Operators and Service Manual
Avery Dennison
S
ONIC
1000w with Telsonics
Knife
05571392 Rev 4.4 06 March, 2019
Original Instructions
© 2016 Avery Dennison Corp. All rights reserved
User’s Manual—Sonic Knife
WARNING
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions:
1) this device may not cause harmful interference, and
2) this device must accept any interference that may cause undesired operations.
This Class A digital apparatus meets all requirements of the Canadian Interference
Causing Equipment Regulations. Cet appareil numérique de la classe A respecté toutes les
exigences du Règlement sur le matériel brouilleur du Canada
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User’s Manual—Sonic Knife
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Table of Contents
1.0 Introduction 7
2.0 Safety Information 9
3.0 Installation 11
3.1
Preparing for the installation 11
3.1.1 AC Power Line 11
3.1.2 Location Considerations 11
3.1.3 User Safety 11
3.2
Receiving 12
3.2.1 Unpacking 12
3.2.2 Repacking 13
3.2.3 Disassembly and Disposal 13
3.2.4 Storing Sonic Knife When Not In Use 13
3.3
Installing the Sonic Knife to the Printer 13
3.4
Cables from Sonic Knife to the Printer 15
3.5
Connecting the Ultrasonic Power Supply 15
3.6
Components 17
4.0 Operation 19
4.1
Ultrasonic Power Supply Introduction 19
4.1.1 Fuse 19
4.1.2 RF Cable to Sonic Converter 19
4.1.3 Custom Trigger 20
4.1.4 Air Cooling 20
4.2
Power Supply Settings 20
4.3
Ultra Sonic Horn "Stack" 21
4.4
Threading stock through the sonic knife 21
5.0 Sonic Knife Cleaning 24
6.0 Sonic Knife Maintenance 25
6.1
Replacing the Knife Blade 25
6.2
Leveling the Knife Blade 27
6.3
Knife Pressure and Dwell Gap Adjust 28
6.4
Proximity Switch Adjustment 32
6.5
Horn Replacement / Adjustment 34
6.6
Lifter Bracket / Adjustment 35
7.0 Troubleshooting 36
8.0 Sonic Knife Specification 37
9.0 Appendix A 38
9.1
Manufactures of Hearing Protectors 38
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User’s Manual—Sonic Knife
10.0 Electrical Schematic 39
10.1 115V / 230V Schematic 40
10.2 500 Downstacker Schematic 41
11.0 Assembly Drawings Mechanical 42
11.1 Cover Assembly 43
11.2 Drive Assembly and Parts List 43
11.3 PCB Electrical Assembly and Parts List 44
11.4 InFeed Conveyor Assembly 46
11.5 Infeed Conveyor Assembly Parts List 47
11.6 H Frame Assembly 48
11.7 H Frame Assembly Parts List 49
11.8 Frame Assembly and Parts List 50
11.9 Exit Conveyor Assembly and Parts List 51
11.10 Safety Guards 52
11.11 Safety Guards Parts List 53
12.0 Revision Record 54
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1.0 Introduction
AVERY DENNISON has designed the sonic knife to work in-line with the
SNAPTM family of printers. It is not intended for stand-alone operation.
The sonic knife uses ultra-sonic vibrations to produce a cut in a woven polyester
label. These vibrations create micro-pockets of heat which melt the polyester
fibers on a microscopic level, cut through the fibers, and join the fibers to
adjacent fibers. The result is a smooth cut that is:
fray resistant, and
soft to the touch.
Cutting the woven polyester with a standard knife requires that the ends of the
label be sewn in or “loop sewn”. Otherwise, the label will fray as there is nothing
physical to keep the weave together.
Other cutting technologies such as a hot knife will cut and melt the fiber ends
together, but the resulting bead of the cut is sharp and uncomfortable for skin
contact.
Only a sonic cut woven polyester label has satisfactory fray resistance and soft
edge suitable for skin contact.
This manual guides the printer operator as an easy-to-use, quick-reference
guide. It contains procedures for receiving, handling, set-up, installation,
operation, and maintenance of the sonic knife.
The SNAP 500 printer with the sonic knife is show here. Note that the power
supply is not shown.
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Throughout this manual, a system of NOTES, CAUTIONS, and WARNINGS
identify key information to ensure your personal safety and to proper printer
operation. Please review these carefully.
NOTE: Call attention to information that is especially significant to
understanding and operating the equipment. Provided suggestions and
help.
User’s Manual—Sonic Knife
CAUTION: Inform you of actions or situations in which the printer might be
damaged.
WARNING: Describe situations in which lack of attention or insufficient
equipment knowledge could cause either personal injury or damage to the
printer.
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2.0 Safety Information
Follow all of the safety requirements and procedures established for your
facility.
Turn off the power to the printer before cleaning, servicing, or replacing
any components.
You do not have to turn off the power when loading or changing supplies.
Follow all cautions and instructions marked on the product
There are hazardous moving parts in the printer. Service should be
performed only by trained service personnel.
All covers and guards must be in place when operating the printer and
should be removed only by trained service personnel.
Do not push objects of any kind through openings in the equipment.
Dangerous energy might be present and cause fire, electric shock, or
damage to the equipment.
Do not block or cover the openings of the equipment.
Do not place the equipment near a radiator or heat register. This could
cause the product to overheat.
Turn off the printer and disconnect the power cord before servicing the
printer.
Operators should read and understand the Operators manual before
operating the printer
If the printer operates improperly or fails to respond to commands, turn
the printer off using the power switch. If the problem continues to occur,
obtain service for the printer.
The AC mains supply for the printer should be properly grounded and
provide overcurrent protection as required to meet all local electrical and
building codes.
The AC mains supply for the printer should be properly grounded and
should meet all local electrical and building codes and provide
overcurrent protection as required.
The AC mains supply for the printer should be properly grounded and
should meet all local electrical and building codes and provide
overcurrent protection as required
Do not remove, deface, or defeat any safety guards or warning labels.
Do not operate the printer with any parts missing or broken
The printer has been designed to be as safe as possible. However, there
are moving parts during the normal operation of the printer. Obey all
warning labels and safety instructions during operation.
Do not access the knife or Sonic Horn area when the printer is running.
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User’s Manual—Sonic Knife
This machine has some pinch points and warm surfaces. All of these
areas have been well guarded and it is recommended that the safety
features of this machine are never altered or defeated.
Since ultrasonic is high frequency sound, some noise will be produced
as it makes its cut. It is recommended that people in the immediate area
wear ear protection. (See appendix “A” for a list of manufacturers of
hearing protection.)
High voltage is present in the power supply. Never attempt to operate
the unit with the cover off.
To prevent the possibility of electrical shock, make sure the power supply
is properly grounded.
Keep hands from under horn. High pressure and vibrations can cause
injury to hands and fingers.
Do not allow the ultrasonically activated horn to touch a metal base or
metal fixture.
Do not press the “TEST” switch when the stack assembly is removed
from the equipment
For information about supply compatibility or environmental information,
contact your local Avery Dennison Customer Service.
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3.0 Installation
3.1 Preparing for the installation
3.1.1 AC Power Line
NOTE: AVERY DENNISON requires that the minimum electrical service be 10
Amps @ 115VAC or 6 Amps @ 230VAC. This will allow the printer, Sonic
Knife, and any additional support or service equipment to be plugged into
the same service. It is highly recommended that the printer and its
accessories be on a dedicated circuit.
The electrical service should meet standard electrical code practices, including
proper grounding and neutrals.
3.1.2 Location Considerations
The Sonic Knife weighs about 25 pounds (12 kg), and the power supply weighs
12 pounds (6 kg). The Sonic Knife with printer weighs 80 pounds (43 kg). This
equipment combination requires a table of sufficient quality and strength to
handle this load.
Locate the sonic knife in an area so that the cutting noise emitted from the knife
operation will not affect others. While AVERY DENNISON strives to keep the
sonic knife noise to the lowest level, it is not recommended for an office
environment.
The power source of the sonic knife should be a dedicated line. Signs appear
when power is not sufficient. In this case, the ultrasonic action will stop cutting
but the rest of the sonic knife will appear fully functional.
CAUTION: Each customer must take responsibility to ensure the
workstation created for the system meets the recommended
requirements to ensure optimal operation.
3.1.3 User Safety
1. Follow all of the safety requirements and procedures established for your
facility.
2. Turn off the power to the printer and sonic knife before cleaning, servicing, or
replacing any components.
3. You do not have to turn off the power when loading or changing supplies.
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User’s Manual—Sonic Knife
CAUTION: The Sonic Knife has some pinch points which have safeguards
design in. AVERY DENNISION strongly recommends that you do not modify
or bypass these safeguards.
CAUTION: Danger of explosion if battery is incorrectly replaced. Return
product to Avery Dennison for proper replacement and disposal.
WARNING: There are hazardous moving parts at the print head station.
Keep hair, loose garments, jewelry and fingers away
3.2 Receiving
The sonic knife shipping carton is large and specially made to protect the knife. It
may be awkward or difficult to move by hand to its installation location.
CAUTION: Do not remove the printer from the carton or unpack in the
shipping/receiving department. Move the carton to the installation location.
Move the sonic knife with a forklift, fork cart, or handcart to its intended location.
It is easier and safer to use one of these handling devices Leaving the knife in
the carton while it is being moved within your facility will help protect it until
placed in its new location.
3.2.1 Unpacking
1: Remove binding straps from the
carton and discard.
2: Lift and remove the carton top,
top foam, and all parts. The
remaining base packing foam is
shown in Figure 1.
3: Set aside the information packet.
4: Lift up sonic knife and power
supply up, out of the foam pocket.
5: Remove Poly Bags.
FIGURE 1 - Poly bag removed
from around components.
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6: Set the sonic knife on its back cover (the same position as it sits in
the carton).
7: Remove the tool bag, machine manual and power cord.
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3.2.2 Repacking
Follow procedure in reverse order. It is required to band the package
with straps due to the tray carton design.
3.2.3 Disassembly and Disposal
1. No special steps are needed to decommission the printer.
2. Disconnect the Sonic Knife from the printer and remove it from
the printer
3. Dispose of the Sonic Knife in accordance with local laws and
ordinances.
3.2.4 Storing Sonic Knife When Not In Use
If the sonic knife
it’s stored in a safe location and manner to prevent it from falling or
tipping over causing personal injury or damage to the unit.
The sonic knife has a support bracket that can be extended on the
base of the printer to keep the unit upright.
If the sonic knife is stored in a busy work area or a bench that is not
stable it should be laid on its back for greater stability.
is removed from the printer care should be taken that
3.3 Installing the Sonic Knife to the Printer
1. Locate the two mount posts on the printer used to hold the stacker.
2. Place the sonic knife in front of and to the right of the printer. Position the
knife so that the support bracket on the sonic knife aligns with the bottom
stacker support post as shown in Figure 2. The sonic knife is not freestanding to keep positive control over the knife until it is securely installed
on the printer.
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User’s Manual—Sonic Knife
3. Slide the sonic knife onto the bottom post and move the sonic knife back
until it is aligned with the printer.
4. Adjust the sonic knife forward/backward so the stock coming from the
printer is centered on the horn face.
5. Install the printer stacker on the stacker posts on the sonic knife. Those
posts mimic the printer stacker posts and installation of the stacker is the
same.
6. Plug the stacker into the stacker receptacle on the printer. If the stacker
power cord does not reach, check the position of the sonic knife.
Sonic knife mounting
bracket
FIGURE 2
Stacker
posts on
sonic knife
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connector
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3.4 Cables from Sonic Knife to the Printer
1. The sonic knife requires an internal cable in the printer. This
internal cable receives the data cord from the sonic knife and
connects it to the proper board locations inside the printer. If
this internal cable is not installed, call service.
2. Connect the sonic knife cable to the receptacle on the printer
as shown in Figure 3.
Printer
Sonic Knife
Stacker
connector
FIGURE 3
3.5 Connecting the Ultrasonic Power Supply
1. Locate the ultrasonic power supply in a convenient location
near the sonic Knife.
2. Connect the coaxial converter cable from the ultrasonic stack
to the ultrasonic power supply by pressing the connector firmly
into the socket.
3. Connect the 37-pin D-shell connector to the 37-pin connector
on the rear of the power supply. Tighten the mounting screws
to secure the connector.
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User’s Manual—Sonic Knife
4. Connect the large D-shell connector to the connector installed
in the printer (step 1). Tighten the mounting screws to secure
the connector.
5. Connect the power cord to the ultrasonic power supply and the
AC power source.
NOTE: The 230v power supply has no AC (mains) power switch. Plugging it
in energizes it. Ultrasonic energy is generated only while cutting.
Coaxial
Converter
Cable
AC Power
Cable
37 pin
Connector
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WARNING: Locate the Ultrasonic Power Supply in a location where it will
not be bumped or knocked over
FIGURE 4
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3.6 Components
Snubber
(not visible)
Thread
path
Web
guides
Web
guide
knob
Component Cover
Stacker
posts
Feed
knob
Mounting
sleeve
Stability
foot
FIGURE 5a
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