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Dukane 403-573-02 - page 1
ISO 9001:2008 Products ar e manufactured in ISO register ed facilities. Intelligent Assembly Solutions www .dukane.com/us Dukane Part No. 403 - 573 - 02 iQ Series UL TR ASONIC GEN ER A T OR / PO WER SUP PL Y Auto User’ s Manual Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 - 4900 ...
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Dukane 403-573-02 - page 2
Page ii iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 Printed in the United States of America. Part Number: 403–573–02 This ultrasonic equipment is manufactured under one or more of the following U.S. Patents: 3,7 80,9 26 3,8 25, 481 4, 131, 505 4 ,277 ,710 5,79 8,59 9 5,8 80, 580 6,984,921, 7,225,965 ...
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Dukane 403-573-02 - page 3
Page iii Dukane Manual Part No. 403-573-02 R e vis ion H istor y Revision Revision Number Summary Date - 00 Original release. 10/09/2007 - 01 20kHz and 30kHz models added. 08/27/2009 System I/O Connector signals modied. Amplitude control added. - 02 I/O Connector Pin 9 signal scale revised. 12/15/2010 Miscellaneous spelling errors cor ...
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Dukane 403-573-02 - page 4
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Dukane 403-573-02 - page 5
Page v Dukane Manual Part No. 403-573-02 Contents Section 1- Introduction . . . . . . . . . . . . . . . . . . . . . . . 1 General User Information . . . . . . . . . . . . . . . 3 Generator Overview . . . . . . . . . . . . . . . . . . . 4 Key Generator Features . . . . . . . . . . . . . . . . 4 Thermal Considerations . . . . . . . . . . . ...
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Dukane 403-573-02 - page 6
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Dukane 403-573-02 - page 7
Page 1 Section 1 – Intr oduction Dukane Manual Part No. 403-573-02 SECTION 1 Intr oduction General User Information . . . . . . . . . . . . . . . . . . 3 Read The Manual First . . . . . . . . . . . . . . . . . . . . . . 3 Notes, Cautions and W arnings . . . . . . . . . . . . . . . . . . 3 Drawings and T ables . . . . . . . . . . . . . ...
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Dukane 403-573-02 - page 8
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Dukane 403-573-02 - page 9
Page 3 Section 1 – Intr oduction Dukane Manual Part No. 403-573-02 General User Information Read This 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 or ganized to allow you to learn how to safely oper ...
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Dukane 403-573-02 - page 10
Page 4 iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 Generator Overview This generator is designed for ultrasonic applications con- trolled by a Programmable Logic Controller (PLC). Us- ing the available system control inputs and outputs, the generator can easily be integrated into a wide variety of autom ...
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Dukane 403-573-02 - page 11
Page 5 Section 2 – Health & Safety Dukane Manual Part No. 403-573-02 Thermal Considerations The thermal design of this generator is for applications that require 600 watts or less of power at less than a 50% duty cycle. For applications that require higher duty cycles, an optional cooling package is available, Part Number 438- 962. ...
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Dukane 403-573-02 - page 12
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Dukane 403-573-02 - page 13
Page 7 Section 2 – Health & Safety Dukane Manual Part No. 403-573-02 SECTION 2 Health and Saf ety G e n e r a l C o n s i d e r a t i o n s .............................. 9 P l a s t i c s H e a l t h N o t i c e ................................ 9 E l e c t r i c a l S a f e t y ................................... 1 0 Power Groundi ...
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Dukane 403-573-02 - page 14
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Dukane 403-573-02 - page 15
Page 9 Section 2 – Health & Safety Dukane Manual Part No. 403-573-02 General Considerations Ple ase obser ve th ese he alth and safe ty rec omme nda tion s for saf e, e fc ient , a nd i nju ry-f ree ope rat ion of your equi pment . In th is ma nua l, the ter m sy stem re fer s to a comp lete grou p of comp onent s ass ociat ed w ...
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Dukane 403-573-02 - page 16
Page 10 iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 Electrical Safety Power Grounding Connection Figure 2-1 illustrates how the AC line is connected. Figure 2–1 AC Line Connection CAUTION If there is any question about grounding of your equipment and/or its elec- trical power source, con ...
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Dukane 403-573-02 - page 17
Page 1 1 Section 2 – Health & Safety Dukane Manual Part No. 403-573-02 St ep 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 bend ing at the knees (not your waist). Tu ck your chin while keeping your back as vertical as possibl ...
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Dukane 403-573-02 - page 18
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Dukane 403-573-02 - page 19
Page 13 Section 3 – Installation Dukane Manual Part No. 403-573-02 SECTION 3 Installa tion Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 P l a c i n g ......................................... 1 5 Power Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 C h a s s i ...
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Dukane 403-573-02 - page 20
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Dukane 403-573-02 - page 21
Page 15 Section 3 – Installation Dukane Manual Part No. 403-573-02 Unpacking Carefully open your shipping container , and make sure it contains the items shown on the shipping documents. Inspect all items, and report any missing items or damage immediately . Placing Make certain generator placement and cable routing do not interfere wi ...
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Dukane 403-573-02 - page 22
Page 16 iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 Power Grounding For safety , the iQ Auto chassis must be properly ground- ed. The power line ground connection is located on the center screw terminal on the AC Power Inlet pluggable screw terminal connector . This syste ...
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Dukane 403-573-02 - page 23
Page 17 Section 3 – Installation Dukane Manual Part No. 403-573-02 Connecting Cables Standard Model Conguration Complete three basic connections for the standard con- guration as shown below: • AC Line Input • System Control Inputs/Status Outputs • Ultrasound Output • Grounding Details about the various system connectors ...
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Dukane 403-573-02 - page 24
Page 18 iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 Pin Signal Name 1 Enable Out (+22V Current Limited) 2 Enable In (Jumper to Pin1, without an E-Stop switch) 3 Overload Out (system overload status output) 4 U/S Status Out 5 Any Fault Out 6 Power OK Out 7 Output Common (c ...
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Dukane 403-573-02 - page 25
Page 19 Section 3 – Installation Dukane Manual Part No. 403-573-02 Pin 1 (Enable Out) This is a current limited voltage source output intended to connect to an E-Stop circuit. If an E-Stop circuit is not used, Pin 1 must be jumpered to Pin 2 for ultrasound operation to be enabled. Pin 2 (Enable In) The output from the E-Stop circuit is ...
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Dukane 403-573-02 - page 26
Page 20 iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 Optional MPC Interface Connections Complete the same basic connections used for the stan- dard iQ Auto conguration as previously described. • AC Line Input • System Control Inputs/Status Outputs • Ultrasound Out ...
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Dukane 403-573-02 - page 27
Page 21 Section 3 – Installation Dukane Manual Part No. 403-573-02 Pin Signal Name 1 Setup Bit 0 Input 2 Setup Bit 1 Input 3 Setup Bit 2 Input 4 Setup Bit 3 Input 5 Input Common 6 MPC Ready Out 7 Output Common T able 3-II MPC I/O Connector Signals MPC I/O Connector Pinout The MPC I/O connector is a two-piece pluggable termi- nal block ...
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Dukane 403-573-02 - page 28
Page 22 iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 NOTE Ultrasound Output Connector The ultrasound output connector used with all standard generators is a high voltage (5000V) coaxial style SHV -BNC connector . This connector provides superior shielding of electri- cal n ...
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Dukane 403-573-02 - page 29
Page 23 Section 3 – Installation Dukane Manual Part No. 403-573-02 MPC Module Installation Guide MPC modules are designed for assembly systems where one ultrasonic generator is sequenced to as many as 16 ultrasonic probes. The MPC module is typically supplied as a stand-alone bench-top unit, or as a component that can be mounted in a t ...
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Dukane 403-573-02 - page 30
Page 24 iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 Connecting Cables For stand-alone modules and securely installed panel mounted modules: Rear Connections Refer to Figure 3-4 below . Complete these connections. 1. Earth ground - Connect one end of a user-supplied 14-Gau ...
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Dukane 403-573-02 - page 31
Page 25 Section 3 – Installation Dukane Manual Part No. 403-573-02 MPC Module Status LEDs System Status The front panel SYSTEM ST A TUS LED lights up GREEN when the system is powered and ready - E in Figure 3-6. If this LED is lit with a YELLOW/ORANGE color , a recoverable fault condition has tripped. This indicates that the system is ...
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Dukane 403-573-02 - page 32
Page 27 Page 26 iQ Series , Auto User ’s Manual Section 4 –System Operation Dukane Manual Part No. 403-573-02 Page 27 Page 26 iQ Series , Auto User ’s Manual Section 4 –System Operation This page intentionally left blank ...
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Dukane 403-573-02 - page 33
Page 27 Page 26 iQ Series , Auto User ’s Manual Section 4 –System Operation Page 27 Page 26 iQ Series , Auto User ’s Manual Section 4 –System Operation Dukane Manual Part No. 403-573-02 SECTION 4 System Oper a tion Standard iQ A ...
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Dukane 403-573-02 - page 34
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Dukane 403-573-02 - page 35
Page 29 Page 28 iQ Series , Auto User ’s Manual Section 4 –System Operation Page 29 Page 28 iQ Series , Auto User ’s Manual Section 4 –System Operation Dukane Manual Part No. 403-573-02 Standard iQ Auto System Operational T est ...
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Dukane 403-573-02 - page 36
Page 31 Page 30 iQ Series , Auto User ’s Manual Section 4 –System Operation Dukane Manual Part No. 403-573-02 Page 31 Page 30 iQ Series , Auto User ’s Manual Section 4 –System Operation Five fault conditions are monitored by the ...
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Dukane 403-573-02 - page 37
Page 31 Page 30 iQ Series , Auto User ’s Manual Section 4 –System Operation Page 31 Page 30 iQ Series , Auto User ’s Manual Section 4 –System Operation Dukane Manual Part No. 403-573-02 Options for U/S Activation Connections : ? ...
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Dukane 403-573-02 - page 38
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Dukane 403-573-02 - page 39
Page 33 Section 5 – Specications Dukane Manual Part No. 403-573-02 SECTION 5 Specica tions Generator Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . 35-36 W e i g h t .......................................... 3 7 O p e r a t i n g E n v i r o n m e n t .............................. 3 7 A C P o w e r R e q u i r ...
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Dukane 403-573-02 - page 40
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Dukane 403-573-02 - page 41
Page 35 Section 5 – Specications Dukane Manual Part No. 403-573-02 Figure 5-1 Generator Outline Drawing TOP REAR MOUNTING BRACKET BOTTOM REAR MOUNTING BRACKET BASE MOUNTING BRACKETS(2) 2.00 [50.8] 10.61 [269.49] 7.38 [187.45] 10.73 [272.54] 2.00 [50.8] .75 [19.05] 3.35 [85.09] 3.47 [88.14] 1.44 [36.58] .91 [23.1 1] 1 1.25 [285.75] 9 ...
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Dukane 403-573-02 - page 42
Page 36 iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 Figure 5-2 Generator with Optional Heat Sink Outline Drawing NOTE: ALL MOUNTING HOLES ARE .219 DIA. FOR M5 OR #10 SCREWS. OPTIONAL HEA T SINK KIT - 438-962 9.75 [247.7] OAL 9.02 [229] 2.05 [52.1] 0.38 [9.7] 1.20 [30. ...
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Dukane 403-573-02 - page 43
Page 37 Section 5 – Specications Dukane Manual Part No. 403-573-02 Operatin g En vi ron m en t Operate the generator within these guidelines: T emperature : 40° F to 100° F ( +5°C to +3 8°C) Air Particulates : Keep the equipment dry . Minimize exposure to moisture, dust, dirt, smoke and mold. Humidity : 5% to 95% non–condensin ...
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Dukane 403-573-02 - page 44
Page 38 iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 AC Power Requirements Operating Frequency Generator Model Number Overload Power Ratings (W atts) Input AC Power Requirements Nominal AC V olt @ Maximum RMS Current North America/ Japan AC Outlet Rating 20kHz 20A T060 ...
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Dukane 403-573-02 - page 45
Page 39 Section 5 – Specications Dukane Manual Part No. 403-573-02 FCC The generator complies with the following Federal Communications Commission regulations. • The limits for FCC measurement procedure MP-5, “Methods of Measurement of Radio Noise Emissions from ISM Equipment”, pursuant to FCC T itle 47 Part 18 for Ultrasonic ...
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Dukane 403-573-02 - page 46
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Dukane 403-573-02 - page 47
Section 6 – Automation Interface Page 41 Dukane Manual Part No. 403-573-02 SECTION 6 A utoma tion Interface Input/Output Connection Examples . . . . . . . . . . . . . . . . . . . 43 PNP (Sourcing) T ype Input Circuit . . . . . . . . . . . . . . . . . . . . . . . . 43 NPN (Sinking) T ype Input Circuit . . . . . . . . . . . . . . . . . . ...
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Dukane 403-573-02 - page 48
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Dukane 403-573-02 - page 49
Section 6 – Automation Interface Page 43 Dukane Manual Part No. 403-573-02 iQ Auto (same as above) Input Common U/S Activate Fault Reset Ground +DC Input V oltage Range DC 24V 10% Input Current 10mA(typ) @ DC 24V input PNP (Sourcing) T ype Input Circuit (Pin 13) (Pin 12) (Pin 11) System I/O C onnec tor ± Figure 6-1 PNP T ype Input Cir ...
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Dukane 403-573-02 - page 50
Page 44 iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 iQ Auto (same as above) Input Common U/S Activate Fault Reset Ground +DC NPN (Sinking) T ype Input Circuit Input V oltage Range DC 24V 10% Input Current 10mA(typ) @ DC 24V input System I/O C onnec tor (Pin 13) (Pin 1 ...
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Dukane 403-573-02 - page 51
Section 6 – Automation Interface Page 45 Dukane Manual Part No. 403-573-02 (same as above) Overload U/S Status Ground +DC NPN T ype Output Circuit Rated Output V oltage DC 24V 10% Maximum Output Current 500mA/1 Output Output Driver N Channel Power MOSFET Gate Drive L L (same as above) (same as above) Any Fault Power OK Output Common iQ ...
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Dukane 403-573-02 - page 52
Page 46 iQ Series , Auto User ’s Manual Dukane Manual Part No. 403-573-02 Figure 6-4 E-Stop Circuitry iQ Auto Enable Out Enable In Dedicated E-Stop Switch Wiring Diagram System I/O Connector (Pin 1) (Pin 2) User supplied E-stop switch iQ Auto Enable Out Enable In Automation System Safety C ...
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Dukane 403-573-02 - page 53
Section 7 – Contacting Dukane Page 47 Dukane Manual Part No. 403-573-02 SECTION 7 Contacting Dukane ...
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Dukane 403-573-02 - page 54
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Dukane 403-573-02 - page 55
Section 7 – Contacting Dukane Page 49 Dukane Manual Part No. 403-573-02 Co ntacting D uka ne Identify Equipment When contacti ng Dukane about a servi ce–related problem, be prepared to give the following information: • Model number , line voltage and serial number . • Fault status. • Problem description and steps taken to resol ...
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Dukane 403-573-02 - page 56
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Dukane 403-573-02 - page 57
Dukane ISO ISO CER TIFICA TION Duka ne chose to become ISO 900 1:2008 certi- fied in order to demonstrate to our customers our continuing commitment to being a quality ve ndor . By pa ssin g it s aud it, Du kane can assu re you that we have in place a well–defined and systematic approach to quality design, manu- facturing, deliver y and ser vic ...
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Dukane 403-573-02 - page 58
Part No. 403- 573-02 Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797- 4900 • F AX (630) 797- 4949 iQ Series , Ultrasonic Generator/Power Supply Auto User's Manual Printed in the United States of America www .dukane.com/us Please r ef er to our website a t: www .dukane.com/us/s ...
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