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Models
2050 / 2055
Presses
I N S T R U C T I O N M A N U A L
Sonics & Materials, Inc.
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W A R N I N G
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SAFETY PRECAUTIONS
READ BEFORE INSTALLING OR USING THE EQUIPMENT
Our systems have been designed to assure maximum operator safety.
However, no design can completely protect against improper usage. For
maximum safety and equipment protection, observe the following warnings at
all times and read all applicable instruction manuals carefully before you
attempt to operate any equipment.
– The equipment has safety devices that require both hands to be on the
palm buttons until the horn contacts the work piece. Do not defeat or
modify these safety devices.
– Do not use with foot switch or other means of actuation unless alternate
means of pinch-point protection is provided.
– High voltage is present in the equipment. Disconnect plug before removing
cover or servicing.
– Make sure equipment is properly grounded with a 3-prong plug. Before
plugging in equipment, test outlet for proper earth grounding.
– High voltage potential may be present in the converter as a result of
temperature changes. Do not touch the converter contact unless you first
short both pins or the button to the converter case with an insulated tool.
– Never squeeze or grab a vibrating horn.
– Do not modify horn configurations.
–20kHz, 30 kHz and 40 kHz ultrasonic welders operate above normal
audibility for most people. Ear protection is recommended.
– Do not affix any device to any portion of the horn.
Sonics & Materials, Inc.
Corporate Headquarters European Office
53 Church Hill Road • Newtown, CT 06470 USA 13, Rue Pre-de-la-Fontaine • CH - 1217 Meryin/Satigny, Switzerland
203.270.4600 • 800.745.1105 • 203.270.4610 fax (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax
Information contained in this manual is subject to change without notice. Sonics & Materials, Inc. is not responsible for any typographic errors.
© Sonics & Materials, Inc. 2007 Printed in U.S.A. Rev 8/09
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T A B L E O F C O N T E N T S
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IMPORTANT SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Manual Change Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Visible Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Concealed Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
OVERVIEW OF ULTRASONIC PLASTICS ASSEMBLY . . . . . . . . . . . . . .5
What is Ultrasonics? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Principal of Ultrasonic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Ultrasonic Assembly Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
GLOSSARY OF ULTRASONIC TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . .7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Control Panel (2050 Press) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Controls (2055 Press) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
INITIAL EQUIPMENT SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Assembling and Mounting Converter, Booster and Horn . . . . . . .14
Horn and Fixture Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Positive Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
FINE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Booster Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Re-Establishing Proper Booster/Horn Interfaces . . . . . . . . . . . . .20
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Repairs / Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Draining Air Filter Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Limitation of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
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I M P O R T A N T S E R V I C E L I T E R A T U R E
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The system supplied with this instruction manual is constructed of the finest
material and the workmanship meets the highest manufacturing standards. It
has been thoroughly tested and inspected before leaving the factory and
when used in accordance with the procedures outlined in this manual, will
provide you with many years of safe and dependable service.
NOTE: Please read
carefully before operating
the equipment, then
forward to your service
department.
MANUAL CHANGE INFORMATION
We continually strive to be at the forefront of the latest electronic
developments by adding circuit and component improvements to our
equipment as soon as they are developed and tested.
Sometimes, due to printing and shipping requirements, we cannot incorporate
these changes immediately into printed manuals. Hence, your manual may
contain new change information. Change information, if any, is located in the
Appendix.
We reserve the right to make any changes in the design or construction of our
equipment at any time, without incurring any obligation to make any change
whatsoever in units previously delivered.
The technical data and schematics in the manual are for informational
purposes only and may not reflect the current configuration being shipped
from our factory. Upon formal request, complete and up-to-date information
can be provided from the factory free of charge.
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U N P A C K I N G A N D I N S P E C T I O N
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Before unpacking the equipment, check the shipping carton for any visible
damage. If you see any, be sure to follow the procedures described below
under “Visible Loss or Damage.” Otherwise, proceed to remove the equipment
from the carton. Before disposing of any packing material, check it carefully
for small parts. Then perform a visual inspection of the equipment to detect
NOTE: We recommend
keeping all carton(s) and
packing material in case it
might be necessary to
move the equipment, or to
ship it for repair.
any evidence of damage which might have occurred during shipment. Check
the following:
1. all components against the enclosed packing list,
2. all module plug-in units,
3. all wire plug-in connections.
The equipment was carefully packed and thoroughly inspected before leaving
our factory. All units are tested and checked for problems prior to shipping. It
is asked that when a problem does occur that all parts and components be
inspected for damage (especially when the unit is not in working order when
received). Responsibility for safe delivery was assumed by the carrier upon
acceptance of the shipment. Claims for loss of damage sustained in transit
must therefore be made upon the carrier, as follows:
VISIBLE LOSS OR DAMAGE
Any external evidence of loss or damage must be noted on the freight bill or
express receipt, and signed by the carrier’s agent. Failure to adequately
describe such external evidence of loss or damage may result in the carrier’s
refusal to honor a damage claim. The form required to file such a claim will
be supplied by the carrier.
CONCEALED LOSS OR DAMAGE
Concealed loss or damage means loss or damage which does not become
apparent until the merchandise has been unpacked. The contents might have
been damaged in transit due to rough handling even though the container
may not show external damage. When the damage is discovered upon
unpacking, make a written request for inspection by the carrier’s agent within
48 hours of the delivery date. Then file a claim with the carrier since such
damage is the carrier’s responsibility. The form required to file such a claim
will be supplied by the carrier. Do not destroy packing materials, or move
material from one location to another before the carrier makes their
inspection.
If the system or any unit is damaged, notify “Sonics.” “Sonics” will arrange for
repair or replacement of damaged equipment without waiting for the claim
against the carrier to be settled, provided a new purchase order is issued to
cover the repair or replacement costs. Should any damage, shortage or
discrepancy exist, please notify us immediately.
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I N T R O D U C T I O N
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The models 2050 and 2055 presses are 20 kHz precision benchtop
pneumatic actuators/presses used for ultrasonic plastics assembly. The 2050
and 2055 presses can be supplied with the following GX-Series power
supplies:
■ GXT . . . . . . .Weld by digital time
■ GXE . . . . . .Weld by digital time and/or constant energy
■ GXL . . . . . . .Weld by digital time, constant energy and/or distance*
*Available with Model 2050 press only.
Both presses are also compatible with E and F Series power supplies.
O V E R V I E W O F U L T R A S O N I C P L A S T I C S A S S E M B L Y
WHAT IS ULTRASONICS?
Ultrasonics refers to vibrational waves with a frequency above the human
audible range which is usually above 18,000 cycles per second (Hz).
PRINCIPLE OF ULTRASONIC ASSEMBLY
The basic principle of ultrasonic assembly involves conversion of high
frequency electrical energy to high frequency mechanical energy in the form
of reciprocating vertical motion which, when applied to a thermoplastic,
generates frictional heat at the plastic/plastic or plastic/metal interface. In
ultrasonic welding, this frictional heat melts the plastic, allowing the two
surfaces to fuse together; in ultrasonic staking or insertion, the controlled flow
of molten plastic is used to capture or lock another material in place (staking)
or encapsulate a metal insert (insertion).
ULTRASONIC ASSEMBLY SYSTEMS
“Sonics” ultrasonic assembly systems are generally composed of the following major elements: a power supply, converter, booster, horn, pneumatic
press/actuator and holding fixture, as detailed in the diagram on the next
page. A review of this diagram will help you understand the basic elements
involved in the assembly process and their relation to each other.
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“SONICS” ULTRASONIC ASSEMBLY SYSTEMS
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Power Supply/Generator
Actuator/Press
Provides compressive force
and mounting for Converter,
Booster, Horn assembly
(Stack)
50/60 Hz
Electrical power
Generates ultrasonic electrical energy
(15/20/40 kHz)
Ultrasonic
electrical energy
Converter
Transforms ultrasonic electrical energy
to ultrasonic mechanical vibrations
Ultrasonic Vibrations
Holding Fixture
Aligns and supports part
Booster
Increases or decreases amplitude
Ultrasonic Vibrations
Horn
Contacts and transfers vibrational
energy to plastic part
Ultrasonic Vibrations
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G L O S S A R Y O F U L T R A S O N I C T E R M S
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POWER SUPPLY/GENERATOR – The solid state power supply converts
standard 50/60 Hz electrical power to 15,000 Hz, 20,000 Hz, 30,000 Hz or
40,000 Hz (15/20/30/40 kHz) electrical energy (depending on frequency of
model purchased).
ACTUATOR/PRESS – The pneumatic actuator provides compressive force
and mounting for the converter, booster, and horn assembly. The benchtop
press consists of a base assembly, column and actuator (head).
CONVERTER – The converter changes the high frequency electrical energy
supplied by the power supply to high frequency mechanical vibrations.
BOOSTER – Successful ultrasonic welding often depends on having the right
amplitude at the horn face. Often it is not possible to design a horn which has
both the necessary shape and required gain (ratios of input amplitude to
output amplitude). Therefore, a booster is placed between the converter and
the horn to either increase or decrease the amplitude of the horn. In addition
to changing/maintaining the amplitude, the booster provides support and
alignment in the welding system. (See page 19 for booster selection.)
HORN – The horn is a tuned component of the system which comes in
contact with the parts to be assembled. The horn 1) transfers the ultrasonic
vibrations produced from the converter to the parts being welded, and 2)
applies necessary force to the assembly while the material resolidifies.
HOLDING FIXTURE – The holding fixture or nest assures proper alignment
and support of the parts being assembled.
MODEL 2050 MODEL 2055
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I N S T A L L A T I O N
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ELECTRICAL POWER
The press is powered by the power supply. Consult your power supply
instruction manual to determine power specifications.
AIR SUPPLY
The press requires a source of dry, filtered (5 micron), oil-free, compressed
air capable of supplying a constant line pressure of 85 psig. (586 kPa / 6 bar)
at a minimum capacity of 2 CFM.
Do not connect the press
to an air source supplied
by a compressor lubricated
with synthetic oils or oils
containing phosphate
esters or chlorinated hydrocarbons. This type of
lubricant may cause the air
filter to malfunction, and
the plastic bowl to rupture.
NOTE: If the power supply
is to be run continuously,
air cooling of the converter
and horn is required. Use
clean, dry compressed air
filtered down to 5 microns
(supplied to converter
fitting).
SETTING UP
The press should be installed in a clear, uncluttered location that is free from
excessive dirt, dust, corrosive fumes, and temperature and humidity extremes. The selected installation site should be near the electrical power and
air supply sources and away from any equipment that generates abnormally
high electrical transients. Observe the following additional instructions when
installing the press:
a. The press should be placed on a sturdy, level table or bench capable of
supporting a minimum of 500 pounds (227 kg).
b. Allow at least 6 inches (152.4mm) at the rear of the press for cable
connections.
KEY COMPONENTS
PRESSURE
GAUGE
REGULATOR
CONVERTER
HOUSING DOOR
AIR CONNECTION
(in rear of Press)
SPEED CONTROL KNOBS
HEAD DOWN SWITCH
CONVERTER HOUSING
with converter, booster &
horn (stack) assembly
PALM BUTTONS
EMERGENCY STOP
BUTTON
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NOTE: Do not strain or
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kink the cables. When
going around corners,
allow as wide a bend as
possible. Do not run the
cables parallel to any
power line within a distance
of less than 1 foot
(304.8mm).
CONNECTIONS
When making the initial connections, make sure all electrical power is
disconnected.
1. Connect the air supply source to the press air connection located at the
rear of the press head, using a hose having a minimum inside diameter of
1/8 inch (3 mm).
A 1/4 NPT threaded female elbow connector is provided to attach your air
line service. Connectors are typically an instant (push-to-connect) plastic
tube fitting or a male sleeve lock type quick connect fitting.
MODEL 2050
CONNECTOR
MODEL 2055
AIR
CONNECTOR
(IN REAR)
2. Connect the RF and base (actuating) cables of the press to the power
supply. (Consult your power supply instruction manual for details.)
3. Check with your electrician if you have any wiring questions.
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OPTIONS
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A Linear Encoder is available as an option on Model 2050 only. The Linear
Encoder allows distance-controlled welding in incremental and absolute
modes.
The Linear Encoder is supplied with a 9-pin male connector that connects to
a matching 9-pin female connector on the FDL power supply (factory
installed).
LINEAR ENCODER
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O P E R A T I N G P R O C E D U R E S
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CONTROL PANEL (2050 PRESS)
Located above the converter housing on the 2050 press are the following
controls:
❶
❷
❸
Excessive velocity may be
unnecessary and harmful
to the system.
1. SPEED CONTROL knobs allow regulation of the velocity at which the
horn descends and returns (stroke speed).
These controls are factory adjusted for average operating conditions.
When minor adjustments are necessary, be sure to adjust in small
degrees.
Pull the red ring out to release and push in to lock setting.
The left knob, labeled "UP," controls the return speed - turn the knob
clockwise to slow the speed, counterclockwise to increase speed.
The right knob, labeled "DOWN," controls the descending speed – turn the
knob clockwise to slow the speed, counterclockwise to increase speed.
2. PRESSURE REGULATOR with corresponding gauge that allows
regulation of the (air) pressure with which the horn contacts the part(s). Pull
the knob to make adjustments, and then push in to lock setting when
desired pressure is displayed on the gauge. Once pulled, turning the knob
clockwise increases pressure, and turning it counterclockwise decreases
pressure.
3. HEAD DOWN switch when depressed, allows the head to move down
under gauge pressure. (For set up only – this action does not cause
ultrasonics to be activated.)
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CONTROLS (2055 PRESS)
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Located at the top rear of the 2055 press are the following controls:
1. PRESSURE REGULATOR with corresponding gauge that allows
regulation of the (air) pressure with which the horn contacts the part(s). Pull
the knob to make adjustments, and then push in to lock setting when desired
pressure is displayed on the gauge. Once pulled, turning the knob clockwise
increases pressure, and turning it counterclockwise decreases pressure.
PRESSURE
REGULATOR
PRESSURE
GAUGE
AIR FILTER
BOWL
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2. SPEED CONTROLS
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The velocity at which the horn descends and returns can be adjusted via
the two small threaded screws located at the top of the press as shown
below. These controls are factory adjusted for average operating conditions. If a minor adjustment is necessary, adjust in small degrees.
Excessive velocity may be
unnecessary and harmful
to the system.
Turn the Descend Speed Control screw clockwise to slow the descend
speed, counterclockwise to increase the speed. Turn the Return Speed
Control screw clockwise to slow the return speed, counterclockwise to
increase speed.
DESCEND
SPEED
CONTROL
RETURN
SPEED
CONTROL
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I N I T I A L E Q U I P M E N T S E T U P
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ASSEMBLING AND MOUNTING CONVERTER, BOOSTER,
AND HORN
If the converter, booster, and horn are not already assembled, follow these
instructions:
1. Clean the mating surfaces of the converter and booster, as well as the
Never tighten the horn to
the booster using the
housing door as the upper
wrench as this may cause
damage to the booster
and/or converter.
threaded stud and hole. Check that the stud is tight (see recommended
torque requirements on page 15).
2. Hand assemble the converter and booster together. Using spanner
wrenches as shown below, tighten until snug. Then, using a torque wrench,
tighten to 25-35 foot-lbs. (34-47 newton-meters).
Do not force or overtighten.
CONVERTER/BOOSTER
3. Clean the mating surfaces of the booster and horn, as well as the threaded
stud and hole. Check that the stud is tight. (See recommended torque
requirements on next page.)
4. Hand assemble the horn to the booster. Using a spanner and an openended wrench as shown below, tighten securely. Then, using a torque
wrench, tighten to 25-35 foot-lbs. (34-47 newton-meters).
Do not overtighten.
CONVERTER/BOOSTER/HORN
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Page 16
NOTE: When performing
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any of the operations
described on this page and
pages 16-17, DO NOT turn
on the power supply.
5. Using the 3/16" (4.7 mm) T-handle wrench provided, loosen (turn
counterclockwise) the two cap screws on the hinged converter housing and
open the door.
6. Place the converter / booster / horn assembly (stack) in the housing with
the horn facing down. Fit the male brass button on the top of the converter
into the female brass fitting in the bottom of the contact block assembly
housing, and gently push the assembly up and in so that the booster
mounting ring rests on the lower support ridge.
CONVERTER / BOOSTER /
HORN ASSEMBLY
BRASS BUTTON
BOOSTER RING
Never tighten the horn to
the booster using the
housing door as the upper
wrench as this may cause
damage to the booster
and/or converter.
NOTE: If you do not close
the housing door once the
assembly is in place, the
assembly can fall out.
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7. Close the converter housing door and tighten (turn clockwise) the two
socket head cap screws until they are snug. Do not tighten the horn to the
booster using the door as a clamp. Hand-forcing the horn on and off in this
manner can twist wires in the converter and cause a failure. If the horn is
not correctly oriented to the part, re-position the stack assembly by
loosening the converter housing cover and rotating the stack.
RECOMMENDED TORQUE REQUIREMENTS
Component Foot-Lbs. Newton-Meters
Converter / Booster 25 - 35 34-47
Booster / Horn 25 - 35 34-47
Stud 45 61
Tips 25 - 35 34-47
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Page 17
Support the head before
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releasing the column
clamps so that it cannot
crash down or fly up.
Ignoring this warning might
result in injury and/or
damage to the equipment
and part being welded.
HORN AND FIXTURE ALIGNMENT
For maximum productivity, the clearance between the horn and the part
should be at a minimum. However, adequate clearance should be provided to
enable easy loading and unloading of the part from the holding fixture. The
maximum stroke distance is 4" (101.6 mm). Ensure that the horn does not
contact the part when the head is close to the limit of its down travel distance.
Otherwise, the horn may not have sufficient distance to travel downwards to
achieve a full depth of weld. Set welding height as follows:
First, position the holding fixture loosely on the machine base using 3/8-16
screws. Then, place the part to be welded in the fixture.
1. Prepare to loosen the column clamps, but be sure to hold onto the head
assembly firmly as it can move rapidly up or down with heavy tooling once
the clamps are released. While holding the head assembly, loosen the two
column clamps (counterclockwise) and move the head up or down as
required. Then tighten the column clamps.
2. Using the PRESSURE REGULATOR (turn counterclockwise) and
corresponding gauge, set the air pressure to zero.
3. Loosen the column clamps once again and manually lower the head until
the horn contacts the part. Tighten the clamps.
4. Loosen the cap screws on the converter housing door and gently rotate the
head and horn as required to ensure proper horn-to-part alignment.
PRESSURE GAUGE
PRESSURE REGULATOR
HEAD DOWN SWITCH
COLUMN
CLAMPS
BASE PLATE
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NOTE: For maximum
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safety and productivity,
adjust the clearance
between the horn and the
part to a minimum that will
still allow ease of loading
and unloading.
5. Lock the two column clamps, tighten the converter housing door screws,
and then tighten the fixture on the base plate.
6. Check for proper mating of fixture, parts, and horn. If the horn and part are
not in parallel contact, shim the fixture or adjust leveling screws as
required.
7. Set the PRESSURE regulator to a reading of 20 psig (140 kPa/1.4 bar) on
the pressure gauge. (Turn the PRESSURE knob clockwise.)
8. To check that the horn and parts are properly aligned, the horn needs to
be lowered. Read through the Operation instructions on page 18, and then
proceed to lower the horn as detailed. If the horn and parts are not
sufficiently aligned, then repeat steps 4 through 8. However, if you are
working with small, delicate parts, then fine adjustments can be made
using the positive stop adjustment knob as explained below.
POSITIVE STOP ADJUSTMENT
The positive stop is set to limit the downward travel of the horn to
approximately 75%. Readjustments may be required. Coarse adjustment of
the clearance between the face of the horn and part should be made using
the elevation control. Fine adjustment should be made using the positive stop.
KNURLED
THUMBSCREW
POSITIVE
STOP
ADJUSTMENT
KNOB
The positive stop adjustment knob is located offset from the converter
housing. Turning the knob clockwise will decrease downward travel distance.
Turning the knob counterclockwise will increase the downward travel distance. Rotate the knurled thumbscrew to lock and unlock the positive stop.
A different positive stop is available for oversize horns. Contact factory for
details.
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O P E R A T I O N
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The equipment has safety
devices that require both
hands to be on the palm
buttons until the horn
contacts the workpiece. Do
not defeat or modify
these safety devices.
ACTUATION
Each 2050 and 2055 press is equipped with two maintained anti-repeat (nontie-down) palm buttons, one located on the left and one on the right side of
the base of the press. Both palm buttons must be pressed simultaneously to
activate the press to cycle the welder. To operate the press, follow these
simple steps:
1. Depress both black palm buttons simultaneously.
2. Once the horn comes in contact with the part, the pressure switch closes
and the ultrasonics are activated, release the palm buttons. If you release
the buttons before contact is made, the head will immediately return to its
“home” position.
EMERGENCY STOP
To abort the 2050 or 2055 press during welding, simply press the red
EMERGENCY STOP button located at the front center of the press base.
Once the EMERGENCY STOP button has been depressed, the head will
retract and return to its “home” position. Simply rotate the EMERGENCY
STOP button clockwise 1/4 turn to release the press for further operation.
NOTE: Power supply
cannot be shut off once the
weld cycle has started.
Termination of cycle can
only be achieved by using
the EMERGENCY STOP
button.
Do not use with a
footswitch unless alternate
means of pinch-point
protection is provided.
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F I N E A D J U S T M E N T S
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BOOSTER SELECTION
The first step in optimizing welding conditions is to select a booster which will
provide the necessary amplitude. For parts one inch (25.4mm) in diameter or
greater, start with a moderately high amplitude booster such as a gold. For
smaller parts, start with a green booster. Determine optimum amplitude by
NOTE: Consult the
Applications Manual or call
our Applications Lab for
proper booster selection.
welding a few parts, and repeat the procedure with boosters giving higher or
lower amplitude. If there appears to be little or no difference, use the booster
giving the highest amplitude.
Seven standard boosters, color coded or engraved for ease of identification,
are available either to increase or decrease the amplitude.
Color Part No. Part No. Gain Amplitude Effect
Black BHN15TBK BHNR15BK 2.50 Increase
BOOSTER
O-Ring Mount Rigid Mount
(standard) (optional)
High gain boosters, such
as silver and black in
combination with high gain
horns can result in the horn
cracking or failing.
Silver BHN15TSI BHNR15SI 2.00 Increase
Gold BHN15GD BHNR15GD 1.50 Increase
Brown BHN15BR BHNR15BR 1.25 Increase
Green BHN15GR BHNR15GR 0 No Change
Purple BHN15PU BHNR15PU 0.75 Decrease
Blue BHN15BU BHNR15BU 0.50 Decrease
PRESSURE
During the welding process, sufficient pressure should be applied to the part
so that the mating surfaces contact each other. If the pressure is too low, the
process will run inefficiently causing unnecessarily long weld time cycles,
marking of the parts or poor welding. If the pressure is too high, the horn may
stop vibrating, the part(s) might fracture, or the power supply might overload.
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NOTE: Contact between
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the booster and horn
should be parallel. When
encountering symptoms
such as loud noises or
tuning difficulties, examine
the booster / horn
interfaces for parallelism,
corrosion, galling or foreign
deposits. Also check the
integrity and tightness of
the stud.
RE-ESTABLISHING PROPER BOOSTER / HORN INTERFACES
To re-establish proper interfaces, follow these instructions:
1. Using open-ended wrenches, separate the booster from the horn. Clean
each item and then examine interfaces for irregularities (scoring).
2. If irregularities are present, remove the stud.
3. Tape a sheet of 400 grit emery cloth to a smooth, flat surface. (Do not use
coarser than 400 grit.)
4. Grasp the lower portion of the booster or horn and move it across the
emery cloth. To ensure proper lapping, a) hold the part straight, b) apply
light downward pressure, and c) move in one direction only in a figure 8
pattern.
Repeat the figure 8 pattern once more.
DO NOT use anything
coarser than 400 grit
emery cloth.
Machining of booster / horn
may alter the ability to tune
the component to the
system. System inoperation
may occur.
5. Then, rotate the booster or horn 1/3 of a turn in a clockwise direction and
then repeat step 4.
6. Repeat step 5.
7. Using wire brush, clean stud, then replace securely. Tighten new stud to
the recommended torque specifications on page 15.
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M A I N T E N A N C E
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NOTE: If packing unit for
return shipment, DO NOT
use styrofoam “peanuts.”
REPAIRS / SERVICE
If problems are encountered, contact our Service Department as follows:
Phone: 1-800-745-1105 • 1-203-270-4600 ext. 343 or 366
Fax: 1-203-270-4610
E-Mail: [email protected]
It is suggested that a system in need of repair be sent back to the factory, with
a written description pertaining to the nature of the problem.
Always contact the factory for return authorization before shipping any
instrument. Include date of purchase, model number, and serial number. For
units not covered by the warranty, a purchase order should be forwarded to
avoid unnecessary delay. Care should be exercised to provide adequate
packing to insure against possible damage in shipment. The system must be
sent with all transportation charges prepaid and return method of shipment
indicated.
DRAINING THE AIR FILTER BOWL
Periodically check the Air Filter Bowl for any moisture and/or condensation,
and drain as necessary.
AIR FILTER
BOWL
To drain, simply unscrew the knurled brass fitting at the bottom of the bowl.
Drain any collected moisture, and then replace the fitting.
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Always disconnect the
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power supply from the
electrical source before
removing covers.
COVER REMOVAL
MODEL 2050 COVER REMOVAL
To remove the side panel cover:
a. Maintain air pressure and unplug the power supply from the electrical
source.
b. Loosen and remove the 2 Phillips pan head screws on the back of the
cover.
c. Loosen and remove the 2 socket head cap screws at the bottom of
the cover.
d. Loosen column clamps.
e. Raise head as shown below to bottom of column cap.
PAN HEAD
SCREWS
COLUMN
CAP
Do not operate press
without covers in place.
CAP SCREWS
f. Slide the cover back and then lift it up and off.
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To remove the pinch point cover:
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a. Loosen and remove the cover’s 4 screws - 2 on each side of the cover.
PINCH POINT
COVER
SCREWS
b. Pull the cover to the front and then pull it down and off as shown below.
Always disconnect the
power supply from the
electrical source before
removing covers.
MODEL 2055 COVER REMOVAL
To remove the side panel cover:
a. Maintain air pressure and unplug the power supply from the electrical
source.
b. Loosen and remove the 4 Phillips pan head screws - 2 on the top of the
cover and 2 on the bottom. (See photo on the next page.)
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Do not operate press
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without covers in place.
NOTE: Pressure switch is
factory set and should not
be adjusted unless
authorized by Sonics
Service Department.
PAN HEAD
SCREWS
PRESSURE SWITCH ADJUSTMENT
For systems mounted in the normal vertical position with downward travel, no
adjustment should be necessary. The minimum trigger pressure is factory set
at 4-7 psig.
However, if the minimum trigger pressure requires recalibration or readjustment, the pressure switch can be accessed and adjusted.
To access the pressure switch, it is first necessary to remove both the side
panel cover and the pinch point cover as described above (for either the
model 2050 or 2055 press). Then, observe the following procedure:
Do not operate press
without covers in place.
1. Loosen the jam nut holding the 1/4-20 cap screw in place.
2. Rotate the small, knurled, threaded rod upward until the Pressure Switch
closes.
PRESSURE
SWITCH
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3. Next rotate the cap screw down until the Pressure Switch opens.
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4. Rotate cap screw down one turn past the Pressure Switch open position.
5. Tighten the jam nut to lock cap screw in position.
6. Replace pinch point cover and the side panel cover and position securely.
7. Plug the power supply into the electrical source.
8. Cycle the welder.
The press is now set to trigger at the minimum trigger pressure of 4-7 psig.
A press actuating in an upward or horizontal direction should be set to trigger
at a minimum of 8-10 psig. Lower values may affect trigger performance
where false triggering may be observed.
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W A R R A N T Y
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Sonics & Materials, Inc., hereinafter referred to as "Sonics", warrants its products
for a period of one year from the date of original shipment against defects in
materials and workmanship under normal installation, use and maintenance as
described in the operating instructions which accompany such equipment.
During the warranty period, Sonics will, at its option, as the exclusive remedy,
either repair or replace without charge for material and labor, the part(s) which
prove upon our examination to be defective, provided the defective unit is
returned to us properly packed with all transportation charges F.O.B. Sonics
dock, Newtown, CT. Warranty period on equipment rentals that are converted to
purchase are deemed to have commenced on the date of original rental
equipment shipment.
Ultrasonic plastics welding horns constructed of titanium or aluminum are
guaranteed against defects for a period of one year from date of shipment.
Sonics will repair or replace a cracked or defective horn once without charge, if
failure occurs within the warranty period.
Ultrasonic plastics welding horns constructed of steel are guaranteed against
defects for a period of ninety days from date of shipment. Sonics will repair or
replace a cracked or defective steel horn once at a charge of 50% of the original
purchase price, if failure occurs within the warranty period.
Ultrasonic metal welding horns constructed of titanium or steel are guaranteed
against defects for a period of one year from date of shipment. Sonics will repair
or replace a cracked or defective horn once without charge, if failure occurs
within the warranty period.
Sonics warrants its ultrasonic converters for a period of one year from date of
shipment with a one-time replacement if a converter proves to be non-repairable.
When customer site service is required, all travel, living and related expenses will
be billed at cost. In-warranty service labor time (including travel time) at the
customers facility is provided Monday through Friday (excluding holidays) from
8:00 am to 5:00 pm. Any in-warranty service time requested outside of these
days and hours will be billed at 150% of Sonics current rate per hour for such
site service work.
LIMITATION OF WARRANTY
This warranty does not apply to items subject to normal wear and tear or, to
equipment or tooling which has been subject to unauthorized repair, misuse,
abuse, negligence or accident. Misuse includes operation of equipment with
tooling that is not qualified for the equipment or tooling not properly installed on
the equipment.
Equipment which, in our judgment, shows evidence of having been used in
violation of operating instructions, or which has had the serial number altered or
removed, will be ineligible for service under this warranty.
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For components and parts not manufactured by Sonics but included in Sonics
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manufactured equipment, this warranty shall be limited to the warranty as given
to Sonics by said original component or part manufacturer.
Ultrasonic horns supplied by Sonics are manufactured to exacting specifications
and are tuned to vibrate at a specific frequency. Using an out-of-tune horn will
cause damage to the equipment and may result in warranty nullification. Sonics
assumes no responsibility for converters, horns or fixtures not supplied by
Sonics or for consequential damages resulting from their usage.
Ultrasonic converters showing signs of excessive heat or contamination, such as
but not limited to, oils and moisture, are not covered by this warranty.
Warranty does not apply to ultrasonic horns quoted as prototype, experimental
or of unusual design which, in our judgment are more likely to fail in use.
Warranty does not apply to re-sharpening of ultrasonic blade type cutting or
slitting horns.
Warranty does not apply to knurl pattern wear on ultrasonic plastics and metal
welding horns and tips.
Warranty does not apply to ultrasonic horn or tip face wear when used with
plastics that are molded with fillers, such as but not limited to, glass or talc.
This warranty does not apply to ultrasonic plastics welding equipment, horns or
fixtures where metal-to-metal tooling contact time is in excess of 250
milliseconds.
This warranty does not apply to used or re-built equipment.
This warranty is non-transferable.
Data supplied in Sonics instruction manuals has been verified and validated and
is believed adequate for the intended use of the equipment. If the equipment or
procedures are used for purposes other than those specified herein, confirmation
of their validity and suitability should be obtained in writing from Sonics.
Otherwise Sonics does not guarantee results and assumes no obligation or
liability.
This warranty is in lieu of any other warranties, either express, implied, or
statutory. Sonics neither assumes nor authorizes any person to assume for it any
other obligation or liability in connection with the sale of its products. Sonics
hereby disclaims any warranty or merchantability or fitness for a particular
purpose. No person or company is authorized to change, modify, or amend the
terms of this warranty in any manner or fashion whatsoever. Under no
circumstances shall Sonics be liable to the purchaser or to any other person for
any incidental or consequential damages or loss of profit or product resulting
from any malfunction or failure of this Sonics product.
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A P P E N D I X
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2 0 5 0 L A Y O U T
F R O N T V I E W
Dimensions are shown in inches and millimeters,
i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
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A P P E N D I X
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2 0 5 0 L A Y O U T S I D E V I E W
Dimensions are shown in inches and millimeters,
i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
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A P P E N D I X
2 0 5 0 E X P L O D E D A S S E M B L Y D R A W I N G
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A P P E N D I X
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2 0 5 5 L A Y O U T
F R O N T V I E W
Dimensions are shown in inches and millimeters,
i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
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A P P E N D I X
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2 0 5 5 L A Y O U T S I D E V I E W
Dimensions are shown in inches and millimeters,
i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
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A P P E N D I X
2 0 5 5 E X P L O D E D A S S E M B L Y D R A W I N G
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I N S TRU C T I O N M A N UA L • M O D E L 2 0 5 0 /20 5 5
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A P P E N D I X
Go To Top Of Document
B A S E L A Y O U T
Dimensions are shown in inches and millimeters,
i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
I N S TRU C T I O N M A N UA L • M O D E L 2 0 5 0 /20 5 5
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A P P E N D I X
Go To Top Of Document
O P T I O N A L S T A N D - A L O N E
M O U N T I N G H U B L A Y O U T
Dimensions are shown in inches and millimeters,
i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
I N S TRU C T I O N M A N UA L • M O D E L 2 0 5 0 /20 5 5
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