Dukane IQ Explorer 3 User manual

IQ Explorer 3
www.dukane.com [email protected]
QUICK START GUIDE

Copyright © 2021
Dukane
2900 Dukane Drive
St. Charles, IL 60174 USA
Noce of Rights:
All rights reserved. No part of this manual including the interior design, cover design and icons may be
reproduced, transmied or ulized in any form or by any means, electronic, mechanical, photocopying,
recording, or by any informaon storage and retrieval system, without wrien permission from Dukane.
Noce of Liability:
The informaon contained in this manual is distributed on an “As is” basis, without warranty. While
every precauon has been taken in the preparaon of this manual, Dukane shall not have any liability
to any person or enty with respect to any liability, loss, or damage caused or alleged to be caused
directly or indirectly by the instrucons contained in this manual, or by the hardware products
described herein.
Specicaons subject to change without noce.
This user’s manual documents product features, hardware, and controls soware available at the me
this user’s manual was published.
Dukane Part Number: 403-620-00
Dukane ultrasonic equipment is manufactured under one or more U.S. Patents.
Find the list of all the Ultrasonic Equipment Patents on our website below:
hps://www.dukane.com/patents/

SECTION 1 - Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Press System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
General User Informaon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
AC Power Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
IQ Explorer 3 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Key Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SECTION 2 - Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HMI Cable Connecons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
System Cable Connecons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
SECTION 3 - Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Geng Started Using IQ Explorer 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Regulatory Agency Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Contacting Dukane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Dukane ISO Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Contents

SECTION 1 - INTRODUCTION
IQ Explorer 3 QUICK START GUIDE 1
SECTION 1
Introducon

IQ Explorer 3 QUICK START GUIDE 2
SECTION 1 - INTRODUCTION
Press System Overview
The Innity Series Servo Ultrasonic Press System is used for welding thermoplascs. A typical Innity™ ultrasonic welding
system is shipped completely with a press (thruster, base, and column), generator, an ultrasonic stack (transducer, booster,
horn), xturing, cables, and a HMI (with the IQ Explorer 3 soware installed) for applicaon setup and data acquision.
General User Information
This Quick Start Guide provides informaon to set up and operate Dukane’s HMI and IQ Explorer 3 soware. Please read
it before using the system to become familiar with the equipment to ensure correct and safe operaon.
Figure 1-1 Typical Press System
THRUSTER
HMI
GENERATOR
Introducon

SECTION 1 - INTRODUCTION
IQ Explorer 3 QUICK START GUIDE 3
AC Power Requirements
Dukane HMI
AC line voltage - 90-260 VAC
AC line current - 1 Amp
IQ Explorer 3 Overview
The IQ Explorer 3 soware comes standard on a Dukane HMI. This program connects with the Innity™ generator/press
through a user interface and is used for conguraon and setup.
Key Features
IQ Explorer 3 User Interface
• Windows 10 operang system - Familiar le folder menu structure, requiring no special training.
• Touch screen input - Makes programming easier. All welder setup parameters are programmed from one menu page.
(Applies to the HMI or PCs with touch screen, such as tablets.)
• Ethernet connecvity - For communicaons to the Innity™ welder.
• Control - Control feature for locking out system controls that complies with FDA 21 CFR Part 11.
• Remote connecvity - Dukane hotline is available for system diagnoscs and troubleshoong 24-hours a day. (VPN
access to the welder’s network is required. Consult with your IT sta about availability.)
• One screen operaons page - Most recent weld cycle and graph data with ability to modify commonly used process
sengs.
• F1 Help command - Instantly displays explanaon of funcon.
• IQ Explorer 3 User Interface - It is a peripheral device. Operaon is independent of the generator, and removal or
malfuncon of the IQ Explorer 3 does not aect machine funconality.
• Eight user-selectable graph parameters - Velocity, energy, power, distance, amplitude, frequency, force and pressure
for viewing and storage of each weld.
• Producon analysis screen - Displays eight-hour shi producon stascs: good, bad, suspect quanes and
percentages.
• Advanced stack diagnoscs - Includes power and frequency graphs for stack (horn) documentaon and future
reference for troubleshoong.
• Tool idencaon - Uses barcode system to idenfy tooling.
• Work cell - A Dukane Lean Work Cell can be integrated with basic PLC managed operaons.
• Data Analysis for SPC - Feature that aggregates and charts large quanes of cycle data results.
• Barcodes - Feature that allows scanned barcodes from parts to be aributed to cycle data.

IQ Explorer 3 QUICK START GUIDE 4
SECTION 2
Cable Connecons

SECTION 2 - CABLE CONNECTIONS
IQ Explorer 3 QUICK START GUIDE 5
HMI Cable Connecons
Figure 1-1 HMI Connecons
AC POWER CONNECTION HMI POWER SWITCHETHERNET PORTS

IQ Explorer 3 QUICK START GUIDE 6
SECTION 2 - CABLE CONNECTIONS
System Cable Connecons
Typical system components are:
• Ultrasonic Generator
• Press
• HMI
Make cable connecons in the following order, referring to the Fig 1-2 and Table 1-1 on the next page:
1. Connect cables 1-5. Cables 3 and 4 are to be connected to an eecvely grounded rod.
2. Connect cable 9 if oponal automaon equipment is used with the system.
3. Connect power cords 6-8.
4. Arrange cables as desired, but do not bundle the power cords (6-8) with any other cables.
CAUTION
Before connecng or disconnecng cables: Put power switches for the generator, press,
and any user-supplied automaon equipment in the OFF posion. Turn o electrical power.
Remove AC power cords from their receptacles.
DO NOT operate the generator unless the ultrasound coaxial cable is connected, and the
transducer is installed in the thruster. Otherwise, an overload condion could occur, with
possible damage to the generator.

SECTION 2 - CABLE CONNECTIONS
IQ Explorer 3 QUICK START GUIDE 7
Figure 1-2 Cable Connecons
Table 1-1 Cable Connecons
Cable Number Cable Description Standard Length (Meters)
1 Ultrasound 2
2 Press Interface 2
3 Press Grounding 5
4 Generator Grounding 5
5 HMI Communicaons (CAT 5 / RJ45 Ethernet cable) 3
6 Press Power Cord (line voltage: 90-240 VAC, 50/60 Hz, 10 A) 2
7 Generator Power Cord (line voltage depends on generator model) 2.5
8 HMI Power Cord (line voltage: 90-240 VAC, 50/60 Hz, 10 A) 2.5
9 Automaon I/O (oponal) 3