Sonics FC User Manual

INSTRUCTION MANUAL

Sonics & Materials, Inc.

Model FC Power Supply

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

1

WARNING

SAFETY PRECAUTIONS READ BEFORE INSTALLING OR USING THE EQUIPMENT

This system has 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 the instruction manual carefully before you attempt to operate the equipment.

– 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.

– Ultrasonic welders operate above normal audibility for most people. Ear

protection is recommended. Consult the Appendix for a list of manufacturers of ear protectors

Sonics & Materials, Inc.

Corporate Headquarters European Office

53 Church Hill Road • Newtown, CT 06470 USA 22 ch du Vernay • CH - 1196 Gland, Switzerland

203.270.4600 • 800.745.1105 • 203.270.4610 fax (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax

www.sonicsandmaterials.com • [email protected] [email protected]

Information contained in this manual is subject to change without notice. Sonics & Materials, Inc. is not responsible for any typographic errors.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

2

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

3

TABLE OF CONTENTS

IMPORTANT SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Manual Change Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Visible Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Concealed Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

OVERVIEW OF ULTRASONIC PLASTICS ASSEMBLY . . . . . . . . . . . . . .6

What is Ultrasonics? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Principal of Ultrasonic Assembly . . . . . . . . . . . . . . . . . . . . . . . . .6

Ultrasonic Assembly Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .6

GLOSSARY OF ULTRASONIC TERMS . . . . . . . . . . . . . . . . . . . . . . . . . .8

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Electrical Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Starting up the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Repairs / Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Limitation of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

4

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

IMPORTANT SERVICE LITERATURE

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.

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.

NOTE: Please read carefully before operating the equipment, then forward to your service department.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

5

UNPACKING AND INSPECTION

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 storing any packing material, check it carefully for small parts. Then perform a visual inspection of the equipment to detect 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.

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.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

6

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

INTRODUCTION

The FC model power supply is an auto-tuned ultrasonic generator that can be operated on a continuous basis, or pulsed via an outside control. This power supply can be used with a stand-alone converter, or with a pneumatic actuator. The FC does not offer time or energy-based control.

OVERVIEW OF ULTRASONIC PLASTICS ASSEMBLY

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 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.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

7

“SONICS” ULTRASONIC ASSEMBLY SYSTEMS

Generates ultrasonic electric energy

(15/20/40 kHz)

50/60 Hz Electrical power

Ultrasonic electrical energy

Ultrasonic Vibrations

Provides compressive force and mounting for Converter, Booster, Horn assembly

Aligns and supports part

@@@@@@@@e? @@@@@@@@e? @@h? @@h? @@h? @@h? @@h? @@h?

@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e? @@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?

@@@@@@@@ @@@@@@@@

@@ @@ @@ @@ @@ @@

@@ @@ @@ @@ @@ @@ @@ @@

?@@ ?@@ ?@@ ?@@ ?@@

?@@ ?@@@@@@@@ ?@@@@@@@@

?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@ ?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@

@@g @@g @@g @@g @@g @@g @@@@@@@@ @@@@@@@@

@@ @@ @@ @@ @@ @@ @@ @@

Transforms ultrasonic electrical energy

to ultrasonic mechanical vibrations

Increases or decreases amplitude

Contacts and transfers vibrational

energy to plastic part

Converter

Booster

Horn

Ultrasonic Vibrations

Power Supply/Generator

Actuator/Press

Holding Fixture

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

8

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

GLOSSARY OF ULTRASONIC TERMS

POWER SUPPLY/GENERATOR – The solid state power supply converts standard 50/60 Hz electrical energy to 15,000 Hz, 20,000 Hz or 40,000 Hz (15/20/40 kHz) electrical energy.

ACTUATOR/PRESS – The pneumatic actuator provides compressive force and mounting for the converter, booster and horn assembly. The tabletop 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). In such cases, 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.

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.

NOTE: For additional information on set-up and adjustment of the converter / booster / horn / holding fixture, refer to the Welding Press Instruction Manual.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

9

INSTALLATION

ELECTRICAL POWER REQUIREMENTS

The power supply requires a fused, single-phase, standard 3-terminal grounding type receptacle capable of supplying the requisite voltage and current. Refer to the table below for power specification.

SETTING UP

The power supply is a free-standing assembly. It 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 source and away from equipment that generates abnormally high electrical transients. Observe the following additional instructions when installing the equipment:

a. Allow at least 6 inches (152.4mm) at the rear of the power supply for cable

connections.

b. Position the power supply so that the front panel controls are visible and

readily accessible.

c. The power supply is air cooled; allow sufficient space around the assembly

to ensure adequate ventilation. If the power supply must be housed in a confined space, forced air cooling may be necessary to keep surrounding air within acceptable ambient temperature limits. Periodically check the ventilation grille and clean as necessary.

The line cord of the controller/power supply is equipped with a 3-prong, grounding plug. Do not, under any circumstances, remove the ground prong. The plug must be plugged into a mating 3-prong, grounding type outlet.

POWER SPECIFICATIONS

NOTE: If 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 – see page 11).

Model Power Rating 115 vac 230 vac

FC740 700w 15 amps 10 amps

FC1020 1000w 15 amps 10 amps

FC1520 1500w N/A 15 amps

FC2020 2000w N/A 20 amps

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

10

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

ELECTRICAL CONNECTIONS

The standard cable supplied with a “Sonics” press is 10 feet. Optional extension cables are available up to 15 feet without modification.

When making the initial electrical connections, make sure the power is disconnected and follow these precautions.

1. Do not strain or 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 (305mm).

2. To prevent the possibility of an electrical shock, ensure that the power supply line cord is properly grounded. Also make sure that the voltage rating of the electrical power source matches the power supply requirement (refer to the “Power Specifications” table on preceding page).

3. Check with your electrician if you have any wiring questions.

NOTE: Do not plug the power supply into an electrical outlet until all other connections have been made.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

11

CABLE CONNECTIONS:

Located at the rear of the power supply are the cable connections as illustrated below. (The interconnecting cables will be supplied with your system.)

1. A round, 12-pin RF cable that connects the welding press or converter to the power supply.

2. An actuation cable that connects the power supply to a trigger source (refer to wiring diagrams in Appendix).

3. The power line cord that plugs into the appropriate electrical outlet.

Once these connections have been made, the power supply is ready for operation. If applicable, be sure to consult your welding press instruction manual to insure that all connections on the press side are correct, and that the press is ready for operation.

Also located at the rear of the power supply are the following:

4. fuses (fixed 0.5 amp),

5. fuses (based on requirements listed in “Power Specifications” table, p. 8),

6. fuses (based on requirements listed in “Power Specifications” table, p. 8),

7. outputs J7 (see wiring diagrams in Appendix),

8. outputs J8 (see wiring diagrams in Appendix),

9-12. optional.

❷

❶

❸

❹

❺

➏

❼❽

NOTE: Detailed wiring diagrams are supplied in the Appendix at the back of this manual.

❿

❾

11

12

Fan

NOTE: To see a list of converters that can be connected to the power supply, see the table on the following page.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

12

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

AVAILABLE CONVERTERS

Item No. Description

CV00015 20 kHz with Button connector

CV00151 20 kHz with Lemo connector

CV00154 20 kHz with Lemo connector and fitting for

air cooling

CV00157 20 kHz with Button connector and fitting for

air cooling

CV00158 20 kHz Hand Gun with handles and cables

CV00331 20 kHz with Fischer connector

CV00334 20 kHz with Fischer connector and fitting for

air cooling

CV00023 40 kHz with Button connector

CV00231 40 kHz with Lemo connector

CV00232 40 kHz with SHV connector side mounted

CV00234 40 kHz with Lemo connector and fitting for

air cooling

CV00238 40 kHz Hand Gun with trigger switch and

cable

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

13

OPERATING PROCEDURES

FRONT PANEL CONTROLS

Located on the front panel of the power supply are the following controls:

1. Red POWER button which turns the unit on and off.

2. Yellow RESET button which resets the power supply following an overload condition. If an overload condition exists, the button lights up. In addition, the RESET button must be depressed after the unit is first turned on before any operation can proceed.

3. Green TEST button which can be used to test ultrasonic operation (pressing it only manually activates the ultrasonics).

4. OUTPUT CONTROL DIAL which controls fine adjustment of the amplitude of the system’s high-frequency vibrations over the full operating range. (Major adjustments of amplitude are made through the use of different boosters – consult your press manual for further information.)

5. LED LOAD METER which indicates the level of ultrasonics that is being transmitted to the welding press.

RESET

POWER

TEST

OUTPUT CONTROL

100

90

80

70

60

50

40

30

40 60 80 100200

The RESET button is a built-in safety feature. When the power supply is connected to a press, be sure the press head actuation signals are not activated (or closed). If they are activated, the press head will descend immediately when the RESET button is depressed.

❷❶❸❹

❺

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

14

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

STARTING UP THE POWER SUPPLY

Press the red POWER button to turn the power supply on. The POWER button will light up. The yellow RESET button will also come on and will remain lit.

INITIAL OPERATION

After the power supply is turned on (as described above), follow these steps:

1. Make sure that all necessary preparations have been made with regard to the ultrasonic system and tooling, and that the items to be welded are in position.

2. Before pressing the RESET button, make sure the press head actuation (cycle start) signals are not activated (or closed). Then, press the RESET button to activate power supply operation.

3. Press the TEST button. While depressing the TEST button, check the LED Load Meter reading to make sure that it does not exceed 20%.

a) If the meter reading is above 20%, contact Sonics immediately for further

instructions before proceeding.

b) If the meter reading is below 20%, you can proceed with operation.

During the testing process, keep in mind that the ultrasonics are only activated as long as the TEST button is depressed – once you release the TEST button, ultrasonics is terminated.

4. The power supply is now in ready mode.

NOTE: The TEST and Load Meter check should always be done for all cold start-ups, and for any start-up after the system has been idle for 20 minutes or more.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

15

OVERLOAD PROTECTION

The overload protection circuit will terminate the welding cycle when the system is operated under adverse conditions, i.e., improper tuning, excessive power supply loading, loose or failed horn or booster, thereby protecting the power supply and other system components. When an overload condition exists, the RESET button will illuminate and remain lit until the condition has been corrected and the button is pressed. If the condition is not corrected, the RESET button will remain lit. If a repeated overload condition exists, resolve the problem before a failure of the power supply occurs.

If an overload condition exists, try the following:

— decrease horn force

— decrease amplitude (change booster or decrease output control)

— decrease downspeed

— check for loose or broken studs

— check the coupling surfaces between horn/booster and booster/converter

— check for cracked horn or booster

— check to see if the load meter exceeds 100% during weld process (if so, a

higher powered unit is needed)

If you cannot remedy the situation, contact Sonics.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

16

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

MAINTENANCE

GENERAL

1. Always make sure the power supply has adequate ventilation by keeping sufficient space around the assembly.

2. Periodically check the ventilation grilles and clean as necessary.

If problems are encountered, contact our Service Department at 1-800-745-

1105.

REPAIRS / SERVICE

If problems are encountered, contact our Service Department at 1-800-745-

1105.

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 should be sent with all transportation charges prepaid and return method of shipment indicated.

NOTE: If packing unit for return shipment, DO NOT use styrofoam “peanuts.”

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

17

WARRANTY

Sonics & Materials, Inc., hereinafter referred to as “Sonics,” warrants its products for a period of one year from the date of shipment against defect in material 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 prepaid.

LIMITATION OF WARRANTY

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.

This warranty does not apply to equipment which has been subject to unauthorized repair, misuse, abuse, negligence or accident. 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.

No liability is assumed for expenses or damages resulting from interruptions in operation of the product or damages to material in process.

“Sonics” equipment is designed for maximum operator safety and incorporates built-in safety devices. Any modifications to these safety features will void the warranty. “Sonics” assumes no responsibilities for consequential damages incurred due to modifications to the said equipment.

“Sonics” reserves the right not to warrant horns of unusual or experimental design which in our judgment are more likely to fail in use.

Data supplied in the instruction manual 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.”

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

18

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

Model Actuation J2 I/O J7 I/O J8

FC E2962 E-3014 E-3013

Drawing Part No. Description

E-2962*/2962-1* 201-0179 FC continuous duty cable

E-3013* 201-0206 F-Series general I/O

E-3014* 201-0207 F-Series General I/O

APPENDIX

EQUIPMENT WIRING DIAGRAMS AND ASSOCIATED I/O

*See drawing on following pages.

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

19

APPENDIX

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

20

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

APPENDIX

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

21

APPENDIX

• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

22

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

APPENDIX

Sonics & Materials, Inc.

Corporate Headquarters European Office

53 Church Hill Road • Newtown, CT 06470 USA 22 ch du Vernay • CH - 1196 Gland, Switzerland

203.270.4600 • 800.745.1105 • 203.270.4610 fax (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax

www.sonicsandmaterials.com • [email protected] [email protected]