Dukane iQ Auto-Plus 20AT060-U Series User manual

www.dukane.com
Dukane Part No. 403 - 591 - 01
Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 - 4900
Dukane products are manufactured in
ISO registered facilities
iQ Series
ULTRASONIC GENERATOR/POWER SUPPLY
Auto-Plus
User’s Manual
AUTOMATED PRESS
HAND PROBE

Page ii
iQSeries,Auto-Plus User’s Manual
Dukane Manual Part No. 403-591-01
Printed in the United States of America.
Dukane Part Number: 403-591-01
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,
7,819,158, 8,052,816, and 10,710,310.
Copyright © 2020 Dukane
2900 Dukane Drive
St. Charles, IL 60174 USA
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.
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 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.

Page iii
Dukane Manual Part No. 403-591-01
Revision History
Revision Revision
Number Summary Date
- 00 Original release. March 14, 2014
- 01 Updated table of contents on Pgs. v-iv. January 18, 2021
Patents 5,798,599 / 5,880,580 / 6,984,921 made
inactive on Pg. ii.
Added patent number 10,710,310 on Pg. ii.
Added hyperlinks to all sections.
Temperature note was 100°F on Pg. 5.
Changed sound caution note on Pg. 10.
Added MPC-E note and link to pg. 20.
Revised Table 4-I on Pg. 32.
Added distance and ANYBUS options on Pg. 36.
Removed Computer Interface section on Pg. 36.
Added new iQLinQ Protocols on Pg. 44.
Removed all iQLinQ RS-232 Interface Option and information
for S Model on Pg. 44.
Added iQ Commander download and installation instructions.
Revised Power Requirements table on Pg. 55.
Revised Model Number chart on Pg. 57.
Revised Regulatory Compliances on Pg. 58.

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iQSeries,Auto-Plus User’s Manual
Dukane Manual Part No. 403-591-01
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Page v
Dukane Manual Part No. 403-591-01
Contents
Section 1 - Installation .......................................1
General User Information...................................3
Generator Overview.......................................4
Key Generator Features ...................................4
Thermal Considerations....................................5
Section 2 - Health and Safety ..............................7
General Considerations ....................................9
Plastics Health Notice ....................................10
Electrical Safety .........................................10
Section 3 - Installation .......................13
Unpacking .............................................15
Placement .............................................15
Power Grounding........................................16
Chassis Grounding Stud ..................................16
Connecting Cables.......................................17
MPC Module Installation Guide .............................22
Section 4 - System Operation . . . . . . . . . . . . . . . . . 25
Introduction ............................................27
iQ Auto-Plus System Operational Test........................28
iQ Auto-Plus System with MPC Module Operational Test .........29
LED Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Section 5 - Options..........................33
Heat Sink ..............................................35
Distance Option .........................................36
ANYBUS Option ........................................36
Section 6 - Automation Interface ..............37
Input/Output Connection Examples..........................39
Dedicated E-Stop Switch Wiring Diagram .....................43
Automation System Safety Circuit Wiring Diagram ..............43
iQLinQ™.............................................44
iQ Commander
™.......................................45
TM

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iQSeries,Auto-Plus User’s Manual
Dukane Manual Part No. 403-591-01
Contents
Section 7 - Contacting Dukane ................47
Section 8 - Specications ....................51
Generator Outline Drawing ................................53
Weight, Operating Environment.............................54
AC Power Requirements ..................................55
Interpreting the Model Number .............................56
iQ Auto to iQ Auto Plus Inputs /Outputs Comparison.............57
Regulatory Agency Compliance.............................58
Section 9 - Appendices ......................59
Appendix A, List of Figures ................................60
Appendix B, List of Tables .................................61
Index .....................................62

Page 1
Section 1 – Introduction
Dukane Manual Part No. 403-591-01
SECTION 1
Introduction
General User Information . . . . . . . . . . . . . . . . . 3
Read The Manual First . . . . . . . . . . . . . . . . . . . . . . 3
Notes, Cautions and Warnings . . . . . . . . . . . . . . . . . . 3
Drawings and Tables . . . . . . . . . . . . . . . . . . . . . . . 3
Generator Overview . . . . . . . . . . . . . . . . . . . . 4
Key Generator Features . . . . . . . . . . . . . . . . . . 4
Thermal Considerations . . . . . . . . . . . . . . . . . . 5

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iQSeries,Auto-Plus User’s Manual
Dukane Manual Part No. 403-591-01
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Page 3
Section 1 – Introduction
Dukane Manual Part No. 403-591-01
NOTE
Note statements provide additional
information or highlight procedures.
Condition
or Practice
Electrical
Hazard
Hearing
Protection
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.
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.
Particular models are listed in Section 8 - Specications .
Notes, Cautions and Warnings
Throughout this manual we use NOTES to provide infor-
mation 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 increas-
ing levels of important information. These statements help
you to identify and avoid hazards and recognize the conse-
quences. 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
number begins with one in each section. The gures and
tables are numbered separately. The gures use Ara-
bic 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.

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iQSeries,Auto-Plus User’s Manual
Dukane Manual Part No. 403-591-01
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
automated systems.
The generator design accepts several control input signals,
provides system output signals, has a variety of status LED
indicators, and built-in USB and EtherNet connectors.
The Multi-Probe Control (MPC) interface allows the gen-
erator to power multiple probes selected by an automated
control system.
This product’s rugged internal ultrasonic generator cir-
cuitry ensures a continuous resonant frequency lock at
the start of each weld. Users can modify generator per-
formance to meet a wide variety of ultrasonic processing
requirements if needed.
The generator’s compact size allows multiple units to be
placed into an industrial equipment cabinet, and the gen-
erator will operate at the same international line voltage
input specications as the other generators of this product
family. It also includes an RFI line lter that passes strict
CE test specications for global applications.
Key Generator Features
• Compact Enclosure Size requires a small footprint for
either vertical or horizontal mounting into your equip-
ment cabinet.
• 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 gen-
erator operation and increased reliability.
• Linear Ramp Soft Start circuitry allows the acous-
tic stack to ramp up to operating amplitude smoothly,
minimizing the startup surges and abnormal stress to
the stack and generator.
• Automatic Tuning tracks the resonant frequency of
the acoustic stack (horn, booster, transducer) and ad-
justs the generator output frequency to match it. This
is done for every weld cycle and eliminates the need
to manually tune the generator.
• Line Voltage Regulation automatically maintains
constant amplitude regardless of line voltage devia-
tion. 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 amplitude auto-
matically regardless of power draw. The ultrasonic
output amplitude level is held to within ±1% to pro-
vide weld process consistency and reduced weld cycle
times.
• Power Factor Corrected Universal AC Power
Source means that standard 600 watt systems will
operate worldwide at all industrial high line voltage
levels, whether it is 100-200VAC @60Hz in Japan,
240VAC @50Hz in Europe or 100-240VAC @60Hz
in the United States. There are no internal transformer
taps to change for worldwide operation.
• Amplitude Adjustment Control allows the peak -to-
peak excursion of the horn at its workface to be ad-
justed between 20% and 100% of the horn’s nominal
amplitude.
• Multiple Electronic Overload protection circuits
prevent instantaneous component failure in the event
of extreme output overload conditions and rated over-
load power limit is based on the actual true RMS
power output level.
• Optional Weld by Distance Feature to monitor up
to four analog 0-10 VDC encoders (requires customer
supplied encoders).
• CE Certication means that the system meets the
required European standards to be sold and used in
Europe.
• ISO Certied means that this system has been manu-
factured to high quality standards and assures you of
manufacturing excellence.
• TUV Certication - TÜV Rheinland certies Dukane
products comply with applicable UL (Underwriters
Laboratories) and CSA (Canadian Standards Associa-
tion) requirements.

Page 5
Section 1 – Introduction
Dukane Manual Part No. 403-591-01
Thermal Considerations
The thermal design of this generator is for applications
that require 100% of rated power at no more than a 50%
duty cycle.
NOTE
Add transducer cooling as necessary to keep
front mass temperature to 110 °F or less.

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Dukane Manual Part No. 403-591-01
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Page 7
Section 2 – Health and Safety
Dukane Manual Part No. 403-591-01
SECTION 2
Health and Safety
General Considerations............................. 9
Plastics Health Notice ............................. 10
Electrical Safety .................................. 10
Power Grounding Connection ............................11

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iQSeries,Auto-Plus User’s Manual
Dukane Manual Part No. 403-591-01
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Page 9
Section 2 – Health and Safety
Dukane Manual Part No. 403-591-01
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, switches, controls, cables,
transducer, booster, horn, and xture.
CAUTION
At some time you may be asked
to remove equipment covers
by the Dukane Service Dept.
personnel. Before doing so, dis-
connect the unit electrically from
the incoming AC power line.
General Considerations
Please observe these health and safety recommenda-
tions 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 Du-
kane. Unauthorized modications could cause equipment
damage and/or injury to the operator. In addition, unauthor-
ized modications will void equipment warranty.
Keep the Cover On - Do not remove any equipment cover
unless directed to do so by Dukane. The generator produces
hazardous electrical voltages which could cause injury.
Grounded Electrical Power - Operate this equipment only
with a grounded electrical connection.
See Electrical Safety for grounding instructions, Page 10.
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 E-STOP (Abort) Switch - Install a system
E-STOP (abort) switch at each operator station when
ultrasonic plastic assembly equipment is used with auto-
matic material handling equipment in an automated system.
Foot Switch - Do not use a foot switch. Using a foot switch
in place of the optical touch nger switches (operate switch-
es) violates OSHAregulations. Do not install a foot switch.
Any xture manufactured by
a third party must comply
with all OSHA and ANSI re-
quirements. All xtures must
be guarded as necessary.
Dukane does not assume
any responsibility or liability
for fixtures manufactured
by the customer or any third
party manufacturer.
WARNING
Continued
Never operate the generator
with the cover off. This is an
unsafe practice and may
cause injury.
WARNING

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iQSeries,Auto-Plus User’s Manual
Dukane Manual Part No. 403-591-01
Continued from Previous Page
General Considerations
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 medica-
tions. 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.
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 pro-
vided 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.
Electrical Safety
The iQ Series generator provides the operating power
and power returns. Make sure the generator is grounded
properly.
In addition to the safety considerations, proper grounding
is essential for the effective suppression of RFI (Radio
Frequency Interference). Every generator contains a RFI
lter which blocks noise on the AC power line from enter-
ing the generator control circuitry. This lter also prevents
ultrasonic RFI from being fed back into the AC power line.
Always connect the included ground wire from the PE
ground of the generator to the nearest grounded metal pipe
or equivalent earth ground by means of a ground clamp.
CAUTION
When making cable connec-
tions 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 se-
curely connected and the
connections and cable rout-
ing checked a final time,
the power may be restored.
WARNING
Keep head, hands, limbs
and body at least six inch-
es (152 mm) away from an
operating press/thruster. A
vibrating, descending horn
can cause burns and/or
crushing injuries.
See TUV test report num-
ber 31370614.003 for more
detail on specific model
numbers and frequencies.
CAUTION

Page 11
Section 2 – Health and Safety
Dukane Manual Part No. 403-591-01
Electrical Safety
Power Grounding Connection
Figure 2-1 illustrates how the AC line is connected to the
iQ Auto-Plus generator.
Figure 2–1 AC Line Connection
Terminal Wire Color
North America Europe
L (Live) Black Lt. Brown
(Ground) Green Green w/yellow
stripe
N (Neutral) White Lt. Blue
Table 2-I Conventional Wire Color Code
L
N
iQ Auto Plus Power
Inlet
Pluggable AC
Line Connector
For safe system operation: To
avoid the risk of re, electrical
shock, serious injury or death,
the power line safety ground
must be securely connected
to the center terminal on the
(pluggable) AC line connector.
CAUTION
If there is any question
about grounding of your
equipment and/or its elec-
trical power source, con-
tact a qualified electrician.
CAUTION
Continued from Previous Page

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Dukane Manual Part No. 403-591-01
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Page 13
Section 3 – Installation
Dukane Manual Part No. 403-591-01
SECTION 3
Installation
Unpacking ..................................... 15
Placement ...................................... 15
Power Grounding ................................ 16
Chassis Grounding Stud .......................... 16
Connecting Cables............................... 17
Basic Connections....................................17
P1 System I/O Connector Pinout.........................18
Multi-Probe Control (MPC) .............................20
MPC Module Installation Guide..................... 22
Connecting Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
MPC Module Status LEDs..............................24

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