45 mm 171 5 mm 57 2 mm MPC0808 10 88 1 75 10 50 2 25 277 mm 45 mm 266 7 mm 57 2 mm MPC1616 18 25 1 75 18 00 2 25 464 mm 45 mm 457 2 mm 57 2 mm Cut Outs For panel mounted modules Use Figure 3 4 below to determine the size of the cut needed...

Page 29: ...ic generator 3 MPC Interface cable Dukane P N 200 1408 XXM Order the correct cable length for your installation Connect one end of the cable to the right rear MPC Interface connector C in Figure 3 5 The other end of the cable connects to the MPC INTERFACE con nector on the ultrasonic generator Figure 3 6 MPC Module Front Connectors System Frequency Probe P N Cable P N MPC to Probe 20kHz 41Q20RE or...

Page 30: ... would be a generator overload that will automatically reset when the next weld cycle begins or the automation control system is selecting a channel that doesn t exist trying to select channel 10 for an 8 channel system for instance If this LED lights up RED a hardware fault has been sensed and the unit should be returned to Dukane for servicing Probe Selection Status The PROBE SELECTION STATUS LE...

Page 31: ...tion 4 System Operation Dukane Manual Part No 403 591 01 SECTION 4 System Operation Introduction 27 iQ Auto Plus System Operational Test 28 iQ Auto Plus System with MPC Module Operational Test 29 LED Indication 31 ...

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Page 33: ...ay be used as a stand alone generator or with its integrated Multi Point Controller MPC Interface The MPC interface when connected to the Dukane MPC module allows one generator to control up to 16 probes The generator s USB EtherNet and ANYBUS ports extend communication and control functions depending on the specifications of a particular generator model This section deals primarily with basic ope...

Page 34: ...ionally the Any Fault Status Out status output can be monitored on system I O connector Pin 5 This status output signal will activate when power is not OK Optionally the READY output can be monitored This status output signal will activate when the generator is ready to operate 3 After completing Step 2 test ultrasound output by activating system I O connector Pin 13 Normal Condition The system is...

Page 35: ...should light up GREEN The MPC module SYSTEM STATUS LED should light up GREEN The system is ready to operate when all status LEDs light up GREEN 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 STATUS LED Not Green If the status LED is not GREEN refer to Table 4 I for mo...

Page 36: ...s the fault is Overtempera ture or Power Not OK 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 ...

Page 37: ...al Part No 403 591 01 LED Indication There are six LEDs on the iQ Auto Plus generator POWER 1 ETHERNET 2 MOD 1 NET 1 STATUS 1 Figure 4 2 shows LED location and Table 4 I shows their indications Figure 4 2 LED Locations POWER ETHERNET MOD STATUS NET ...

Page 38: ...een Steady Device is Operational Green Blinking Standby Gray Off No power NET Red Steady Duplicate IP Address Not Supported Red Blinking Connection Time Out Green Steady Connection Green Blinking No Connection STATUS Green Steady Ready Yellow Steady E STOP is Active Orange Steady In Cycle Red Steady Overload Average White Steady Over Temperature Purple Steady Invalid Auto In Red Blinking Overload ...

Page 39: ...Page 33 Section 5 Options Dukane Manual Part No 403 591 01 SECTION 5 Options Heat Sink 35 Distance Option 36 ANYBUS Option 36 ...

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Page 41: ... 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 When operating an iQ Auto Plus 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 A i r F l o w CAUTION Operate...

Page 42: ...ustomer supplied encoder per ultrasound channel If more than one channel is needed a Dukane MPC module is required With this option weld by position and distance functionality is available See https documents dukane com AppNote AN528 pdf for more information ANYBUS Option This option is required for iQLinQ communication via mounts Profinet ProfiBus PowerLink EtherCAT or CC Link ...

Page 43: ...ut Output Connection Examples 39 PLC Sourcing PNP Type Output Circuit 39 PLC Sinking NPN Type Output Circuit 40 PLC Sourcing PNP Type Input Circuit 41 PLC Sinking NPN Type Input Circuit 42 Dedicated E Stop Switch Wiring Diagram 43 Automation System Safety Circuit Wiring Diagram 43 iQLinQ 44 iQ Commander 45 ...

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Page 45: ...rrent 10mA typ 24VDC input Remote Setup 0 pin 8 Remote Setup 1 pin 9 Remote Setup2 pin 10 Remote Setup 3 pin 11 Remote Common pin 12 U S Common pin 14 24V Supply PLC Sourcing PNP Output Card OVdc Return OVdc Return 01 234 55 23678 9 01 PNP Type Input Circuit iQ Auto Plus Sinking NPN Input Input Output Connection Examples PLC Sourcing PNP Type Output Circuit ...

Page 46: ...ent 10mA typ 24VDC input iQ Auto Plus Sourcing PNP Input Remote Common pin 12 24V Supply OVdc Return PLC Sinking NPN Output Card Remote Setup 0 pin 8 Remote Setup 1 pin 9 Remote Setup 2 pin 10 Remote Setup 3 pin 11 pin 13 U S Common pin 14 01 234 55 23678 9 01 NPN Type Input Circuit 24V Supply Input Output Connection Examples PLC Sinking NPN Type Output Circuit ...

Page 47: ...t Voltage Range 24VDC 10 Input Current 10mA typ 24VDC input Output Driver PHOTOMOS RELAY Input Output Connection Examples PLC Sourcing PNP Type Input Circuit 24 Volt Supply OVdc Return Output Common pin 7 iQ Auto Plus NPN Sinking Output Ready pin 4 Any Fault pin 5 U S Status pin 6 Overload pin 3 PLC Sourcing PNP Input Card ...

Page 48: ...put Card Output Common pin 7 Ready pin4 AnyFault pin5 U S Status pin6 Overload pin3 01 234 55 23678 9 01 PNP Type Output Circuit 5 5 A B C DE7F Figure 6 4 PLC Sinking NPN Type Input Circuit Input Voltage Range 24VDC 10 Input Current 10mA typ 24VDC input Output Driver PHOTOMOS RELAY Input Output Connection Examples PLC Sinking NPN Type Input Circuit ...

Page 49: ...ety Circuit iQ Auto Enable Out Enable In Dedicated E Stop Switch Wiring Diagram System I O Connector Pin 1 Pin 2 User supplied E stop switch iQ Auto Enable Out Enable In Automation System Safety Circuit Wiring Diagram System I O Connector Pin 1 Pin 2 User automation control hardware Master control relay Relay contact block ...

Page 50: ...y Peak Power Dis tance and or Position Set associated 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...

Page 51: ... 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 Operations that can be done via iQ CommanderTM 1 Update the iQ Auto Plus generator firmware 2 Test the ultrasonic stack 3 Scan an ultrasonic stack to determine the optimal Free Run Frequency 4 W...

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Page 53: ...Section 7 Contacting Dukane Page 47 Dukane Manual Part No 403 591 01 SECTION 7 Contacting Dukane ...

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Page 55: ...on 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 ussales dukane com Fax Main 630 797 4949 Service Parts 630 584 0796 Website The website has information about our products processes solutions and technical data D...

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Page 57: ...art No 403 591 01 SECTION 8 Specifications Generator Outline Drawing 53 Weight 54 Operating Environment 54 AC Power Requirements 55 Interpreting the Model Number 56 iQ Auto to iQ Auto Plus Inputs Outputs Comparison 57 Regulatory Agency Compliance 58 ...

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Page 59: ...Section 8 Specifications Page 53 Dukane Manual Part No 403 591 01 Figure 8 1 Generator Outline Drawing ...

Page 60: ... 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 Weight Standard Model 10 pounds 4 54 kg Shipping Add 5 pounds 2 3 kg to unit weight for...

Page 61: ...ps Max 20kHz 20AT120 2X XX 1200 200 240V 50 60 Hz 15 Amps Max 30kHz 30AT060 UX XX 600 100 240V 50 60 Hz 15 Amps Max 30kHz 30AT120 2X XX 1200 200 240V 50 60 Hz 15 Amps Max 35kHz 35AT060 UX XX 600 100 240V 50 60 Hz 15 Amps Max 35kHz 35AT120 2X XX 1200 200 240V 50 60 Hz 15 Amps Max 40kHz 40AT060 UX XX 600 100 240V 50 60 Hz 15 Amps Max 50kHz 50AT060 UX XX 600 100 240V 50 60 Hz 15 Amps Max 70kHz 70AT01...

Page 62: ...nch Chassis AL Automation Limited Bench Chassis Pow er Level 120 1200 Watts 060 600 Watts 012 120 Watts 0 0 6 U AC Line Input 2 200 240 for AT AP AL and HP 1200W U 100 240V Universal voltage input for AT AP AL and HP 600 W System Process Control F C 5 Options A1 Power Monitor Output M only D1 Analog Distance Input EIP communications only C1 iQLinQ PROFIBUS Interface Module F only C3 iQLinQ PROFINE...

Page 63: ...set at beginning of the next cycle 12 U S Activate Input 13 U S Activate Same function but moved to Pin 13 13 Input Common isolated 14 U S Common isolated Common for U S Activate only Provides higher level of safety MPC I O Connector 1 Setup Bit 0 Input 8 Remote Setup Bit 0 Input Same function but moved to single I O connector 2 Setup Bit 1 Input 9 Remote Setup Bit 1 Input Same function but moved ...

Page 64: ...mité 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 Equipmen...

Page 65: ...Section 9 Appendices Page 59 Dukane Manual Part No 403 591 01 SECTION 9 Appendices Appendix A List of Figures 60 Appendix B List of Tables 61 ...

Page 66: ...C Module Cutout Guide 22 3 5 MPC Module Rear Connectors 23 3 6 MPC Module Front Connectors 23 3 7 MPC Module Status LED s 24 4 1 Generator POWER LED Detail 28 4 2 LED Locations 31 5 1 Generator with Heat Sink Option 35 6 1 PLC Sourcing PNP Type Output Circuit 39 6 2 PLC Sinking NPN Type Output Circuit 40 6 3 PLC Sourcing PNP Type Input Circuit 41 6 4 PLC Sinking NPN Type Input Circuit 42 6 5 E STO...

Page 67: ... Tables No Description Page 3 I P1 System I O Connector Signals 18 3 II SMPC I O Connector Signals 21 3 III System I O Remote Setup Inputs 21 3 IV Probe Cables 23 4 I LED Colors and Indication 32 8 I AC Power Requirements 55 8 II iQ Auto to iQ Auto Plus Inputs Outputs Comparison 57 ...

Page 68: ...gs 3 Read This Manual First 3 Generator Overview Key Features 4 Generator Overview 4 Thermal Considerations 5 H Health and Safety Electrical Safety 10 General Considerations 9 Plastics Health Notice 10 Recommendations 9 Heat Sink 35 I Installation Connecting Cables 17 MPC Interface Connections 20 P1 System I O Connector Pinout 18 MPC Module Installation Guide 22 Placement 15 Placement in a Seismic...

Page 69: ... Pinout 18 R Regulatory Agency Compliance 58 S Specifications AC Power Requirements 55 Interpreting the Model Number 56 iQ Auto to iQ Auto Plus Inputs Outputs Comparison 57 Operating Environment 54 Weight 54 System Operation Introduction 27 iQ Auto Plus System Operational Test 28 LED Indication 31 T Thermal Considerations 5 ...

Page 70: ...ds establish 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 individual processes Dukane s quality management system is based on the following three objectives 1 Customer oriented q...

Page 71: ...ukane Drive St Charles Illinois 60174 USA TEL 630 797 4900 iQ Series Ultrasonic Generator Power Supply Auto Plus User s Manual www dukane com Please refer to our website at www dukane com contact us to locate your local representative ...

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