Dukane iQ Series User Manual

ISO 9001:2008Products are manufactured in ISO registered facilities.Intelligent Assembly SolutionsDukane Intelligent Assembly Solutions • 2900 Dukane

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 3Page 2 Dukane Manual Part Number 403-572-03Dukane Manual Part Number 403-572-

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 92 Dukane Manual Part Number 403-572-03DO NOT make any modi-cations to the ge

Section 12 - Contacting DukanePage 93Dukane Manual Part Number 403-572-03SECTION 12Contacting Dukane

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Section 12 - Contacting DukanePage 95Dukane Manual Part Number 403-572-03Contacting DukaneIdentify EquipmentWhen contacting Dukane about a service–rel

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AppendicesPage 97Dukane Manual Part Number 403-572-03APPENDICESList of Figures... 99List of Tables...

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AppendicesPage 99Dukane Manual Part Number 403-572-03List of Figures2-1 Example of 220 Volt, Grounded, 3-prong Receptacle ...

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 100 Dukane Manual Part Number 403-572-0310-6 MPC Interface Cutout Guide ...

AppendicesPage 101Dukane Manual Part Number 403-572-033-I Standard IEC AC Power Cord Part Numbers ...

Section 1 – IntroductionPage 3Page 2 Dukane Manual Part Number 403-572-03Dukane Manual Part Number 403-572-03General User InformationRead This Manual

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IndexPage 103Dukane Manual Part Number 403-572-03Index

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 104 Dukane Manual Part Number 403-572-03IndexAAcency ComplianceIP (Internation

IndexPage 105Dukane Manual Part Number 403-572-03Manually Operated Probe System 18General Considerations 7PlacingHorizontal Bench Chassis 16Horizon

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 106 Dukane Manual Part Number 403-572-03System Outputs Connector 29System Out

Dukane ISOISO CERTIFICATIONDukane chose to become ISO 9001:2008 certi-fied in order to demonstrate to our customers our continuing commitment to being

Part No. 403  - 572 - 03Dukane Intelligent Assembly Solutions • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 - 4900 • FAX (630)

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 4 Dukane Manual Part Number 403-572-03Generator OverviewThis generator is desi

Section 2 – Health and Safety Page 5Dukane Manual Part Number 403-572-03SECTION 2Health and SafetyGeneral Considerations ...7Plas

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Section 2 – Health and Safety Page 7Dukane Manual Part Number 403-572-03ProperInstallation - Operate system components only after they are properly i

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 8 Dukane Manual Part Number 403-572-03Pre-triggerSwitchAdjustment - The pre-

Section 2 – Health and Safety Page 9Dukane Manual Part Number 403-572-03Approved 2 pole, 3 wire grounding receptacle HUBBELL No. 5652 or equivalent to

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 10 Dukane Manual Part Number 403-572-031. Stand close to the load with your f

Section 3 – InstallationPage 11Dukane Manual Part Number 403-572-03SECTION 3InstallationBefore Installation ... 13When t

Page ii Dukane Manual Part Number 403-572-03 iQ Series, Automation-Controlled Probe Generators LS User’s ManualCopyright © 2013Notice of Rights:All r

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Section 3 – InstallationPage 13Dukane Manual Part Number 403-572-03Before InstallationAs you plan for the installation of your generator, please cons

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 14 Dukane Manual Part Number 403-572-03Continued from Previous PageProceduret

Section 3 – InstallationPage 15Dukane Manual Part Number 403-572-03UnpackingCarefully open your shipping container, and make sure it contains the item

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 16 Dukane Manual Part Number 403-572-03Horizontal Bench ChassisGenerator place

Section 3 – InstallationPage 17Dukane Manual Part Number 403-572-03RFI GroundingIn addition to the safety considerations previously men-tioned, proper

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 18 Dukane Manual Part Number 403-572-03CAUTIONThe power cord is equipped with

Section 3 – InstallationPage 19Dukane Manual Part Number 403-572-03Table 3 - I Standard IEC AC Power Cord Part NumbersPart Number Continent of Use200-

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Section 4 – Standard ConnectionsPage 21Dukane Manual Part Number 403-572-03SECTION 4Standard ConnectionsPanel Layout Overview . . . . . . . . . . . .

Page iiiDukane Manual Part Number 403-572-03Revision HistoryRevision RevisionNumber Summary Date - 00 Original release. 07/10/2008 - 01

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Section 4 – Standard ConnectionsPage 23Dukane Manual Part Number 403-572-03Panel Layout OverviewVertical Panel Mount ChassisThis section provides an o

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 24 Dukane Manual Part Number 403-572-03Horizontal Bench ChassisThis section pr

Section 4 – Standard ConnectionsPage 25Dukane Manual Part Number 403-572-03AC Power Inlet Panel The standard AC power inlet panel is described in this

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 26 Dukane Manual Part Number 403-572-03System I/O PanelThe standard system I/O

Section 4 – Standard ConnectionsPage 27Dukane Manual Part Number 403-572-03System Inputs Signal DescriptionsPin 1 (+22V)This pin can supply +22VDC at

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 28 Dukane Manual Part Number 403-572-03Pin 5 (Remote Setup Selection Bit 2 In

Section 4 – Standard ConnectionsPage 29Dukane Manual Part Number 403-572-03Pin 15 (Automation Cycle Stop Input)Pin 15 is an input control signal that

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 30 Dukane Manual Part Number 403-572-03System Outputs Signal DescriptionsPin 1

Section 4 – Standard ConnectionsPage 31Dukane Manual Part Number 403-572-03Figure 4  - 6DB 25-F for Generator Output ConnectorFigure 4 - 7DB-25M f

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iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 32 Dukane Manual Part Number 403-572-03Pin 14 (Not Used)Pin 14 is connected to

Section 4 – Standard ConnectionsPage 33Dukane Manual Part Number 403-572-03Pin 23 (Suspect Part Status Output) NOT AVAILABLEPin 24 (Isolated Common

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Section 5 – Standard System Status and ControlsPage 35Dukane Manual Part Number 403-572-03SECTION 5Standard System Status and ControlsControl Panel an

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Section 5 – Standard System Status and ControlsPage 37Dukane Manual Part Number 403-572-03Control Panel and Display OverviewThis section provides an o

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 38 Dukane Manual Part Number 403-572-03Display ControlsThe four keys on the to

Section 5 – Standard System Status and ControlsPage 39Dukane Manual Part Number 403-572-03LCD DisplayThe 4-line LCD display gives the operator a basic

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 40 Dukane Manual Part Number 403-572-03INFO KeyPress the INFO key.Figure 5 - 6

Section 5 – Standard System Status and ControlsPage 41Dukane Manual Part Number 403-572-03NOTEA welding cycle cannot be started when the mode is OFFLI

Page vDukane Manual Part Number 403-572-03ContentsSection 1- Introduction ...1 General User Information Read the Manual First

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 42 Dukane Manual Part Number 403-572-03System Parameter SettingsThis section p

Section 6 – Process Control SettingsPage 43Dukane Manual Part Number 403-572-03Section 6Process Control SettingsUser- Provided Process Control Overvie

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Section 6 – Process Control SettingsPage 45Dukane Manual Part Number 403-572-03User- Provided Process Control OverviewThis type of generator does not

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 46 Dukane Manual Part Number 403-572-03Programming ExamplesThis section gives

Section 6 – Process Control SettingsPage 47Dukane Manual Part Number 403-572-03HOW TO - Adjust Ramp Up/Down Times The RampUpfeature,also calledso

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 48 Dukane Manual Part Number 403-572-03 1. Press CANCEL until you see the Main

Section 7 – System Operational TestingPage 49Dukane Manual Part Number 403-572-03SECTION 7System Operational TestingSystem Verication Tests ...

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Section 7 – System Operational TestingPage 51Dukane Manual Part Number 403-572-03System Verication TestsPreliminary Setup1. Plug in the AC line cord

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage viiPage vi Dukane Manual Part Number 403-572-03Dukane Manual Part Number 403-5

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 52 Dukane Manual Part Number 403-572-03System TestTo test the system’s ultraso

Section 7 – System Operational TestingPage 53Dukane Manual Part Number 403-572-03Probe Operation1. If the generator is not online, press the ONLINE k

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 54 Dukane Manual Part Number 403-572-03 Stop Ultrasound OutputPress the OF

Section 8 – TroubleshootingPage 55Dukane Manual Part Number 403-572-03SECTION 8TroubleshootingNo Ultrasonic Output ... 57P

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Section 8 – TroubleshootingPage 57Dukane Manual Part Number 403-572-03No Ultrasonic OutputProbeMake sure that the probe coaxial cable is connected to

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 58 Dukane Manual Part Number 403-572-03INFO Status LED: REDRED - Fault Conditi

Section 8 – TroubleshootingPage 59Dukane Manual Part Number 403-572-03Welding ProblemsWeak WeldsWeak welds or under welding is caused by insufcient e

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 60 Dukane Manual Part Number 403-572-03This page intentionally left blank

Section 9-MaintenancePage 61Dukane Manual Part Number 403-572-03SECTION 9MaintenanceDisplay/Control Panel ... 63Cleaning ..

Section 1 – IntroductionPage viiPage vi Dukane Manual Part Number 403-572-03Dukane Manual Part Number 403-572-03Section 8 - Troubleshooting ...

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Section 9-MaintenancePage 63Dukane Manual Part Number 403-572-03Display/Control PanelCleaning• Do not use any solvents or abrasive cleaners o

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 64 Dukane Manual Part Number 403-572-03Air Ventilation SlotsKeep the ventilati

Section 10 - OptionsPage 65Dukane Manual Part Number 403-572-03SECTION 10OptionsPower Inlet Options ... 67 120V Systems f

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 66 Dukane Manual Part Number 403-572-03This page intentionally left blank

Section 10 - OptionsPage 67Dukane Manual Part Number 403-572-03This section of the User’s Manual provides a general overview of some options/upgrades,

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 68 Dukane Manual Part Number 403-572-03Terminal Block AC LineConnectionVertica

Section 10 - OptionsPage 69Dukane Manual Part Number 403-572-03I/O Panel Options Single I/O Connector See B in Figure 10 - 4 where the I/O panel is se

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 70 Dukane Manual Part Number 403-572-03Option Panel ModulesA single optional m

Section 10 - OptionsPage 71Dukane Manual Part Number 403-572-03Pin Signal Name Connector3 Setup Bit 0 InputJ2 (Pages 26-27)4 Setup Bit 1 Input5 Setup

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 1Page viii Dukane Manual Part Number 403-572-03Dukane Manual Part Number 403-5

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 72 Dukane Manual Part Number 403-572-03MPC Interface Installation GuideThe MPC

Section 10 - OptionsPage 73Dukane Manual Part Number 403-572-03Connecting CablesFor stand-alone interfaces and securely installed panel mounted interf

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 74 Dukane Manual Part Number 403-572-03MPC Interface Status LEDsSystem StatusW

Section 10 - OptionsPage 75Dukane Manual Part Number 403-572-03Confirm probes are retracted from weld position.Load part to be welded.Move part to the

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 76 Dukane Manual Part Number 403-572-035mA0mA20%0%40%60%80%100%10mA 15mA 20mA4

Section 10 - OptionsPage 77Dukane Manual Part Number 403-572-03Isolated I/O Conversion ModulePart Number - 110- 4397The Isolated I/O Conversion Module

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 78 Dukane Manual Part Number 403-572-03NPN TO PNP CONVERSIONSPECIFICATIONS:INP

Section 10 - OptionsPage 79Dukane Manual Part Number 403-572-03PNP TO NPN CONVERSIONSPECIFICATIONS:INPUTS:MINIMUM VOLTAGE: 5.0 VdcCURRENT: 1.5mA @ 5

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 80 Dukane Manual Part Number 403-572-03+5V TO +24V PNP CONVERSION+5VIN 1 @ 0V

Section 10 - OptionsPage 81Dukane Manual Part Number 403-572-03iQLinQ communication options allow automated systems to monitor and change settings in

Section 1 – IntroductionPage 1Page viii Dukane Manual Part Number 403-572-03Dukane Manual Part Number 403-572-03SECTION 1IntroductionGeneral User Info

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 82 Dukane Manual Part Number 403-572-03ContinuedContinued from Previous PageJ2

Section 10 - OptionsPage 83Dukane Manual Part Number 403-572-03Continued from Previous PageiQ LinQTM Ethernet/IPTM ModulePart Number - 110- 4644The Et

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 84 Dukane Manual Part Number 403-572-03This page intentionally left blank

Section 11 - SpecicationsPage 85Dukane Manual Part Number 403-572-03SECTION 11SpecicationsDrawings... 87 Low

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Section 11 - SpecicationsPage 87Dukane Manual Part Number 403-572-03Figure 11-1 Low Prole Chassis DrawingOPTIONALFRONT RACK MOUNTINGOPTIONALREAR RAC

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 88 Dukane Manual Part Number 403-572-03Figure 11- 2 High Prole Chassis Drawi

Section 11 - SpecicationsPage 89Dukane Manual Part Number 403-572-03Operating EnvironmentOperate the generator within these guidelines:Temperature:

iQ Series, Automation-Controlled Probe Generators LS User’s ManualPage 90 Dukane Manual Part Number 403-572-03AC Power RequirementsThe AC input power

Section 11 - SpecicationsPage 91Dukane Manual Part Number 403-572-03Interpreting the Model Number20 HB 120 - 2 C - R1Power L