Dukane AiM iQ Series User manual

Dukane Part No. 403-610-02
iQ Series
AUTOMATION IN MIND
ULTRASONIC POWER SUPPLY
AiM™
Color Front Panel
Dukane IAS • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL [phone]
Dukane products are manufactured in
ISO registered facilities
www.dukane.com
AUTOMATED HAND PROBE PRESS

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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Dukane Manual Part No. 403-610-02
Printed in the United States of America.
Dukane Part Number: 403-610-02
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.

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Dukane Manual Part No. 403-610-02
Revision Revision
Number Summary Date
- 00 Original release. March 28, 2019
- 01 Added patent number 10,710,310 on Pg. ii. January 25, 2020
Changed Sound Caution note on Pg. 5.
Added Optional Power plugs on Pg. 9.
Added No Cords pictures on Pg. 10.
Added DC Power Information page on Pg. 10.
Added 380/480V AC Line Wiring Information page on Pg. 11.
Added Descriptions to J5 Pins 14 and 15 on Pg 20.
Added MPC-E note and link to Pg. 38.
Added additional outline drawings on Pgs.53-55.
Revised AC Power Requirements table on Pg. 54.
Revised Model Number chart on Pg. 55.
Revised Regulatory Agency Compliance on Pg. 56.
- 02 Added SCCR to Pg. 6. April 6, 2021
Revision History

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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Dukane Manual Part No. 403-610-02
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Dukane Manual Part No. 403-610-02
Contents
Section 1 - Introduction, Health and Safety ...........1
General User Information .................................. 3
General Considerations ................................... 4
Plastics Health Notice ..................................... 5
Electrical Safety ......................................... 5
Section 2 - Installation ............................7
Connecting Cables ....................................... 9
Proper Handling of Cable Slack ............................ 13
Section 3 - Standard Connections .................15
Bottom Panel Layout Overview ............................ 17
AC Power Inlet Panel .................................... 17
System Inputs/Outputs Connector .......................... 18
Ultrasound Output Connector .............................. 23
Ethernet/IP Port Connector................................ 24
USB Port Connector ..................................... 24
iQ CommanderTM ..................................... 25
Section 4 - Standard System Status and Controls . . . . 27
Front Panel Controls..................................... 29
Screen Basics.......................................... 32
Multi-Point Control (MPC) Interface ......................... 38
iQLinQTM .............................................. 40
System Verication Tests ................................. 41
Section 5 - Contacting Dukane ....................45
Section 6 - Specications ........................49
Generator Drawings ..................................... 51
Operating Environment................................... 56
AC Power Requirements ................................. 57
Interpreting the Model Number ............................. 58
Regulatory Agency Compliance ............................ 59

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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
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Page 1
Section 1 – Introduction, Health and Safety
Dukane Manual Part No. 403-610-02
SECTION 1
Introduction
Health and Safety
General User Information .....................3
Read the Manual First......................................3
Notes, Cautions and Warnings ...............................3
Drawings and Tables.......................................3
General Considerations.......................4
Plastics Health Notice ........................5
Electrical Safety .............................5
Domestic Power Grounding .................................6
International Power Grounding ...............................6
Short-Circuit Current Rating .................................6

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Dukane Manual Part No. 403-610-02
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Page 3
Section 1 – Introduction, Health and Safety
Dukane Manual Part No. 403-610-02
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
organized to allow you to learn how to safely operate this
generator. The examples given are chosen for their sim-
plicity to illustrate basic operation concepts.
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 have important
information that, if ignored, could have increasingly se-
vere outcomes. These statements help you to identify and
avoid hazards and recognize the consequences. One of
three different symbols also accompany the CAUTION
and WARNING blocks to indicate whether the notice per-
tains 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 num-
ber followed by a sequence number. The sequence num-
ber begins with one in each section. The gures and tables
are numbered separately. The gures use Arabic 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 3 while Table 3- II
would be the second table in Section 3.
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.

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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Dukane Manual Part No. 403-610-02
Continued
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 Dukane.
Unauthorized modications could cause equipment dam-
age and/or injury to the operator. In addition, unauthorized
modications will void equipment warranty.
Keep the Cover On - Do not remove any equipment
cover unless directed to do so by Dukane. The genera-
tor 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 5.
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 - WearANSI approved safety impact
goggles.
Acoustic Stack Hazard - When an acoustic stack (trans-
ducer, 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 ultra-
sonic plastic assembly equipment is used with automatic
material handling equipment in an automated system.
NOTE
These recommendations apply to the weld-
ing 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. Typical of the
iQ Series AiM™system consists of the iQ
generator, cables, transducer, booster, horn,
and xture.
General Considerations
Please observe these health and safety recommenda-
tions for safe, efcient, and injury-free operation of your
equipment.
Any fixture manufactured by
a third party must comply
with all OSHA and ANSI re-
quirements. All fixtures must
be guarded as necessary.
Dukane does not assume any re-
sponsibility or liability for xtures
manufactured by the customer
or any third party manufacturer.
WARNING
CAUTION
At some time you may be asked
to remove equipment covers
by the Dukane Service Dept.
personnel. Before doing so,
disconnect the unit electrically
from the incoming line AC power.
WARNING
Never operate the genera-
tor with the cover off. This is
an unsafe practice and may
cause injury.

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Section 1 – Introduction, Health and Safety
Dukane Manual Part No. 403-610-02
Continued
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 medi-
cations. 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.
General Considerations
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 provided where such materials are processed.
Inquiries should be made to the U.S. Department of Labor
concerning OSHAregulations 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 theAC 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.
Continued from Previous Page
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 number
31370614.003 for more detail
on specic model numbers
and frequencies.
CAUTION
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 securely connected
and the connections and cable
routing checked a nal time,
the power may be restored.

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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Dukane Manual Part No. 403-610-02
Approved 2 pole, 3 wire grounding
receptacle HUBBELL No. 5652 or
equivalent to NEMA 6–15R or 6–20R
Figure 1–1 Example of 220/240 Volt,
Grounded, 3-Prong Receptacle
Electrical Safety
Domestic Power Grounding
For safety, the power cords used on this product have a
three-wire, grounding-type power cord. Figure 1-1 il-
lustrates the appropriate electrical outlet to use with the
power cord that is included with systems shipped to North
America.
International Power Grounding
The power cable normally provided for international use is
compatible with the power outlet used in many Continen-
tal European countries (Refer to Figure 1–2). However,
if your application requires another type of power cord,
check with your equipment supplier, and follow local reg-
ulations concerning proper wiring and grounding.
Grounding Contacts
Typical Outlet
Provided Cable
Figure 1-2 International 220/240V Grounding
CAUTION
If you have a two-prong elec-
trical receptacle, we strongly
recommend that you replace
it with a properly grounded
three-prong type. Have a
qualied electrician replace it
following the National Electric
Code and any local codes
and ordinances that apply.
See Figures 1-1 and 1-2.
If there is any question about
the grounding of your recep-
tacle, have it checked by a
qualified electrician. Do not
cut off the power cord ground-
ing prong, or alter the plug in
any way. If an extension cord
is needed, use a three-wire
cord that is in good condition.
The cord should have an ad-
equate power rating to do the
job safely. It must be plugged
into a grounded receptacle.
Do not use a two-wire exten-
sion cord with this product.
CAUTION
Short-Circuit Current Rating
The SCCR (Short-Circuit Current Rating) value is the
maximum short-circuit current an electrical component
can safely withstand without causing a shock or fire
hazard. For integration into an electrical control panel/
cabinet, some customers require the generator SCCR
rating. The iQ generator include a AC line circuit breaker
that has a SCCR rating as indicated below.
For generators rated between 700-2600 watts of output
power, the SCCR rating is 250 Amps. For generators rated
3600 watts and above, the SCCR rating is 1500 Amps.
Continued from Previous Page

Page 7
Section 2 – Installation
Dukane Manual Part No. 403-610-02
SECTION 2
Installation
Connecting Cables ...........................................9
AC Power ................................................. 9
DC Power ................................................ 10
Wiring Information for 380/480 VAC 3 Phase Lines .................11
Automation Controlled Probe System........................... 12
RFI Groundings............................................ 13
Proper Handling of Cable Slack .................13
Coil Extra Slack............................................ 13
Avoid Excessive Bending .................................... 13

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Section 2 – Installation
Dukane Manual Part No. 403-610-02
Connecting Cables
Details about the various system connectors and their pin
assignments are covered in Section 3.
The connections are the same for both the vertical and
horizontal generator congurations. However, the panel
location of the connectors differs between the two chassis
styles.
AC Power
Detached Cords
The AC line cords supplied with the standard generators
are matched to the ultrasonic output power rating and the
continent of specied use. See Table 2-I.
Attached Cords
240 Volt Single Phase Systems - High power genera-
tors with power ratings above 2600W use permanently at-
tached power cords.
Table 2 - I Standard IEC AC Power Cord Part Numbers
Continent of Use Power Cord
Part Number
Power
North America 200-1109 120V, 15A
200-1110 240V, 15A
Continental Europe 200-1111 240V, 16A
The power cord is equipped
with a three-prong, ground-
ed-type plug for your safety.
Whenever a two-slot re-
ceptacle is encountered, we strongly
recommend that it is replaced with a
properly grounded three-lead receptacle.
Have a qualified electrician do the
replacement in accordance with the
National Electrical Code and local
codes and ordinances. DO NOT
cut off the power cord grounding
prong or alter the plug in any way.
CAUTION
Optional Plugs Available
NEMA L6-30P
Dukane part number 570-296
Figure 2-1 North American Plug
IEC 60309 (Sleeve 332P6)
Dukane part number 570-301
Figure 2-2 International Plug

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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Dukane Manual Part No. 403-610-02
No Cords
Three-Phase Systems - High power 380/480 VAC Three-
Phase generators do not include a AC line cord and must
be directly wired. It is recommended that the AC cord
wires be stranded.
The AC terminal connector has four terminals labeled L1,
L2, L3 and N (GND). The three different phase wires get
attached to L1, L2 and L3. The terminal labeled “N” must
be connected to the ground wire. Insert the AC wire into
the side hole of the terminal and move the white terminal
lever completely down facing the terminal hole.
Figure 2-3 shows the AC strain relief connector used to
secure the power cord. To secure a power cable, remove
the four black hex screws to remove the cord mounting
plate. Then unscrew the silver cap and place it onto the
power cable. The cable is then inserted into the connector
and the cap is screwed back onto the connector to secure
the cable rmly. Leave enough cable on the back side of
the cable connector to insert the cable wires into the AC
input terminals shown in Figure 2-4.
380/480 VAC 3 Phase Line Wiring Information is found
on Page 11.
DC Power
Some generators, such as 3 phase 480 VAC versions, have
a separate +24 VDC (3 Amps Max.) input that powers the
logic portion of the generator. This allows the AC power
to be removed without affecting communication and con-
trol functions. iQLinQ™, front panel and iQ Explorer II
interfaces can modify and monitor all parameters as long
as the +24 VDC input is active. At the end of the cable is
a white and a black wire. The white wire is connected to
the +24 VDC supply and the black wire is connected to the
supply ground. The +24 VDC cable must have power in
order for the generator to operate.
Continued from Previous Page
Figure 2 - 4 AC Wires Terminal Connector
Figure 2 - 3 AC Power Cord Mounting Plate
Figure 2 - 5 +24 VDC Control Power Cord

Page 11
Section 2 – Installation
Dukane Manual Part No. 403-610-02
Wiring Information for 380/480 VAC 3 Phase Lines
For more details, refer to Application Note AN524 found on the Dukane website at:
https://documents.dukane.com/AppNote/AN524.pdf
Wiring from a 3 Phase Circuit (WYE)
3 Phase 380/480 Volt connections should be wired as shown below.
Figure 2 - 6 Wiring a 3 Phase 380/480 Volt Circuit (WYE)
Wiring from a 3 Phase Circuit (Delta)
3 Phase 380/480 Volt connections should be wired as shown below.
Figure 2 - 7 Wiring a 3 Phase 380/480 Volt Circuit (Delta)

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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Dukane Manual Part No. 403-610-02
Continued from Previous Page
Automation Controlled Probe
System
1. Ground the generator chassis using the supplied
14-Gauge wire, and attach it to the grounding stud
PE: Ain Figure 2-8.
2. Recommended – Ground the probe support. This is a
user–supplied 14-Gauge wire. This is required if the
probe support does not have a good earth ground
through the machine.
3. Input Cable/Output Cable - Attach the automation
control cable from the user–supplied automation
equipment to the system input HD-26 connector, J5
on the I/O panel: Bin Figure 2-8.
4. Attach the high voltage coaxial cable from the probe
to the ultrasound output connector J1:
Cin Figure 2-8.
5. Connect the AC power cord to the generator IEC
power inlet connector, and plug the other end into
an approved AC outlet: Din Figure 2-8.
Figure 2-8 Generator - Bottom View (Vertical Panel Mount Chassis)
CULTRASOUND
A
AC POWER ENTRY
D
PE
BSYSTEM I/O

Page 13
Section 3 – Standard Connections
Dukane Manual Part No. 403-610-02
Earth
Ground
#14 Gauge
Stranded or
Solid Wire
Fixed Probe Mount
or 2nd Chassis
Grounding Stud
3rd Chassis
Grounding
Stud
Chassis Grounding
Stud
Recommended protective
earth ground connection
wire color: green or green
with yellow stripe.
To minimize electrical noise
and eliminate ground currents,
ground the chassis as shown.
Use a STAR configuration
(illustrated below). Do not
DAISY CHAIN the grounds.
RFI Grounding (PE)
In addition to the safety considerations previously men-
tioned, proper grounding at the generator power cord is
essential for the effective suppression of electrical noise
or RFI (Radio Frequency Interference). Every ultrasonic
generator contains a RFI lter which blocks noise on the
AC power line from entering the system control circuitry.
This lter also prevents ultrasonic frequency noise from
being fed back into the AC power line. In order for the
RFI lter to operate properly, it is necessary to correctly
ground the system. Run a grounding wire from the ground-
ing stud PE connection to the nearest grounded metal pipe
or equivalent earth ground, and secure it with a ground
clamp.
See Figure 2-8 on Page 12 for the location of the PE stud.
Proper Handling of Cable Slack
Coil Extra Slack
When taking up slack in cables, the extra length should
be coiled up as shown in Figure 2-9 rather than folded as
shown in Figure 2-10.
Avoid Excessive Bending
Avoid excessive tension and bends on cables. Cables
should be routed so that there are no abrupt bends in the
cables, especially near their connectors.
Figure 2-9 Cable Slack Take-up - Correct Figure 2-10 Cable Slack Take-up - Incorrect
NOTE
Cables shown in the two gures below are
representative samples. If cables have
slack, coil them rather than fold them.

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