Dukane 403-574-01 User Manual

Intelligent Assembly Solutions

Series

ULTRASONIC GENERATOR/POWER SUPPLY

AUTOMATED HAND PROBE PRESS

User’s Manual

Dukane Part No. 403-574-01

Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • FAX (630) 797- 4949

Products are manufactured in ISO

ISO 9001:2008

registered facilities.

www.dukane.com/us

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 the manufacturer.

Notice of Liability: The information contained is this manual is distributed on an “As is” basis, without warranty. While every precaution has been taken in the preparation of this manual, the manufacturer 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.

Specications are 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.

Part Number: 403 - 574 - 01

This ultrasonic equipment is manufactured under one or more of

the following U.S. Patents:

3,780,926 3,825,481 4,131,505 4,277,710 5,798,599 5,880,580 6,984,921 7,225,965 7,475,801, and

7,819,158 B2

Page ii

Dukane Manual Part No. 403-574-01

Revision History

Revision Revision Number Summary Date

- 00 Original release. 01/25/2008

- 01 Add High Power models. 09/21/2010 Update system I/O pin descriptions. Add Trigger by Power. Add iQ LinQTM. Web address revised. Revise Regulatory Agency Compliance statement. Health and Safety - Add safe lifting practices. Installation - Add lockout/tagout information and seismic zone information.

Page 25 - Edited to clarify need for external power supply. 11/24/2010

Dukane Manual Part No. 403-574-01

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Dukane Manual Part No. 403-574-01

Contents

Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

General User Information

Read the Manual First

Notes, Cautions and Warnings

Drawings and Tables

Generator Overview Key Generator Features

Section 2 - Health and Safety . . . . . . . . . . . . . . . . . . . . . . 5

General Considerations Plastics Health Notice Electrical Safety Lifting the Equipment

Section 3 - Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Before Installation Unpacking Placement RFI Grounding Connecting Cables Manually Operated Probe System

Power Cords

Automation Controlled Probe System

Section 4 - Standard Connections . . . . . . . . . . . . . . . . . 21

Rear Panel Layout Overview

AC Power Inlet Panel System I/O Panel

Section 5 - Standard System Status and Controls . . . . 35

Front Panel Overview System Displays Control Keys

Start-up Sequence

Stopping the Weld Cycle System Parameter Settings Overview

Dukane Manual Part No. 403-574-01

Continued on next page

Page v

Contents Continued

Section 6 - Process Control Settings . . . . . . . . . . . . . . . . . 45

User-Provided Process Control Overview Manual Welding Automated Welding Automated Process Control Input Signals Status Output Signals Screen Navigation Basics

Programming the Generator - Some Examples

Section 7 - System Operational Testing. . . . . . . . . . . . . . . 55

Section 8 - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 61

No Ultrasonic Output System Power Output Level: Red System Power Diagnostics Procedures Welding Problems Pop-up Status Screens

Section 9 - Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Section 10 - Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Power Inlet Options Electrical Safety AC Power Inlet Panel I/O Panel Options

Multi-Probe Control (MPC) Interface Module

Remote Amplitude Control Module

Automation Thruster Control Module

Isolated I/O Conversion Module

Section 11 - Specications . . . . . . . . . . . . . . . . . . . . . . . . . 93

Section 12 - Contacting Dukane . . . . . . . . . . . . . . . . . . . . 103

Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Page vi

List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Guide to Generator Menu Structure . . . . . . . . . . . . . . 111

Dukane Manual Part No. 403-574-01

Section 1 – Introduction

SECTION 1

Introduction

General User Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Read the Manual First. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Drawings and Tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Generator Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Key Generator Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Dukane Manual Part No. 403-574-01

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iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual

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Dukane Manual Part No. 403-574-01

General User Information

Read the 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

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.

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 an operator protection issue.

Drawings and Tables

The gures and tables are identied by the section number followed by a sequence number. The sequence num-

ber begins with one in each section. The gures and tables are numbered separately. The gures 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.

Section 1 – Introduction

NOTE

Note statements provide additional information or highlight procedures.

CAUTION

Caution statements identify conditions or practices that could result in damage to the equipment or other property.

WARNING

Warn ing st a te men ts point out conditions or practices that could result in personal injury or loss of life.

 

Condition or Practice

Electrical Hazard

Hearing Protection

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iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual

Generator Overview

This generator is designed for basic ultrasonic applications that use either manually operated hand probes or ultrasonic probes controlled by automation systems. Using the available system control inputs and output status signals, it can easily be controlled by automated machines.

The generator design accepts several control input signals, and provides system status output signals.

This product has rugged internal ultrasonic generator circuitry and ensures a continuous resonant frequency lock at the start of each weld.

Users may program the generator setup parameters to meet a wide variety of ultrasonic processing requirements.

The generator’s compact size allows multiple units to be placed into an industrial equipment cabinet. This generator will operate at the same international line voltage input specications as the other generators of this product family (unless the 120V option is installed). It also includes an RFI line lter that passes FCC and strict CE test specications for global applications.

Key Generator Features

Program the Generator with up to 16 setups.

•

Process Parameters such as frequency, amplitude

•

and power are all updated at a .5 ms rate.

Pulse Width Modulation incorporates patented

•

circuitry giving the power supply the ability to

efciently change the output amplitude. This makes

it possible to start large horns with reduced power. It also provides more power-efcient switch-mode generator operation and increased reliability.

Linear Ramp Soft-Start circuitry allows the acoustic

•

stack to be brought to operating amplitude smoothly, minimizing start-up surges and abnormal stress to the stack and generator.

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 deviation. The available output power is maintained with any voltage input within the specied range. This provides consistent system performance regardless of line

voltage uctuations. It also eliminates the need

for bulky, external constant–voltage transformers.

Load Regulation provides constant ultrasound

•

amplitude automatically regardless of power draw. The ultrasonic output amplitude level is held to within ±1% to provide weld process consistency and reduced weld cycle times.

High Line Voltage Power Supply means that

•

standard systems will operate worldwide at the local high line voltage level, whether it is 200VAC @60Hz in Japan, 240VAC @50Hz in Europe or 208VAC @60Hz in the United States. There are no internal transformer taps to change for worldwide operation.

Low Line Voltage Power Supply - This optional

•

120V power supply is designed for North American applications.

Flow Through Cooling Tunnel with a matched

•

high–performance heatsink and thermostatically controlled fan reduces thermal gradients and increases component life.

AC Power Inrush protection reduces electrical

•

stress on the internal components by protecting them from AC power startup transient current surges.

Multiple Electronic Overload protection circuits

•

prevent instantaneous component failure in the event of extreme output overload conditions.The overload power limit is based on the actual true RMS power output level.

Process Limits include: time only, time and en-

•

ergy, and peak power. These programmable limits provide the means to adapt to a wide variety of welding applications.

Control Board Option Modules - The user can

•

select one of the following: Multi-Probe Control, Automation Thruster Control, or Remote Amplitude Control. An isolated I/O Conversion Module is also available as a DIN rail-mounted module.

CE Certication means that the system meets

•

the required European standards to be sold and used in Europe (high line voltage models only).

ISO 9001 Certication means that this system

•

has been manufactured to high quality standards and assures you of manufacturing excellence.

Page 4

Dukane Manual Part No. 403-574-01

Section 2 – Health & Safety

SECTION 2

Health and Safety

General Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Plastics Health Notice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Domestic Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

International Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Lifting the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Dukane Manual Part No. 403-574-01

General Considerations

Please observe these health and safety recommendations for safe, efcient, and injury-free operation of your equipment. In this manual, the term system refers to a complete group of components associated with the welding of plastic or metal parts, also known as an ultrasonic assembly system. A typical system consists of a generator and/or ultrasonic process controller, start and stop switches, power controls, connecting cables, and the probe assembly which includes the transducer, booster, horn and replaceable horn tip.

Proper Installation - Operate system components only after they are properly installed and checked.



Section 2 – Health & Safety

WARNING

Never operate the generator with the cover off. This is an unsafe practice and may cause injury.

No Unauthorized Modications - Do not modify your system in any way unless authorized to do so by the

manufacturer. Unauthorized modications may cause injury to the operator and/or equipment damage. In addition, unauthorized modications will void the equip-

ment warranty.

Keep the Cover On - Do not remove any equipment cover unless specically directed to do so by the manufacturer. The generator produces hazardous electrical

voltages which could cause injury.

Grounded Electrical Power - Operate this equipment only with a properly grounded electrical connection. (See Electrical Safety Grounding Instructions on the next page.)

Comply with Regulations - You may be required to add accessories to bring the system into compliance with applicable OSHA regulations for machine guarding and noise exposure.

Plastics Health Notice

Before using any ultrasonic welding system, be sure you are familiar with OSHA regulations from the U.S. Department of Labor about the particular type of plastic(s) you are using.

CAUTION

Parts being joined ultrasonically sometimes vibrate at audible frequencies. Wear ear protection to reduce annoy ing or uncomfor table sounds. In addition, sound absorbing materials, enclosures or sound

deectors may be installed

to reduce the noise level.

When plastic materials are being processed, they may emit fumes and/or gases that could be hazardous. Make sure you have adequate ventilation whenever these plastics are processed.

Dukane Manual Part No. 403-574-01

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iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual

Grounding Contacts

Typical Outlet

Provided Cable

Electrical Safety

Domestic Power Grounding

For safety, the power cords used on this product have a three-wire, grounding-type power cord. Figure 2-1 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 2 - 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 2- 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.



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

qualied electrician replace it

following the National Electric Code and any local codes and ordinances that apply.

See Figures 2 - 1 and 2 - 2.

CAUTION

If there is any question about the grounding of your receptacle, have it checked by a

qualied 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 two-wire extension cord with this product.

Figure 2 - 2 International 220/240V Grounding

Page 8

NOTE

See Section 10, Options if your system has a non-detachable power cord for 120VAC operation.

Dukane Manual Part No. 403-574-01

Lifting the Equipment

High Prole Low Prole High Power 3600W High Power 4800 W

lb kg lb kg lb kg lb kg

Generator Only

Generator + Packing Materials

Table 2–I iQ Generator Weights

How to Lift Safely

• Before lifting, take a moment to think about what you’re about to do.

• Examine the object for sharp corners, slippery spots

or other potential hazards. Know your limit and don’t try to exceed it.

25 11.3 20 9.1 32 14.5 34 15.4

30 13.6 25 11.3 37 16.7 39 17.7

Section 2 – Health & Safety

• Ask for help if needed, or if possible, divide the load to make it lighter.

• Know where you are going to set the item down, and make sure it and your path are free of obstructions. Then follow these steps:

Step 1. Stand close to the load with your feet

spread apart about shoulder width, with one foot slightly in front of the other for balance.

Step 2. Squat down bending at the knees (not your

waist). Tuck your chin while keeping your back as vertical as possible.

Step 3. Get a rm grasp of the object before be-

ginning the lift. Begin slowly lifting with your LEGS by straightening them. Never twist your body during this step.

Step 4. Once the lift is complete, keep the object

as close to the body as possible. As the load’s center of gravity moves away from the body, there is a dramatic increase in stress to the lumbar region of the back.

CAUTION

Ta k e c a r e i n l i f t i n g t h e e q u i p m e n t . W e recommend using a mechanical lift device to assist.

Step 5. If you must turn while carrying the load,

turn using your feet-not your torso. To

place the object below the level of your

waist, follow the same procedures in reverse order. Remember, keep your back as vertical as possible and bend at the knees.

Dukane Manual Part No. 403-574-01

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Dukane Manual Part No. 403-574-01

Section 3 – Installation

SECTION 3

Installation

Before Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 13

When to Use Lockout/Tagout Devices. . . . . . . . . . . . . . . 13

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

RFI Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Connecting Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Manually Operated Probe System . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Power Cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Automation Controlled Probe System. . . . . . . . . . . . . . . . . . . . . . . . 20

Dukane Manual Part No. 403-574-01

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Dukane Manual Part No. 403-574-01

Before Installation

As you plan for the installation of your generator,

please consider these important subjects as listed

below:

• When to use lockout / tagout devices

• Lifting the generator safely - See Section 2

- Health and Safety, P. 9

When to Use Lockout /

Section 3 – Installation

Tagout Devices

Figure 3-1 Lockout Device In Open Position,

Unlocked

The typical kind of LOTO device for this generator is a clam shell type device (with lockout capability). The LOTO device is placed over the plug end of the generator electrical cord. This effectively prevents access to the energy isolation point. See the example

of one such device in the gure above.



WARNING

Electrical safety hazards exist inside the generator chassis. Before making any internal adjustments to the generator, apply a lockout/tagout (LOTO) device to the generator chassis.

The gure to the right shows the lockout device in the

closed, locked position.

Continued

Dukane Manual Part No. 403-574-01

Figure 3-2 Bottom Lockout Device In

Closed Position, Locked

Page 13

iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual

Lockout/Tagout

Continued from previous page

Procedure to use BEFORE making any internal adjustments to the generator:

1. Push the generator's AC power switch/ breaker to the OFF position.

2. Unplug the generator's electrical cord from its source.

3. Authorized personnel apply a lockout/ tagout (LOTO) device to the plug end of the generator's electrical cord. Using a typical clam shell type LOTO device:

1) Open the clam shell.

2) Place the electrical cord plug end inside the shell.

3) Close the shell.

4) Secure the shell with its lock, and lock it.

4. Wait a minimum of ve minutes for the

generator to discharge its electrical energy.

5. After taking these steps, make the necessary

adjustments to the generator.

Assuming the generator is being put back into service. . .

Procedure to use AFTER making any internal adjustments to the generator:

1. Authorized personnel remove the lockout/

tagout device from the plug end of the generator's electrical cord. Using a typical clam shell type LOTO device:

1) Unlock the protective shell.

2) Open the shell, exposing the electrical cord end.

3) Remove the LOTO device, and set it aside.

2. Plug the generator's electrical cord into its AC power source.

3. Push the generator's AC power switch/breaker to the ON position.

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Dukane Manual Part No. 403-574-01

Unpacking

8060 100400 20

SYSTEM POWER OUTPUT LEVEL

SYSTEM OPERATING MODE

LOAD

OVER

ON LINE

OFF LINE

POWER TEST

OPERATOR

CONTROLS

IN [mm]

3.81

[96.8]

3.45

[87.53]

17.16

[435.86]

OPERATOR

DISPLAY

COOLING AIR

INLET

EXHAUST AIR

OUTLET

Carefully open your shipping container, and make sure it contains the items shown on the shipping documents. Inspect all items, and report any damage immediately.

Section 3 – Installation

Placement

Generator placement and cable routing should permit easy access and not interfere with normal system operation.

Allow at least 5 inches (13 cm) of space on both ends of the generator chassis for air circulation. Allow a 3 inch space (8 cm) at the rear of the chassis for cable clearance.

See Specications, Section 11, for detailed generator drawings.

CAUTION

Allow 5 inches for air ventilation at the cooling air inlet and at the exhaust air outlet. The fan draws in fre sh air

to cool the internal c omponents, reduce thermal gradients and increase component life.

Figure 3 -3 Generator - Front View (low prole model)

Dukane Manual Part No. 403-574-01

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iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual

400-2251

3.82

[97.0]

3.44

[87.3]

3.25

[82.5]

12.57

[319.2]

12.99

[330.0]

ALLOW 5" BOTH SIDES FOR COOLING

ALLOW 3" IN BACK FOR CABLES

IN (mm)

.25 X .50 SLOT (2 PLCS)

18.76

[476.4]

18.16

[461.2]

17.16

[435.8]

OPTIONAL RACK MOUNT BRACKETS 147-4720

11.37

[288.9]

.81

[20.6]

.12

[3.0]

Placing the Generator when Used in an Active Seismic Region

If the iQ generator is to be used in an active seismic region, secure the unit by rack-mounting it or by securing the unit to a benchtop.

Rack- Mounting

Install the four brackets from Dukane's rack-mount kit to the generator. See Table 3-I, and Figure 3- 4 (showing a

low prole unit) below.

Mount the generator to a 19-inch equipment rack.

System Type Dukane Part Number

High Prole 147-4721

Low Prole 147-4720

Table 3- I Rack Mount Bracket Part Numbers

NOTE

Figure 3-4 Rack Mounting iQ Generator

The figure shows how a typical iQ generator is rack mounted. Your generator’s appearance may be different from what is shown here.

Page 16

Dukane Manual Part No. 403-574-01

Benchtop Mounting

12.54

[318.61]

?.280 HOLE

18.04

[458.15]

18.84

[478.47]

OPTIONAL HOLD DOWN BRACKETS

OPTIONAL HOLD DOWN BRACKETS 147-1398

ALLOW 5" BOTH SIDES FOR COOLING.

400-2254 E

(mm)

ALLOW 3" IN BACK FOR CABLING.

5.50

[139.59]

ALLOW 5" BOTH SIDES FOR COOLING.

5.19

[131.83]

17.16

[435.76]

13.20

[335.37]

1.40

[35.7]

1.14

[29.0]

10.00

[254.0]

If you choose to mount the generator on a benchtop follow these instructions:

1) Install the four (4) optional hold down brackets. See Figure 3-5 below.

2) Secure one side of each L backet to the generator's sheet metal cover.

3) Secure the other side of each l bracket to the bench itself.

Section 3 – Installation

NOTE

The gure shows how a typical iQ generator is bechtop mounted. Your generator’s appearance may be different from what is shown here.

Figure 3-5 Securing iQ Generator to Benchtop

Dukane Manual Part No. 403-574-01

Page 17

iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual

Earth Ground

#14 Gauge

Stranded or

Solid Wire

Fixed Probe Mount

or 2nd Chassis Grounding Stud

3rd Chassis Grounding Stud

Chassis Grounding Stud

Recommended protective earth ground connection wire color: green or green with yellow stripe.

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 ultrason-

ic generator contains a RFI lter which blocks noise on

the AC power line from entering the system control cir-

cuitry. This lter also prevents ultrasonic frequency noise

from being fed back into the AC power line. In order for the RFI lter 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.

See Figure 3-6 on Page 20.



CAUTION

To m i n i m i z e e l e c t r i cal noise and eliminate ground currents, ground the chassis as shown. Use a STAR conguration (illustrated below). Do not DAISY CHAIN the grounds.

Page 18

Dukane Manual Part No. 403-574-01

Connecting Cables

(Quick Start Guide)

Details about the various system connectors and their pin assignments are covered in Section 4.

Manually Operated Probe System

(Hand Probe)

Step 1. Ground the generator chassis using the supplied

14-Gauge wire, and attach it to the grounding stud:

A in Figure 3 -6.

Step 2. Attach the hand probe’s HD–15 system input con-

nector to J2 on the I/O panel: B in Figure 3 -6.

Step 3. Attach high–voltage coaxial cable to J1, the ultra-

sound output connector: C in Figure 3 -6.

Step 4. Connect the AC power cord to the IEC power inlet

connector on the ultrasonic generator (D in Figure 3 -6), and plug the other end into an approved AC outlet.

Power Cords

The AC line cords supplied with the standard generators are matched to the ultrasonic output power rating and the

continent of specied use. See Table 3-II.



Section 3 – Installation

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 p r o p e r ly g r o u n d e d th ree - le ad rec ep ta cl e .

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.

Continent of Use Power Cord

Part Number

200 - 1110 240V, 15A

North America

200 - 1541 240V, 10A

200 - 1111 240V, 16A

Continental Europe

200 - 1542 240V, 10A

Table 3 - II Standard IEC AC Power Cord Part Numbers

Power

NOTE

Refer to Section 10, Options for informa- tion about optional features.

Dukane Manual Part No. 403-574-01

Page 19

iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual

LINE VOLTAGE: 200-240 Vac 50/60Hz, 10A

AC POWER

INLET

GROUNDING

STUD









ULTRASOUND OUTPUT

INPUTS

OUTPUTS

J7 is optional.

Figure 3 - 6 Generator - Rear View (low prole model)

Automation Controlled Probe System

Step 1. Ground the generator chassis using the supplied

14-Gauge wire, and attach it to the grounding stud:A in Figure 3 -6.

Step 2. Optional – Ground the probe support. This is a

user–supplied 14-Gauge wire.

Step 3. Input Cable - Attach the automation control

cable from the user–supplied automation equipment to the system input HD-15 connector, J2

on the I/O panel: B in Figure 3 -6.

Step 4. Output Cable - Attach an output cable - DB25

type - from J3 to your equipment to monitor system status.

Step 5. Attach the high voltage coaxial cable from the

probe to the ultrasound output connector J1:

C in Figure 3 -6.

Step 6. 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 3 -6.

NOTE

Refer to Section 10, Options for information about other features.

Section 4 – Standard Connections

SECTION 4

Standard Connections

Rear Panel Layout Overview . . . . . . . . . . . . . . . . . . . . . . . . 23

AC Power Inlet Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

IEC AC Power Inlet Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Power Switch/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Chassis Grounding Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

System I/O Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

System Inputs Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

System Inputs Connector Pinout. . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

System Inputs Signal Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . 26

System Outputs Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

System Outputs Connector Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . 28

System Outputs Signal Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . 28

Ultrasound Output Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Conguration Port Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual

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Section 4 – Standard Connections

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Section 4 – Standard Connections

Rear Panel Layout Overview

LINE VOLTAGE: 200-240 Vac 50/60Hz, 10A

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 4 - 1 illustrates the panel layout.

Section 4 – Standard Connections

Figure 4 - 1 Generator Rear Panel

AC Power Inlet Panel

A IEC Power Inlet Connector – Attaches to an IEC style

power cord.

B Power Switch – Circuit Breaker – Used to switch

system power ON and OFF.

C Chassis Grounding Stud – Chassis connection for a

protective earth ground.

The System I/O Panel

Options Module Panel

(A blank panel is installed on standard systems.)

K An option module can be installed here.

NOTE

See Section 10, Options for more information.

D System Input Connector – Connections for system

control input signals.

E System Output Connector – Connections for system

status output signals.

F Ultrasound Output Connector – Coaxial high voltage

connection to ultrasonic stack.

G Conguration Port Connector – Digital control port

to modify system parameters.

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iQ Series, Ultrasonic Generator/Power Supply LS User’s Manual

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Section 4 – Standard Connections

LINE VOLTAGE: 200-240 Vac 50/60Hz, 10A

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 congured IEC

compliant power cord, which enables worldwide system operation by simply changing the power cord.

Low prole systems are equipped with a 10 amp rated IEC inlet connector. The high prole systems include a 16/20

amp rated IEC inlet connector. 120VAC and 3600W/4800W systems include a non-detachable power cord.

An appropriately rated power cord must be securely attached to the welding system’s IEC inlet connector. If the

correct power cord conguration 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. Note that the system undervoltage lockout will inhibit system operation if a North

American power cord congured for 120V is connected to

the system. A minimum of 200V is required for the system to operate.

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.

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 envi-

ronment. The chassis ground stud is C in Figure 4-2. Proper system grounding is discussed in Section 3.

Figure 4 - 2 IEC AC Power Inlet Connector

System I/O Panel

The standard system I/O panel is described in this section.

System Inputs Connector

The SYSTEM INPUTS connector mounted on the system I/O panel includes connections for all of the basic system control input signals, that will typically come from 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 one connection to this connector in order to activate the ultrasound output. All of the input signals on this connector are electrically isolated (signals are NOT referenced to chassis ground) and activated when a 24VDC voltage source is connected to the signal input pin, referenced to the isolated common pin. The electrically isolated input signals can be driven from an automation controller output that is either sinking (NPN) or sourcing (PNP), depending upon how the isolated common connection is terminated. All inputs sink or source 10mA of current from a 24VDC power supply.

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