Dukane AiM iQ Series User manual

Dukane • 2900 Dukane Drive • St. Charles, Illinois 60174 USA • TEL (630) 797 - 4900
Dukane products are manufactured in
ISO registered facilities
www.dukane.com
Dukane Part No. 403-611-00
iQ Series
AUTOMATION IN MIND
ULTRASONIC POWER SUPPLY
AiM™
AUTOMATED HAND PROBE PRESS

Page ii Dukane Manual Part Number 403-611-00
iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Printed in the United States of America.
Dukane Part Number: 403-611-00
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 and, 8,052,816
Copyright © 2019 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 Number 403-611-00
Revision History
Revision Revision
Number Summary Date
- 00 Original release. March 28, 2019

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Dukane Manual Part Number 403-611-00
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
RFI Grounding.......................................... 11
Proper Handling of Cable Slack ............................ 11
Section 3 - Standard Connections .................13
Bottom Panel Layout Overview ............................ 15
AC Power Inlet Panel .................................... 16
System Inputs/Outputs Connector .......................... 16
Ultrasound Output Connector .............................. 21
Ethernet/IP Port Connector................................ 22
USB Port Connector ..................................... 23
Section 4 - Standard System Status and Controls . . . . 25
Status LED ............................................ 27
Multi-Point (MPC) Inteface ................................ 29
iQLinQ™.............................................. 31
Section 5 - Contacting Dukane ....................33
Section 6 - Specications ........................37
Generator Drawing ...................................... 39
Operating Environment................................... 40
AC Power Requirements ................................. 41
Interpreting the Model Number ............................. 42
Regulatory Agency Compliance ............................ 43

iQ Series Aim™Automation in Mind, Ultrasonic Power Supply User’s Manual
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Section 1 – Introduction, Health and Safety
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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

iQ Series Aim™Automation in Mind, Ultrasonic Power Supply User’s Manual
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Section 1 – Introduction, Health and Safety
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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.
CAUTION
Caution statements
identify conditions or
practices that could result
in damage to the equip-
ment or other property.
WARNING
Warning statements
point out conditions or
practices that could re-
sult in personal injury or
loss of life.
NOTE
Note statements provide additional
information or highlight procedures.
Condition
or Practice
Electrical
Hazard
Hearing
Protection

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iQ Series AiM™ Automation in Mind, Ultrasonic Power Supply User’s Manual
Page 4 Dukane Manual Part Number 403-611-00
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 - Wear ANSI 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
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.
Typical of the iQ Series AiMTM system
consists of the iQ generator, cables, trans-
d u c e r , b o o s t e r , h o r n , a n d  x t u r e .
CAUTION
At some time you may be
asked to remove equipment
covers by the Dukane Service
Dept. personnel. Before doing
so, disconnect the unit electri-
cally from the incoming line AC power.
General Considerations
Please observe these health and safety recommenda-
tions for safe, efcient, and injury-free operation of your
equipment.
WARNING
Never operate the genera-
tor with the cover off. This
is an unsafe practice and
may cause injury.
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 re-
sponsibility or liability for xtures
manufactured by the customer or
any third party manufacturer.
WARNING
Continued
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