Home

WELDING generators

1. On the picture above is shown an example for connecting 1 kW generator with the following specs Main ferrite transformer at 200V output voltage Inductive compensation choke at 1000uUH Capacitors should be chosen from LabView software by relays starting from 10nF Setting the generator to an unknown load When adjusting the generator to an unknown load it is very important to start with a safer level of the secondary voltage on the main transformer the best would be to start with 100V to avoid too high values of the output voltage to the transducer because this could damage the transducer or the electrical parts inside the generator The matching circuit between the main ferrite transformer and the transducer is a LC filter with selectable C values from LabView software of the capacitors 5nF to 40nF and manually selectable inductive choke in two values 500uH or 1000uH 116 After scanning the load by LabView software scanning procedure we have two possibilities 3 Self tuning of the generator is complete if the resonant curve appears on the graphic in this case just continue working and start the generator Test the generator on desired amplitude value and if the generator reaches the desired value of amplitude and phase SAVE the settings If not increase the voltage of the main transformer manually using the jumper to the next value and repeat the above procedure without changing the inductive com
2. Principal eg wale BEES for controlling oe generators Third TAB St ps t dee A or r scanning points max We a 7 side scigen Max phase Baireine measured phase upper EES Cen Phase red color curve H Max frejusnicy This is the frequency which corresponds to Max phase value in reality this is Bremen frequency Cursors Can be visualized and moved ragged d mouse on the right side scanning screen Scain By pressing this button phase frequency Sanming is activated In order to find optimal operating frequency range Span it is necessary to apply LabVIEW software scanning right side of the software screen When applying software scanning It is important that ultrasonic load is operating in air being not loaded a Corrected effective phase white color curve 50 Before analyzing scanning and using frequency phase tracking mode select proper operating frequency range which corresponds to a known operating frequency range of ultrasonic transducer or load Elliptically encircled setting zones of LabVIEW software MPlwelding exe are not used in a resonant frequency phase tracking mode When performing low power scanning using our LabView software in order to find or estimate optimal frequency range of certain transducer compensating capacitance should be set on minimum 5 nF save Write inside of the generator memory last operating situation Save Write settings as any computer file
3. Error DSUB PIN 7 11 This is the output of an internal relay root to PIN 5 9 This relay reports generator malfunctions This means that if the generator is switched on and for some reason the power output does not correspond to the set level this relay is activated Factory default settings Closed in the event of a malfunction It is possible to change the polarity in the Settings menu under the heading I O Polarities Error detect An external voltage connected to HF DA Error can of course also be switched through here max 24 VDC 100 mA 7 Signal FAN ON DSUB PIN 12 At this output there is a control voltage 12 Volt for monitoring the fan function when the internal fan is running 8 Signal FS 24 Volt DSUB PIN 13 Switching on the generator Ultrasound On by connecting a voltage between 15 24 Volt between PIN 13 and GND PIN 4 15 9 Signal FS GND DSUB PIN 14 Switching on the generator ultrasound ON with a relay contact or switch by connecting PIN 14 on the DSUB socket to GND PIN 4 15 10 Signal lt gt Nominal DSUB PIN 11 Open Collector output high signal if a window function is active and the generator is operated outside the window set low signal if a window function is active and the generator is operated within the window set 11 Signal GND DSUB PIN 4 15 The GND signal is available on multiple pins of the DSUB socket It is the common referen
4. I j I WH 800 1000 1200 Extra span 0 01 0 2 03 Input voltage i z 4 Hight Low Middle Hight 19 9 Frequency kHz on orr Mode status Untested iim E sonicate 1 Ai Overcurrent 400 600 A Overheat Start Stop Overvoltage HF overcurrent o w 106 LCD controls of Welding generator for SONICATOR regimes Total Time Ttot This defines the TOTAL TIME for operating welding generator in sonicator regime T ON Ton is periodically repeatable time interval in which the generator is ON the generator is generating ultrasonic signal For example the generator is working one minute this is T ON and later is not working 2 minutes this is T OFF T OFF Toff is periodically repeatable time interval when generator is not operating The generator is not generating ultrasonic signal at the output 107 St time St time is smallest time interval or STEP for changing the variables T ON T OFF and T TOTAL in this case is 1 second It could be selected as second minute or hour Ampli AMLITUDE of the output voltage supplied to the load expressed in percent from the maximal acceptable voltage Bar Graph symbols meaning A actual amplitude f actual phase value it depends on working conditions and on what is selected from the adjustments menu R actual value of the frequency regulator inside the span window when it is not totally filled or total empty the generator wo
5. compensation maces nF tion UH F kHz 100 71 71 21 53 08 50 35 500 500 500 500 500 45 04 500 500 500 500 41 11 38 06 35 61 33 57 ECH NO O O 71 21 50 35 41 11 35 61 31 85 29 07 26 92 25 18 23 74 NM TM NM O O JO Mh MT jh O 1O JO O 41 Principal software user interface for controlling WELDING generators First TAB basic settings Continuous mode LG control_panel_v2 vi cn in eS File Edit View Project e Operate Tools Window Help o2 oe Tutput capacitor ammang Ct Proper capacitan ew Kat omni 5 ee Dooce diececeseooo ci a EE 5 f Start frequency S sch A i GGG Uni prrrerennen Unit 1 oe SE SE kHz P o b 0 S K vw 32 33 34 35 g H S on Lef d 8 E Tene Sp e g 0 792 kHz 0 02 heli E A ae X 4 4 iett 8 Amplitude LA 2 EEE d SKS Oa Tit Tt es Sa Dk SL e a E a Ck Te n E E o a a LR I 60 4 A ys frequency Transduser we BEE e z av e MIN fgfquency A MAX frequgncy span 319 H J manual CES Ets SE 36 D __Droper 2 Sey L O Se GC Eed Pre Nominal poy Untested A Si 100 150 200 250 300 D a 400 i Ai Overcurrent 50 uni ti ea l K egen i Write 9 H 4 S S Ad d Overload A 5 7 A T inda e S P T aa T Lee Weed Sta 0 W e e e e H e 2 Y 5 l mceeme mnie bomen SR hee CO en sn man tar S
6. 2 kW Install all necessary Lab View software read the manual for welding generators Activate our Lab View software welding scan exe or MPlwelding exe First Tab parameters Select proper Serial port Rescan Verify that connection to your PC is activated small green light Connection starts blinking Set Time Peak power and Energy to 0 Select Fre quency Range e is expected that transducer will operate manual or automatic Set Nominal pow 9 W respond to hardware in this example 2000 83 Always stop the generator before changing Output capacitor and or Output choke third Tab see below the block diagram of the output stage of generator Output capacitors are selected in all type of generators 400 1000 2000 3000 W from Vab View software wit istider The preferred value of Output voltage and Compensating inductance are gelected from the software 2000 and 3000W generators only or by jumpers inside the generator older versions are base WILY JaaAuo OnF Before Scanning set the joutpu S Scan weldind y i or to Minimum 5nF with the slider in top left corner third Tab File Edit Operate Sie parameters ts scaning Output caf k TEEN EECH 5 10 20 30 Output choke Zoo up I I 800 1000 1200 Extra span A Ss O E T T hee ey E EOT O OE AC J01 0 0 1
7. 51 equal f start 0 5 Span Later real operating frequency regime under automatic effective phase regulation found by internally implemented hardware and software will find its average or effective operating frequency inside of the new Span interval and we will be able to perform set large frequency Sweeping around that frequency in both directions 1 For safety reasons when ultrasonic system is started first time when any or all of ultrasonic transducer booster sonotrode and output sonotrode tool are unknown or new or replaced set a low Amplitude value 20 for instance Later after scanning and proper operating regime is found when proper f start is found power level can be readjusted if necessary Start frequency f start can be changed adjusted also during the generator operation The generator has an automatic frequency tuning inside the frequency capture range see the explanation that follows The frequency capture range can be set by Span parameter from 0 to 1 KHz below the start frequency towards lower frequencies f capture f start Span If we set Span 0 generator will not search for optimal operating frequency between Series and Parallel resonances and generator will operate in a relatively fixed and forced non resonant not automatically controlled oscillating regime with fixed and forced frequency sweeping regardless of impedance characteristics and natural resonant frequencie
8. E kHz fz kHz Ai Untested power Nominal power A Overcurrent f 400 WW Ai Overheat 1000W Write fe C 2000 w A Overload EI Start Scanning range Applicabl in cases of auto tuning With this manual regulation we can define the scanning window which is equal to F start Scanning range when we select any of automatic frequency ranges Inside of this window the Span window will be automatically selected and displayed without user s intervention after we apply Frequency Phase Scanning on the third Tab We can also select manual ranges as first time selected frequency and Span range for first time scanning Operating frequency Span window will be equal to the frequency interval between F start and the point of operating frequency where the Phase signal has maximum see the third Tab In such case generator will be 92 locked to operate only inside automatically selected or calculated Span window which is on the right side of Phase frequency resonant curve on the Third Tab The best Phase frequency operating point horizontal cursor line in this case is also automatically selected and dynamically controlled and can also be automatically readjusted in real time during transducer loading by internal software of the generator Here relevant Phase Feedback Signal value FS certain phase value on the WHITE curve that is presenting complex
9. GE SCSI and RAID controllers Sound video and game controllers H See Storage volumes A d System devices Universal Serial Bus controllers When a PC trough communication cable and RS485 interface is connected to the generator PC automatically starts regulating the generator with higher priority When a PC is disconnected it is immediately possible to use regulations on the front panel of the generator LCD rotary encoder small ON OFF start stop button Of course WELDING generators can also be externally controlled using a PLC or analog controls For safety reasons when ultrasonic system is started first time when any or all of ultrasonic load transducer booster sonotrode are unknown or new or replaced set the Amplitude value to certain low value for instance on 10 Then start low power testing and scanning in order to find the best operating frequency interval 31 After activating older Welding _scan exe or newer soniweldicator exe software you will see the following LabVIEW user interface for controlling WELDING generators which has 3 software settings TABs all Scan weldind vi e Fichier Edition Ex cution Outils Fen tre Aide Select 400 W if you have welding Adow tienerator D a wae vi WI Select 1000 W if Ley hav welding 1000W generator D LU BE Ae ef D a gf af Select 2000 G to ou es welding 2000W generator erf Select 3000 W
10. Low Power Scanning or Frequency Phase measuring mode the safe operating low power frequency scanning of ultrasonic load Ultrasonic converter booster sonotrode etc where the scanning display would visualize the phase difference between a load current and load voltage versus frequency red color curve and Effective corrected Phase curve white color curve Such frequency scanning is realized using the LabView software MPlwelding exe supplied with ultrasonic generator In order to make scanning personal computer with installed Lab View software should be connected to ultrasonic generator trough RS485 interface When applying software scanning or frequency phase tracking it is recommendable to make scanning when ultrasonic load is operating in air being not loaded and later to make the same scanning when transducer is loaded and to compare results which should be mutually similar Initially first safe operating low power frequency scanning should be selected to cover only the expected operating frequency range of ultrasonic system For instance if we know the series and parallel resonant frequency of certain transducer measured by impedance analyzer selected scanning frequency interval should be little bit wider and overlap both series and parallel resonant frequencies In here described scanning frequency is smoothly changing towards lower values starting from f start which is higher than parallel resonant frequ
11. MODI FI ED PHASE curve realized after the first time scanning visible on the third Scanning TAB Cursor phase where horizontal yellow cursor line is crossing WHITE modified phase curve Modification of the real PHASE RED curve is made internally inside of the generator and instead of RED color real PHASE FREQUNCY curve we will use as very relevant artificially created inside of the generator new MODIFIED WHITE PHASE curve Modified phase curve is kind of specific mixed signal curve between real phase and load current This is the relevant curve for settings and regulations RED color real PHASE curve has only an informative function for real mechanical resonant zone recognition while WHITE MODIFIED PHASE curve should be overlapped inside below RED color REAL PHASE curve Where RED and WHITE curves are not mutually overlapping and not creating typical resonant bell shape peaks we will not have proper real and operating resonant regime s there we could have only non resonant forced and frequency modulated operating regimes If automatically selectable frequency ranges are not covering the best operating frequency range of certain ultrasonic load instead of auto Range we can manually and numerically define any other operating frequency range by activating Manual button which has windows for MAX frequency MIN frequency and MAX span see first Tab lower corner right side Practically manually sele
12. liquids atomizing and powders sieving applications as well as for operating high amplitude in air This operating regime has very high oscillating amplitudes and high oscillating velocity 73 Fig 11 Well selected frequency operating area for moderate and high power for most of applications Select the frequency interval that covers only darallel resonance and higher frequencies and does not cover series resonance This is the safest operating regime for low and moderate acoustic loads for welding Sonochemistry liquids atomizing and powders sieving applications as well as for operating high amplitude in air This operating regime has very high oscillating amplitudes and high oscillating velocity 74 0 0 i Lag i i 1 i is 19 5 e 19 6 19 7 0 15 8 19 9 20 0 20 1 20 22 20 3 Wat Jee soe Frequency dtizgesesseccssecee Fig 12 Frequency operating area for high po wer heavy duty for metals welding applications Operate ofly under loading not in air Risky operating regime In all cases when series resonant frequency and certain frequency interval below is captured this is presenting very risky operating zone Test carefully and modify parameters until safe operating regime is found Moderate power Safe operating frequency area operating in air for atomizing and powders sieving applications 75 KE ke 3 0 2 0 eg eeeeeeeeeeeeeeeeee ee a i TR i i i i j Le 1
13. st d CONNECTORS OF RS485 USB ADAPTER AMMM FRONT PANEL MPI RS485 USB RJ 45 DB 9 DB 15 GND 1 1 o 1 Die e 3 4850 ieg o 4 5 6 7 8 4 485 9 10 4850 11 12 13 14 4 GND 15 109 110 ADDRESSING amp NETWORKING We can also apply only as an option non standard version additional 25 pin connector for external manual switchable addressing of different converters and sonotrodes with in advance memorized settings as for example 24V_OUT c 1 2 Ou P_EXTING HF_DA_ERROR f 5 ND HF_DAG 7 ven ERROR Ts RS Wm 10 BO NOMINAL 2 em sw2 SW3 sw4 FAN_ON 13 FS_24V 14 oer ofr orf os TRANSDUCERO Le CANON_25 oer oer OFF TRANSDUCER 1 S SSES ON oF OFF OFF ON OFF OFF TRANSDUCER 2 19 21 x D OFF OFF ON OFF TRANSDUCER 4 Rem K Ka e Te Ss S oF on oer mee W i E ON OFF OFF ON TRANSDUCER 9 _Generators have network function s but all of them until now are on the same address 06 02 address is reserved for LabView software All other addresses are free for use To set the new address of AMMM generator will be possible allowed from LCD panel And or from LabView software ammm exe The address is on the LCD like parameter Every new generator is working on address 6 and could be changed from LCD to every upper address from 7 to 30 KKEKLEKKE yy ECOLE AKKU In case of network
14. 0 2 0 3 Startup mode A Normal without scan Scan Input voltage L Low I I 1 Low Middle Hight Current ratio eege 3 0 0 0 FEUERRUESCHSRSEEHEUEECRE ES RRAEEEMCTERE TER 1 995 ee Frequency kHz 0 1 2 a 4 5 ON OFF scaning A Rigsted power A Conection Nominal power A Overcurrent soo 1000 1500 C 40w 2 2000 A A Overheat 0 e 1000 Ww Write x e 2000 w A Overload s a Ai Overvoltage 169 wW Set or selectwith jumpers the output voltage to minimum 100V first time for untest d converter Set or select with jumpers the Compensating inductance to 1000uH or 500uH relative to resonant frequency of ultrasonic converter see complete user manual chapter Output capacitor selection Make SCa N procedure see the user manual chapter AMMM amp Welding Ultrasonic Power Supplies Examples of proper selection of operating frequency ranges during Scanning Slowly change increase the OUTPUT CAPACITOR OUTPUT VOLTAGE and COMPENSATING INDUCTANCE to obtain the best operating conditions and automatic power and phase regulation as explained in the user manual NOW YOUR GENERATOR IS READY FOR CONTINIOUS OPERATION 84 OPTIMAL GENERATOR SETTINGS Whatever we do with different generator settings the answer if this is beneficial for ultrasonic operating regime is the output power level that should be maximized with every particular setting watch analog power level meter The second important criteria is that ultras
15. OUT 12 Volt for external use POUT Output 0 10 Volt Power output 0 100 P EXT IN Input O 10 Volt for power control GND Shared reference point Ground ERROR Relay output ERROR HF DA Relay output HE DAT A signal of RS 485 interface HF DA ERROR Relay root shared for HE DAT and ERROR HF DA ERROR Relay root shared for HE DAT and ERROR PF UR GND Shared reference point Ground C NM ATTENTION A shielded control cable must always be used for the RS485 interface RS485 industrial interface is available on pin 8 10 We can give our Interface protocol to interested clients Otherwise generator could be controlled with on off 12 to 24 volts signal on pins 13 14 Output power could be controlled by 0 10V on pins 3 4 All these features make our WELDING generator very flexible for controls by PLC HMI or SCADA systems Our new digital WELDING generator could be set at any operating frequency in the range 15 to 100 kHz with accuracy of 0 03 Hz of course ultrasonic transducer and load should be able to operate in a desirable frequency range 10 Interface Description RS485 1 Signal 12 Volt Out DSUB PIN 1 A voltage of 12 V is available at this output This voltage can be loaded with max 100 mA and can for example be used to output a voltage for the function HF DA and or Error This voltage can also be used to switch on the generator on the inp
16. S gem i gt TRANSDUCER 500uH gt gt TRANSDUCER 16_ 100V 9 F mx A Al S TRF2 E 2 men 20nF 10nF 5nF TRF1 9 main transformer REL 3 REL 2 REL 1 On the picture above is shown an example for connecting 400 W generator with the following specs Main ferrite transformer at 200V output voltage Inductive compensation choke at 1000uUH Capacitors should be chosen from LabView software by relays starting from 10nF Setting the generator to an unknown load When adjusting the generator to an unknown load it is very important to start with a safer level of the secondary voltage on the main transformer the best would be to start with 100V to avoid too high values of the output voltage to the transducer because this could damage the transducer or the electrical parts inside the generator The matching circuit between the main ferrite transformer and the transducer is a LC filter with selectable C values from LabView software of the capacitors 5nF to 40nF and manually selectable inductive choke in two values 500uH or 1000uH After scanning the load by LabView software scanning procedure we have two possibilities 113 Self tuning of the generator is complete if the resonant curve appears on the graphic in this case just continue working and start the generator Test the generator on desired amplitude value and if the generator reaches the desired value of amplitude and phas
17. Stop generator 06stop lt cr gt Answer for stop ok gt lt cr gt Write to eeprom memory 06wre lt cr gt Answer for write ok gt lt cr gt 19 GENERATOR CONTROLS Operator elements and display on the front panel LED on Lights up when the device is being supplied with mains voltage correctly and the power switch is ON LED error Lights up in the event of an error ON OFF button The generator is switching on and off by pressing this button Menu Encoder Select For setting and entering values The LCD Amplitude Display shows the set value of output power and its performance on A bar From 0 to 100 of nominal generator power During initial testing of new sonotrodes set the amplitude to some low value example 5 to 10 Start Frequency Here encoder can be used to set the initial operating frequency which is little bit higher than f p Here the encoder can be used to adjust the starting frequency Start frequency f start can be changed adjusted also during the generator operation The generator has an automatic frequency tuning inside the frequency capture range see the explanation which follows The frequency capture range can be set by Span parameter from 0 to 1 kHz below the start frequency towards lower frequencies f capture f start Span The operating resonant frequency of ultrasonic system must be found in advance before operating the system full power per
18. amplitude are the Same as regulated operating phase and amplitude then go to a higher power level for instance to 40 and do the same until reaching stable regulation if necessary change something Capacitance inductance output voltage reduce set phase value Span after reaching stable regulation on 40 do the same for 50 and continue with higher values until your ultrasonic system will accept For instance some loads converter booster sonotrode will follow stable linear regulation only until 60 or until 70 or 55 because of a design geometry and non linear properties of the system Anyway you will see in no load conditions in air what will be the maximal amplitude when set phase and set amplitude levels are still under stable control Now go back to 30 of set amplitude level and verify that phase and amplitude are still well regulated and stable If necessary make small adjustments of all available parameters again until you rich stable amplitude and phase regulation from certain minimal amplitude to certain maximal amplitude for instance from 30 to 60 Then change the amplitude scale and instead of zero as the beginning type in our LabView operating software your minimal well operating amplitude value for instance 30 Instead of 100 on the LabView software type your maximal well operating amplitude value for instance 60 Now your generator and ultrasonic system will effectively operat
19. any PC file Later we can simply invite Read one of such files for a specific load and WELDING generator will start operating as previously memorized Blue Write button is for internal memory saving inside of the generator should be applied after scanning and any change of settings 35 Generators produced in 2012 and later have an additional software option on the second LabView software TAB to limit the converter current This is the Advanced current limiting How to use such load current limit will be explained later Auto rescan If we are using in the same time a PC LabWiew software and LCD rotary encoder controls auto rescan will be activated meaning generajor will automatically make new scanning in order to update all settings values Select 400 ou have welding 400W generator elect 1000 W if you have welding 1000W generator Select 2000 W if you have welding 2000W generator Select 3000 W if you have welding 3000W generator made before 2012 Select S008 Lm if you have welding 3000W generator made after Octeber 2012 SSE eo Literature e seen nttp bookstore yi ultrasonics com ind 36 Output capacitor selection third TAB Software selectable Output capacitor Compensating S related to the output ultrasonic load circuit and it is optimizing transducer impedance matching with the ultrasonic generator When Capacitance is selected properly ultrasonic load wil
20. application s of many generators all units should be connected to the same ground Otherwise galvanically optically isolated rs485 converters are needed also supplied by us 111 ONLY FOR EXPERTS AND TRAINED BY MPI Our ultrasonic power supplies beside software settings can also be internally adjusted to operate number of different ultrasonic transducers For instance if ultrasonic transducer has certain low or high maximal safe operating voltage on piezoceramics output generator voltage should be and can be changed internally by selecting proper jumpers In addition internal compensating inductance could have different values selectable by jumpers in cases when effective static capacitance of certain transducer is too low or too high not covered by factory default settings We are not suggesting to our clients to play with such options except if they are trained by MPI and already well experienced in Ultrasonics R amp D They can get such training from MPI and they anyway need to have specific test and measurement equipment such as an Oscilloscope with differential floating inputs with amplitude gain from 1 to 1000 in order to measure low and very high RMS voltage Impedance analyzer R L C meter etc See such jumpers adjustable situations on the next three pages 112 Internal output voltage and inductive compensation jumpers for 400 W generators JUMPER INDUCTIVE COMPENSATION oe BO
21. can produce customized Ultrasonic Power Supplies of any higher power on demand customized for specific loads Ultrasonic World Message 1 Our ultrasonic power supplies are compatible or easily modifiable to drive almost any piezoelectric ultrasonic transducer presently used known in High Power Ultrasonics Industry operating between 15 and 100 kHz or wider of course modifications in critical and demanding cases should be made in our labs The same generator can operate on any frequency between 15 and 100 KHz digital software settings easy frequency selection in any range and easy frequency window selection in any range 2 We have the largest and modifiable frequency window controls almost any frequency interval compared to 1 until 2 kHz from competition 3 We can replace almost any industrial ultrasonic power supply that is presently available from well known worldwide producers including generators for metals welding atomizing ultrasonic sieving cutting etc of course not immediately but still after a very short time after we get necessary information from a client 4 Our ultrasonic power supplies are using advantages of dynamic load power regulation between series and parallel resonance capturing even wider frequency intervals We can operate any piezoelectric ultrasonic transducer in its resonant fixed frequency regimes in any numerically selected operating frequency interval and in many forced arbitrary frequen
22. is also valid for other software TABs Of course this is not valid for other setting parameters that are not establishing defining basic operating modes Phase set point start frequency Compensating capacitance and frequency Span can be later slightly changed in real time during ultrasonic generator operating high power until we reach desired operating amplitude regulation while still keeping automatic phase regulation These are very important and very useful options Literature e book http bookstore mpi ultrasonics com index php main page product info amp cPath 48 amp products id 165 43 Principal software user interface for controlling WELDING generators First TAB basic settings Welding by Peak power ge File Edit View Project Operate Tools Window Help CN Screen example for Welding by limiting the Peak power on the load Welding process will stop when Peak power is reached h re 189 W There are no limits for total operatin Time and delivered Energy because of zero settings Every time when parameters of certain operating mode variable are sef KD zero like here encircled the LabVIEV software for ultrasonic generators is considering this as function not in use or function without limits and or as a continuous operating regime this is also valid for other software TABs Of course this is not valid for other setting parameters that are not establishing defining basic operating
23. lt cr gt answer for peak power scale 1W 02exxxxx lt cr gt answer for energy scale 1Ws 02rxxxxx lt cr gt answer for time limit plus scale 0 01s 020xxxxx lt cr gt answer for time limit minus scale 0 01s 02Ixxxxx lt cr gt answer for peak power limit plus scale 1W 02uxxxxx lt cr gt answer for peak power limit minus scale 1W 02Vxxxxx lt cr gt answer for energy limit plus scale 1Ws 02wxxxxx lt cr gt answer for energy limit minus scale 1Ws 02cxxxxx lt cr gt answer for output capacitor scale 1nF 02Sxxxxx lt cr gt answer for scanning range scale 1Hz 17 02Cxxxxx lt cr gt answer for current gain scale 0 01 02Mxxxxx lt cr gt answer for startup mode 0 normal 1 scan on save start 2 scan every time 3 hot start 02HxXxxxx lt cr gt answer for output choke 1 800UH 2 1000UH 3 1200UH 02Txxxxx lt cr gt answer for output voltage 1 low 2 midle 3 high 02 aaapppfffffsvvvaaaeeeetittrrrrnhhhme lt cr gt answer for parameters aaa amplitude scale 0 1 ppp phase scale 5mV fffff frequency scale 1Hz S status O off 1 on 2 overheat 3 overcurrent 5 limit time 6 limit peak power 7 limit energy 8 untested 9 overload vvv actuator value of internal regulator scale 0 1 aaa power scale 1W eeee last weld energy scale 1Ws tttt last weld time scale 0 01s rrrr peak power scale 1W n load number only 1000W generators hhh transducer current in relative units m mode of operation 0 off state 1 n
24. maximum when in the same time the frequency is going towards lower frequencies The frequency area which is covered by this type of regulation depends on the device type it is impedance characteristic dependent f capture f start Span Frequency capture range should be found when generator is performing the safe operating low power frequency scanning of ultrasonic load Ultrasonic converter booster sonotrode sonotrode tool where the scanning display LabVIEW software would visualize the effective phase difference between a load current and load voltage versus frequency white color curve Such low power frequency scanning is realized using the LabVIEW software supplied with ultrasonic generator In order to make scanning personal computer with installed Lab View software should be connected to ultrasonic generator trough RS485 interface as explained before Initially first safe operating low power frequency scanning should be selected to cover only the expected operating frequency range of ultrasonic system Span to cover frequency area of both series and parallel resonant frequencies The ideal situation is to have network impedance analyzer and measure Impedance Phase frequency curves in order to find series and parallel resonant frequency of the converter Later we will select Span that should cover the frequency area that is little bit larger than zone covered by series and parallel resonant frequency For instanc
25. modes 44 Principal software user interface for controlling WELDING generators First TAB basic settings Welding by delivered Energy 3 control_panel_v2 vi E File Edit View Project Operate Tools Window Help den A pararftters limits l scaaning l Phase Output capacitor A a Aies IN ee Pert peetepertegpenen Unit aS S O55 2s 2S Ste Za Ss Sa 6 AD Start frequency EES Sy TREE Ge TERT mamen w rend 135 248 kHz i 4 31 32 33 34 35 36 i S i Span q Peak ppwer S ce j D EES eech i T E A R EN SEAE EE KK AISTIA ASS oes eat Va aA be MS e 0 792 GA W EA Fel SRA Re ee ce es WY iP oe LS ZEUS oD yt at ESR ER SH S We i B02 GA RER T 22 FJA K 33 z2 Ee 0 50 100 150 200 250 300 350 400 S eweg Amplitude e Energy ae Gm ls da 1208 We ro H SO Le 3000 2 W i mm mg Serial port frequency Transduser atanninsh Shh e Auto range com ei 34 714kHe 0 auto 34 36 kHz i amplitude MIN PNY MAX frequency MAX span J om 74 3 A manual e CEN kHz ds kHz qe kHz Tam A EE power Nominal power e Ee Overcurrent Ha a Ge SE BS e m EE Overload G SE e v P TT EE Screen example tor Welding by limited amount of Energy which should be sent to a load Welding process will stop when given amount of Energy is delivered to a load here 1208 Ws There are no limits for total operating Time and operating Peak power because of zero settings Every time when
26. on a larger display and we will be able to estimate the frequency which is in the middle of that frequency interval and which is approximately equal f start 0 5 Span Later real WELDING operating frequency regime under automatic regulation found by internally implemented hardware and software will find its average or central operating frequency inside of the new Span interval and we will be able to perform set large frequency sweeping around that frequency in both directions One of examples showing such experimental frequency Span determination of the most promising WELDING operating zone will be presented later 26 M PI WELDING Generators Software This is National Instruments Lab View based operating software for controlling and setting our ultrasonic generators In order to operate such software from a personal computer it is necessary to install Lab View Run Time and NI serial ports drivers before using our ultrasonic generators software NI software can be downloaded from the web links listed below Lab View Run Time Engine 2009 SP1 Windows 2000 7 7 64 bit XP Server 2008 R2 64 bit Vista Vista x64 Server 2003 R2 32 bit 32 bit Standard RTE http joule ni com nidu cds view p id 1600 lang en Standard download Find if there is more recent version Additional install driver for serial ports NI VISA Run Time Engine 4 6 2 Windows 2000 7 7 64 bit XP Server 2008 x64 Vista Vista x64 Server 2003 http joule ni co
27. parameters of certain operating mode variable are set to 0 zero like here encircled the LabVIEV software for ultrasonic generators is considering this as function not in use or function without limits and or as a continues operating regime this is also valid for other software TABs Of course this is not valid for other setting parameters which are not establishing defining basic operating modes For this operating mode Time and Peak power should always be set to 0 zero because if we set either Time or Peak power to other non zero values Energy mode will be deactivated 45 Principal software user interface for controlling WELDING generators Second TAB setting of basic operating intervals boundary conditions and limitatioris Welding by delivered Energy Here delivered energy amount Is E limit d on the first TAB and setting limits on this TAB are only Peak Power and Time ba control_panel_v2 vi parameters Soe scaaning S Peak power plus naska eet ee oi Sa eege E e 4 peeeegae eye r 193 H Ge efast peak power Se d LP O 50 100 150 200 250 300 350 40g d gt i e e a9 Peak power minus d H Ad Le d e E D e ei e e eel rey 785 e d VEH O 50 100 150 200 250 300 350 400 VE e d d e e Energy plus See e L d 8 2 8 gy P if ast measure 8 Ge Ka Xa E Katz t Tate 1 KSE e857 8 D Ka Kat a 0 Ws D E DEU gt m 500 1000 1500 2000 2500 3000 ty Se e D Energ
28. r AS rm Loe Gab 1 tune Ee S gew eee A 7 52 5 welding d r H Oo E 2 23 4 SS TA D W e A Ve o a Z IT Nime minus i KS ef e K H WW o fe o E Errar e H se i T P a Bees 4 3 2S SE N 10 bi Untested power dhs power 100 150 200 250 390 a 400W IS e Overcurrent 5O yas ene 350 e sig Write T eF Ai 4 e E 9 Overload ejo o o Sof b beeeiseeeeeee he nrak ht Commuter J E uiretcanic AN plus maximal allowed Energy which can drive a load here 1651 Ws If real load Energy would be for some reason higher than Energy plus generator will produce error message on the front panel of generator box and on the software user interface nerd minus s minimal allowed Energy which can drive a load here 866 Ws If real load Ene ergy would be for some reason lower than Energy minus generator will produce error messa e on the front panel of generator box and on the software user interface Time plus maximal allowed operating time which can drive a load here 7 52 s If real operating time would be for some reason higher than Time plus generator will produce error message on the front panel of generator box and on the software user interface Time minus minimal allowed operating time which can drive a load here 2 08 s If real actual load operating time would be for some reason lower than Time minus generator will produc
29. regulato Power regulator indicator shows te actuator driving value of internal power regulator which corresponds to the duty cycle of PWM driving signal on the gates of output Mower transistors expressed in This regulator either keeps or shows the desired value of oscillating amplitude what is directly pfoportional to the output voltage on the transducer or keeps generated delivered power to the transducer depending on transducer ading conditions For instance if Amplitude of 400W generator is set at 50 generator supplies 500V on its output if the transducer s not loaded meaning operating in air When transducer is loaded and consumes more than 50 of power meaning more than 200W ben the power regulator reduces the output voltage meaning oscillating amplitude until the generated power delivered to the transducer reaghes 50 or 200W This is the double closed feedback loops regulating system regulating amplitude and power which is giving higher pridrity to the output power regulation Analog Power indicator of Operating Power when generator is operating and converter is loaded from the total power of the generator Analog Power Indicator shows the actual generated practically realized load power 50 200W for 400W generators supplied to the input terminals of ultrasonic transducer 82 WELDING GENERATOR OPERATING IN A CONTINUOUS MODE SETTING amp SCANNING example for 20 kHz welding converter
30. scanning of phase frequency characteristics after certain time or in case of noticing problems during ultrasonic oscillations maybe resonant characteristics are significantly changed and new generator settings should be applied 4 Set the PHASE initial value first bar in the range from 0 5 to 3V ideally and preferably below 2 5 V because maximal phase comparator DC voltage is 5 V 909 see the picture below Do not start the generator until all initial settings are verified and sett to safe low power and low risk positions 5 After all initial settings are made Ultrasonic Generator can be activated from a PC and it will start driving ultrasonic converter by pressing Start see the picture below First press on the Start button will find and memorize the proper average operating frequency which corresponds to the selected effective phase difference value Generator will operate low power very short time and stop In the second activation of the Start button generator will start operating with selected settings regulating amplitude phase and frequency 6 After all settings are tested we can transfer them to the generator internal memory by using the Write button see below This is very important operation because all 57 software settings are still virtual and present only in the LabView software on a PC screen until we transfer them to the internal memory of the generator 7 Generator can b
31. second slider on the right upper side corner iS presenting the current feedback amplification coefficient which is smoothly defining the weight of the output load current signal GREEN line on the Scan Graph Third Tab within the MODIFIED WHITE PHASE curve When load Current gain is selected to have value near zero 0 generator is working like typical parallel resonance high impedance loads ultrasonic generators such as Branson Sonics and many other of USA made generators When load Current gain is selected to have value near to five 5 generator is operating closer to series resonance low load impedance generators dominantly being controlled by output load current like many ultrasonic generators made in Germany By selecting a compromising Load Current gain value of 2 in many cases will produce good operating regimes should be experimentally adjusted Next two pictures are showing how different Current gain coefficients are changing the shape of MODI FIED WHITE PHASE curve Current gain welding 0 B Scan weldind vi ID x File Edit Operate Tools Window Help parameters l limits scaning Output capacitor xY Graph Plot 0 Output choke GE AR 21000 i I I 800 1000 1200 Extra span 0 0 1 0 2 0 3 Startup mode e Normal without scan gt Scan Input voltage C SD Didde D 1 j Middle Hight Low Current ratio 1 20 2 Frequency kHz Ai Untested O
32. to 50 If consuming power will increase over 50 generator will start regulating only the power taking 50 as the nominal generator power or set point for power and amplitude will automatically decrease giving priority to the power regulation If the consumed power will drop below 50 amplitude regulation will automatically become dominant regulating process and amplitude will be regulated on 50 Power regulator Gel Is the actuator value of the automatic closed loop regulator for amplitude and or power This is real time indicator Ideal situation is for power regulator is to be close to the set point of amplitude and or power 81 ammm_v2 vi Operate Tools Window Help File Edit Ce i V AT Parameters Sweeping Scaring ria Phase Tracking mode Tracking C eee iE Wat Ts Tay El A MAN Pet EL EN KL EA Ed E ba Kl E a Lal La DT EA OT KI EA ES KE CL KEN E OS KI EL Te KOL 2 49 y Ai e o G5 AL HE 2 25 3 35 4 5 5 Start Frequency Auto rescan Wada TE G E ia UO SU DS Yat J LY fi e ST Se ta Pad SUI Sea E PL Pag PS TiS Ts A O AE ES CE LAE A G TRIE R e D A S A E A EE a E I EA ds ze kHz 14 4 146 148 15 152 154 156 15 8 16 GR Span SE need is REG el gl Kuala Elke TE Us fy JL J pet Dee ET edu Jest ay face Clay LSU PS Jace ie JSC ic fe tec eh at k A 0 0204 06 088 1 L 1416 18 2 22 24 26 28 3 Amplitude varying amplitude 5 y Ge VG d K Ia ba ta Ia H EA IS OS T a e a a Gi EER bai ET d De A E a A
33. to activate cooling on ultrasonic converter if operating in heavy duty conditions 13 Monitor operating temperature on all oscillating parts converter booster sonotrode and if temperature is non uniformly distributed and significantly increasing in certain zones stop the generator and find reasons causing temperature rising apply refastening new scanning Literature e book SETTING amp SCANNING example for DUKANE 20 kHz welding converter 2 kW SHORT REMINDER FOR BEGGINERS e control panel _v2 vi Install all necessary LabView software read our manual Activate MPI welding exe Select proper Serial port Rescan Verify that connection to your PC is activated Set output capacitor to minimum 5nF before scanning Set Time Peak power Energy to 0 Set Nominal power to what correspond to hardware here 2000W Select frequency Range or MIN and MAX frequency amp MAX span If Auto frequency range is used span is automatically selected to be 1 kHz Always stop the generator before changing Output capacitor 87 Do not forget to activate blue button Write after every modification Set all values to 0 minimum before scanning Do not forget to activate blue button Write after every modification 88 max phase Cursor phase 4 995 Vv 4 995 d max frequency Cursor frequency 19 8571 kHz 19 8571 kHz l l l l 22 203 20 4 2 5 A Untested EI Overc
34. voltage on ultrasonic transducer 100 amplitude in the software settings is equal to maximal safe operating and acceptable voltage over the transducer measured directly on piezoceramics The RMS voltage should be measured directly on the transducer during all impedance matching and manipulations with output voltages on the output ferrite transformer Output ferrite transformer has 3 jumper selectable voltage outputs in order to be able to adjust maximal safe operating voltage Special high voltage high frequency wideband RMS voltmeter should be applied when measuring voltage on the transducer also oscilloscope with differential isolated channel inputs for high voltage applications lf transducer has piezoceramics which are 5 mm thick each of them maximal RMS voltage on such transducer can be 1000 V 1000 x 1 41 V peak If transducer has piezoceramics which are only 1 mm thick each of them maximal applied RMS voltage on it should not be higher than 200 V 200 x 1 41 V peak Be sure you are working in the CONTINUOUS MODE set Time Peak power Energy to 0 First TAB upper right side when performing first time tuning and matching of new transducer When performing low power scanning using our LabView software in order to find or estimate optimal frequency range of certain transducer compensating capacitance should be set on minimum 5 nF Examples for calculating compensating capacitance transducer
35. which is activating the safe operating low power ultrasonic load scanning kind of load impedance scanning Before Scan is activated it is important to select scanning frequency resolution number of steps which is selectable from 40 to 100 See Scan and steps positions on the picture below After certain time scanning will stop and on the upper right corner of the user software interface we will see the plots of scanned phase red color curve and Effective corrected Phase white color curve The examples of scanning screen are presented on the pictures below parameters limits scaaning Y h Plot 0 steps scaning phase SURGE a 65 70 75 5 0 60 Sanm 80 H v RES SC 85 scaning power 50 90 169 wW 4 0 457 95 gt En scaning frequency 40 100 3 5 32 896 kHz SHI pa 9 2 97 max phase Cursor phase SE max frequency Cursor frequency Wee 19 947 kHz 34 962 kHz ngs Ha 0 0 I I I I I 1 I 1 I 31 4 31 6 31 6 32 0 See 32 4 32 6 32 8 32 9 Frequency kHz E control panel vie Fichier Eqition x cution Quils Fente Aide Slelei parameters limits scaaning stepa scanning phase 45 A0 75 i Sp La Sp D wa Ti sie 85 scaning power 50 4 30 o w 457 op n scaning frequency 40 100 Keeseren 20 04 kH max phase Cursor phase lags N 1 85582 max frequency 119 8781 R is power Nominal power sog II 1500 f 400 Ww o 2000 Co mow fe 0w i E Start 30
36. 00 WwW a WW Hl Literature e book http bookstore mpi ultrasonics com index php main_page product_info amp cPath 48 amp products_id 165 63 AMMM amp Welding Ultrasonic Power Supplies Examples of proper selection of operating frequency ranges during Scanning If you have impedance analyzer make impedance measurements and select initial scanning range that will capture both series and parallel resonant frequency and little bit wider on both sides Fig 1 Typical scanhing curve wide scanning range Somewhere in this area is series resonance here close to 19 82 kHz Somewhere in this area is parallel resonance here close to 19 92 kHz Before performing scanning set amplitude to O zero set output capacitor to minimum 5 nF set operating mode to continuous disable all sweeping parameters set them to 0 set operating frequency range minimal and maximal frequency and Span inside the expected operating frequency interval 64 Fig 2 Typical scanning curve wide scanning range Ze Ze Ze Somewhere in this area it will be the best to select set point for phase regulation For example on this curve optimal phase values are between 0 5 and 2 V Here selected optimum is 1 25 V 65 Fig 3 Typicaf scanning curve wide scanning range Here is relatively safe operating frequency area Frequency capture range should be reduced to here encircled area Fo
37. 9 6 19 7 19 8 gt 19 9 20 0 20 1 20 20 3 Pe cccc ccc doccccce D ag ag s ag s wot oot ap ag ag ag ag Fig 1 Well selected frequency operating area for moderate high power for most of Se applications On this frequency capture range frequency area below series resonance is avoided Select the frequency interval that covers only parallel resonance and higher frequencies and does not cover series resonance This is the safest operating regime for low and moderate acoustic loads for welding Sonochemistry liquids atomizing and powders sieving applications as well as for operating high amplitude in air This operating regime has very high oscillating amplitudes and high oscillating velocity 76 s Le i i i Lef 19 7 REN Ge Frequency kHz Fig 14 Well selected p hase set point here L vi Should always be selected in a lower linear zone of phase curve with negative slope Ei This is very well selected frequency Area for most of moderate and high power applications Select the frequency interval that covers only parallel resonance and higher frequencies and does not cover series resonance This is the safest operating regime for low and moderate acoustic loads for welding Sonochemistry liquids atomizing and powders sieving applications as well as for operating high amplitude in air This operating regime has very high oscillating amplitudes and high oscillating
38. Deag 3 Fil 119 Setting the generator to an unknown load When adjusting the generator to an unknown load it is very important to start with a safer level of the secondary voltage on the main transformer the best would be to start with 100V to avoid too high values of the output voltage to the transducer because this could damage the transducer or the electrical parts inside the generator The matching circuit between the main ferrite transformer and the transducer is a LC filter with selectable C values from LabView software of the capacitors 5nF to 40nF and manually selectable inductive choke in two values 500uH or 1000uH After scanning the load by LabView software scanning procedure we have two possibilities 1 Self tuning of the generator is complete if the resonant curve appears on the graphic in this case just continue working and start the generator Test the generator on desired amplitude value and if the generator reaches the desired value of amplitude and phase SAVE the settings If not increase the voltage of the main transformer manually using the jumper to the next value and repeat the above procedure without changing the inductive compensation If 300V is chosen but still not producing well enough amplitude start increasing the capacitor value gradually If the amplitude is still not good enough then increase the inductive compensation to 1000 uH and start with 100V and 10 nF The main s
39. E E 66 1 0 10 20 30 40 50 D H 80 90 100 Output capacitor auto Auto d Range 19 21 kHz begin SP E bel litem Seen aay S Met Ka Ay lina Ae J Serial port manuel Max frequency MIN frequency MAX span I 9 1 i coms ha fren Hie kz 23 kHz 7 kHz A Overcurrent Ai Overheat phase Frequency 0 004 te amplitude Amplitude Output voltage Oscillating mechanica voltage of ultrasonic generatg easured on input terminalk software display user ipterface shows the de generators 100 am flitude 1000V on Smm thick g Amplitude indicator on Lab View software i operating amplitude on jultrasonic transdy er desired Amplitude set point is equal tg is not always the case and in order t tor regulation we are scanning ultrasonic load and making differant settings until we rich that Amplitude set point Amplitude indicator is showing Generator regulates the Amplitude or output voltage over the transduce dower in Watts when transducer is loaded increases to the value selected in with varying amplitua de slider Example for 400W generators When selected Amplitude is 50 and Amplitude indicatorAhows50 this m ans that in such regulation the voltage over transducer is 500V If in the sametime indicator sh ws 30 this means that consumed power is 120W 30 from 400W 120W Power regulator indj ator is organized tg show any value between 10 and 100 Analog power
40. ENT TE NAE EE ET EA T pees eg L 66 De ot d ees ESEN D KO Er Gei CA KL 20 AF JEE S Oe Wee ele nosene EC H ny twitter A g Time e d X J en HO S HAAN on E SES KS s 8 aj ma 2 38 a E eege Bee SS aos NN H neous E a Com Ke CAL Bvt os te 5 if Um Wal oof 8 Q79 Hz ee Hee KL AN II 0 WI Mh ai TTT E E E A ie H gd 100 150 200 250 am KE 4008 e r ea ef 4 LIN Ze Kg pree pene pene pene bes SSS lt oe opr El See Pig hile E dc Mee GEN Veit ESCH GA a Le dest 1 te H Ko Was EE E ated d WW wi seh W rof veer Men Auto range v l 4 S em EN 0 00V E 34 36kHz IF See amplitude fv MAX frequency MAX span KK 10 0 2 31 9 A manual gt ES 31 kHz 36 SR k J F ESE ds Mr SS 5 SE a J Nominal pewer brence settifgs after scanning optimal 2V fom 1 V until 3 5 V hage Start frequency sg fection Usyatly eo Saves frequency of the transducer Span operz fn frequenty iatdrval efecti ecalized inside Start frequency Span Amplitud scitata feeds eftance added to the transducer capacitance should be selected Ae able fields for arbitrary selections of operating intervals which are inside of operating T x ins of WELDING generators Power Selector Should be selected in relation to applied standard generator Read Write options After all settings are properly and optimally made we can save the file wilh such settings using Write button like saving
41. KE e D g S J Marais 36 Phone 41 0 32 9314045 2400 Le Locle email mpi mpi ultrasonics com Switzerland http www mpi ultrasonics com mpi bluewin ch http mastersonics com WELDING generators Can drive any kind of ultrasonic transducers for cleaning welding sonochemistry bonding machining Automatic Frequency Tuning Digital Amplitude Control Good Part Bad Part Output Signal Multiple Job Storage 1000 W and up Weld quality monitoring is available in time energy and distance Ultrasonics Load Meter Scale Upper and Lower Weld Quality Settings PLC WO Input Output Ports Soft Start Overload Protection Circuitry Load Regulation Circuitry Power available in 400W 1000W 2000W and 3000W higher power on demand Item WG 400 W WG 1000 W WG 2000 W max 400 W max 1000 W max 2000 W 20 kHz 100kHz constant and load independent amplitude at the transducer possible with analog voltage RS 485 interface status LED s PLC interfaces Remote support via RS485 overload short circuit over temperature line connector RF connector HV BNC interface connector Canon 15 RS485 216 240VAC 50 60Hz dependent on the model max 7A 250 x 210 x 2 0 x 250 x 435 x 380 x 80 mm 135 mm 100 mm 4 kg 6 kg 10 kg CE conformity welding bonding ATTENTION A shielded control cable must always be used for the RS485 USB interface We
42. N OFF Scaning power Q Conection Nominal power al Overcurrent 200 00 600 son C 400w lt 1000 PI Overheat 0 ow write Wf i 2000 W PI Overload i D on A MI zy Ai Overvoltage 0 wW Current gain 0 Maximal value on the white phase curve is around 4 75 V After such phase maximum white line is falling down towards lower frequencies 95 reaching below the automatically selected calculated operating phase level which is in this case equal to 1 8V Vertical and horizontal YELLOW lines are Phase and Frequency cursors defining automatically found new operating area Current gain welding 5 IS Scan weldind vi O x File Edit Operate Tools Window Help A parameters limits sang eg Output capacitor XY Graph O N d E D D H D D D H D H H H D D D J 15 nF 50 5 10 20 30 40 Output choke 4 5 A 1000 uH 4 0 600 1000 1200 Extra span 3 5 A A o 3 0 bi a ed Ota EL DA ei GK SST TVS a ISL Dil ey KCL iat Dehn v 0 D 1 0 2 0 3 2 wee 15 ER Startup mode 2 0 A Normal without scan 2 Das Scan Input voltage US C AER ac 0 5 1 Middle Hight Low Current ratio 0 0 i i i 1 1 20 0 20 0 20 1 20 2 20 3 20 4 Frequency kHz ON OFF caning Untested power L3 Conection Nominal power A Overcurrent opp 1009 600 cp C 400w 1000 Ai Overheat d 1000 W Write Start e Stop P Overvoltage o w Read Write Yv Current gain 5 Maximal value on the whit
43. OPERATING MODES OF WELDING ULTRASONIC GENERATORS A WELDING generators can operate in the CONTINUOUS TEST MODE for scanning testing and first time settings B WELDING by given Time Welding by limiting only a welding time Welding process will stop after given Time interval There are no limits for operating Power and delivered Energy C WELDING by Peak power Welding by limiting the Peak power on the load Welding process will stop when Peak power is reached There are no limits for total operating Time and delivered Energy D WELDING by Energy Welding by limited amount of Energy which should be sent to a load Welding process will stop when given amount of Energy is delivered to a load There are no limits for total operating Time and operating Peak power Important comments Programmable Welding by Height is still not applied is our welding generators To make Welding by Height it will be necessary to use certain controller which drives the step motor and switches ultrasonic generator ON and OFF and conveniently update the software This generator presently reacts only as a SLAVE device Our LabView software is only the test and adjusting software which cannot operate like data logger software it cannot collect data about the welding process and save them It only shows the momentary temporary immediate values of the running parameters Presently we are offering only free LabView source software and for addition
44. Suitable location that will protect the device from moisture water excessive sunlight and heat ATTENTION e Choose a location that will prevent steam or any other aggressive vapors from penetrating the device e Over a period of time chemically contaminated ambient air can lead to the device being irreparably damaged Power supply The ultrasonic generator draws its power 230 V 50 60 Hz via the connection cable MAINS 230 VAC It has an internal main fuse 10 AF lf you need to change the fuses unscrew the top of the housing ATTENTION e For safety reasons always disconnect the unit from the mains before changing fuses e Plug racks into earthed sockets only e Always replace blown fuses with new fuses of the same type e This should only be performed by qualified skilled personnel Connections on the back of the generator HF OUTPUT Output of the HF voltage possible to have different high voltage Ke connectors a a a a a a a a LU Be RS485 Fuis Main Supply Input ATTENTION e Use only cables specified by the manufacturer e Use only shielded transducer connection cables e Connect the shielding to the PE conductor on the generator side e Only use cables with sufficient cross section e Minimum wires cross section 1 5 mm Assignment of the 15 pole DSUB interface socket RS485 REMOTE 8 41 15 9 PIN No on DSUB SOCKET Signal name Description Interface X1 12 VOLT
45. W D have welding 3000W generator made before 2012 s Select 3000 W m if you have welding 3000W generator made after October 2012 Literature e book ER How to change numerical and other setting values for operating frequency and scanning ranges If we cannot select automatically by default proper frequency Range proper Start frequency proper Span value and proper scanning range there is a simple way to do it manually and numerically by direct writing of new desired values into proper windows For instance if operating frequency Range should be something else compared to what we see on the Range window we can simply click with a mouse over the area where frequency interval numbers should appear and type write on the same 2 way same format new frequency interval like on the picture below IESSEN If we would like to change Start frequency and Span because by default we do not see desired numbers there we will again simply click over the last existing numerical position and type new numbers there like on the pictures belgw Old number s can be simply manually by typing be replaced by new numbers This way we will be able to modify settings and scanning values in order to get most appropriate intervals for specific ultrasonic loads Of course certain logic should be respected since we should not select new numerical values to be outside of the operating limits of WELDING generators 33
46. activated in the same time when one is active the other is passive To be able to use our Lab View based software for Welding Sonicator generators lease follow the following initial steps Install NI Runtime for Windows version 2012 2014 Go here and download all necessary software files MS Windows XP 7 32 64 bits http www mastersonics com documents mmm_basics mmm_ power supplies AMMM ALL welding generators Welding Sonicator Sonicator 20weldind 29102013 Comment Create WELDING Sonicator directory box on a PC that will be used to control your WELDING generator Place inside of the WELDING box the following files controls and regulations of welding generators latest pdf Ed soniweldicator exe Ed soniweldicator ini IP Sonicator welding vi Ed soniweldicator aliases Always download from Internet and install Latest NI Visa drivers drivers for all PC ports http www ni com download ni visa 5 4 4230 en Latest FTDI USB to RS485 converter drivers Proper NI Runtime for windows 29 1 Connect ultrasonic generator to a PC using the RS485 USB adapter supplied with the WELDING generator see the picture below Switch ON the main switch of your WELDING ultrasonic generator This is only a main supply power input for instance 230 Vac 50 60 Hz Ultrasonic output power is still not activated PC will not connect to ultrasonic generator if generator is not powered by main supply input Ka
47. ad here 2 08 s If real actual load o operating time would be for some reason lower than Time minus generator will produce error message on the front panel of generator box and on the software user interface 46 Principal software user interface for controlling WELDING generators Second TAB setting of basic operating intervals boundary conditions and limitations Welding by Peak Power Here operating Peak power is defined vince onthe first TAB and setting limits on this TAB are only Aee and Time en a control_panel_v2 vi se ke e So z Gee e parameters limit scaaning E S Peak power plus S BE e of edad A ep 3 1 C2 L a 1 KSE 1 Ae K KA LL CEA tree LE 1 st a i fi 0 W Bi w peak power Ze air o 50 100 150 200 250 300 350 400 A 4 Ev W Peak power minus 5 e d V JN ur d Gegen fio d Ag 0 50 100 150 200 250 300 350 404 ef Sa Energy plus v e y o A ae 6 d We see e j Lost measured 8 S es amet Fs 8 8 1 Sec UIT SE 1 el Fike Ze AA OK aay fee A 1 A 1651 s w f ast eg A L p D D H 500 1000 1500 2000 2500 3008 We abue V Energy minus a N S S v es Ws H s e LU 8 d en SR A A A A EM Wil re ae AA Weed Ny ae AE foe KEE EE EE EENS Dak tee EA Se Krk Se 866 5 we memorized from P 7 aes 0 500 1000 1500 2000 2500 3000 Se Zei A e wg D See Time plus PEF a previous e ee o e ef VE CE n oo v e bh a vi peee D reese t KITS treet l
48. afety rule is to start carefully preferably with 100V 10 nF and 500uH If the inductive compensation is increased from 500uH to 1000UH then start with 10nF capacitor value again If self tuning of the generator is still not completed and the resonant curve does not appear on the scanning tab then you have to search it in another frequency range or the load is damaged In case the load is not damaged change the frequency range by LabView software and repeat the procedure described in case under 1 120 SAFETY INSTRUCTIONS Before starting up your device please read through the following instructions carefully both for your own safety and for the safety of the device Keep this manual where it can be readily accessed by all systems users Installation is to be carried out by qualified technical personnel only The ultrasonic generator is to be operated by properly trained personnel only Due to the way it operates additional safety measures must be taken if the device is to be used in areas posing an explosion risk The electromagnetic compatibility corresponds to the standards and regulations listed in the specifications All necessary settings were either made in the factory or are described in this handbook However should problems occur on start up please do not make any prohibited adjustments to the device as this would endanger your warranty rights If in doubt please contact our technical service staff Please contac
49. al allowed operating time which can drive a load here 2 08 s If real actual load operating time would be for some reason lower than Time minus generator will produce error message on the front panel of generator box and on the software user interface Peak power plus maximal allowed Peak power which can drive a load here 193 W If real actual load Peak power would be for some reason higher than Peak power plus generator will produce error message on the front panel of generator box and on the software user interface 22 23 Peak power minus minimal allowed Peak power which can drive a load here 85 W If real actual load Peak power would be for some reason lower than Peak power minus generator will produce error message on the front panel of generator box and on the software user interface The numeric operating power value is not shown on the LCD but on the menu Amplitude it is possible to see the selected value for amplitude xxx and on the bottom of the same LCD it is the bar graph showing instantaneous amplitude like on an analog indicator The exact operating power is visible on generator LabView software and it is also accessible through RS485 communication Energy plus maximal allowed Energy which can drive a load here 1651 Ws If real load Energy would be for some reason higher than Energy plus generator will produce error message on the front panel of generator box and
50. al functions it is necessary to create new updated software Since client has the source software new functions can easily be realized on number of ways lf the green lamp _ Connection in the generator LabView software is not blinking there is no active connection between ultrasonic generator and PC no software settings and regulations can be made In such case check the software installation and reinstall if necessary check the RS485 USB adapter maybe conneciors are not in place check the ports and wires Follow manual and first connect the generator to your PC and to proper LabView software applicable for your generator and later you can change settings and see actual operating parameters For realizing remote control generator has input START STOP on the pini3 For controlling start stop it is possible to apply an external free independent voltage potential connected between pin1 and pin13 or to apply external voltage from 12Vdc to 24Vdc between pin13 and pin14 When we apply voltage on the pin13 generator is ON other option is OFF 34 PARAMETERS amp BASIC SETTINGS Principal software user interface for controlling WELDING generators First TAB File Edit View Project Operate Tools ale parameters ged scaaning l Window Help 2S OOF ee Gees SS jee 9 8 20880 Coenen od reek f V EE aaeanoa d RE OS Jis y k PEPE Pee epee EEE E
51. and Phase regulation could be non linear and irregular The next important operating regime settings are related to timing parameters such as Time ON Operating period Time OFF No activity period Process Energy Desired selected energy that should be given to a liquid load when reaching d sired amount of energy generator will stop Sonicator weldind Fichier Edition Ex cution Outils Fen tre Aide Sa parameters Sonicator Welding scaning Time ON Process Time 10 43 25 process time indicator time on indicator time off indicator energy indicator Process Time in seconds 38845 38843 o H SC Wee status Yntested power J Conection Nominal pora Sonicator 1 A Tee 400 W 1000W Overheat 2000 W 3000 W 3000 W m 1kW inox a Overload Start Stop Overvoltage KR HF overcurrent W Output current 0 31 CCS vn HJ rs We can also set the total Process Time meaning how long generator will operate in a pulse repetitive regime 104 All timing and processing parameters can be regulated from the LCD front panel rotary encoder It is important to notice that Start frequency should not be changed from the LCD panel by unexperienced users since this parameter is found by scanning and for certain ultrasonic transducer it is not probably that start frequency will suddenly change except when transducer
52. ated phase value and the ee re i eurarcanice haara dh Cen een par bone 80 Amplitude This is very particular amplitude regulator which is starting to regulate amplitude from certain minimal threshold point which is specific for every ultrasonic load Below that amplitude threshold point there is no automatic amplitude regulation amplitude is too small to be regulated Starting from the amplitude threshold AMMM generator is making automatic amplitude regulation percentage wise which should be almost equal to the set point level of amplitude given on the first TAB settings Upper amplitude level that can be reached by automatic regulation is also limited Example For certain transducer we will be able to have smooth automatic amplitude regulation only between 20 and 70 of the full scale and we should never expect that autoinatic amplitude regulation will operate from 0 to 100 Amplitude SCH e a97 l I l E I l I lE l I l I l l I l I l I IBAN lI I l I Tey l I E l I l I Wl I l NW WW E l NW WW E l ch 49 7 to j 10 ZU 30 22 40 50 DU ZU OU 90 100 If mechanical ultrasonic load starts consuming power that numerically corresponds to the percentage of the amplitude set_point generator will start regulating power instead of regulating amplitude but using the same numerical value of the amplitude Example If the set point of amplitude is 50 generator will regulate amplitude on 50 in the power range from 0
53. by default there is always 5 nF capacitance installed in parallel connection to an output transducer which cannot be changed or disconnected by LabVIEW software Only maximum of 35 nF can be added parallel to a transducer by LabVIEW software This will create the total added capacitance that will go until max 40 nF non counting capacitance of the transducer When we set by LabVIEW software the value of 40 nF this will show that 40 nF is added in parallel to ultrasonic transducer 5 nF which are always there and 35 nF which are added by software Mathematical formula for calculating necessary parallel capacitance which should be added to transducer is 1 1 LEE HZ 2n LC 2m LC a SN a C C C Lo l L compensating Am 1 03H or 0 5mH compensating eq transducer All transducer gt 1 1000 Ca oe eeben SS aie C onnensa At _ transducer compensating xternally added capacitance Example f 20000Hz 1 transducer p Coa 20 Ve ge ie Ar 8 60nF C anede 20nF 20 10 7F gt gt transducer L 1mH 1 O H Bee Coa 7 E 60 20 nF 40nF We can measure Coa inside of WELDING generator on its output parallel to a connected transducer and compare it with calculated value for Cag in order to be sure that proper equivalent capacitance is reached or to be sure that proper parallel capacitance C is compensating connected to the transducer Parallel capacitance C until 40 nF is soft
54. ce point for all input and output signals 12 Relay WARNING DSUB PIN 16 This is the output of an internal relay root to PIN 5 9 This relay reports generator malfunctions This means that if the generator is switched on and for some reason the power output does not correspond to the set level this relay is activated Factory default settings Closed in the event of a malfunction 12 Overload Occurred Some of Welding limits An external voltage connected to HF DA Error can also be switched through here max 24 VDC 100 mA 13 DSUB PIN 22 23 24 25 selecting internal programs with different settings In this manual there is an additional picture for 25 pin DSUB connector which is applicable only for 1000W generator with selecting switches for different transducers for welding clients using number of transducers but the names and numbers of all other pins are the same as described above 24V_OUT S 4 doud P ENT We 3 HF_DA ERROR 5 ND HF_DAS Ta ebe L SR 10 B NOMINAL 11 12 FAN_ON 13 Fs_z4y Y S CANON_25 Sa RELAY_WARNINGC e 18 19 20 71 TA INS 22 DIN3 vn DIN2 DINIC SW a I Swi VON SW SW SW4 CECCI TRANSDUCER cleats on ovr on f or trmoveens 13 Important Comments High power Welding generators have the ability to store more than one weld setup in memory so an operator can simply pick and recall a setup from memory Presently only 1000W welding ge
55. ce such areas are easy forsautomatic regylation Yellow horizontal and vertical lines are manually moveable cursors that ase useful for estimating and marking most probable operating phase and frequency where automatic regulation will be optimal In this frequency area we should select the Start frequency fstart Ultrasonic generator will start operating from selected start frequency and very fast find its optimal resonant frequency that is under automatic regulation here If converter is operating in air this frequency will be very close to its parallel resonant frequency 55 5 0 EE i 4 5 4 0 KA Ae L e LO 0 5 0 0 A i i i 19 3 19 8 19 9 ZU Two examples different piezoelectric converters of properly selected phase set point that will be automatically regulated 56 3 Find proper resonant mode and start frequency f start by measuring Impedance Phase Frequency characteristics using Lab View software as already explained Have in mind that initial resonant frequency characteristics will change after certain time because of ultrasonic oscillations and involved materials aging and stabilization stress relief friction between contact surfaces thermal aging operating temperature Also resonant frequencies will be very much operating temperature dependent converter and sonotrode could heat during operation Repeat
56. ch ay E E WEINI ay RA E 4 4 7 i ean We 2 Activate RS485 USB connection line between your WELDING generator and your PC PAIIIOILLIOE In the lower left corner of the software interface First TAB it is necessary to select a free available COM port_and press Rescan this will activate the connection between the generator and a PC and the green lamp Connection will start blinking the blinking green light is always a sign that there is established communication between generator and PC e mm van T 8 Urteste Overcurrent overheat Cverload Ai Overvoltage 169 WW 30 For better checking regarding COM port selection go to Control Panel MS Windows XP to verify which COM port is assigned to USB RS485 adapter see the picture below Device Manager E Belt File Action View Help m g CG AMPI BY9DSE2135E d Computer S Disk drives E Display adapters JA DVDICD ROM drives Floppy disk controllers A Floppy disk drives Human Interface Devices IDE ATAJATAFI controllers 1 Sa IEEE 1394 Bus host controllers 38 Imaging devices Keyboards A Mice and other pointing devices Monitors T 4 A fl Bai Network adapters Other devices Ports COM amp LPT EI Brother MFC F7620M USB Remote Setup Port COM y Communications Port COM1 4 d USB Serial Port COM g s Processors 1 Sa SBP IEEE 1394 Devices
57. ches on and later automatically resets on every next ON signal 3 In the RS485 serial communications protocol generator returns a warning status number read relevant information in this User Manual MAINTENANCE The ultrasonic generator does not need special maintenance Dust and dirt should be removed regularly using a damp cloth ATTENTION e Do not use aggressive cleaning solvents e Not suitable for ultrasonic cleaning 124 WARRANTY The length and coverage of the warranty can be found in the terms of delivery as part of the general terms and conditions valid at the time of purchase or in the sales contract order confirmation should any special agreements have been made The following cases are not covered by warranty Damage caused by inappropriate operation The device not being used for its intended purpose Inappropriate alterations or modifications made without prior authorization from the manufacturer Damage caused by extreme circumstances such as knocks falling over moisture and dirt Insufficiently qualified operating staff Non compliance with current safety and accident prevention regulations Damage resulting from modifications made to the operating instructions SERVICE HOTLINE Should you still have questions after reading through the operating instructions thoroughly please feel free to call our service hotline Please have the following information to hand to help us answer your questions quic
58. creen example for continuous operat TEST operation without limits for implementing basic tuning ow loads Welding process can be controlled by Start and Stop buttons Output capacitor can be adjusted for optimal impedance power matching Ever time when parameters of certain operating mode variable are set to 0 zero like here encircled the LabVIEV software for ultrasonic generators is considesitig this as function n t in use or function without limits and or as a continuous opeyating regime this is also valid for other software TABs Of course this is not valid for other setting parameters that are not establishing defining basic operating modes Auto fange If switch is selected for Auto range upper position only frequency ranges given in the software by default will be visible and selegtable If lower switch postan is chosen it is possible to enter manually different frequency and span values Range Operating frequency range for certain ultrasonic load should be selected or typed here MIN frequency amp MAX frequency corresponds to end values of the Start_frequency slider for instance here 31 and 36 kHz MAX Span By default automatically we have 1 kHz wide Max Span but manually we can select and type another value Span is frequency capture interval for resonant regime tracking 42 Principal software user interface for controlling WELDING generators First TAB basic settings Welding b
59. cted it is immediately possible to use regulations on the front panel of the generator After all initial settings are made using a PC and supplied Lab View software Ultrasonic Generator can be activated and it will start driving ultrasonic converter by pressing ON OFF button which is on the front panel Do not start the generator until all initial settings are verified and sett to safe low power and low risk positions LCD symbols meaning TA TR OF V J All of these are not messages for the customer only for service factory use When the encoder is in the regime J it is changing the values of the selected parameter Regime V is changing the parameter The default settings are stored in memory D If we change the value of some of the parameters and store in memory 7 what is the procedure We cannot make it if we follow the instructions from the manual This is not an address in the memory but it is an address of the device when generator is communicating with the computer through RS 485 It is not possible to set anything in memory 7 Only the present last settings could be saved in the memory Attempt to do tis will change the factory settings 25 Frequency capture range Span This is the safe operating low power frequency scanning of ultrasonic load Ultrasonic converter booster sonotrode etc where the scanning display would visualize the phase difference versus frequency between a load current and load v
60. cted operating frequency range is important for initial scanning interval definition when certain ultrasonic load transducer is tested first time Later automatic tuning process will define new safe operating frequency Span 93 The best safe operating frequency and best set phase point FS will be automatically found after scanning by internal software calculation inside of the Operating frequency Span window where NEW MODI FIED PHASE FS FSmin FSmax FSmin 3 After first Scanning procedure third Tab we will see that all new automatically produced values are dynamically in real time changing the initially selected values of Operating frequency Span and Phase in relation to loading conditions existing during scanning On the phase frequency scanning curve third TAB Scanning we see WHITE LINE Principal Regulation curve MODIFI ED PHASE curve RED LINE Real PHASE measured on the load ultrasonic converter between load current and voltage GREEN LINE Output Load current The YELLOW cursor lines are showing crossing the value of Modified Phase where ultrasonic generator is auto tuned after Scanning procedure pelini eest Pi gent f Set plase hee Aulo 3 gd E d Lei 1 d d F d P aF Ee i d Eun i Sa A d P p F F e j d F a 8 F T d e Pi i F Li D j i Fmi D I tine Sab Scomin Pange F max 94 Current gain First Tab
61. cy modulated wideband regimes Our generators are much better in many aspects when compared to the well known ultrasonic generators from others Our generators can be used on the same way as any other ultrasonic generator and on many other unique ways All presently known industrial and manual control options are available manual LCD front panel settings and controls analog PLC Everything can be arranged as any other producer or user of ultrasonic generators is doing 5 We implement safe operating internal scanning procedure in order to select the optimal operating regime and settings for certain ultrasonic transducer D If ultrasonic tool sonotrode load is operating in a very large temperature range from 300 C until 1000 C resonant frequency of such system could change for several kHz Our ultrasonic generators can make automatic frequency amplitude and power tracking in such situations f If a user would make mechanical corrections on a sonotrode for instance cutting blade sharpening this will change resulting resonant frequency but our generator can still track it in a much wider frequency range compared to any other ultrasonic generator from competitors 8 Our Ultrasonic Power Supplies have smooth power and amplitude regulation We are applying limitation of maximal load power maximal transducer amplitude and maximal output voltage on piezoceramics We are applying overheating short circuit over current and ove
62. cy range of ultrasonic transducer or load or enter other numerical values manually in the following format 19 21 kHz just an example asf ial fo mee ke e many of predefined frequency ranges will automatically appear upper er greed LED will light If we need another frequency range we can simply type new numbers lf the Range Switth is in lower ten Manual range user can enter arbitrarily chosen frequency and span values lower green LED will light Every ultrasonic transducer and or ultrasonic load has its acceptable tolerable and optimal operating frequency range s It is usually designed and optimized to operate on certain resonant frequency Do not select frequency ranges that are not acceptable for ultrasonic transducer and ultrasonic load something will be damaged In addition frequency ranges that are too much different compared to the producer specified operating frequency range of applied ultrasenic transducer should not be used In many cases operating ranges should be selected manually because standard default values are not covering desired operating frequency zone 11 Effective Phase set point start frequency and frequency Span can be later slightly changed in real time during ultrasonic generator operating high power until we reach desired operating amplitude regulation while still keeping automatic phase regulation These are very important and very useful options 12 Do not forget
63. d A Overvoltage 169 Stop Untested when start frequency is changed on the LCD appears in the right up corner TS and the red diode lights Overcurrent when there is an overcurrent on the LCD appears in the right up corner OC and the red diode lights Overheat when there is overheating inside of the generator on the LCD appears in 123 the right up corner OH and the red diode lights Overload when resonant frequency is missing damaged sonotrode broken cable etc on the LCD appears in the right up corner OL and the red diode lights what corresponds to No HF detected or Frequency not found Overvoltage when there is an overvoltage on the output of the generator bad or wrong sonotrode broken cable etc on the LCD appears in the right up corner OV and the red diode lights All these errors are sent via RS485 to Lab View software see the next picture Errors about welding setting limits In case of getting errors regarding any limits which are set by user of peak power energy and time there will be the following consequences error messages or actions 1 In the top right angle of LCD will appear one of the messages LP peak power limit or LE energy limit or LT time limit 2 For ultrasonic generators that have 25 pin Canon connector on the back The internal relay connected between pin 16 and pins 5 9 read relevant information in this User Manual swit
64. d operation of the generator This is the feature that extends the life of the transducer and attached sonotrodes and increases the reliability of the generator as well If you want to eliminate this feature simply place the slider at its maximal value Additional words in the communication protocol for advanced current level Requests 06A lt cr gt request for Advanced HF current level Answers O2AXXxXxxX lt cr gt answer for Advanced HF current level Set values OOAXXxxx lt cr gt set Advanced HF current level INITIAL SCANNING amp SETTINGS VERY IMPORTANT RECOMMENDATIONS Ultrasonic loads are electro acoustic resonant devices and oscillating amplitude depends on components of relevant resonance loop INTDUCTIVE CAPACETIVE compensation transformer voltage Our generator gives freedom to select big number of combinations of these components to reach different levels of Q factor of resonance loop producing different levels of maximal amplitudes of a load It is recommended initially to make SCAN on lover amplitudes for safe operation and later to increase the amplitude in small steps selecting higher voltage value bigger number of compensating capacitors different inductive compensation We suggest starting calibrating or adjusting capacitance inductance and output voltage in no load conditions in air from certain minimum which could be 20 or 25 101 or 30 If you see that set points of phase and
65. e Request for parameter 06f lt cr gt request for frequency 06d lt cr gt request for amplitude 06s lt cr gt request for span 06p lt cr gt request for phase 06t lt cr gt request for time 06k lt cr gt request for peak power 06e lt cr gt request for energy 06r lt cr gt request for time limit plus 060 lt cr gt request for time limit minus 06l lt cr gt request for peak power plus 06u lt cr gt request for peak power minus 06v lt cr gt request for energy limit plus 06w lt cr gt request for energy limit minus 06c lt cr gt request for output capacitor 06 lt cr gt request for parameters Answers 02fxxxxx lt cr gt answer for frequency scale 1Hz 02dxxxxx lt cr gt answer for amplitude scale 0 1 02sxxxxx lt cr gt answer for span scale 1Hz 02pxxxxx lt cr gt answer for phase scale 5mV 02txxxxx lt cr gt answer for time scale 0 01s 02kxxxxx lt cr gt answer for peak power scale 1W 02exxxxx lt cr gt answer for energy scale 1Ws 02rxxxxx lt cr gt answer for time limit plus scale 0 01s 020xxxxx lt cr gt answer for time limit minus scale 0 01s 02Ixxxxx lt cr gt answer for peak power limit plus scale IW 02uxxxxx lt cr gt answer for peak power limit minus scale LW O2vxxxxx lt cr gt answer for energy limit plus scale 1Ws 02wxxxxx lt cr gt answer for energy limit minus scale IW 02cxxxxx lt cr gt answer for output capacitor scale 1nF 02 aaapppfffffsvvvaaaeeeettttrrrr lt cr gt answer for parameters aaa ampl
66. e SAVE the settings If not increase the voltage of the main transformer manually using the jumper to the next value and repeat the above procedure without changing the inductive compensation If 300V is chosen but still not producing well enough amplitude start increasing the capacitor value gradually If the amplitude is still not good enough then increase the inductive compensation to 1000 uH and start with 100V and 10 nF The main safety rule is to start carefully preferably with 100V 10 nF and 500uH If the inductive compensation is increased from 500uUH to 1000UH then start with 10nF capacitor value again If self tuning of the generator is still not completed and the resonant curve does not appear on the scanning tab then you have to search it in another frequency range or the load is damaged In case the load is not damaged change the frequency range by LabView software and repeat the procedure described in case under 1 114 Internal output voltage and inductive compensation jumpers for older 400 W generators produced until 2010 Lbs ie Brz AMG renz imH aF d ii Dk IST 115 Internal output voltage and inductive compensation jumpers for 1kW generators JUMPER INDUCTIVE COMPENSATION 1000uH ee EN 3 A js gt TRANSDUCER 500uH gt gt TRANSDUCER 16_ 100V 9 TRF2 2 F mx A Al S oe 20nF 10nF 5nF TRF1 Li H main transformer REL gd REL 2 REL 1
67. e if certain converter has series resonance on 19 kHz and parallel resonance on 21 kHz we can select Span which will cover the area from 18 5 until 21 5 KHz Initial Start frequency and Span can be adjusted on the left side of the software screen see the picture below 60 In here described scanning frequency is smoothly changing towards lower values starting from f start and finalizing scanning at the frequency that is equal to f start Span Span is the frequency interval we select as a frequency capture range in LabVIEW Software For instance if ultrasonic system consists of 20 KHz ultrasonic converter 20 KHz booster 20 kHz sonotrode 20 KHz sonotrode tool where not all of them are exactly tuned to operate on 20 kHz or to have single operating frequency of 20 kHz we know that we should expect the resulting central operating frequency of a sonotrode tool to be somewhere close to 20 kHz and consequently we could select the initial scanning frequency range to be between 20 and 21 kHz meaning f start 21 kHz and Span 1 kHz Of course another relevant example could be to select such frequency scanning between 19 5 kHz and 20 5 kHz meaning f start 20 5 kHz Span 1 kHz Bake 61 Later during scanning the Lab View software will draw the Phase characteristics versus frequency inside of the area covered by scanning by Span On the lower left side of third scan TAB there is the Scan button
68. e between 30 and 60 or between other two levels but in relative full scale this will be a full range as operating from 0 to 100 102 LabView executive software for Sonicator operating is Mb 15 Dec 2013 and can be downloaded from here en gx C A am tA ya Pe EE Laro TA Aanr em eines oe pf ef ff eben f ef ien Y For liquids processing mixing homogenization electrochemical deposition and other sonochemistry applications we can operate ultrasonic generator when selecting Sonicator regime Fs SEN ae Normal without scan Everything else related to initial generator scanning Ssettings and tuning is the same as described in this manual Next important operating parameter is ultrasonic transducer Amplitude which is directly related and proportional to ultrasonic power delivered to a 103 load or to a liquid under processing It is important to know that under certain loading conditions there is always certain minimal and maximal amplitude threshold when ultrasonic generator can drive ultrasonic transducer in a controllable linear operating regime For instance for most of applications minimal Amplitude when generator starts regulating Amplitude is 30 and maximal Amplitude until automatic regulation is still operating properly is 80 or 90 Do not force ultrasonic generator to operate below 30 or higher than 90 because Amplitude
69. e controlled either manually rotary encoder LCD or from a PC but not in the same time from both of them Read Write options After all settings are properly and optimally made we can save the file with such settings using Write button like saving any PC file Later we can simply invite Read one of such files for a specific load and WELDING generator will start operating as previously memorized 58 av Is the actuator value of the automatic closed loop regulator for effective phase This is real time indicator Ideal situation is that av is close to 50 meaning to be somewhere in the linear zone of the phase curve E control_panel_v2 vi Fichier Edition Ex aution Quils Fen tre Ade ee 4995 w 1 85582 V max frequency Cursor frequency 179 8781 Ris 19 9156 kHz lf av is showing 0 zero value this means that starting frequency f start is selected too low Change f start and place it slightly higher compared to the value selected before If av is closer to maximal values either starting frequency is selected too high or Span value is not large enough Change f start and Span value until getting av between 30 and 50 Later after scanning and proper operating regime is found when proper f start is found sweeping parameters and power level can be readjusted if necessary Phase set point start frequency and frequency Span can _ be later slightly changed in real time during ult
70. e e etror message on the front panel of generator box and on the software user interface 47 All settings that are available on our Lab View operating software can be realized from the back panel 25 pin connector using PLC for instance start stop the generator with discrete external signals to build RS485 network etc Generator can be fully interfaced and controlled thru the rear panel connector to any PLC controller External PLC will start the weld cycle via bringing pins 1 amp 13 together In our operating Lab View software it is possible to set amp control limits for power energy and time The limits given in settings are generating warning closing relay warning back panel 25 pin DSUB connector and sending warning status via RS485 communication see the communication parameters only if the selected limited parameter is outside the chosen limits during a real welding When all limits are set to zero no warning occurs this is how the software is organized practical convention The weld to levels can be selected on the main tab on the operating Lab View software see the picture below SIE File Edit Operate Tools Window Help gt e er GE En po f y ceee E al 14 For instance if it is necessary to weld with energy until 100Ws you have to set Energy value to 100Ws simply type 100 in the Energy window and enter If you want to receive warning from the generator if th
71. e phase curve is close to 1 9 V After such phase maximum white line in a direction towards lower frequencies is NOT falling below the automatically selected operating phase level which is in this case close to 0 8V Vertical and horizontal YELLOW lines are Phase and Frequency cursors defining automatically found new operating area or Operating frequency Span 96 Extra span In addition to regular safe Operating frequency Span found after scanning or after auto tuning it is possible to make certain manually and numerically selectable extension of the Span towards lower frequencies in the area of series resonance This way automatically found safe operating Span will become larger and ultrasonic load will be able to operate under heavy loading like in cases of metals welding IS Scan weldind vi Piel x File Edit Operate Tools Window Help EK EN parameters l limits scaning x L Output capacitor XY Graph Plot 0 as D D H I DU D U I U H B J 15 nF 5 0 5 10 20 30 40 Output choke 4 5 C Se ioo WH 4 0 1 D 600 1000 1200 Extra span 3 5 ker LET A KL el ko S bal Wi EIN KA a RY E ai G fet UL fat EIDEL S PR 3 0 o 0 1 0 2 0 3 r 0 25 BE a Startup mode 2 0 J Normal without scan EI l Das Scan Input voltage GEN C AR Didde 0 5 1 i Low Middle Hight Current ratio H l 1 1 1 1 20 0 20 0 20 1 20 2 20 3 20 4 Frequency kHz ON OFF Sraning Untested power J Conecti
72. e welding process is away from 100Ws set the Energy limits in certain desired window i e Energy plus on 130Ws and Energy minus on 80Ws see the picture below 48 E gt Scan weldind vi Ioj x File Edit Operate Tools Window De ke In case of getting errors regarding any limits which are set by user of peak power energy and time there will be the following consequences error messages or actions 1 In the top right angle of LCD will appear one of the messages LP peak power limit or LE energy limit or LT time limit 2 For ultrasonic generators that have 25 pin Canon connector on the back The internal relay connected between pin 16 and pins 5 9 read relevant information in this User Manual switches on and later automatically resets on every next ON signal 3 In the RS485 serial communications protocol generator returns a warning status number read relevant information in this User Manual 49 PHASE FREQUENCY SCANNING Third TAB TE control panel v2 vi ell x Fichier dition Pente Quills Fen tre Aide gt 2 ri EC V e max Feier cursor frequency en e e 119 9156 KHz wi e Pi SEN e e ek Py J e e e ON OFF s P Untested power H P Nominal power GC Li 0 W e Overcurrent E e 3000 w e MM e e S i BR ZS ees Gen k e s j Overload Dw set WT spe er k ZC ei PS e e e gt e e e E e Zei sl 4 DK a
73. ective corrected phase white color curve A typical scanning screen is presented on the picture below Span is well selected capturing the area of both series and parallel resonant frequencies and wider 54 AY Graph SZ 4 5 dm E 1 5 1 0 0 0 1 i i F i i i l 19 3 19 4 195 o eh T aa 199 20 0 AN L 20 2 203 Dh Atequency kHz Relevant most probable operatin oint which Je good for automatic frequency and phase e e k kd regulation on the white coler curve S K J o D e D D D Real phase curv d color curve has only informative meani to recognize where the well operating fre cy interval is White and r d phase curve should be seen on a similar way together inny other case e In this frequency frequency capture area here from 19 5 until 20 kHz converter will be operational and automatically regulated by ultrasonic enerator under different dynamic loading conditions Series and parallel resonances are inside the encircled ar a not visible on this scanning plot but if measured by npedance Analyzer would be here This is the most probable and expecfed phase level phase set point that will be regulated by ultrasonic generator here about 0 75 V We are intentionally selecting such smooth linear phase area sin
74. ency and finalizing scanning at the frequency that is equal to f start Span Span is the frequency interval we select as a frequency capture range in Lab View Software For instance if ultrasonic system consists of 20 kHz ultrasonic converter 20 KHz booster 20 kHz sonotrode where not all of them are exactly tuned to operate on 20 kHz or have single operating frequency of 20 KHz we know that we should expect the resulting central operating frequency of such system to be somewhere close to 20 kHz Consequently we could select the scanning frequency range to be between 20 and 21 kHz meaning f start 21 KHz and Span 1 kHz Of course another relevant example could be to select such frequency scanning between 19 5 kHz and 20 5 kHz meaning f start 20 5 kHz Span 1 kHz Later during scanning the Lab View software will search and find real average operating frequency somewhere inside of the area covered by scanning In the next step next safe operating frequency scanning we should select new shorter value for Span to cover only the central part of the phase curves both red and white color curves New f start will be again at the point where the phase curve is minimal meaning closer to parallel resonance This way we will visualize mentioned part of the phase difference curve on a larger display and we will be able to estimate the frequency which is in the middle of that frequency interval and which is approximately
75. equency interval we select as a frequency capture range in LabVIEW Software For instance if ultrasonic system consists of 20 kHz ultrasonic converter 20 kHz booster 20 kHz sonotrode 20 kHz sonotrode tool where not all of them are exactly tuned to operate on 20 kHz or to have single operating frequency of 20 kHz we know that we should expect the resulting central operating frequency of a sonotrode tool to be somewhere close to 20 kHz and consequently we could select the initial scanning frequency range to be between 20 and 21 kHz meaning f start 21 kHz and Span 1 kHz Of course another relevant example could be to select such frequency scanning between 19 5 kHz and 20 5 kHz meaning f start 20 5 kHz Span 1 kHz 19 71 kHz ka R 36 Later during scanning the Lab View software will draw the Phase characteristics versus frequency inside of the area covered by scanning by Span On the lower right side of the third TAB there is the Scan button which is activating the safe operating low power ultrasonic load scanning kind of load impedance scanning Before Scan is activated it is important to select scanning frequency resolution number of steps which is selectable from 40 to 100 See Scan and steps positions on the picture below SE After certain time scanning will stop and on the upper right corner of the user software interface we will see the plots of scanned phase red color curve and eff
76. er generator from competitors Of course when somebody is using computer to control our generators this will be an excellent tool for learning training R amp D factory settings but not necessary Any other control can be used available We are presently using windows XP or Windows 7 compatibility mode with XP Computer is good mostly for internal factory operations before generator is sent to end users Literature e book Load current and load voltage Start up rising times until getting regulated and stable amplitudes CURSOR Mode Site Type Sobel dk aas MRE 1 546m Measured transient time intervals presented here are in the range of 2 ms enabling very fast welding and pulse repetitive regimes Compare it with competition and you will see that we are for an order of magnitude faster INTRODUCTION Please read these operating instructions carefully and follow them before installing or commissioning your product Failure to observe these instructions can present a risk to life Units may be operated by trained personnel only Failure to comply with this will result in a loss of warranty rights The device may only be operated and maintained by personnel who have read and understood this operating manual and are familiar with the applicable legal regulations for accident prevention and workplace safety ASSEMBLY In addition ambient temperatures of over 30 C should be avoided Choose a
77. ers limits scaning l Peak power plus T ce 00 OU OO ein OO OOo Pee CeCe Oe OO TO iG I air o 200 400 600 EE w Energy plus E Jo ws Gs LE 0 500 1000 1500 2000 2500 3000 Energy minus A do pee 0 500 1000 1500 2000 2500 3000 Last nergy 130 Ws Time plus D r GM 5 gun 8 123415678990 ee oe 2 41 dvanced current limiting a TT SR Ce ELSE ET pati Ther HUET IS Te ET 1 2 3 5 y J inal ON OFF Scaning status J Untested power PI Conection i pith Ai Overcurrent 200 i neg 300 i 400W 0 Nit 1000 fo 1000W Overheat F Overload Wi 3000 W Read JL weie f A Overvoltage 169 W Output current 0 3000 W m Wite Such setting is limiting and avoiding dangerous l vels of a load currents that could damage the ultrasonic transducer or generator Setting Method When working first time during scanning on fhe second TAB with an unknown transducer it is recommendable to set the slider at the maximum value in order to find what the maximal relative load current level Is Then it is necessary to scan and adjust the generator as described in this manual 100 During normal high power operation of the generator and ultrasonic converter the operator can see what the maximum value of a load current is shown in the field Output current Then it is possible to select the desired maximal load current level in the field Advanced current limiting which should not be crossed during the launch an
78. forming initial low power scan testing with the generator Lab View software This frequency will be found somewhere below the frequency where scanned generator current is maximal and where the scanned phase function is smoothly rising from its minimal value towards its maximum when in the same time the frequency is going towards lower frequencies The frequency area which is covered by this type of regulation depends on the device type it is impedance characteristic dependent f capture f start Span 20 Welding process will stop after given Time interval here 3 83 s There are no limits for operating Power and delivered Energy because of zero settings Welding by limiting the Peak power on the load Welding process will stop when Peak power is reached There are no limits for total operating Time and delivered Energy because of zero settings Welding by limited amount_of Energy which should be sent to a load Welding process will stop when given amount of Energy is delivered to a load here 1208 Ws There are no limits for total operating Time_and operating Peak power because of zero settings 21 Time plus maximal allowed operating time which can drive a load here 7 52 s If real operating time would be for some reason higher than Time plus generator will produce error message on the front panel of generator box and on the software user interface Time minus minim
79. ical scanging curve wide scanning range Select this frequency rea for continuous operating under moderate and high power loading like for welding and liquids processing Here selected safe frequency range is from 19 84 to 20 3 KHz Select the frequency interval that covers only parallel resonance and higher frequencies and does not cover series resonance This is the safest operating regime for low and moderate acoustic loads for welding Sonochemistry liquids atomizing and powders sieving applications as well as for operating high amplitude in air This operating regime has very high oscillating amplitudes and high oscillating velocity 69 XY Graph Plot 0 Fig 7 Typical s anning curve optimal safe operating range Here is well selected total safe frequency capture and regulation area for most of high power welding and liquid processing applications Whenever operating frequency area or frequency Span is overlapping series resonant frequency this presents potentially risky operating regime which should be well tested Operating frequency in this area will be automatically regulated from parallel resonant frequency to series resonant frequency and towards lower frequency values 70 XY Graph Phot 0 e deeg l 20 6 2 7 20 8 20 9 KA eekeeeeleeeedeeeekheeedeeeeleee eh 19 4 19 5 19 6 19 7 KO 19 9 20 0 20 1 20 2 20 3 20 4 20 5 e R ees a a Fig 8 Another example of ve
80. itude scale 0 1 ppp phase scale 5mV fffff frequency scale 1Hz S status O off 1 on 2 overheat 3 overcurent 5 limit time 6 limit peak power 7 limit energy 8 untested 9 overload vvv actuator value of internal regulator scale 0 1 aaa power scale 1W eeee last weld energy scale 1Ws tttt last weld time scale 0 01s rrrr peak power scale 1W Settings 06fxxxxx lt cr gt set frequency scale 1Hz 06dxxxxx lt cr gt set amplitude scale 0 1 06sxxxxx lt cr gt set span scale 1Hz O6pxxxxx lt cr gt set phase scale 5mV O6txxxxx lt cr gt set time scale 0 01s 06kxxxxx lt cr gt set peak power scale 1W 06exxxxx lt cr gt set energy scale IW O06rxxxxx lt cr gt set time limit plus scale 0 01s O60Xxxxx lt cr gt set time limit minus scale 0 01s 061xxxxx lt cr gt set peak power limit plus scale IW 06uxxxxx lt cr gt set peak power limit minus scale IW O6vxxxxx lt cr gt set energy limit plus scale IW 06wxxxxx lt cr gt set energy limit minus scale 1Ws 06cxxxxx lt cr gt set output Capacitor scale Int Answer for settings gt lt cr gt Remark lt cr gt is ASCII code for Carriage return hex code Ox0D decimal 13 Start generator 06start lt cr gt Answer for start ok gt lt cr gt Stop generator 0O6stop lt cr gt Answer for stop ok gt lt cr gt Write to eeprom memory 06wr lt cr gt Answer for write ok gt lt cr gt 15 16 Updated Latest Protocol for serial
81. kly Device type serial number the serial number is on the backside of the generator SPARE PARTS We can only deliver spare parts and accessories if you order them specifically Literature e book
82. l produce maximal output power on certain resonant frequency of bald ultrasoni transducer see the picture E Select also By default automatically we have 1 kHz wide Max Bi but manually we can select and type another value instance here 32 and 38 kHz For simplified logical understanding of such resonant matching we can imagine that what we connect to the secondary side of the output ferrite transformer is a simple serial L C inductance certain capacitance circuit Ultrasonic converter is connected in parallel to the capacitance of mentioned serial L C circuit Inside of the generator series compensating inductance is fixed and has two values internally selectable by jumpers usually it is 1 mH for most of high power transducers operating around 20 kHz and 0 5 mH in cases of higher frequency transducers operating around 40 kHz and higher 37 In order to adjust the load impedance to operate optimally on certain operating frequency f ancqucer gt we will effectively increase capacitance of the transducer by adding different compensating parallel capacitances C Output capacitor this way creating necessary equivalent capacitance compensating Lan Internally Welding generator has 8 values of selectable combinations of Compensating in steps of 5 nF such as 5 10 15 20 25 30 35 40 nF Maximal capacitance of 40 nF can be connected in parallel to certain ultrasonic transducer Inside of the generator
83. m nidu cds view p id 1606 lang en Find if there is more recent version The generator is communicating with Lab View software trough USB to RS485 adapter Install the latest driver from here http www ftdichip com FTDrivers htm Necessary software for our ultrasonic generators is also here http Awww mastersonics com documents mmm_basics mmm_power_supplies AMMM and here http www mastersonics com documents mmm _basics mmm_power_supplies AMMM ALL welding generators Our ultrasonic generators can operate autonomously without computer or anything else attached to the generator It is not necessary to use personal computer and Lab View software Software is useful and necessary only for first time settings factory settings service and maintenance reasons when ultrasonic load or converter sonotrode booster is changed or in case of problems Software is also useful as the diagnostic testing and educational tool to explore different potentially well operating oscillating modes If ultrasonic generator is sold to somebody together with ultrasonic transducer booster sonotrode all necessary tuning and settings are already made before delivery and client can operate such ultrasonic system without connecting it to a computer Our older Lab View 8 5 based software for controlling ultrasonic generators is here labview8_5 software http www mastersonics com documents mmm _basics mmm_ power supplies AMMM labview8 _5 software hitp ww
84. nerators have such options 16 sets of different settings for different converters sonotrodes combinations can be memorized and later selected from memory Such settings can be selected with the switching PCB on the back side connector inside of the generator box The same back side connector with switching PCB can also be installed on 2000 3000 W welding generators on request but still not on 400W welding generators not enough space power board should be modified If somebody is interested to have such options on 2000 3000 welding generators it is necessary to order customized new generator where an additional switching circuit PCB will be installed and this has certain price We are not proposing to make such modifications on older generators that are sold without such option and we are not selling additional interface boards and connectors in order to make such hardware updates since this will be complicated for clients to implement Presently clients having older 2 3 kW generators without selectable memory options can realize similar functionality and much more complex and more flexible programing trough RS485 communications To start the generator externally connect pin1 to pin13 to stop the generator disconnect these pins See the picture Protocol for serial port communications for Welding generators produced until the end of 2010 Data format 115200 baud 8 bit no parity 2 stop bits RS485 100 ohm standard lin
85. nt transducer d K After every power up it is absolutely necessary to test and find new operating frequency of transducer s Why Lets imagine that generator and transducer are operating for long time under some conditions which are related to ambience temperature temperature of piezoceramics temperature of sonotrode Such conditions are defining operating frequency of ultrasonic system which could vary deviate until 1 KHZ compared to initially tested frequency when transducer was on a standard room temperature If the generator shuts down for some reason and after certain time again powers up when temperature of critical components will naturally change the applied automatics 85 PLC which is controlling ultrasonic generator should test again all transducers all older program parameters are still in the memory of the generator but new situation related to temperature dependent acoustic properties is no more the same After all initial settings are made using a PC and supplied Lab View software Ultrasonic Generator can be activated and it will start driving ultrasonic converter by pressing green Start button which is on the software front panel lower left corner on all three TABs Do not start the generator until all initial settings are verified and sett to safe low power and low risk positions after the safe operating ultrasonic load scanning Now ultrasonic power output can be switched ON ase if ultrasonic t
86. oad Optimal operating conditions are related to reaching maximal load power on ultrasonic transducer reaching maximal and safe operating voltage on piezoceramics while still Keeping automatic amplitude control and automatic or regulated frequency tracking In order to get sufficiently high and still safe operating conditions on ultrasonic load it is recommendable to start with minimal output voltage value on the secondary side of the output ferrite transformer by connecting proper jumper which corresponds to minimal output voltage If maximal ultrasonic loading power is still not high enough we will increase output voltage on the ferrite transformer by selecting the next value and this will automatically increase maximal voltage on ultrasonic transducer We need to be careful that voltage on piezoceramics has its safe limits and that we need to operate below maximal acceptable voltage which is usually until 200 V rms per every millimeter of piezoceramics thickness When performing low power scanning using our LabView software in order to find or estimate optimal frequency range of certain transducer compensating capacitance should be set on minimum 5 nF Later in high power regime it should be again adjusted to its optimal value increased 39 WARNING only for experienced and experts In cases of new ultrasonic transducers resonant matching first time testing and tuning it is important to be very careful with the output
87. oltage red color curve and input DC generator current white color curve Such frequency scanning is realized using the Lab View software supplied with ultrasonic generator In order to make scanning personal computer with installed Lab View software should be connected to ultrasonic generator trough RS485 interface Initially first safe operating low power frequency scanning should be selected to cover only the expected operating frequency range of ultrasonic system In here described scanning frequency is smoothly changing towards lower values starting from f start and finalizing scanning at the frequency which is equal to f start Span Span is the frequency interval we select as a frequency capture range in Lab View Software For instance if ultrasonic system consists of 20 kHz ultrasonic converter 20 kHz booster 20 kHz sonotrode where not all of them are exactly tuned to operate on 20 kHz or to have single operating frequency of 20 KHz we know that we should expect the resulting central operating frequency of such system to be somewhere close to 20 kHz and consequently we could select the scanning frequency range to be between 20 and 21 kHz meaning f start 21 KHz and Span 1 kHz Of course another relevant example could be to select such frequency scanning between 19 5 kHz and 20 5 kHz meaning f start 20 5 kHz Span 1 kHz Later during scanning the Lab View software will search and find real average ope
88. on Nominal power ill Overcurrent 200 00 600 cp C 400w P Overheat 0 aan f 1000 W 2000 W Ai Overload C Start a Stop Ai Overvoltage D Ww 97 Selectable Startup Modes for AMMM and Welding generators First Tab third window on the right upper side 1 Normal without scan This is normal operation every time starting from F Start and stopping when manually selected phase value is found and later automatically controlled 2 Hot Start After power up or after safety stop after every accidental Situation generator always starts from F start finds automatically the selected Phase level value of Modified White Phase Curve FS and Stops Generator is not making scanning and auto tuning Every next start will be from the last previously memorized well operated frequency like in cases of welding generators 98 3 Safe_start After power up or after safety stop or after accidental Situation generator will perform new SCANNING inside of the previously selected SCANNING window see first Tab Scanning range first slider upper right which is manually selected using Scanning range slider This way generator will automatically adjust the new values of Phase FS and Span performing AUTOTUNING For every next start generator is operating from F start but without new SCANNING and inside the SCANING window which was selected manually using Scanning range slider Gene
89. on the software user interface Energy minus minimal allowed Energy which can drive a load here 866 Ws If real load Energy would be for some reason lower than Energy minus generator will produce error message on the front panel of generator box and on the software user interface 24 Memory After turning the encoder the display returns to the start frequency and all settings for all parameters are stored in memory Once a setting parameter for example Feta Is changed manually using the front panel encoder on LCD module this can also be stored in the internal generator memory by the same LCD module By selecting the Memory write menu and then it is necessary to turn the encoder clockwise for one step The Memory write menu will disappear and we will see the next menu F meaning memorizing is executed This way new parameters are written in the internal memory of generator Menu option Address which is located between Energy and Memory via front panel encoder LCD is the address of the device in a network working solution RS485 network All devices by default are on the address 6 factory settings This is the address where it is initially placed the communication with generator LabView software When a PC trough communication cable and RS485 interface is connected to the generator PC automatically starts regulating the generator with higher priority When a PC is disconne
90. onic load would operate very smoothly without producing sharp strange cracking whistling clipping and or low frequency noise or similar effects The most important criterion to be able to say that ultrasonic system is operating properly and safely and that will last very long time is that nothing is significantly and rapidly heating For instance ultrasonic transducer other metal parts executive resonating tools and load should not dissipate too much heat energy and no one joint should heat Also ultrasonic generator box should not heat Temperature during operation for all mechanical parts should always be close to room temperature and below 50 C After certain settings are made when generator is not operating or during generator operation in real time including additional settings and adjustments made later every time is necessary to save such seitings regardless if generator is operating or not if we would like that next time after switching OFF the generator and repeating switch ON generator would start using last settings When make SAVE Write by pressing blue button on the bottom right side of the software user interface panel the last settings are stored in the generator for currently operating transducer If the save button blue button is not pressed nothing is saved in the jenerator even if adjustments are made during tests when generator operates The same procedure should be repeated for every new differe
91. or sonotrode are damaged Setting for Process Time counter totalizer of working time of generator when generator is switched ON and generates continuous or pulsing ultrasonic waves The setting range is from O to 9 h 59 min 59 s Setting for periodically pulsing ON OFF independent setting for ON and OFF time each of them can be from 0 to 59 seconds Energy meter totalizer energy set point continuously monitors the amount of energy delivered to ultrasonic load and stops the generator when reaches the desired value Setting range is from O to 9 999 999 J oule seconds Watts When Sonicator operating regime is selected Welding operating regime is not active and parameters on the Welding Tab cannot be manipulated see the following picture Z Sonicator weldind Fichier Edition Ex cution Outils Fen tre Aide eee OR 105 Scanning for Sonicator or Welding operating regime is the same as described in this manual We need to select continuous operating not to use ON and OFF settings in order to properly finalize scanning An example of very good scanning picture for Sonicator operating regime is presented on the following picture H F Sonicator weldind vi c o x Fichier dition Ex cution Outils Fen tre Aide Se parameters l Sonicator l Welding scaning Output capacitor ha 1 LES TE LRT yu ce say 5 5 10 20 30 40 Output choke CA i
92. ormal operation 2 scanning Settings 06fxxxxx lt cr gt set frequency scale 1Hz 06dxxxxx lt cr gt set amplitude scale 0 1 06sxxxxx lt cr gt set Span scale 1Hz 06pxxxxx lt cr gt set phase scale 5nV 06txxxxx lt cr gt Set time scale 0 01s 06kxxxxx lt cr gt set peak power scale 1W 06exxxxx lt cr gt set energy scale 1Ws 06rxxxxx lt cr gt set time limit plus scale 0 01s 060xxxxx lt cr gt Set time limit minus scale 0 01s 06Ixxxxx lt cr gt set peak power limit plus scale 1W 06uxxxxx lt cr gt set peak power limit minus scale 1W 06vxxxxx lt cr gt set energy limit plus scale 1Ws 06wxxxxx lt cr gt set energy limit minus scale 1Ws 06cxxxxx lt cr gt Set output Capacitor scale 1nF 06Sxxxxx lt cr gt set scanning range scale 1Hz 06Cxxxxx lt cr gt set current gain 0 01 06Mxxxxx lt cr gt set startup mode 06HxXxxxx lt cr gt set output choke 06Txxxxx lt cr gt set output voltage 18 Advanced current level controls and settings for generators made in 2011 and later Requests 06A lt cr gt request for Advanced HF current level Answers O2Axxxxx lt cr gt answer for Advanced HF current level Set values O6Axxxxx lt cr gt set Advanced HF current level Only for welding generators 2000W and 3000W Answer for settings gt lt Ci gt Remark lt cr gt is ASCII code for Carriage return hex code 0x0D decimal 13 Start generator 06start lt cr gt Answer for start ok gt lt cr gt
93. ortened to the required length due to the risk of overheating With the exception of the permitted tasks listed in the handbook you should never attempt to repair or modify the device yourself In the following cases you should disconnect the device from the mains and contact a qualified service engineer If the mains cable or plug is damaged If liquid has penetrated into the device If the device has fallen over or the housing is damaged If the device displays noticeably different behavior than standard operation ATTENTION Repairs and modifications may only be carried out by competent skilled personnel 122 ERROR MESSAGES AND TROUBLESHOOTING The following error messages may appear in the display OC OVERCURRENT The electronic over current fuse has detected an error Possible causes _ Transducer is defective Power supply or plug is defective Remedy Unscrew the transducer connection on the housing Switch on the generator without the transducer connected a Error message still displayed Generator is defective b Error message no longer displayed Check the transducer and power supply OH OVERHEATING The electronic overheating fuse has detected an error Possible causes Not enough space around the generator Working surroundings are too hot There are 6 possible errors or error messages S amplitude AM 0 0 0 0 K A Untested power Ai Overcurrent 200 Ai Overheat 0 PD A Overloa
94. pensation If 300V is chosen but still not producing well enough amplitude start increasing the capacitor value gradually If the amplitude is still not good enough then increase the inductive compensation to 1000 uH and start with 100V and 10 nF The main safety rule is to start carefully preferably with 100V 10 nF and 500uH If the inductive compensation is increased from 500uH to 1000uH then start with 10nF capacitor value again If self tuning of the generator is still not completed and the resonant curve does not appear on the scanning tab then you have to search it in another frequency range or the load is damaged In case the load is not damaged change the frequency range by LabView software and repeat the procedure described in case under 1 117 Internal output voltage and inductive compensation jumpers for older 1kW enerators produced until 2010 im Pd Rink wi Ube Ft We Ji Ure ai ooo O 3 pnaition on the PCE H JP ta ffir J715 h JP moor Use JP Use JPL drain 118 Internal output voltage and inductive compensation jumpers for 2 amp 3 kW generators for older generators produced until 2010 new generators 2011 and later have all of such settings realized by LabView software Ap2ti 124 mH ez 1 0 mH hipaa OG mH La Jp26 Lz Jp2 Li Jp28 283k L L8 L en Tz Jp Ti J14 Ti dpe L3 L6 Tz Heft DRGECEL
95. port communications for new WELDING generators which are produced and sold starting from February 2011 Since latest ultrasonic power supplies generators have more complex and advanced software controls it was necessary to introduce new command lines blue color text in this document Data format 115200 baud 8 bit no parity 2 stop bits RS485 100 ohm standard line Request for parameter 06f lt cr gt request for frequency 06d lt cr gt request for amplitude 06s lt cr gt request for span 06p lt cr gt request for phase 06t lt cr gt request for time 06k lt cr gt request for peak power 06e lt cr gt request for energy 06r lt cr gt request for time limit plus 060 lt cr gt request for time limit minus 06l lt cr gt request for peak power plus 06u lt cr gt request for peak power minus 06v lt cr gt request for energy limit plus 06w lt cr gt request for energy limit minus 06c lt cr gt request for output capacitor 06S lt cr gt request for scanning range 06C lt cr gt request for current gain 06M lt cr gt request for startup mode 06H lt cr gt request for output choke 06T lt cr gt request for output voltage 06 lt cr gt request for parameters Answers 02fxxxxx lt cr gt answer for frequency scale 1Hz 02dxxxxx lt cr gt answer for amplitude scale 0 1 02sxxxxx lt cr gt answer for span scale 1Hz 02pxxxxx lt cr gt answer for phase scale 5nV 02txxxxx lt cr gt answer for time scale 0 01s 02kxxxxx
96. r instance in this case proper selection for safe operating frequency area is from 19 82 to 20 23 kHz This is good operating frequency area for very high power plastic welding Sonochemistry liquids processing and similar applications Whenever operating frequency area or frequency Span is overlapping series resonant frequency this presents potentially risky operatifg regime which should be well tested Operating frequency in this area will be automatically regulated from parallel resonant frequency to series resonant frequency and towards lower frequency values If we like to select operating regime only in the close vicinity of parallel resonance operating frequency range and frequency Span should be selected like here Series resonance should be excluded by setting minimal frequency sufficiently high This will be the safest operating regime for low and moderate acoustic loads for welding Sonochemistry liquids atomizing and powders sieving applications as well as for operating high amplitude in air This operating regime has very high oscillating amplitudes and high oscillating velocity Here below series resonance is the most powerful most risky and heavy duty high stress operating frequency range Converter has increased heat dissipation in this area 66 Do not operate converter in air or low load conditions here Converter should be fully loaded before being activated in this frequency area Avoid operating in this a
97. r voltage protections H We can produce customized ultrasonic power supplies without power limitations from 100 W until 100 kW operating until 100 KHz or higher 10 our standard line of Ultrasonic Power Supplies is operating on European main supply voltage input being tolerable to input voltages from 200 Vac until 240 Vac 50 60 Hz We can easily produce the same Power supplies for other input voltages 115 Vac 50 60 Hz Internally all of our standard Ultrasonic Power Supplies have stabilized universal voltage SMPS for control and logic modules operating from 95 to 265 Vac We can also optionally apply high power PFC input for customized Power Supplies 11 We have the largest number of settings regarding operating parameters and conditions controls frequency modulations forced and or automatic resonance regimes driving applicable for all presently known Industrial Ultrasonics Applications such as welding cleaning sonochemistry materials processing ultrasonically assisted metallurgy bonding sieving cutting machining atomizing driving multi frequency amp wideband transducers etc Nevertheless it is good to know that the biggest challenge in operating different ultrasonic loads and transducers is related to the fact that all electrical adjustments and settings are completely related to properties of mechanical system we would like to drive The same transducer with different mechanical loading can produce different outpu
98. ransducer meaning complete ultrasonic load ig Dadi ST DING generator generator will stop operating and show ERROR a Overcurrent overheat overload Red color LED on the generator box pan l will light and one of visual indications either Overcurrent or Overheat Ov rload on the Lab VIEW user interface lower left side will be activated Redue the amplitude readjust operating frequency find new settings slightly diff rent o pared tg what was before and repeat the process until successfully resta ing the g nerator Read Write op tions After allAettings are properly and optimally made we can save the file with such settings using Write button ke saving any PC file We are giving to such files any name s we like with tune ending Later we can simply invite Read one of such filgs for ad specific load and WELDING generator will start operating as previously memorized taking settings data from a specific tune file Power Power elector Proper power level should be selected related to applied generator Power Visyal analog indication of the power level Power indicator actually regulated power which corresponds to the PWM duty cycle Numerical duplicate of the analog power indicator Non editable fields only indicators 86 10 Before exploring any of OPERATING MODES OF WELDING ULTRASONIC GENERATORS select proper operating frequency Range which corresponds to a Known operating frequen
99. rasonic generator operating high power until we reach desired operating amplitude regulation while still keeping automatic effective phase regulation These are very important and very useful options The generator has an automatic resonant frequency tuning inside the frequency capture range see the explanation that follows The frequency capture range can be set by Span parameter from 0 to 1 kHz below the start frequency towards lower frequencies f capture f Start Span If we set Span O generator will not search for optimal operating frequency between Series and Parallel resonances and generator will operate in a relatively fixed and forced non resonant not automatically controlled oscillating regime regardless of impedance 59 characteristics and natural resonant frequencies In such situations we can set start frequency anywhere we like no automatic regulation Manually we can select any other Span which is wider or shorter than 1 kHz because certain converters will request larger Span values The operating resonant frequency of ultrasonic system must be found in advance before operating the system full power performing initial low power scan testing with the generator LabVIEW software This frequency will be found somewhere below the frequency where scanned generator current is maximal not visible during scanning and where the scanned phase function is smoothly rising from its minimal value towards its
100. rating frequency somewhere inside of the area covered by scanning When where generator input DC current during such scanning is reaching certain relative maximum at certain frequency this is indicating that ultrasonic load is also consuming certain power and or increasing its oscillating activity This is the reason why we are taking such DC current maximum as the upper reference point for frequency scanning In reality this is also related to impedance curve of ultrasonic system under testing since empirically we know that central operating frequency of a stable operating regime of ultrasonic system in WELDING regime under wideband frequency sweeping should be below the frequency when the input DC current is reaching its maximum This is also the reason to select an initial f start just below the frequency where DC current is reaching maximum and where the phase difference function has its minimum with a tendency to grow towards lower frequencies In the next step next safe operating frequency scanning we should select new shorter value for Span to cover only the closest part of the phase curve red color which is showing the part of phase difference curve starting from certain minimal value until its first maximal value below the frequency where input DC generator current is maximal New f start will be again at the point where the phase curve is minimal This way we will visualize mentioned part of the phase difference curve
101. rator makes scanning and auto tuning procedure only if some error occurred in a last operation cycle 4 Scanning every time Generator after activating start signal will always make new SCANNING from F start inside the SCANNING window see first Tab Scanning range first slider upper right which should be manually selected using Scanning range slider on the first Tab Every time ultrasonic generator will automatically adjust the new values of Phase and Span performing AUTOTUNING and it will operate with newly found values Generator is operating the same way repeating scanning and finding new Phase and Span after every new start signal This regime is good for applications where fast start is not very important such as sonochemistry ultrasonic cleaning ultrasonic materials processing stress relief liquids atomizing continuous cutting process Generator starts from Fstart every time scanning the load selecting the best operation point and start working with selected power on it 99 Advanced HF current level Advanced HF current level is a value of the output load current through piezoelectric ultrasonic transducer expressed in relative units ru Setting the desired maximum value of this current is realized by the slider Advanced HF current limiting Output current Field is showing the maximal load current Si Scan weldind vi Fichier Edition Ex cution Outils Fen tre A gt paramet
102. rea whenever possible and not absolutely necessary Figi 4 Typical scanning curve wide scanning range Here is very risky frequency area high stress high amplitude increased converter heating high oscillatory pressure Better to avoid this area This is the area below series resonant frequency Be very careful if operating in this area Operate here only under heavy loading not in air like in cases of metal welding applications 67 Fig 5 Typical scanning curve wide scarining range Select this frequency area for heavy duty operations under loading like metals welding Here selected frequency range is from 19 79 t 20 21 kHz Do not operate in air Whenever operating frequency area or frequency Span is overlapping series resonant frequency this presents potentially risky operating regime which should be well tested Operating frequency in this area will be automatically regulated from parallel resonant frequency to series resonant frequency and towards lower frequency values Select the frequency interval that covers only parall l resonance and higher frequencies and does not cover series resonance This is the safest operating regime for low and moderate acoustic loads for welding Sonochemistry liquids atomizing and powders sieving applications as well as for operating high amplitude in air This operating regime has very high oscillating amplitudes and high oscillating velocity 68 Fig 6 Typ
103. requency to be in the low phase low current zone far from any other resonare and to have the value fan lt f 3Af f 4Af start below maximal frequency XY Graph Ze Fig 2 Typical scanning curve Li Here is series resonant frequency f Her is parallel resonant frequency f St 6 7 L 4 DS Make all scanning testing and tuning as already explained in this manual while also respecting points 1 2 3 and 4 see above on this page Test the generator and verify if amplitude and phase are being regulated correctly and automatically Try operating mostly around parallel resonance Readjust only start frequency going from higher to lower frequencies until reaching proper and stable automatic regulation of phase and amplitude Do not increase the Span Optimal operating conditions in this case will found only by readjusting start frequency All other setting parameters will stay unchanged as previously selected 79 EXTREMELY IMPORTANT The most important unavoidable ultimate objective for resonance or frequency phase tracking modes is to achieve stable automatic real time phase and amplitude regulation when transducer is loaded and operating on a sufficiently high power above the critical power threshold To recognize that we realized such operating regime we should compare a Phase set point value with the actual real time regul
104. rks regulates properly Best is to be somewhere in the middle 108 FRONT PANEL MANUAL SETTINGS amp REGULATIONS After all optimal settings are found and memorized using LabVIEW software MPlwelding exe we can disconnect RS485 USB controls stop using PC controls and continue using only manual settings and controls from the generator front panel LCD Rotary encoder RJ45 connector for G BR z Manual ON OFF or RS485 control has O emm BE e the same function as RS485 on the back panel start stop button for ultrasonic output power Memory Write Blue switch on the LabVIEW software interface Changing the Menu options on LCD can be realized by pressing the Menu knob Changing actual numerical values on LCD can be realized by rotating the Menu knob in the middle It is always better safer and more comfortable to make such modifications and setting using LabVIEW user interface software WELDING generators can also be controlled using a PLC or analog signals In some of customized WELDING generators we could find either 15 pin or 25 pin Canon Sub D connectors for RS485 interface usually on the back plate All pins from 1 to 15 on 15 pin connector are identical to pins from 1 to 15 on 25 pin connector On the front panel of WELDING generators there is another RJ45 connector which is also used for RS485 communications between generator and PC see below COMPUTER PATCH CABLE wi 2
105. ry wide frequency interval Scanning Well selected frequency capture area for most of moderate and high power applications K Frequency area for metals welding and other heavy duty applications under loading do not operate in air Whenever operating frequency area or frequency Span is overlapping series resonant frequency this presents potentially risky operating regime which should be well tested Operating frequency in this area will be automatically regulated from parallel resonant frequency to series resonant frequency and towards lower frequency values 71 XY Graph Plot 0 Lam i i i i Le i i i 193 49 9 20 0 Mids ME E 20 7 20 8 20 9 Zkoencx kHz a a geg D Fig 9 Heavy duty frequency operating area operate only under loading Here is very risky high stress operating area Avoid operating here 72 XY Graph nor e Phase V ha a in i BJ w i 7 Bh Ahh w ZE pi j CR rd I 1 LO i i pee i i i 49 8 19 9 20 0 20 4 a2 2 3 2 4 2 5 206 a7 2 8 20 9 E wre ce ce Gel Mere 2 a D _ Ws n Q Ze Se e e e e e e e Ze e Fig 10 Wide moderate and high power frequency operating area for most of applications Select the frequency interval that covers only parallel resonance and higher frequencies and does not cover series resonance This is the safest operating regime for low and moderate _acoustic loads for welding Sonochemistry
106. s In such situations we can set start frequency anywhere we like no automatic regulation The operating resonant frequency of ultrasonic system must be found in advance before operating the system full power performing initial low power scan testing with the generator LabVIEW software This frequency will be found somewhere below the frequency where scanned generator current is maximal and where the scanned phase function is smoothly rising from its minimal value towards its maximum when in the same time the frequency is going towards lower frequencies The frequency area which is covered by this type of regulation depends on the device type it is impedance characteristic dependent f capture f start Span Initially first safe operating low power frequency scanning should be selected to cover only the expected operating frequency range of ultrasonic system Span Initial Start frequency and Span can be adjusted on the left side of the software screen see the picture below Start Frequency orror yore bo pr gourd tor yu rr typ EEEE EEE EEEE EEEL peel ele kHz OTR eee Ol eee eel lte Span E A Ons Prerrryprurreryprerrrypruerrryprerrryprurrryprurrbrrpruererdy NW NI ef UO kHz l O Ol U2 03 O4 US D Of Ua Ug 1 52 In here described scanning frequency is smoothly changing towards lower values starting from f start and finalizing scanning at the frequency which is equal to f start Span Span is the fr
107. t our technical service if you have any doubts or questions Work inside the device may only be carried out to the extent described and as with the electrical connection should only be performed by skilled personnel When performing such work the ultrasonic generator must be completely disconnected from the mains unplug the mains connection Inputs or outputs that are used for controlling or monitoring purposes should be twisted and shielded The device must not be in close proximity to electrically charged components or cables The shielding should be connected to the generator s earth on one side of the generator Attention All connections for the signal or control lines are in galvanic connection with the generator Always observe any warnings or instructions given on the device itself The device must always be disconnected from the mains before cleaning or when installing uninstalling an option 121 Do not use liquid cleaners or sprays Only use a damp cloth The platform for the device must be sufficiently stable as the device being jolted or falling could cause severe damage Ensure that the power supply specifications given on the device are met Only those transducers that have the correct frequency power output and dimensions may be used with this generator HF cables from the generator to the transducer as well as mains cables to the generator may not be rolled up if they are too long Instead they must be sh
108. t power at the same output voltage and frequency In certain cases it is necessary that the first time modifications and settings be made in our labs Systematically we are converging to design solutions for ultrasonic power supplies which are close to universal but there will always be a space when client will need our assistance Until present nobody is offering such options In addition we have internally adjustable compensating inductive and capacitive components adjustable voltage outputs etc 12 Our Ultrasonic Power Supplies have all kind of modern industrial control options PLC PC software controls LabView ModBus USB analog input controls We can customize and introduce any other control option Our ultrasonic generators can be controlled with any kind of PLC analogue control signals from 0 10V amplitude variable and discrete signals on off switching error signals etc or with RS485 based communications we are giving the communication protocol 13 Once after optimal settings are made on certain of our ultrasonic power supplies and for certain converter there is almost no need to do anything more Just use it on a usual way as using any other modern ultrasonic generator and control only basic parameters like timing amplitude energy etc There is no more need to use Lab View software controls 14 No need for using computer Generators can operate without externally connected computers like any oth
109. urrent Ai Overheat Overload Scanning diagram after scanning In this case we do not see series resonance but after we add booster sonotrode we will be able to see series resonance Select Phase set point in the middle linearity area of white curve here 2 V looks OK and go to the first TAB parameters and set selected Phase Do not forget to activate blue button Write after every modification 89 90 Operating situation after scanning First TAB parameters Increase output capacitor gradually as long automatic amplitude and phase regulation is operating correctly For first Start select Amplitude to 20 later increase First Start will repeat and verify Scanning and if everything is OK generator will stop without generating error message Second Start green button will activate converter In case if when adding changing booster sonotrode converter repeat scanning Later follow manual Set operating mode Time Peak power Energy Always stop the generator before changing Output capacitor Do not forget to activate blue button Write after every modification 91 New features of WELDING generators which are produced and sold starting from February 2011 Auto rescan Scanning range Current gain 4 Selectable Startup modes Extra Span Users and owners of older generators sold before February mee could also use this latest updated Lab View software version but ne
110. ut FS 24 V 2 Signal POUT DSUB PIN 2 At this output a voltage proportional to the power output of between 0 and 10 V 0 100 power output is available Reference point GND 3 Signal P EXT IN DSUB PIN 3 By connecting a voltage between 0 V and 10 V the output of the generator can be set to operate between 0 and 100 of its nominal amplitude or power To regulate the generator via an external 0 10V signal it is also necessary to connect such signal between pin 3 and pin 4 pin 4 is GND To allow to such external DC signal to drive the generator it is important to set via LabView software the Amplitude value to 0 when the input analog signal starts to have priority Reference point GND 4 Signal HF DA ERROR DSUB PIN 5 9 Shared in output for the internal relays HF DA and ERROR these PINs are connected internally 5 Signal HF DA DSUB PIN 6 If the ultrasonic generator has been switched on via of the signals FS 24 V FS GND and is producing HF voltage i e there is no malfunction an internal floating relay contact is closed between PIN 6 und PIN 5 9 The root of this relay contact leads through to a PIN 5 9 these pins are connected internally in the DSUB socket A voltage connected to Pin 5 9 can be switched through max 24 VDC 100 mA Standard factory setting Contact closed when the generator outputs HF voltage 6 Signal
111. velocity 77 i l I I I I l I I o I 19 0 19 2 19 4 19 6 19 68 20 0 202 2 4 20 6 AR 21 0 e Frequency kHz lt e s e e Zeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee eeeoeeeeeeeeeeeeee e Fig 15 Well selected reduced freq uency operating area for moderate and high power for most of applications and for very fast welding start up transient time between two welds is very short Select the frequency interval that covers only parallel resonance and higher frequencies and does not cover series resonance This is the safest operating regime for low and moderate acoustic loads for welding Sonochemistry liquids atomizing and powders sieving applications as well as for operating high amplitude in air This operating regime has very high oscillating amplitudes and high oscillating velocity 78 Very good settings strategy for reaching optimal operating conditions d If you have impedance analyzer make impedance measurements and select initial scanning range that will capture both series and parallel resonant frequency and little bit wider on both sides Measure and or calculate the frequency interval between series and parallel resonant frequency Af f f f f Set the Span value on the first settings tab to be between Af lt Span lt 6Af optimal Span could be between 2 and 4 Af Test later different Span values and select one that is producing optimal operating conditions Initially set the Start f
112. w mastersonics com documenits mmm_basics mmm_ power _supplies AMMM 27 To be able to use our Lab View based software fOr operating generators produced and sold in 2011 until 2013 please follow the following initial steps Go here and download all necessary software files MS Windows XP 7 32 64 bits http www mastersonics com documents mmm_basics mmm_ power _supplies AMMM ALL welding generators welding scan current limit 20 11 2012 Comment Create WELDING directory box on a PC that will be used to control your WELDING generator Place inside of the WELDING box the following files http www mastersonics com documents mmm_basics mmm_ power _supplies AMMM ALL welding generators welding scan current limit 20 11 2012 controls and regulations of welding generators latest pdf P Welding_scan exe Ed Welding_scan ini D I Scan weldind vi Ed Welding_scan aliases Always download from Internet and install Latest NI Visa drivers drivers for all PC ports http Awww ni com download ni visa 5 4 4230 en Latest FTDI USB to RS485 converter drivers Proper NI Runtime for windows 28 Latest versions of generators starting from October 2013 have two selectable operating regimes such as Welding generators and Sonicator or sonochemistry processors oe Ea ao r Um me See more about Sonicator operating regime at the end of this manual Both Welding and Sonicator operating regime cannot be
113. ware compensating selectable in AMMM generators with LabVIEW software Welding scan exe Parallel Capacitance can also be added in some other values manually by soldering specific capacitors inside of the generator only for experts Every time when we manually change C compensating Output capacitor by LabVIEW software we need to stop the generator since Output capacitor will not be automatically changed in real time when ultrasonic converter is powered by 38 ultrasonic frequency high voltage signal When we stop the generator software selected output Capacitor command will activate internal relays and apply selected capacitor and after that we can start the generator in other words compensating capacitor can be changed only when ultrasonic transducer is not operating generator is not producing high voltage output Calculated value of C presents only an approximated and maximal target value of compensating Capacitance that can be added in parallel to ultrasonic transducer that we know how far we can go In reality when we make such capacitive impedance matching we should start testing ultrasonic transducer when operating in real loading conditions from minimal value of which is 5 nF Then we should gradually increase it until calculated value or compensating better to say until the other lower value which could be below calculated C until we compensating get optimal operating conditions on ultrasonic l
114. wly introduced functions such as scanning range current gain extra span start up mode and scan will not work Everything else what was present in older Lab View software will work as before Applying this new lab View software on old generators will not produce negative effects except presence of few not working new functions EZ Scan weldind vi fs E3 File Edit Operate Tools Window Help i gt parameters limits scaning Phase Scaning range Ce i eests s d ze Baas Se ened z WOR ET E e Ey e E ISL E e fet IS ESN fet a a T Ve NA a AS R E O E ett e a E TA E Ae A Bit Ay 1 785 Pee Ree ee eee eee Be eo ee eee ee ee eer ae a eee 0 40 kHz HU ua A ans e e za a E 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 Start frequency Time kL eee eS E 0 369 E E POH HH OUT O T OORT E O A OESCH ELEN fo 5 19 19 25 19 5 19 75 20 20 25 20 5 20 75 21 0 1 2 3 4 5 6 7 8 9 10 Span Peak power CEE A a LOG UTS AMUSE HGH HE Im b eT tea ete fetta Mad bay LU eT Te fit E E we fete at it tay fet at et dl J kHz EET Serr e a a ALPS TIT ELS Pf a ad LKE ba fh W 0 0 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 9 1 0 200 400 600 800 1000 Amplitude Energy 0 z ToN 0 Ws 0 500 1000 1500 2000 2500 3000 PAET A A T O T E HEEL E E E E EL 0 10 20 30 40 50 60 70 8 amp 0 Serial port phase frequency Transducer Range Auto range Kcoms sl E r 20 369kHz o CJ auto 19 21 kHz g MIN jja MAX Frequency MAX span
115. y Time T control_panel_v2vi e Ee m uM oO M File Edit View Project Operate Tools Window Help aleet EN ven parameters limits scaaning l Phase Output capacitor C D GE D PPPeepPeeen pert epee eepereepeeenpeeeepe tee perragpenaey fi 66 v Vas es Wes E E PELAR KES A A AI ESA DA Sra Geet Jura Me fate EZ ad AUU ROERSCH SE nF CO eo ke DE cas eS et be 3 DP PEP A O DBD HS 20 Start frequency GES Ui Lut prrererves prtrrreteer prirna l 31 32 33 34 35 36 Span E N ES R a eo Teer ta ENA RA UN Se E CRNE O bet Coe ha D O02 04 06 08 1 12 14 16 18 2 Amplitude Serial port phase frequency e Range e coms jo oov Gavia P to e EE ET amplitude av MIN requency Maysfrequency MAX span J p aR Jman SMe wett e ON OFF A9 Untested e omine power oO 400 e Overcurrent we EF i Overheat EE Pre Overhea 3000 W Overload Te Bes en Screen example for Welding by limiting only a welding time Welding process will stop after given Time interval here 3 83 s There are no limits for operating Power and delivered Energy because of zero settings ks Every time when parameters of certain operating mode variable are set to 0 zero like here encircled the LabVIEV software for ultrasonic generators is considering this as function not in use or function without limits and or as a continuous operating regime this
116. y minus e 8 S H 4 memorized from SE Gees me 0 W e ay 500 1000 1500 2000 2500 z 8 a previous e Time plus oeren is idi S Se gt P Wan 4 e ef See DEE d Je NW 8 d sE 4 2 F SE Ze 3 Z VE eeneg d aoe LT S L e d e Time minus d Ma 21 gt oo See s e e Y Butt UU UELL lt H 2 08 KE n O ees e Untested power Nominal power d Overcurrent 50 00 1 R jj 29 350 400W Be j GE Write a WT Overheat lt me H Overload z Ces 0 w Rea A wrie eeegleee Peak bowed PE maximal allowed Peak power which can drive a load here 193 W If real actual Joad Peak power would be for some reason higher than Peak power plus generator will produde error message on the front panel of generator box and on the software user interface Peak ower D inus minimal allowed Peak power which can drive a load here 85 W If real actual load Peak power would be for some reason lower than Peak power minus generator will produce error message on the front panel of generator box and on the software user i terface Time d lus maximal allowed operating time which can drive a load here 7 52 s If real operating time would be for some reason higher than Time plus generator will produce error message on the front panel of generator box and on the software user interface Time minus minimal allowed operating time which can drive a lo

WELDING generators

Contents

Download Pdf Manuals

Related Search

Related Contents