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- Page 1 AUTOMATION IN MIND ULTRASONIC POWER SUPPLY ™ 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 www.dukane.com ISO registered facilities...
- Page 2 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.
- Page 3 Revision History Revision Revision Number Summary Date - 00 Original release. March 28, 2019 Page iii Dukane Manual Part Number 403-611-00...
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Page 5: Table Of Contents
Section 5 - Contacting Dukane . . . . . . . . . . . . . . . . . . - Page 6 Series Aim Automation in Mind, ™ Ultrasonic Power Supply User’s Manual Page left intentionally blank Page vi Dukane Manual Part Number 403-611-00...
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Page 7: Section 1 - Introduction, Health And Safety
International Power Grounding .......6 Page 1 Dukane Manual Part Number 403-611-00... - Page 8 Series Aim Automation in Mind, ™ Ultrasonic Power Supply User’s Manual Page left intentionally blank Page 2 Dukane Manual Part Number 403-611-00...
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Page 9: General User Information
(e.g. I, II, III). As an example, Figure 3- 2 would be the second illustration in Section 3 while Table 3- I I would be the second table in Section 3. Condition Hearing Electrical or Practice Protection Hazard Page 3 Dukane Manual Part Number 403-611-00... -
Page 10: General Considerations
No Unauthorized Modifications - Do not modify your ducer, booster, horn, and fixture. system in any way unless authorized to do so by Dukane. Unauthorized modifications could cause equipment dam- age and/or injury to the operator. In addition, unauthorized modifications will void equipment warranty. -
Page 11: Plastics Health Notice
Inquiries should be made to the U.S. Department of Labor mm) away from an operating concerning OSHA regulations for a particular plastic prior press/thruster . A vibrating, to processing with Dukane ultrasonic equipment descending horn can cause burns and/or crushing injuries . Electrical Safety The iQ Series generator provides the operating power and power returns. -
Page 12: Domestic Power Grounding
It must be plugged into a grounded receptacle. Do not use a two- wire extension cord with this product. Grounding Contacts Typical Outlet Provided Cable Figure 1-2 International 220/240V Grounding Page 6 Dukane Manual Part Number 403-611-00... -
Page 13: Section 2 - Installation
Proper Handling of Cable Slack . . . . . . . . . . . . . . . 11 Page 7 Dukane Manual Part Number 403-611-00 Dukane Manual Part Number 403-611-00... - Page 14 Series AiM Automation in Mind, ™ Ultrasonic Power Supply User’s Manual This page intentionally left blank Page 8 Dukane Manual Part Number 403-611-00...
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Page 15: Connecting Cables
2600W use permanently at- tached power cords. No Cords Three-Phase Systems - High power Three-Phase genera- tors do not include an AC Line Cord and must be directly wired. Page 9 Dukane Manual Part Number 403-611-00... -
Page 16: Automation Controlled Probe System
J1: 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: in Figure 2-1. Page 10 Dukane Manual Part Number 403-611-00... -
Page 17: Rfi Grounding
Cables shown in the two figures directly should be routed so that there are no abrupt bends in the above are representative samples. If cables, especially near their connectors. cables have slack, coil them rather than fold them. Page 11 Dukane Manual Part Number 403-611-00... - Page 18 Series AiM Automation in Mind, ™ Ultrasonic Power Supply User’s Manual This page intentionally left blank Page 12 Dukane Manual Part Number 403-611-00...
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Page 19: Section 3 - Standard Connections
USB Port Connector . . . . . . . . . . . . . . . . . . . . . . . . . 23 Page 13 Dukane Manual Part Number 403-611-00... - Page 20 Series AiM Automation in Mind, ™ Ultrasonic Power Supply User’s Manual This page intentionally left blank Page 14 Dukane Manual Part Number 403-611-00...
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Page 21: Bottom Panel Layout Overview
Multi-Point Control Connector - Used to connect an System Input/Output Connector – Connections for MPC module. system control input signals and system status output sig- nals. An option module can be installed here. Page 15 Dukane Manual Part Number 403-611-00... -
Page 22: Ac Power Inlet Panel
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... -
Page 23: System Inputs/Outputs Signal Descriptions
Inputs connector, can configure switch closure inputs to operate referenced to generator chassis ground (non-iso- lated), 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. - Page 24 This output will Activation/Cycle Start Input). Pin 13 is electrically isolated be an open circuit when no system fault conditions are from chassis ground. Using isolated sourcing (PNP) Continued Page 18 Dukane Manual Part Number 403-611-00...
- Page 25 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. Page 19 Dukane Manual Part Number 403-611-00...
- Page 26 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...
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Page 27: Ultrasound Output Connector
Do not use your generator if there is any evidence of arcing (black carbon de- posits) on either the ultrasound output connector or the ultrasound cable con- nectors. Page 21 Dukane Manual Part Number 403-611-00... -
Page 28: 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. NOTE Figure 3-5 J9 Ethernet/IP or Modbus TCP/IP Refer to Section 4, Pg . 31, for more Port Connector information. Page 22 Dukane Manual Part Number 403-611-00... -
Page 29: Usb Port Connector
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 Commander . This tool works with all iQ AiM power supplies and allows the user to easily perform field firmware updates, product setup, parameter configuration and system diagnostics along with other functions. - Page 30 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...
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Page 31: Section 4 - Standard System Status And Controls
..... 31 ™ Control Parameters Available via Ethernet/IP ....31 Page 25 Dukane Manual Part Number 403-611-00... - Page 32 Series AiM Automation in Mind, ™ Ultrasonic Power Supply User’s Manual This page intentionally left blank Page 26 Dukane Manual Part Number 403-611-00...
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Page 33: Status Led
Ramp Up setting. This fault inhibits the ultrasound output when it oc- curs, but will automatically reset when the next ultrasoun activation signal begins. Continued Page 27 Dukane Manual Part Number 403-611-00... - Page 34 Figure 4-1 Status LED BLINKING YELLOW TO RED = Hardware Fault. When this fault occurs the generator needs to be sent to Dukane for repair. NOTE A welding cycle cannot be started when the generator is in E-Stop because this blocks Some system fault conditions will reset automati- the ultrasound output.
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Page 35: Multi-Point (Mpc) Inteface
• 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. - Page 36 On On properly assembled ultrasound cables Off Off can result in high voltage arcing and Off On will destroy the ultrasound connectors. On Off On On Table 4 - II MPC Setup Bit Inputs Page 30 Dukane Manual Part Number 403-611-00...
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Page 37: Iqlinq
Factory View Studio ME) Siemens (TIA Portal) and B&R • Weld Distance (Automation Studio) PLC projects. • Weld End Position Contact your local Dukane representative for more For information on how to control and/or monitor specific pa- information about the iQLinQ options. rameters, iQ Generator iQLinQ Communication and Control ™... - Page 38 Series AiM Automation in Mind, ™ Ultrasonic Power Supply User’s Manual This page intentionally left blank Page 32 Dukane Manual Part Number 403-611-00...
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Page 39: Section 5 - Contacting Dukane
Section 5 - Contacting Dukane SECTION 5 Contacting Dukane Page 33 Dukane Manual Part Number 403-611-00... - Page 40 Series AiM Automation in Mind, ™ Ultrasonic Power Supply User’s Manual This page intentionally left blank Page 34 Dukane Manual Part Number 403-611-00...
- Page 41 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.
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Page 43: Section 6 - Specifications
Regulatory Agency Compliance . . . . . . . . . . . . . . . 43 Page 37 Dukane Manual Part Number 403-611-00... - Page 44 Series AiM Automation in Mind, ™ Ultrasonic Power Supply User’s Manual This page intentionally left blank Page 38 Dukane Manual Part Number 403-611-00...
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Page 45: Generator Drawing
Section 6 - Specifications Figure 6-1 Vertical 2600 watt and below Generator Drawing Page 39 Dukane Manual Part Number 403-611-00... -
Page 46: Operating Environment
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... -
Page 47: Ac Power Requirements
Section 6 - Specifications Page 41 Dukane Manual Part Number 403-611-00... -
Page 48: Interpreting The Model Number
Series AiM Automation in Mind, ™ Ultrasonic Power Supply User’s Manual Figure 6-2 Interpreting the Model Number Page 42 Dukane Manual Part Number 403-611-00... -
Page 49: Regulatory Agency Compliance
Commission). or associated cables as The rating is IP2X, in compliance with finger-safe the changes may re- industry standards. sult in violating one or more regulations under which this equipment is manufactured. Page 43 Dukane Manual Part Number 403-611-00... - Page 50 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...
- Page 51 By passing its audit, Dukane can as- based on partnership for continuous improve- sure you that we have in place a well–defined ment. This concept is key in that Dukane no and systematic approach to quality design, longer focuses on inspection, but on individual manufacturing, delivery and service.
- Page 52 .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...