Dukane 403-575-00 User Manual

Intelligent Assembly Solutions

Series

ULTRASONIC GENERATOR/POWER SUPPLY

AUTOMATED HAND PROBE PRESS

User's Manual

Dukane Part No. 403 – 575 – 00

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

Dukane products are manufactured

ISO 9001:2008

in ISO registered facilities.

www.dukane.com/us

iQ Series Ultrasonic Generator/Power Supply ES User’s Manual

Notice of Rights: All rights reserved. No part of this manual including the interior design, cover design and icons may be reproduced, transmitted or utilized in any form or by any means, electronic, mechanical, photocopying, recording, or by any information storage and retrieval system, without written permission from Dukane Corporation.

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 Corporation 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 subject to change without notice.

This user’s manual documents product features, hardware, and controls software available at the time this user's manual was published.

Printed in the United States of America.

Dukane Part Number: 403-575-00

Dukane ultrasonic equipment is manufactured under one or more of the following U.S. Patents: (* = Inactive)

3,780,926 * 4,131,505* 4,277,710* 5,798,599 5,880,580 6,984,921 7,225,965 7,475,801 and, 7,819,158

Page ii

Dukane Manual Part No. 403-575-00

Revision History

Revision Revision Number Summary Date

- 00 Original release. 08/19/2011

Dukane Manual Part No. 403-575-00

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iQ Series Ultrasonic Generator/Power Supply ES User’s Manual

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Dukane Manual Part No. 403-575-00

Contents

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

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

Press System Overview ..............................4

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

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

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

Plastics Health Notice................................8

Electrical Safety ....................................9

Lifting the Equipment ...............................10

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

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

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

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

Placement in a Seismic Region .......................16

Rear Panel Layout Overview .........................18

RFI Grounding ....................................28

Connecting Cables .................................29

Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Recheck Connections...............................37

Connect AC Power .................................37

Section 4 - Operation ........................39

Overview.........................................41

Start up ..........................................41

Stopping the Weld Cycle ............................42

iQ Explorer Support Features .........................42

Numeric Pad and Keypad .........................42

Help System ...................................43

Quick Start - Servo Welder ........................ 44-55

Quick Start - Pneumatic Welder .................... 56-69

Dukane Manual Part No. 403-575-00

Continued

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iQ Series Ultrasonic Generator/Power Supply ES User’s Manual

Section 5 - System Operational Testing.........71

Section 6 - Troubleshooting ..................79

Section 7 - Maintenance......................93

Section 8 - Options..........................97

Section 9 - Contacting Dukane ...............103

Section 10 - Specications ..................107

Outline Drawings .................................109

Weights, Dimensions, Operating Environment........... 112

AC Power Requirements ...........................113

Interpreting the Model Number....................... 114

Regulatory Agency Compliance ...................... 11 5

Contents Continued

Section 11 - Appendices .................... 117

Appendix A - List of Figures ......................... 119

Appendix B - List of Tables ..........................122

Index ..................................123

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Dukane Manual Part No. 403-575-00

Section 1 - Introduction

SECTION 1

Introduction

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

Press System Overview . . . . . . . . . . . . . . . 4

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

Dukane Manual Part No. 403-575-00

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iQ Series Ultrasonic Generator/Power Supply ES User’s Manual

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Dukane Manual Part No. 403-575-00

General User Information

Read This Manual First

Before operating your ultrasonic system, 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 equipment. The examples given are chosen for their simplicity to illustrate basic operation concepts.

This manual provides information to set up, operate, and interface this generator/power supply as an integral part of

Dukane’s iQ Series ES press system.

Particular models are listed in Section 10 - Specications

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 represent increasing levels of important information. These statements help you to identify and avoid hazards and recognize the consequences. One of three different symbols also accompany the CAUTION and WARNING blocks to indicate whether the notice pertains to a condition or practice, an electrical safety issue or a operator protection issue.

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 three while Table 3–II would be the second table in section three.

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

Warning statements point out conditions or practices that could result in personal injury or loss of life.



Condition or Practice



Electrical Safety Issue

Operator Protection (hearing)

Dukane Manual Part No. 403-575-00

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iQ Series Ultrasonic Generator/Power Supply ES User’s Manual

Press System Overview

An iQ Series Ultrasonic Press System ES consists of these components: the iQ generator, press (with thruster, switches, controls, cables, transducer, booster, horn, and xture) and iQ Explorer software. The software allows the operator to control the system either remotely or at the press location.

The iQ Series ES generator has rugged internal ultrasonic circuitry and ensures a continuous resonant frequency lock at the start of each weld.

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

• Digital Control of all power supply functions, includ- ing digital frequency synthesis, and parameters allows for unique congurations and allows for future upgrades.

• Process Parameters such as frequency, amplitude and power are all updated at a 0.5 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.

• Digi-Trac 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 electri-

cal 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: distance, time only, time

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

• Rear Panel Expansion Slot is available to allow for custom congurations for OEM and cost effec-

tive solutions.

• RS232SerialCongurationPortis used for eld

software upgrades, troubleshooting and advanced hardware setup with optional PC-based congurator.

• 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. 403-575-00

Section 2 - Health and Safety

SECTION 2

Health and Safety

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

Plastics Health Notice . . . . . . . . . . . . . . . . . 8

Electrical Safety ..............................9

Domestic Power Grounding ...................... 9

International Power Grounding .................... 9

Lifting the Equipment .........................10

Dukane Manual Part No. 403-575-00

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Dukane Manual Part No. 403-575-00

General Considerations

Please observe these health and safety recommendations for safe, efcient, and injury-free operation of your

equipment.

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

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

Corporation. Unauthorized modications could cause equipment damage and/or injury to the operator. In addition, unauthorized modications will void equipment

warranty.

Keep the Cover On - Do not remove any equipment cover unless directed to do so by Dukane Corporation. The generator produces hazardous electrical voltages which

could cause injury.

Section 2 - Health and Safety

NOTE

These recommendations apply to the welding system. System in this manual refers to a complete group of components associated with the welding of parts, also known as an ultrasonic assembly system. A typical iQ Series System consists of the iQ generator, a press with thruster, switches, controls, cables, transducer,

booster, horn, and xture, and iQ Explorer

software.

WARNING

Grounded Electrical Power - Operate this equipment only with a grounded electrical connection.

See Electrical Safety for grounding instructions, Page 9.

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

Use Eye Protection - Wear ANSI approved safety impact goggles.

Acoustic Stack Hazard - When an acoustic stack (transducer, booster, horn and tip) is energized by the ultrasound signal, it presents a potential hazard. Stay clear of an energized stack.

System Abort Switch - Install a system abort switch at each operator station when ultrasonic plastic assembly equipment is used with automatic material handling equipment in an automated system.

Foot Switch - Using a foot switch in place of the optical

touch nger switches (activation switches) violates OSHA

regulations.

Never operate the generator with the cover off. This



is an unsafe practice and may cause injury.

CAUTION

At some time you may be asked to remove equipment covers by the Dukane Service Dept. personnel.

Before doing so, disconnect the unit electrically from the incoming line AC power. If the unit is a press/thruster, lock the Air Lockout Valve, located on the rear panel, in its closed position.

Dukane Manual Part No. 403-575-00

Continued

Page 7

iQ Series Ultrasonic Generator/Power Supply ES User’s Manual

General Considerations

Pre-trigger Switch Adjustment - The pre-trigger switch option starts the horn vibrating before contacting the part

to be welded. To ensure safe operation, adjust the pre-

trigger so the ultrasound signal will not activate if the horn is more than ¼ in (7 mm) from the part to be welded.

System Electrical Cabling - Electrical power must be off when connecting or disconnecting electrical cables.

Do Not Wear Loose Clothing or Jewelry - They can become caught in moving parts.

Stay Alert - Watch what you are doing at all times. Use common sense. Do not operate the press when you are

tired or distracted from the job at hand.

Do not Operate the Equipment - Your judgement or reexes could be impaired while taking prescription medi-

cations. If so, do not operate the equipment. Be familiar with warning labels and recommended activity restrictions that accompany your prescription medications. If you have any doubt, do not operate the equipment.

Continued from previous page

Plastics Health Notice

Certain plastic materials, when being processed, may emit fumes and/or gases that may be hazardous to the operator’s health. Proper ventilation of the work station should be provided where such materials are processed. Inquiries should be made to the U.S. Department of Labor concerning OSHA regulations for a particular plastic prior to processing with Dukane ultrasonic equipment.

CAUTION

Parts being joined ultrasonically will at times vibrate at audible frequencies. Wear ear protectors to reduce annoying

or uncomfortable sounds. In addition, ultrasound bafes, sound enclosures, or materials that absorb sound may be located to surround the system.

WARNING

Keep head, hands, limbs and body at least six inches (152 mm) away

from an operating press/ thruster. A vibrating, descending horn can cause burns and/or crushing injuries.

Page 8

CAUTION

When making cable connections to system equipment or disconnecting cables

from system equipment, make sure electrical power to the system is turned off, and AC power cords are removed from their receptacles. After the cables have been securely connected and the connections and cable routing

checked a nal time, the power may be

restored.

Dukane Manual Part No. 403-575-00

Section 2 - Health and Safety

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.

Grounding Contacts

CAUTION

If you have a two-prong electrical receptacle, we strongly recommend that you replace



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.

it with a properly grounded three-prong type. Have a

CAUTION

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



ing 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.

qualied electrician. Do not

cut off the power cord ground-

Typical Outlet

Provided Cable

Figure 2–2 International 220/240V Grounding

Dukane Manual Part No. 403-575-00

100/120 Volt Systems (North America or

Japan)

The power cord (including strain relief) supplied with the 100/120 AC systems is permanently attached to the rear of the generator. Units with this power cord are for use in North America or Japan.

Page 9

iQ Series Ultrasonic Generator/Power Supply ES User’s Manual

Lifting the Equipment

High Prole Low Prole

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.

• Ask for help if needed, or if possible, divide the load

to make it lighter.

25 11.3 20 9.1

30 13.6 25 11.3

CAUTION

Take care when lifting the equipment. We recommend using a mechanical lift device to assist.

• 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.

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.

Page 10

Dukane Manual Part No. 403-575-00

Section 3 - Installation

SECTION 3

Installation

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

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

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

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

Placement in a Seismic Zone..................16

Rear Panel Layout Overview .................. 18

AC Power Inlet Panel .......................... 19

System I/O Panel ............................. 19

Ultrasound Output Connector.................... 27

Conguration Port Connector.................... 27

RFI Grounding ............................ 28

Connecting Cables .......................... 29

Networking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Recheck Connections . . . . . . . . . . . . . . . . . . . . . . . 37

Connect AC Power .......................... 37

Dukane Manual Part No. 403-575-00

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Dukane Manual Part No. 403-575-00

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, Page 10.

When to Use Lockout / Tagout Devices

Section 3 - Installation

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.

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

closed, locked position.

Continued

Figure 3-2 Bottom Lockout Device In Closed Position, Locked

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.

Dukane Manual Part No. 403-575-00

Page 13

iQ Series Ultrasonic Generator/Power Supply ES 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.

Page 14

Dukane Manual Part No. 403-575-00

Unpacking

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 space between 3-6 inches, [8-15 cm] - at the rear of the chassis for cable clearance. (The amount of space depends on the chassis type and what rear panel connections there are.)

See Section 10 - Specications, for generator drawings.

[435.86]

3.45

[87.63]

EXHAUST AIR

OUTLET

17.16

CAUTION

Allow 5 inches for air ventilation at the cooling air inlet and at the exhaust air outlet. The

fan draws in fresh air to cool the internal components, reduce thermal gradients and increase component life.

3.81

[96.8]

COOLING AIR

INLET

IN [mm]

Figure 3-3 Generator Front View (typical) Low Prole

Continued

Dukane Manual Part No. 403-575-00

OPTIONAL

POWER BUTTON

Page 15

iQ Series Ultrasonic Generator/Power Supply ES User’s Manual

Placement in a 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.

17.16

[435.9]

ALLOW 5" BOTH SIDES FOR COOLING

12.99

[330.0]

0.12

[3.0]

ALLOW 5" BOTH SIDES FOR COOLING

ALLOW 3" IN BACK FOR CABLES

Continued from previous page

System Type Dukane Part Number

High Prole 147- 4721

Low Prole 147- 4720

Table 3- I Rack Mount Bracket Part Numbers

11.37

[288.8]

12.57

[319.3]

18.76

[476.5]

18.16

[461.2]

3.82

[97.0]

Figure 3-4 Rack Mounting iQ Generator

Page 16

Continued

0.81

[20.6]

0.25 X 0.50 SLOT (2 PLCS)

3.44

[87.4]

OPTIONAL RACK MOUNT BRACKETS 147-4720

3.25

[82.6]

IN [mm]

Dukane Manual Part No. 403-575-00

Section 3 - Installation

Benchtop Mounting

Continued from previous page

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 the slot side of each bracket to the generator's sheet metal cover.

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

18.84

13.20

[335.28]

[478.47]

18.04

[458.22]

ALLOW 3" IN BACK FOR CABLING.

0.280 HOLE

1.14

[29.0]

ALLOW 5" BOTH SIDES FOR COOLING.

17.16

[435.86]

[mm]

Figure 3-5 Securing iQ Generator to Benchtop

10.00

[254.0]

12.54

[318.52]

OPTIONAL HOLD DOWN BRACKETS 147-1398

5.19

[131.83]

5.50

[139.7]

1.40

[35.6]

OPTIONAL HOLD DOWN BRACKETS

Dukane Manual Part No. 403-575-00

Page 17

iQ Series Ultrasonic Generator/Power Supply ES User’s Manual

Rear Panel Layout Overview

This section provides an overview of the generator rear panel layout, which includes panel areas dedicated to various standard system functions and options that are available. Figure 3-6 illustrates a typical panel layout.

-WARNING-

POWER LINE OUTLET MUST BE GROUNDED.

LINE VOLTAGE: 200-240 Vac 50/60Hz, 15A

DISCONNECT LINE POWER

BEFORE REMOVING COVER.

DUKANE CORP

ST. CHARLES IL 60174 MADE IN U.S.A.

U.S. PATENT 5,880,580 OTHER PATENTS PENDING

J6 BASE/ABORT

J9 ETHERNET

J5 THRUSTER

Figure 3-6 Generator Rear Panel - Pneumatic Press/Thruster

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

J10 RS-232

J11 ENCODER

SYSTEM INPUTS

SYSTEM OUTPUTS

CONFIGURATION

ULTRASOUND J1

Options Module Panel

H Communications board

Shown in the example above are these ports:

J9 - Ethernet, and

J10 - Serial RS232

K Press interface board.

Shown in the example above are these ports:

J6 - Base/Abort

D System Input Connector (J2) – Connections for sys-

tem control input signals.

E System Output Connector (J3) – Connections for sys-

tem status output signals.

F Ultrasound Output Connector (J1) – Coaxial high

voltage connection to ultrasonic stack.

G Conguration Port Connector (J4) – Digital control

port to modify system parameters.

Page 18

J5 - Thruster

J11 - Encoder

NOTE

The press interface board is available in several different congurations. See Section 8, Options for more information.

Dukane Manual Part No. 403-575-00

Section 3 - Installation

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. 120 VAC and 3600/4800W 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.

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 a industrial envi-

ronment. The chassis ground stud is C in Figure 3-7. Proper system grounding is discussed on Page 9.

LINE VOLTAGE: 200-240 Vac

50/60Hz, 10A

Figure 3-7 IEC AC Power Inlet Connector

System I/O Panel

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

Power Switch/Circuit Breaker

The power switch/circuit breaker has a rocker type actuator switch that will activate or deactivate the AC power to the system. The power ON position is marked with the internationally recognized I symbol, the power OFF position is marked with the 0 symbol. This power switch also integrates an appropriately sized over-current protection circuit breaker function in the generator.

If an over-current condition trips the circuit breaker, it will automatically switch to the OFF position. If the overload current that caused the circuit breaker to trip is due to a transient condition, the circuit breaker can be reset by switching the actuator back to the ON position. If when resetting the circuit breaker after it has tripped, it immediately trips again, there is likely an internal system malfunction, and the generator will require service.

Do not repeatedly try to reset the circuit breaker. If it trips, this will only cause more damage to the generator.

System Inputs 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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iQ Series Ultrasonic Generator/Power Supply ES User’s Manual

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Note that a simple switch closure (relay contact) connected to a control input can not activate the input without adding an external power supply to power the input.

Adding jumper connections to pins available on the System Inputs connector, can congure switch closure inputs

to operate referenced to generator chassis ground (nonisolated), without adding a separate power supply, if desired.

Refer to Application Note AN507 (Automation Interface Guidelines) at http://www.dukane.com/us/DL_ApplDa- ta.asp for wiring diagrams of example applications.

System Inputs Connector Pinout

The SYSTEM INPUTS connector is a HD-15F (high density D-subminiature 15 circuit female) connector. Connector pin numbers for this connector are shown in Figure 3-9. The male connector on the cable is a mirror image of the panel-mounted connector and is shown in Figure 3-10. Table 3-II lists the signal names and descriptions, with more detailed descriptions that follow. The wire color coding for the system input cable is listed in Table 3-II, to assist with custom automation system wiring and assembly.

Figure 3-8 System I/O Panel (standard panel shown)

NOTE

Refer to Section 8, Options for information on optional features.

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11 12 13 14 15

Section 3 - Installation

Pin Signal Name Cable Color Code Signal Option Requirements

1 +22V BLK

2 Power Ground WHT

3 Remote Setup Selection Bit 0 Input RED

4 Remote Setup Selection Bit 1 Input GRN

5 Remote Setup Selection Bit 2 Input ORN

6 Remote Setup Selection Bit 3 Input BLU

7 Remote Setup Selection Bit 4 Input WHT/BLK

8 Ultrasound Activation/Cycle Start Input RED/BLK

9 Not Used GRN/BLK Not Used

10 Front Panel Control Lock Input ORN/BLK Not Used

11 Press Inhibit for Hand Probes BLU/BLK Hand Probe

12 System Latch Reset Input BLK/WHT

13 Isolated Common RED/WHT

14 Not Used GRN/WHT

15 Automation Cycle Stop Input BLU/WHT

Table 3-II Generator Input Signals (J2)

System Inputs Signal Descriptions

Pin 1 (+22V)

This pin can supply +22VDC at up to 250mA to power the user’s automation controls.

Pin 2 (Power Gnd)

Pin 2 is the 22VDC return and is tied to the system chassis ground.

Pin 3 (Remote Setup Selection Bit 0 Input)

Pin 3 is the Remote Setup Selection Bit 0, which is the

least signicant bit used to select different welding setups

with an automation control system.

Pin 4 (Remote Setup Selection Bit 1 Input)

Pin 4 is the Remote Setup Selection Bit 1, which is the second least signicant bit used to select different welding setups with an automation control system.

5 4 3 2 1

15 14 13 12 11

Figure 3-9 HD-15F, Generator Input Connector

Figure 3-10 HD-15M, Generator Input Cable

Connector

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Pin 5 (Remote Setup Selection Bit 2 Input)

Pin 5 is the Remote Setup Selection Bit 2, which is the

third least signicant bit used to select different welding

setups with an automation control system.

Pin 6 (Remote Setup Selection Bit 3 Input)

Pin 6 is the Remote Setup Selection Bit 3, which is the second most signicant bit used to select different welding setups with an automation control system.

Pin 7 (Remote Setup Selection Bit 4 Input)

Pin 7 is the Remote Setup Selection Bit 4, which is the

most signicant bit used to select different welding setups

with an automation control system.

Pin 8 (Ultrasound Activation/ Cycle Start Input)

Pin 8 is used to activate the generator ultrasound output. Activation of this control input will switch the ultrasound output ON, and deactivating this signal will switch ultrasound OFF. This input signal will also function as a cycle start input, where the ultrasound activation and timing are completely under the control of the process controller. Depending on the welding process controller setup, this input signal could be activated momentarily to start a welding cycle.

Pin 9 (Not Used) Pin 10 (Not Used) Pin 11 (Press Inhibit for Hand Probes)

Pin 11 is used to disconnect power applied to a press or thruster, if a hand probe is connected to the system input connector, for safety considerations. The hand probe activation switch could unexpectedly start a welding cycle that activates a press or thruster to the down position. The hand probe cable connector is wired to apply chassis ground to this pin, when it is attached to the system, which activates a press inhibit relay that disconnects power from the pneumatic press valves. This pin must be left open whenever a press control board is installed. Connecting this pin to chassis ground will inhibit press operation.

Pin 12 (System Latch Reset Input)

Pin 12 is used to reset the Any Fault or System Overload status outputs (See Status Output descriptions.). If a fault occurs during a weld cycle, these outputs will normally remain active until the next weld cycle is initiated. Activating this input will reset the status output faults and may simplify automation programming.

Pin 13 (Isolated Common)

Pin 13 is electrically isolated from chassis ground. Using isolated sourcing (PNP) output drivers, this common line would be connected to isolated ground potential. Using isolated sinking (NPN) output drivers, this common line would be connected to the isolated positive supply voltage

output.

Pin 14 (Not Used)

Pin 14 is an open connection.

Pin 15 (Automation Cycle Stop Input)

Pin 15 is an input control signal that when enabled, can be used by the automation control system as a redundant signal to shut the ultrasound output off. This signal could

also be recongured through menu selections to function

as an automation end-of-weld control signal input.

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Section 3 - Installation

Pin Signal Name Cable Color Code Signal Option Requirements

1 +22V BLK

2 Spare Output WHT

3 +22V Power Ground RED

4 Programmable Status Output 1 GRN

5 Programmable Status Output 2 ORN

6 Ultrasound Active Status Output BLU

7 Any Fault Status Output WHT/BLK

8 Press Trigger Status Output RED/BLK

9 System Overload Status Output GRN/BLK

10 System Online Status Output ORN/BLK

11 Press Top of Stroke Status Output BLU/BLK

12 Current Loop OK Status Output BLK/WHT Not Used

13 Analog Monitor Signal Common RED/WHT

14 Not Used GRN/WHT

15 Power Signal Monitor Output BLU/WHT

16 Amplitude Monitor Output BLK/RED

17 Amplitude/Power Regulation Status Output WHT/RED

18 MPC Ready Status Output ORN/RED Not Used

19 System Power OK Status Output BLU/RED

20 Bad Part Status Output RED/GRN

21 Good Part Status Output ORN/GRN

22 System Ready Status Output BLK/WHT/RED

23 Suspect Part Status Output WHT/BLK/RED

24 Isolated Common RED/BLK/WHT

25 Not Used GRN/BLK/WHT

Table 3-III System Output Connector Signals (J3)

System Outputs Connector

The SYSTEM OUTPUTS connector mounted on the generator I/O panel includes connections for all of the basic system status and monitor output signals, which will typically connect to an automated control system. The cable attached to this connector includes all of the available system output signals, which will be read or monitored by a digital input card or analog inputs on the user-supplied automation controller. The user can determine which signals are appropriate for each welding application.

The system monitor output signals are analog signals used to monitor ultrasonic amplitude setting and ultrasonic output power levels, referenced to the Monitor Common (Pin 13).

Continued

13 11 9 7 5 3 1

25 23 21 19 17 15

Figure 3–11 DB-25F, Generator Output Connector (J3)

1 3 5 7 9 11 13

15 17 19

21 23 25

Figure 3–12 DB-25M, Generator Output Cable Connector

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This is at system chassis ground potential (non-isolated). All of the digital output status signals on this connector, are isolated (signals are not referenced to generator chassis ground). When a status output signal is activated, it will sink current (500mA Max. sourced by a 24VDC supply) to isolated common. In automation terms, the outputs are NPN (sinking) and would drive a PNP (sourcing) input that is referenced to the Isolated Common pin.

The digital status output signals can only sink current to isolated common. They cannot be changed to a sourcing (PNP) type output. If sourcing status outputs are required, there is an optional isolated NPN to PNP conversion module that is DIN rail mountable. The module converts the standard isolated sinking (NPN) status output signals to isolated sourcing (PNP) status output signals. Consult your local sales representative for information about the conversion module.

System Outputs Connector Pinout

The SYSTEM OUTPUTS connector is a DB-25F (standard D-subminiature 25 circuit female) connector. Connector pin numbers for this connector are shown in Figure 3-11. The male connector on the cable is a mirror image of the panel mounted connector and is shown in Figure 3-12. Table 3-III lists the signal names. Detailed descriptions are listed in System Outputs Signal Descriptions that follow. To assist with custom automation system wiring and assembly, the wire color coding for the system outputs cable is listed in Table 3-III.

System Outputs Signal Descriptions

Pin 1 (+22V Power Supply)

This pin can supply +22VDC at up to 250mA to power the user’s automation controls.

Pin 2 (Not Used)

Pin 2 is an open connection.

Pin 3 (+22V Power Ground)

Pin 3 is the 22VDC return and is tied to the system chassis ground.

Pin 4 (Programmable Status Output 1)

Pin 4 is a digital active low status output that can be reprogrammed and assigned to other system status signals (from the available selections) from the System tab in iQ Explorer.

Pin 5 (Programmable Status Output 2)

Pin 5 is a digital active low status output that can be reprogrammed and assigned to another system status signal (from the available selections) from the System tab in iQ Explorer.

Pin 6 (Ultrasound Active Status Output)

Pin 6 is a digital active low status output that activates when the system is delivering ultrasonic power to the load attached to the ultrasound output connector. This output will be an open circuit when the ultrasound output is off.

Pin 7 (Any Fault Status Output)

Pin 7 is a digital active low status output that activates whenever any fault condition is detected that inhibits ultrasound output and normal system operation. This output will be an open circuit when no system fault conditions are detected. Generator faults that will activate the Any Fault output:

• Overload (Average, Peak, or Frequency)

• Overtemperature Fault

• System Power Fault

Pin 8 (Press Trigger Status Output)

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Pin 8 is a digital active low status output that activates

when the specied trigger type has occurred. It will

remain active until the thruster head raises to the top of the stroke. This output will be an open circuit when a trigger condition hasn’t been detected.

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