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Model GXC / GC
Power Supply
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
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.
Sonics & Materials, Inc.
Corporate Headquarters European Office
53 Church Hill Road • Newtown, CT 06470 USA 13, Rue Pre-de-la-Fontaine • CH - 1217 Meyrin/Satigny, Switzerland
203.270.4600 • 800.745.1105 • 203.270.4610 fax (41) (0) 22/364 1520 • (41) (0) 22/364 2161
www.sonics.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.
© Sonics & Materials, Inc. 2008 Printed in U.S.A. Rev 00 9/10
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T A B L E O F C O N T E N T S
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
Cable Connections
Available Converters For Power Supplies . . . . . . . . . . . . . . . . . . .15
– For Models with 400 to 2200 Watts Power
– For Models with 3500 or 4500 Watts Power
. .11
.13
OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . .16
Keying in Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Operational Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Starting Up the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Ready Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
ADDITIONAL FEATURES AND FUNCTIONS . . . . . . . . . . . . . . . . . . . . .20
Frequency Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
KEYPAD SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Repairs / Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Limitation of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
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APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
G-Series Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
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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
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
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
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.
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.
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I N T R O D U C T I O N
The GXC / GC power supply is an ultrasonic generator with automatic
frequency tuning and a built-in Microprocessor that can be operated on a
continuous duty basis, or pulsed via an outside control. The Microprocessor
is programmed with a multi-function keypad and information is displayed on
the back-lit liquid crystal display (LCD). This power supply can be used with
a pneumatic press or actuator, or with a stand-alone converter.
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
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
Power Supply/Generator
Actuator/Press
Provides compressive force
and mounting for Converter,
Booster, Horn assembly
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
Plastic part
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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
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/WELDING 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.
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I N S T A L L A T I O N
The line cord of the
controller/power supply
is equipped with a 3prong, grounding plug.
Do not, under any
circumstances, remove
the ground prong. The
plug must be plugged
into a mating 3-prong,
grounding type outlet.
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.
POWER SPECIFICATIONS
Power Rating/
Fuse Rating
Model Frequency 115 vac 230 vac
GXC400-40 400w - 40 kHz 15 amps 10 amps
GXC800-40 800w - 40 kHz 15 amps 10 amps
GXC1200-20 1200w - 20 kHz 15 amps 10 amps
GXC1700-20 1700w - 20 kHz N/A 20 amps
GXC2200-20 2200w - 20 kHz N/A 20 amps
GXC3500-20 3500w - 20 kHz N/A 30 amps
GXC2200-15 2200w - 15 kHz N/A 20 amps
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).
GXC3500-15 3500w - 15 kHz N/A 30 amps
GXC4500-15 4500w - 15 kHz N/A 30 amps
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.
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NOTE: Do not plug the
power supply into an
electrical outlet until all
other connections have
been made.
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 (305 mm).
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.
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NOTE: Detailed wiring
diagrams are supplied in
the Appendix at the
back of this manual.
CABLE CONNECTIONS – For GXC Models with 400 to 2200
Watts Power:
Located at the rear of the power supply are the cable connections as
illustrated below. (The interconnecting cables will be supplied with your
system.)
❶ J1, a round, 12-pin RF cable that connects the welding press or
converter to the power supply.
❷ J2, a control cable that connects the power supply to a trigger source
(press cable or external trigger source.) Refer to wiring diagrams in
Appendix.
❸ 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
❺
➏
❼
NOTE: To see a list of
converters that can be
connected to the power
supply, see the table on
page 15.
❸
❹
that the press is ready for operation.
Also located at the rear of the power supply are the following:
❶
❷
Fan
❹ Optional J5 External I/O
❺ Fuse (0.5 amp - internal low voltage)
➏ Line fuse (based on requirements listed in “Power Specifications” table,
page 9),
❼ Line fuse (based on requirements listed in “Power Specifications” table,
page 9),
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NOTE: Detailed wiring
diagrams are supplied in
the Appendix at the
back of this manual.
CABLE CONNECTIONS – For GC Models with 400 to 2200
Watts Power:
Located at the rear of the power supply are the cable connections as
illustrated below. (The interconnecting cables will be supplied with your
system.)
❶ J1, a round Lemo cable that connects the welding press or converter to
the power supply.
❷ J2, a control cable that connects the power supply to a trigger source
(press cable or external trigger source.) Refer to wiring diagrams in
Appendix.
❸ 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
❺
➏
❼
NOTE: To see a list of
converters that can be
connected to the power
supply, see the table on
page 15.
❸
❹
that the press is ready for operation.
Also located at the rear of the power supply are the following:
❶
❷
Fan
❹ Optional J5 External I/O
❺ Fuse (0.5 amp - internal low voltage)
➏ Line fuse (based on requirements listed in “Power Specifications” table,
page 9),
❼ Line fuse (based on requirements listed in “Power Specifications” table,
page 9),
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NOTE: Detailed wiring
diagrams are supplied in
the Appendix at the
back of this manual.
CABLE CONNECTIONS – For GC Models with 3500 or 4500
Watts Power:
Located at the rear of the power supply are the cable connections as
illustrated below. (The interconnecting cables will be supplied with your
system.)
❶ J1, a round, Lemo cable that connects the welding press or converter to
the power supply.
❷ J2, an actuation cable that connects the power supply to a trigger source
(press cable or external trigger source.) Refer to wiring diagrams in
Appendix.
❸ 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.
❺
➏
❸
❹
Also located at the rear of the power supply are the following:
❷❶
NOTE: To see a list of
converters that can be
connected to the power
supply, see the table on
page 15.
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❹ Optional J5 External I/O
❺ Fuse (0.5 amp - internal low voltage)
➏ Circuit breaker
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NOTE: Detailed wiring
diagrams are supplied in
the Appendix at the
back of this manual.
CABLE CONNECTIONS – For GXC Models with 3500 or
4500 Watts Power:
Located at the rear of the power supply are the cable connections as
illustrated below. (The interconnecting cables will be supplied with your
system.)
❶ J1, a round 12 pin RF cable that connects the welding press or converter
to the power supply.
❷ J2, an actuation cable that connects the power supply to a trigger source
(press cable or external trigger source.) Refer to wiring diagrams in
Appendix.
❸ 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.
❺
➏
❸
❹❼
Also located at the rear of the power supply are the following:
❷❶
NOTE: To see a list of
converters that can be
connected to the power
supply, see the table on
the following page.
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❹ Optional J5 External I/O
❺ Fuse (0.5 amp - internal low
voltage)
❼ J6 on 1595 only. Press motor
connector.
➏ Circuit breaker
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AVAILABLE CONVERTERS FOR POWER SUPPLIES
Item No. Description
CV00016 15 kHz with Button connector (O-ring mount)
CV00161 15 kHz with Lemo connector (O-ring mount)
CV00034 15 kHz with Button connector (O-ring mount)
CV00341 15 kHz with Lemo connector (O-ring mount)
CV00344 15 kHz with Lemo connector and fitting for air cooling (O-ring mount)
CV00015 20 kHz with Button connector (O-ring mount)
CVR0015 20 kHz with Button connector (rigid mount)
CV00151 20 kHz with Lemo connector (O-ring mount)
CVR0151 20 kHz with Lemo connector (rigid mount)
CV00154 20 kHz with Lemo connector and fitting for air cooling (O-ring mount)
CVR0154 20 kHz with Lemo connector and fitting for air cooling (rigid mount)
CV00157 20 kHz with Button connector and fitting for air cooling (O-ring mount)
CVR0157 20 kHz with Button connector and fitting for air cooling (rigid mount)
CV00159 20 kHz Hand Gun with handles and cables (O-ring mount)
CVR0159 20 kHz Hand Gun with handles and cables (rigid mount)
CV00029 20 kHz with Button connector (O-ring mount)
CV00291 20 kHz with Lemo connector (O-ring mount)
CV00294 20 kHz with Lemo connector and fitting for air cooling (O-ring mount)
CV00331 20 kHz with Fischer connector
CV00334 20 kHz with Fischer connector and fitting for air cooling
CVR0023 40 kHz with Button connector (rigid mount)
CVR0231 40 kHz with Lemo connector (rigid mount)
CVR0233 40 kHz with SHV connector side mounted (rigid mount)
CVR0234 40 kHz with Lemo connector and fitting for air cooling (rigid mount)
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O P E R A T I N G P R O C E D U R E S
1
2
3
4
5
7
6
8
9
10
3
FRONT PANEL CONTROLS AND INDICATORS
Located on the front panel of the power supply are the following controls and
indicators:
1. ON/OFF keys which turn the unit on and off.
2. LCD SCREEN which displays various settings, parameters and prompts
as detailed in the following pages. In addition, during the weld process it
displays a load meter indicator showing the power level of ultrasonics that
is being delivered to the welding press (see #3 below).
3. LOAD METER SCALE from 0 to 100% which (in conjunction with
vertical line indicators on LCD display) shows the running power (bar
graph at bottom of display) and peak power (single vertical line at top of
display) during the weld. Peak power is reported as %Pmax after the cycle
(see page 18).
4. AMPLITUDE key which controls adjustment of the following amplitude
settings of the system’s high-frequency vibrations over the full operating
range. (Major adjustments of amplitude can be made through the use of
different boosters – consult your press manual for further information.)
a. Amplitude Setting
b. Amplitude Ramp (only on systems configured for more than 2200
watts)
5. FN key. Option not available on this model.
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6. TEST key which can be used to test ultrasonic operation and displays idle
losses of converter/booster/horn as a percentage of maximum power
when key is depressed. Also functions as a frequency display.
7. O.L. RESET key which resets the power supply following an overload
condition. Red LED in upper left corner indicates an overload condition
exists.
8. ENTER/REVIEW key which Enters data into the system as keyed in with
the numerical keys and displayed on the LCD screen. In Review function,
displays the alarm, mode and cycle information.
9. CLEAR key which cancels a prior parameter value when a new value is to
be entered.
10. 0-9 NUMERIC KEY PAD which allows input of numeric data or numeric
selection options by pressing the keys.
KEYING IN PARAMETERS
To make numeric entries into a cursor location that is displayed on a screen
menu, use the numeric keypad. When the desired entry is displayed on the
LCD screen, use the ENTER key to register the new value. Entries are made
left to right.
The CLEAR key will clear an existing value to 0, displayed as a series of
dashes, and relocate the cursor to the extreme left-hand entry position ready
to accept entries again. As soon as a desired value is keyed in and displayed,
pressing the ENTER key makes the system accept that entry. If a number
value is not “Entered,” then it will not be accepted by the system and the
parameter value will return to its former setting (before any numerical values
were changed).
OPERATIONAL FEATURES
– Information displays showing customer resettable counter (CRC) and
number of cycles
– Keypad security.
– Self-diagnostic input test.
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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.
STARTING UP THE POWER SUPPLY
Press the ON/OFF key to turn the power supply on. The LCD screen will
briefly display “Start Sequence” and show wattage and frequency
information. Then the LCD screen will show the following “ready” display:
Ready
INITIAL OPERATION
After the power supply is turned on (as described on previous page), 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. Press and hold the TEST button. While depressing the TEST button,
check the LCD display. Make sure the bar graph indicator on the LCD
display (a series of vertical lines that register to the 0 to 100% load meter
scale – see example below) does not exceed 20%.
0045 Watts
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.
A bar graph indicator reading of above 20%, signals that there may be a
problem with the stack. Check your assembly and re-test.
3. The power supply is now ready for operation.
Frequency Display
The TEST key can also be used to display the running ultrasonic frequency
being used by the system. Refer to page 20 for more information.
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NOTE: Major
adjustments of
amplitude is made on
the press through the
use of boosters.
READY SCREEN
In addition to the start-up ready screen (shown on page 16) there is another
“ready” screen as shown below. The system must be displaying one of these
two ready screens in order for welding to commence. Welding cannot be
initiated from any other display.
Cycles: 00,004,678
CRC: 000,062
Counter Screen
The Counter screen displays the number of cycles run to date and the
customer resettable counter (CRC). The resettable counter can be reset
whenever desired by pressing the Clear key when the counter screen is
displayed (the keypad must be unlocked).
AMPLITUDE
Fine adjustments of the following amplitude and pressure settings can be
made by using the Amplitude key. All settings range from 20% (minimum) to
100% (maximum).
Amplitude Ramp – (only on systems configured for more than 2200 watts)
Used primarily for 15 kHz systems to ensure a slow start-up when welding
with big horns.
Amplitude Setting – this setting is used to specify the vibrational amplitude.
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A D D I T I O N A L F E A T U R E S A N D F U N C T I O N S
FREQUENCY DISPLAY
The TEST key can also be used to display the running frequency. When the
press head is in the UP position, press and hold the TEST key for 3 seconds.
The information on the display will change from the power display (watts) to
a frequency counter display (Hz). After this switch, the power is captured (no
longer updated) and the frequency display will update every second. This
information can help diagnose problems with the horn and/or stack
assembly.
OVERLOAD PROTECTION
The overload protection circuit will terminate ultrasonics 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, a
repetitive beep will sound and the O. L. RESET button will illuminate and
remain lit until the button is pressed (regardless of whether the condition is
corrected or not). If a repeated overload condition exists, resolve the problem
before a failure of the power supply occurs.
If an overload condition exists, refer to the actuator instruction manual which
may recommend one of the following possible solutions:
— 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’ Service Department at
1-800-745-1105.
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K E Y P A D S E C U R I T Y
The keypad can be “locked,” so that no new parameters or commands can
be entered via the keyboard, thereby preventing unauthorized cancellation or
adjustment.
To activate the security feature, press and hold the numeral 7 key on power
up. When the keypad is secured in this manner, any attempt to change or
enter parameters will result in the following message being displayed on the
LCD screen:
To return to normal operation and unlock the keypad, power down and
repeat the lock procedure – press and hold the numerical key 7 on power up.
KEYBOARD LOCKED!
NOTE: for external job recall, the keyboard must be locked.
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M A I N T E N A N C E
NOTE: If packing unit
for return shipment, DO
NOT use styrofoam
“peanuts.”
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.
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.
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W A R R A N T Y
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
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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AA
AA
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A P P E N D I X
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A P P E N D I X
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G-SERIES SWITCHES
SWITCH POS. OFF POS. ON DEFAULT
SW2-4 Program Flash (Production only) Enable-WD (Always on) ON
SW2-3 Not used
SW2-2 Not used
SW2-1 Auto Start Wait for ‘ENTER’ ON
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