Dukane iQ Series, iQ LS, iQ LS-E Application Note

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Page 1

DUKANE

APPLICATION NOTE

AN502

Intelligent Assembly Solutions

iQ Series

ULTRASONIC PROBE SYSTEM

LS/LS-E

Automation Interface Guidelines

Page 2

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APPLICATION NOTE

AN502

Intelligent Assembly Solutions

Index

System Inputs

System Input Cable Pinouts / System Input Cables 3 Connecting System Inputs (PLC Sourcing Output Card) 4 Connecting a PLC Sinking Output Card 5 Connecting a Relay Contact Closure 6

System Outputs

System Output Cable Pinouts / System Output Cables 7 Connecting System Outputs (PLC Sourcing Input Card) 8 Connecting a PLC Sinking Input Card 9 Connecting a Relay Contact Closure 10

Remote Setup Switching 11 Connecting an Automation Safety Circuit 12

iQ LS / LS-E Automation Controlled Probe Generator Timing Diagrams

LS / LS-E (Weld-by-Automation) Timing Diagram 13 LS / LS-E (Weld-by-Time) Timing Diagram 14 LS / LS-E with MPC (Weld-by-Automation) Timing Diagram 15 LS / LS-E with MPC (Weld-by-Time) Timing Diagram 16

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System Input Cable Pinouts

Color

Description

J2-1

BLK

+22V CURRENT LIMITED POWER SUPPLY (250mA MAX)

J2-2

WHT

+22V RETURN (iQ CHASSIS GROUND)

J2-3

RED

REMOTE SETUP SELECTION BIT 0 INPUT

J2-4

GRN

REMOTE SETUP SELECTION BIT 1 INPUT

J2-5

ORN

REMOTE SETUP SELECTION BIT 2 INPUT

J2-6

BLU

REMOTE SETUP SELECTION BIT 3 INPUT

J2-7

WHT/BLK

REMOTE SETUP SELECTION BIT 4 INPUT (NOT USED)

J2-8

RED/BLK

ULTRASOUND ACTIVATION / CYCLE START INPUT

J2-9

GRN/BLK

AUTOMATION THRUSTER CONTROL INPUT (NOT USED)

J2-10

ORN/BLK

FRONT PANEL CONTROL LOCK

J2-11

BLU/BLK

PRESS INHIBIT FOR HAND PROBES (DUKANE USE ONLY)

J2-12

BLK/WHT

SYSTEM LATCH RESET INPUT

J2-13

RED/WHT

ISOLATED COMMON (SOURCING OR SINKING INPUTS)

J2-14

GRN/WHT

OPEN CONNECTION

J2-15

BLU/WHT

AUTOMATION CYCLE STOP INPUT

Note: For detailed signal descriptions, please refer to the product manual.

System Input Cables

Part Number

Length

200-1380-03M

3 meters

200-1380-05M

5 meters

200-1380-07M

7 meters

200-1380-09M

9 meters

200-1380-11M

11 meters

200-1380-13M

13 meters

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Connecting System Inputs

All System Inputs are optically isolated from the internal circuits and can be connected to sinking or sourcing PLC output cards. The inputs will draw approximately 10mA with a 24Vdc supply. The Systems Inputs can also be configured for a contact closure if necessary.

PLC Sourcing Output Card

Notes:

1. All System Inputs share the same Isolated Common (J2-13). It is critical that the isolated common is connected to the positive supply or ground.

2. J2-1 can be used in place of the 24Vdc supply. If so, J2-13 must be connected to J2-2.

Warning: Any connection to the Ultrasound Activation/Cycle Start Input (J2-8) or the Automation Thruster Control Input

(J2-9) should be disabled during an emergency stop condition.

+24Vdc Supply (+30Vdc max)

PLC Output Card

Contact closure or transistor output

iQ System Inputs

0Vdc Return

Isolated Common

J2-13

PLC Digital Outputs Sourcing Current

iQ Digital Input Sinking Current

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Connecting a PLC Sinking Output Card

Notes:

1. All System Inputs share the same Isolated Common (J2-13). It is critical that the isolated common is connected to the positive supply or ground.

2. J2-1 can be used in place of the 24Vdc supply. If so, J2-13 must be connected to J2-1 and 0Vdc to J2-2.

Warning: Any connection to the Ultrasound Activation/Cycle Start Input (J2-8) or the Automation Thruster Control Input

(J2-9) should be disabled during an emergency stop condition.

+24Vdc Supply (+30Vdc max)

PLC Output Card

Contact closure or transistor output

iQ System Inputs

0Vdc Return

Isolated Common

J2-13

PLC Digital Outputs Sinking Current

iQ Digital Input Sourcing Current

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Connecting a Relay Contact Closure

Notes:

1. All System Inputs share the same Isolated Common (J2-13). It is critical that the isolated common is connected to the positive supply or ground.

2. Dukane’s current limited power supply can be substituted for the +24Vdc supply above. Connecting +22Vdc (J2-1) to Isolated Common (J2-13) would allow a dry contact closure between any System Input and 0V Return (J2-2). Connecting the System Inputs in this way would be similar to activating DPC series System Inputs.

Warning: Any connection to the Ultrasound Activation/Cycle Start Input (J2-8) or the Automation Thruster Control Input

(J2-9) should be disabled during an emergency stop condition.

iQ Digital Input Sourcing Current

+24Vdc Supply (+30Vdc max)

PLC Output Card or External Relay

iQ System Inputs

0Vdc Return

Isolated Common

J2-13

PLC Digital Outputs Sinking Current

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System Output Cable Pinouts

Color

Description

J3-1

BLK

+22V CURRENT LIMITED POWER SUPPLY (250mA MAX)

J3-2

WHT

OPEN CONNECTION

J3-3

RED

+22V RETURN (iQ CHASSIS GROUND)

J3-4

GRN

PROGRAMMABLE STATUS OUTPUT 1

J3-5

ORN

PROGRAMMABLE STATUS OUTPUT 2

J3-6

BLU

ULTRASOUND ACTIVE STATUS OUTPUT

J3-7

WHT/BLK

ANY FAULT STATUS OUTPUT

J3-8

RED/BLK

PRESS TRIGGER STATUS OUTPUT

J3-9

GRN/BLK

SYSTEM OVERLOAD STATUS OUTPUT

J3-10

ORN/BLK

SYSTEM ONLINE STATUS OUTPUT

J3-11

BLU/BLK

PRESS TOP OF STROKE STATUS OUTPUT

J3-12

BLK/WHT

CURRENT LOOP STATUS OUTPUT (NOT USED)

J3-13

RED/WHT

ANALOG MONITOR OUTPUTS GROUND (iQ CHASSIS GROUND)

J3-14

GRN/WHT

NOT USED (iQ CHASSIS GROUND)

J3-15

BLU/WHT

POWER SIGNAL MONITOR OUTPUT (1mV = 1 WATT)

J3-16

BLK/RED

AMPLITUDE MONITOR OUTPUT (10.0V = 100%)

J3-17

WHT/RED

AMPLITUDE/POWER REGULATION STATUS OUTPUT

J3-18

ORN/RED

MPC SYSTEM READY STATUS OUTPUT (NOT USED)

J3-19

BLU/RED

SYSTEM POWER STATUS OUTPUT

J3-20

RED/GRN

BAD PART STATUS OUTPUT

J3-21

ORN/GRN

GOOD PART STATUS OUTPUT

J3-22

BLK/WHT/RED

SYSTEM READY STATUS OUTPUT

J3-23

WHT/BLK/RED

SUSPECT PART STATUS OUTPUT

J3-24

RED/BLK/WHT

ISOLATED COMMON (SINKING AND SOURCING OUTPUTS)

J3-25

GRN/BLK/WHT

OPEN CONNECTION

Note: For detailed signal descriptions, please refer to the product manual.

System Output Cables

Part Number

Length

200-1381-03M

3 meters

200-1381-05M

5 meters

200-1381-07M

7 meters

200-1381-09M

9 meters

200-1381-11M

11 meters

200-1381-13M

13 meters

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Connecting System Outputs

All System Outputs are optically isolated from the internal circuits and can be connected to sinking or sourcing PLC input cards. When J3-1 is used to power the outputs, the total maximum output current for all outputs combined is 250mA. If an external supply is used, as shown in the drawing below, each output can sink or source up to 500mA.

PLC Sourcing Input Card

Notes:

1. All System Outputs share the same Isolated Common (J3-24). It is critical that the isolated common is connected to the positive supply or ground.

2. J3-1 can be used in place of the 24Vdc supply. If so, J3-24 must be connected to J3-3.

iQ Digital Outputs Sinking Current

+24Vdc Supply

iQ System Outputs

PLC Input Card

0Vdc Return

Isolated Common J3-24

PLC Digital Input Sourcing Current

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Connecting a PLC Sinking Input Card

Notes:

1. All System Outputs share the same Isolated Common (J3-24). It is critical that the isolated common is connected to the positive supply or ground.

2. J3-1 can be used in place of the 24Vdc supply. If so, J3-24 must be connected to J3-1 and 0Vdc to J3-3.

iQ Digital Outputs Sourcing Current

iQ System Outputs

PLC Input Card

0Vdc Return

Isolated Common J3-24

PLC Digital Input Sinking Current

+24Vdc Supply (+30Vdc max)

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Connecting a Relay Contact Closure

Notes:

1. All System Outputs share the same Isolated Common (J3-24). It is critical that the isolated common is connected

to the positive supply or ground.

2. J3-1 can be used in place of the 24Vdc supply. If so, J3-24 must be connected to J3-3.

+24Vdc Supply

iQ Digital Outputs Sinking Current

iQ System Outputs

RELAY

0Vdc Return

Isolated Common J3-24

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Remote Setup Switching

J2-7

J2-6

J2-5

J2-4

J2-3

Setup

J2-7

J2-6

J2-5

J2-4

J2-3

Setup

Selected

0 0 0 0 0

N/A

17 0 0 0 0 1 2

N/A

18 0 0 0 1 0 3

N/A

19 0 0 0 1 1 4

N/A

20 0 0 1 0 0 5

N/A

21 0 0 1 0 1 6

N/A

22 0 0 1 1 0 7

N/A

23 0 0 1 1 1 8

N/A

24 0 1 0 0 0 9

N/A

25 0 1 0 0 1 10

N/A

26 0 1 0 1 0 11

N/A

27 0 1 0 1 1 12

N/A

28 0 1 1 0 0 13

N/A

29 0 1 1 0 1 14

N/A

30 0 1 1 1 0 15

N/A

N/A 1 1 1 1

N/A

Note: Remote setup mode is available in the LS-E model. It is enabled by selecting “Automation” from the front panel Setup screen. These system inputs receive a Binary code from the automation that is used to select a setup to be used for the next welding cycle. Setup selections 17-32 are reserved and are not available (N/A). An external +24VDC supply can be used instead of the generator internal supply. See the drawings on pages 4 and 5 for more information.

Remote Setup Inputs

Remote Setup Selection Bit 1 Input

J2-5

J2-4

Remote Setup Selection Bit 2 Input

J2-6

Remote Setup Selection Bit 3 Input

PLC

Sourcing

Outputs

Remote Setup Selection Bit 0 Input

J2-3

+22VDC Return (Ground) Isolated Common

J2-2

J2-13

Remote Setup Inputs

Remote Setup Selection Bit 1 Input

J2-5

J2-4

Remote Setup Selection Bit 2 Input

J2-6

Remote Setup Selection Bit 3 Input

PLC

Sinking

Outputs

Remote Setup Selection Bit 0 Input

J2-3

+22VDC Power Supply Isolated Common

J2-1

J2-13

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Connecting an Automation Safety Circuit

Notes:

1. To operate the LS / LS-E Generator, J17 (Left Side) and J17 (Right Side) must be maintained in a closed connection.

2. If the connection between J17 (Left Side) and J17 (Right Side) is opened, the ultrasonic output will be disabled.

WARNING: Consult the appropriate local regulatory agency (OSHA, UL, CE, etc.) regarding all of the safety requirements for your automated machine. Dukane is not responsible for injuries related to improper safety circuits or safety guarding used in an automated machine. EN 12100-1/-2 and EN 60204-1 safety standards are recommended.

Automation E-Stop (Abort) Switch or Similar Safety Circuit

iQ E-Stop (Abort) Circuits

N.C.

Internal +22Vdc Supply

J17 (Left Side)

J17 (Right Side)

To System E-Stop (Abort) Relay

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iQ LS / LS-E Automation Controlled Probe Generator Timing Diagrams

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Normal Weld Cycle - A normal weld cycle lasts as long as the U/S Activate input is in a high state. This cycle shows the

timing between activation/deactivation of the U/S Activate input, U/S Status output and Ready Status output signals. The Ready Status Output: The Ready Status output is used to determine if the generator is ready to start a new weld

cycle. As seen in Figure 1, the Ready Status output requires a minimum of 3ms to change to its deactivated state after the U/S Activate input is activated. For correct operation, a PLC controlling an LS or LS-E Automation generator must delay at least 3ms after activating the U/S Activate input before checking the Ready Status output. At the end of a normal cycle, the Ready Status output requires a minimum of 19.5ms to change to its activated state after the U/S Activate input has deactivated. For correct operation, a PLC controlling an LS or LS-E Automation generator must delay at least 19.5ms after deactivating the U/S Activate input before checking the Ready Status output. It is possible that the stack ring down time (stack stops vibrating), which is stack and application dependent, will make this time much longer.

The U/S Status Output: The U/S Status output is used to determine when the generator has activated its ultrasound ouput to the ultrasonic stack. As seen in Figure 1, the U/S Status output requires a minimum of 5ms to change to its activated state. For correct operation, a PLC controlling an LS or LS-E Automation generator must delay at least 5ms after activating the U/S Activate input before checking the U/S Status output. At the end of a normal cycle, the U/S Status output requires a minimum of 18.0ms to change to its deactivated state after the U/S Activate input has deactivated. For correct operation, a PLC controlling a LS or LS-E Automation generator must delay at least 18.0ms after deactivating the U/S Activate input before checking the U/S Status output.

Weld Cycle with an Overload - This weld cycle shows the same timing relationship as a normal weld cycle except the ultrasound output, indicated by the U/S Status output, is terminated early due to an overload condition.

The Any Fault Status Output: The Any Fault Status output is used to determine when the generator has terminated the weld cycle due to an overload. When an overload occurs, the Any Fault Status output activates at the same time the U/S Status output deactivates. The Ready Status output doesn’t activate until the U/S Activate output deactivates. The Ready Status output requires a minimum of 20.0ms to change to its activated state after the U/S Activate input has deactivated. For correct operation, a PLC controlling an LS or LS-E Automation generator must delay at least 20.0ms after deactivating the U/S Activate input before checking the Ready Status output.The Any Fault Status output will deactivate the next time the U/S Activate input is activated, but is delayed up to 3ms.

The Overload Status Output: The Overload Status output is also used to determine when the generator has terminated the weld cycle due to an overload.The Overload Status output has the same timing as the Any Fault Status output and will deactivate the next time the U/S Activate input is activated, but is delayed up to 3ms.

Figure 1: LS / LS-E Weld-by-Automation Cycle Timing Diagram

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LLSS // LLSS--EE ((WWeelldd--bbyy--TTiimmee)) TTiimmiinngg DDiiaaggrraamm

NNoorrmmaall WWeelldd CCyyccllee::

This is a Weld-by-Time cycle, meaning the Ultrasound output lasts as long as the Time Setting, which is 200ms in this case. A LS / LS-E generator requires communications interface such as Ethernet/IP to configure the weld by Time, Peak Power, and Energy settings. While it is strongly reccomended that the communications network be used instead of the descrete I/O, the network and descete I/O can be used together. Figure 2 shows the timing for weld cycles that were configured via the network interface, but ultrasound is activated using the US Activate input instead of the network. As with Weld-by Automation, the Ready Status output should be used to determine if the generator is ready to start a new weld cycle. As seen in Figure 2, the Ready Status output requires a minimum of 3ms to change to its deactivated state after the U/S Activate input is activated. At the end of the normal weld time, there is stack ring down time, which is stack and application dependent, and may make this time much longer. The Ready Status output activates after a minimum of 1.5ms or when the ring down time is complete, whichever occurs first. For correct operation, a PLC controlling an LS / LS-E generator must delay at least 1.5ms after activating the U/S Activate input before checking the Ready Status output. Since the U/S Status output takes up to 5.0ms to change state, a 5.0ms minimum delay is required when monitoring this output. If a network is connected to the generator, then the US Activation can be controlled by the network. The same is true for monitoring the status outputs. The delays will vary with the network based on network settings, number of devices on the network, etc.

Cycle With an Overload: This weld cycle shows the same timing relationship except the ultrasound output, indicated by U/S Status, is terminated early, in this case after 100ms, due to an overload condition.. The Any Fault Status and Overload Status outputs activate at the same time U/S Status deactivates. The Ready Status output activates after a minimum of 3.0ms or when the ring down time is complete, whichever occurs first. The Any Fault Status and Overload Status outputs will deactivate the next time the U/S Activate input is activated, but are delayed up to 3.0ms.

Figure 2: LS / LS-E Weld-by-Time Cycle Timing Diagram

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LLSS // LLSS--EE WWiitthh MMPPCCQQ ((WWeelldd--bbyy--AAuuttoommaattiioonn)) TTiimmiinngg DDiiaaggrraamm

Probe selection changed between weld cycles: Although the probe selection can be changed at any time this method

is the safest and most predictable. The PLC program should monitor the MPC Ready output and when it becomes active change the probe selection using the Remote Setup inputs. This will insure that the stack ring down from the previous cycle is finished. After a delay of at least 33ms, the MPC Ready output will change to inactive (low in this case) again and stay that way for 33ms. See Figure 3 where Remote Setup 0 changes from low to high. The PLC should continue to monitor the MPC Ready output and start the next cycle when MPC Ready activates (high in this case).

Probe selection changed during a weld cycle: Alternately the Remote Setup inputs can change during the weld cycle. The MPC circuitry will not select a new probe when the MPC Ready output is not active. As can be seen in Figure 3, Remote Setup 0 input is changed to inactive before the weld cycle completes. Once the stack ring down completes the relays switch so that probe 1 is selected almost immediately, but the relay takes up to 8ms to settle. The MPC Ready output will remain inactive for 33ms after ring down completes. In this case the PLC must monitor the MPC Ready output and not activate the U/S Activate input until the MPC Ready signal is active.

Figure 3 LS / LS-E with MPCQ Weld Cycle (Weld-by-Automation)

Timing Diagram Notes: All Signals are active high and the grey areas indicate that the output could be either high or low. The symbol indicates a time break so that the time where nothing is happening doesn’t need to be shown.

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Dukane

Intelligent Assembly Solutions

2900 Dukane Drive St. Charles, IL 60174 USA Tel: (630) 797-4900 Fax: (630) 797-4949

http://www.dukane.com/

Disclaimer: Dukane Corporation assumes no responsibility for any errors which may appear in this document, reserves the right to change devices or specifications detailed herein at any time without notice, and does not make any commitment to update the information contained herein.

Dukane iQ Series, iQ LS, iQ LS-E Application Note

Specifications and Main Features

Frequently Asked Questions

User Manual