Dukane iQ Series Installation and operating instructions

AN502 (REV 07) © Dukane 2016. All Rights Reserved.
Page 1 of 16
DUKANE
APPLICATION NOTE
AN502
Intelligent Assembly Solutions
iQ Series
ULTRASONIC PROBE SYSTEM
LS/LS-E
Automation Interface Guidelines

AN502 (REV 07) © Dukane 2016. All Rights Reserved.
Page 2 of 16
DUKANE
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

AN502 (REV 07) © Dukane 2016. All Rights Reserved.
Page 3 of 16
DUKANE
APPLICATION NOTE
AN502
Intelligent Assembly Solutions
System Input Cable Pinouts
Pin
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

AN502 (REV 07) © Dukane 2016. All Rights Reserved.
Page 4 of 16
DUKANE
APPLICATION NOTE
AN502
Intelligent Assembly Solutions
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

AN502 (REV 07) © Dukane 2016. All Rights Reserved.
Page 5 of 16
DUKANE
APPLICATION NOTE
AN502
Intelligent Assembly Solutions
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

AN502 (REV 07) © Dukane 2016. All Rights Reserved.
Page 6 of 16
DUKANE
APPLICATION NOTE
AN502
Intelligent Assembly Solutions
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

AN502 (REV 07) © Dukane 2016. All Rights Reserved.
Page 7 of 16
DUKANE
APPLICATION NOTE
AN502
Intelligent Assembly Solutions
System Output Cable Pinouts
Pin
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

AN502 (REV 07) © Dukane 2016. All Rights Reserved.
Page 8 of 16
DUKANE
APPLICATION NOTE
AN502
Intelligent Assembly Solutions
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

AN502 (REV 07) © Dukane 2016. All Rights Reserved.
Page 9 of 16
DUKANE
APPLICATION NOTE
AN502
Intelligent Assembly Solutions
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)

AN502 (REV 07) © Dukane 2016. All Rights Reserved.
Page 10 of 16
DUKANE
APPLICATION NOTE
AN502
Intelligent Assembly Solutions
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