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Multipress MP202 Generator PCS

1. PS 58 ABS SAN PMMA Pd AMORPHOUS PE CA POM FA ETP PBTP FE 0P SEMI CRYSTALLINE MP202PCSV20 GB N 1831 18569 Application examples ULTRASONICS A CREST GROUP COMPANY T9 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Retooling 10 5 6 8 T A 8 24 10 Retooling 1 Changing the booster Make sure you the power switch of the generator to OFF before opening the converter housing 7 Release and unscrew the horn 9 with the special wrench A supplied Release the fastening screw 8 with a socket wrench size 6 mm and open the converter housing 7 Move the complete vibration system out of the converter housing Pull the plug out of the RF socket 23 With the booster 25 on top re insert the vibration system in the converter housing 7 Close the converter housing and fix in position with the socket wrench 8 Release the converter 24 with the special wrench A and unscrew from the booster If the thread jams release the conver ter 24 with a slight tap on the wrench MP202PCSV20 GB N 1831 18569 Retooling ULTRASONICS A CREST GROUP COMPANY 9 Re open the converter housing 7 10 Take out the booster 25 11 With the thread for the converter pointing downwards insert the
2. 13 6 13 6 List of fuses Generator 1000 1500W eee nenea manea nau 13 7 13 7 List of fuses Generator 2000 00 eee nenea manea nana 13 7 13 8 List of fuses PCS 13 7 MP202PCSV20 GB N 1831 18569 ULTRASONICS Preface 14 Technical drawings and 14 1 14 1 Dimension drawing of the 14 1 14 2 Actuator PC board need enne it e ta ta a d at x aa p dal 14 2 14 3 Amplitude 14 3 14 4 Amplitudes of 20 kHz generators ssssesssseesreressssrrrsstttrrrststttnnnssttttnnnnstttnnnanattennnnnnttnnnnnnnne 14 3 14 5 Stud length the vibration components 20 KHZ ssssssesssesssenerrnsrrnrrrnnnennsnnsnnnstennnrnnnrnnnnnnn 14 4 15 Service center addresses satin noa ni aa 15 1 Preface Congratulations on having purchased the Multipress This manual is designed to provide buyers and users with all the information they will need to handle install operate and maintain the Multipress To ensure that the system is always ready for operation it is necessary to follow the notes and instructions in this manual The manual is broken down into the following chapters Chapter Chapter Chapter Chapter Chapter Safety information C
3. cxi After you have switched to the adjustment level 4 press the Data Bank key DATA BANK The display now shows the first databank Check function Save Data Print Data T CRE 5 Using the cursor keys select the Print Data function 6 Press the Enter key The number of the last occupied storage location then appears in the display 7 Enter the number of the desired storage location and confirm the entry by pressing the Enter key Q 2 GN If the desired storage location is empty the message No Data appears Select a valid number and confirm the number by pressing the Enter key All data stored in the databank can be PRINTER printed out by selecting the number 00 Printer active After pressing the Enter key the print job is started Ifthe printeris notconnected or notonline the message Not ready appears in the display MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation 7 7 6 Printout of the Data Bank Date Time Data Bank Number Welding Mode Weld Time Hold Time Amplitude Energy maximum Energy minimum Delay Time After Pulse Booster Horn Number Fixture Number Max System Pressure Speed 11 11 55 11 11 40 Time Mode 1 000s 1 000s 10096 1000Ws 0000Ws 0 000s 0 000s 1 2 123456 123456 5 5 44 MP202PCSV20 GB N 1831 18569 Operation 7 8 The F Function
4. i n Operation level o Service 2 3 Enter n 4 Adjustment level o CRE TRAVEL MODE Differential Travel 05 00mm Trigger 2 0 TRAVEL MODE Differential Travel 05 00mm Trigger 2 0 Service CAL RS o Gauge TRAVEL MODE Absolute 1i Travel 02 00mm Trigger 2 0 C Q 8 CRE CLR n TRAVEL MODE Absolute 2m Travel 02 00mm Trigger 10 00mm CLR MP202PCSV20 GB N 1831 18569 RING A CREST GROUP COMPANY Operation Display Differential Travel Trigger Hold Time Amplitude En max En min Energy Travel Time Parts Required Rejects Delaytime US Pulse Power Peak Power Loss Horn Fixture Booster 1 Pressure Speed 7 5 5 Parameters of the Differential TRAVEL Operating Mode Weld depth Ultrasonic trigger Hold time Amplitude Maximum energy Minimum energy Current energy value Current travel value Current time Part counter Required part count Rejected part counter Impulse delay time Delayed impulse Maximum power Power loss Horn number Fixture number Size of the booster System pressure Flow control valve performance 00 00 99 99 mm 0 0 9 9 0 000 9 999 s 0 10 000 Ws 0 10 000 Ws 0 000 1 999 s 0 000 1 999 s 1 Parameter 60 70 80 90 100 Parameter Parameter Parameter Parameter Limit Limit
5. 200000000270000000000 4 4 27 1 2 t DP we 26 33 1 5 2 26 27 Ultrasonic Generator Fastening screws PCS module handle If necessary you can pull out the generator module by holding these grips The fastening screws 34 for opening the generator modu le are located above and below the grip bars 27 1 28 31 32 33 33 1 34 35 The generator module is never to be pulled out or plugged in while mains is connected high voltage PCS module handle with model designation PCS module LCD display Generator module Generator module handle Generator module handle with model designation Keyboard LED display The display shows the power delivered du ring the welding procedure A power level of 25 should not be exceeded when the sono trode is not loaded If a value of 10096 is exceeded an error message appears MP202PCSV20 GB N 1831 18569 Controls and indicators ULTRASONICS A CREST GROUP COMPANY 5 3 Elements of the Operator s Panel A 31 4 line LCD Display 31 37 Numerical Keyboard 38 CLR Key PROCESS CONTROL SYSTEM 39 Time Key camere 21000 43 Power Switch us Test 44 Cursor Keys G3 Or 45 Service Key 4 48 0 Data 46 US TEST Key 41 49 47 gt Key E 42 50 48 Data Bank Key Ga 7 49 System Test Key 43 Made in Switzerland by RINCO Ultrasonic AG 50 Print Key MP202PCSV20 GB N 18
6. SE 7 1 7 1 The welding operation sequence pp 7 1 7 1 2 OF 7 2 7 1 3 Optimization m 7 3 72 Operating the PCS Controller e aaa aa a aaa e ta a a a a i a i 7 5 7 2 1 The Operating 7 5 73 The TIME Operating as 7 6 7 3 1 The Energy Range in the TIME 7 6 7 3 2 Overview of the TIME Mode 7 8 7 3 3 Parameters of the TIME Operating Mode men emen 7 9 74 The ENERGY Operating Mode asserentes a aa RARE a a 7 12 7 4 1 The Time Window in the ENERGY Mode sese 7 12 7 4 2 Overview of the ENERGY Mode Functions pp 7 14 7 4 3 Parameters of the ENERGY Operating Mode ppp 7 15 75 The TRAVEL Operating Mode a ara a 7 18 7 5 1 Differential TRAVEL nenea neant 7 18 7 5 2 Absolute 1 TRAVEL MODE eiecti tere i a RR doe vo ut RS 7 19 7 5 3 Absolute 2 TRAVEL MODE mean nana nana nana 7 19 7 5 4 Overview of Functions for the Differential TRAVEL MODE eene 7 22 7 5 5 Parameters of the Differential TRAVEL Operating 7 23 7 5 6 Overview of Functions for the Absolute 1 TRAVEL MODE e 7 26 7 5 7 Parameters of the Absolute 1 TRAVEL Operating 7 27 7 5 8 Overview of Functions for the Absolute 2 TRAVEL MODE 7 30
7. MP202PCSV20 GB N 1831 18569 Product information ULTRASONICS A CREST GROUP COMPANY PCS Il options 3 9 12 Databank 40 sets of welding parameters can be stored in the databank 3 9 13 Interface RS 232 interface for a printer or for SPC data aquisition 3 9 14 Generator Modules Available maximum power output GM 20 1000 PCS GM 20 1500 PCS PIM 20 2000 PIM 20 3000 3 9 15 Connected loads 230 V 50 60 Hz Maximum current consumption 16A 3 9 16 Dimensions see Fig page 3 8 Eg MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Product information T9 MP202PCSV20 GB N 1831 18569 3 11 A CREST GROUP COMPANY Transportation T9 4 2 MP202PCSV20 GB N 1831 18569 RINCO A CREST GROUP COMPANY Controls and indicators 25555558 BI coos 3 5 Controls and indicators 5 1 Multipress 3 Pressure gauge The pressure gauge shows the set maximum welding pressure 4 System pressure controller The system pressure controller serves to adjust the welding pressure To setthe nominal value pull out the setting knob and push it in again to fix it in the required position Maximum inlet 7 bar 5 Speed throttle The speed throttle enables the lowering speed ofthe feed cylinder to be continuously adjusted over the last 30 mm from the home positi
8. PRINT ns Auto Print offBH Auto Plot off Time Scale 0 72s PRINT Auto Print onlW Auto Plot off Time Scale 0 72s PRINT Auto Print on Auto Plot off i Time Scale 0 72s PRINT Auto Print on Auto Plot oni Time Scale 0 72s 7 36 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation 7 6 5 Parameter Settings of the PRINT PLOT Functions Display Auto Print Auto Plot Time Scale Baud Rate Print Gap Output Print welding data on off Print welding diagram on off Time axis 0 36 0 72 1 44 2 88 5 76 9 72 s Baud Rate 300 1200 9600 Print interval 0 9999 Output Printer SPC Print welding data Using the CLR key the printing of the welding data can be switched on or off The printout depends on the setting ofthe print gap parameter The data for faulty welds are always printed out If the print gap is set to 0000 only the data for faulty welds is printed out The data for the last weld can be printed out after the weld has been completed by pressing the Enter key Print welding diagram Using the CLR key the printing of the welding diagram can be switched on oroff The printout depends on the setting ofthe print gap parameter The diagrams for faulty welds is always printed out If the print gap is set to 0000 only the diagrams for faulty welds are printed out The diagram for the last weld can be printed
9. The Multipress is intended exclusively for the ultrasonic welding of suitable plastics Any other use is regarded as inconsistent with the intended purpose and is undertaken at the user s own risk The manufacturer is not liable for any resultant damage i Intended for industrial use 2 3 Special points to note Before you start up the machine for the first time read this operation manual carefully Being badly informed about how to operate and look after the press and generator can result in damage Always keep the operating manual handy at the site of the Multipress Do not perform any modifications extensions or conversions on the Multipress which might endanger safety withoutthe supplier s consent Donotalterthe programming software of programmable control systems 2 4 Choosing staff Work on the Multipress may only be performed by reliable staff Only use trained or instructed staff and make sure that staff responsibilities for operation set up maintenance and repairs are clearly defined Make sure that the Multipress is only used by authorized staff Work on the electrical installations of the Multipress may only be performed by an electrical specialist or instructed staff under the management and supervision of an electrical specialist accor ding to electrical engineering standards Only trained staff with knowledge and experience of pneumatic systems may work on the pneumatic equipment MP202PCSV20 GB
10. If the weld time is longer than the specified value the error message Time overflow is displayed Minimum Weld Time the weld time is shorter than the specified value the error message Time underflow is displayed Energy Effective measured energy Time Effective measured time Part Counter Counts the number of fault free welded parts The Part Counter can be reset using the CLR key Required Part Count After reaching the specified part count the message Part count reached is displayed Is only active if F 4729 has been initialized to ON Reject Counter Counts the number of incorrectly welded parts The Reject Counter can be reset using the CLR key The Reject Counter is automatically reset when the Part Counter is reset Delay Time The impulse delay time starts after the hold time has run out 7 16 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation US Pulse After the impulse delay time has run out the ultrasonic pulse is activated Using the us pulse an object sticking to the sonotrode can be shaken off Power Peak The setting for the maximum power is displayed Power Loss The power loss of the vibration system is displayed Horn Number The part number of the sonotrode can be noted for informati on purposes Fixture Number The part number of the fixture can be noted for information purposes Booster 1 The size of the booster can b
11. tude is always at 100 Maximum Energy If the amount of energy output is higher than the specified value the error message Energy too high is displayed Minimum Energy If the amount of energy output is smaller than the specified value the error message Energy too low is displayed Energy Effective measured energy Time Effective measured time Part Counter Counts the number of fault free welded parts The Part Counter can be reset using the CLR key Required Part Count After reaching the specified part count the message Part count reached is displayed Is only active if F 4729 has been initialized to ON Reject Counter Counts the number of incorrectly welded parts The Reject Counter can be reset using the CLR key The Reject Counter is automatically reset when the Part Counter is reset Delay Time The impulse delay time starts after the hold time has run out 7 10 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation US Pulse After the impulse delay time has run out the ultrasonic pulse is activated Using the us pulse an object sticking to the sonotrode can be shaken off Power Peak The setting for the maximum power is displayed Power Loss The power loss of the vibration system is displayed Horn Number The part number of the sonotrode can be noted for informati on purposes Fixture Number The part number of the fixture can be noted
12. Measured value Measured value Measured value Measured value Limits Measured value Parameter Parameter Measured value Measured value Info Info Info Info Info Directly influences the welding result The parameters can be changed Limits limit is exceeded an error message is output The values can be changed Measured Value Measured values The values can be read but not changed Info These values are only for information The values can be changed The amplitude cannot be adjusted for the PCS I The ampli tude is always at 10090 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation Travel This parameter specifies the depth of the weld The weld depth is calculated starting after the triggering Trigger This parameter adjusts the triggering of the ultrasonic horn The higher the value the higher the pressure on the object to be welded Hold Time After the welding time has run out the holding time starts The object welded can harden under pressure during the hold time Amplitude The output amplitude can be set to one of five levels from 100 down to 60 The values are changed using the CLR button The amplitude cannot be changed for the PCS The ampli tude is always at 100 Maximum Energy If the amount of energy output is higher than the specified value the error message Energy too high is displayed Minimum Energy If the am
13. 48 7 8 5 Parameter Settings for Code 4711 7 48 AME nocle 8 1 9 1 CONVErter seeders RR RI a aaa nai de ma ada 8 1 SP MEN 8 2 Io 8 3 831 Hornimaterials eicere tr 8 3 MEE ltd 8 4 9 Application examples catia ao darea m enn atas M sud UE as Ma nU i i a ME ERE NN EE 9 1 91 TEWE eienn i 9 1 9 2 c 0 ea i a uta ican ay a ata 9 1 9 3 Spot welding isis ceeace ee dene e ata e tt a E a a E a ui neal E alt ra ei ai a 9 2 9 4 Embedding of metal parts pp 9 2 9 5 Designing of joint ZONES ceni eee ie C ee eta TE Fe aaa aa Da etna Da iid aa a 9 3 9 6 Approximate amplitude values for near field ultrasonic Welding 9 3 AD Retooling sssini ennienni naaa a aea ie aea m aiiin iniaiaiai a 10 1 10 1 Changing 10 1 11 Cleaning and 11 1 11 1 General maintenance JODS a eta aa cai a ene ka oce ERR one Y S 11 1 11 2 ceea en a a ina a a a i e a a ER 11 1 11 3 Pneumatic Unit
14. 6 check on the scale 18 4 Fasten the knurled screw again 5 Release the clamping levers 19 and move the press upwards by means of the height adjustment facility 20 so that the horn cannot collide with the welding object when the stroke is performed 6 Tighten the clamping levers again Attention ifthe horn is not positio ned high enough there will be a risk of collision T om a f MN 6888 IT MP202PCSV20 GB N 1831 18569 ULTRASONICS Initial start up Do touch the sonotrode ul 7 The machine is turned on using the ON OFF key Self test 8 The current welding mode is shown in PE pag re the display after the self test has been Hold Time 2 221s completed Trigger 2 0 9 By pressing the keys Service Enter serie Service MM F Ema Enter Service you enter the ADJUSTING mode ADJUSTING Do not place work locating fixture 12 m with welding object underthe horn 10 Actuate dual safety switch to lower press 11 Center the fixture containing the object 13 to be welded under the horn MP202PCSV20 GB N 1831 18569 6 5 Initial start up A CREST GROUP COMPANY 14 12 Release clamping levers and lower the press gently onto the object to be welded using the height adjustment facility 15 13 Tighten clamping levers 16 14 Fasten clamps 12 using soc
15. 7 5 9 Parameters of the Absolute 2 TRAVEL Operating 7 31 7 6 TIhePRINT JEUFBCUOR edet cr Data ic ae tenen Papeete is 7 34 7 6 1 Possible Selections in the Print Menu seseessseseeesseesrrssseerrrssererrnsstierrsssreennssseennnne 7 34 7 6 2 Printing the Welding Data an aaa a aaa 7 34 7 6 3 Printout of the Welding Diagram 7 35 7 6 4 Overview of FUnctlons occae eta peu dee tete sez a ERE orn RR RARE YE a RR ARA Yen RR ARA 7 36 7 6 5 Parameter Settings of the PRINT PLOT Functions pp 7 37 7 7 The DATABANK se carta ae ana ca date a HY OR EY Fe HY aet aa e adi eee 7 38 7 7 1 Possibilities of the DATA BANK Function nenea nenea nenea 7 38 7 2 Saving Dala iecit aa a a d er d ra a 7 39 7 7 3 Loading wa 7 40 7 4 Deleting cM m 7 41 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY List of contents 7 19 PrintD t PEU 7 42 7 7 6 Printout of the Data Bank eee manea anna 7 43 78 Ther F Function Key caca ei a ce a ate aaa De ana ae a a a Ba a aa a ll 7 44 7 8 1 gt 7 44 7 82 p Code 4729 wesc cca ert inition erated at ah od ete ad re ca ae tr EC s 7 45 7 8 3 Parameter Adjustment Using Code 4729 nenea nn enma 7 45 784 IP Code 4711 unde ERI Wie eadera HE ci EE o Rd ali 7
16. A at the back of each unit as well as on the inside cover flap of this operating manual The design and circuitry of these units are subject to continuous further development and improvement and represent the latest state of the art RINCO ULTRASONICS AG Romanshorn Switzerland MP202PCSV20 GB N 1831 18569 Notes A CREST GROUP COMPANY MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Explanation of symbols and signs 1 Explanation of symbols and signs Special attention should be paid to passages with the following symbols Special information or operating instructions Warnings regarding risk of personal injury or damage to parts of the equipment The item numbers usedin the illustrations and descriptions e g EMERGENCY STOP button 16 correspond to the item numbering adopted in the product over view included in the chapter Product information orto adjacent drawings generally on the same page MP202PCSV20 GB N 1831 18569 Explanation of symbols and signs ULTRASONICS A CREST GROUP COMPANY T9 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Safety information 2 Safety information 2 4 General The design of the Multipress and generator conforms to the current state of engineering and is safe to operate The individual modules and the complete unit are subject to continual inspection by our quality assurance department 2 2 Intended purpose
17. Compressed air connec tion 7 bar maximum Turn compressed air 21 to vertical position closed n 4 Connect compressed air tube 21a to the available com pressed air network 4a 5 Move compressed air valve 21 to working position Fig 4a IO OO IN IAIN Generator 2000 3000W MP202PCSV20 GB N 1831 18569 ULTRASONICS Initial start up A CREST GROUP COMPANY 6 5 Installing the vibration system Make sure you switch off the volta ge supply at generator before installing the vibration system Power OFF 1 Release the screw 8 with the socket wrench supplied size 6 mm 2 Open the cover 7 of the converter housing 3 Plug the RF plug into the RF socket 23 of the converter 4 Insert the vibration system into the converter housing from the front 5 Re close the cover 7 of the converter housing and fasten it with the socket wrench 6 Screw in the horn 9 and tighten it with A the special wrench supplied A Ci Tightening torque 30 40 Nm The vibration system is now ready for opera tion MP202PCSV20 GB N 1831 18569 6 3 Initial start up RINCO ULTRASONICS A CREST GROUP COMPANY 6 6 Setting up 1 Position the locating fixture with inser ted welding object 2 Measure stroke distance D 3 Loosen the knurled screw 6 1 and adjust the stroke with the depth stop
18. Delayed impulse Maximum power Power loss Horn number Fixture number Size of the booster System pressure Flow control valve performance 00 00 99 99 mm 0 0 9 9 0 000 9 999 s 0 10 000 Ws 0 10 000 Ws 0 000 1 999 s 0 000 1 999 s 1 Parameter 60 70 80 90 100 Parameter Parameter Parameter Parameter Limit Limit Parameter Measured value Measured value Measured value Measured value Limits Measured value Parameter Parameter Measured value Measured value Info Info Info Info Info Directly influences the welding result The parameters can be changed Limits limit is exceeded an error message is output The values can be changed Measured Value Measured values The values can be read but not changed The amplitude cannot be adjusted for the PCS I The ampli tude is always at 100 MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY Info These values are only for information The values can be changed Travel This parameter specifies the depth of the weld The weld depth is calculated starting after the triggering Trigger This parameter adjusts the triggering of the ultrasonic horn The higher the value the higher the pressure on the object to be welded Hold Time After the welding time has run out the holding time starts The object welded can harden under pressure during the hold time Amplitude The output ampli
19. N 1831 18569 2 1 Safety information ULTRASONICS A CREST GROUP COMPANY 2 5 Installing the units Always unplug the power cable before making any connections to peripheral units Be sure to fit the power supply with a grounding connector Observe any statutory safety regulations in force in your country Failure to observe these regulations will exempt the manufacturer from all liability for injury to persons or damage to materials Before starting up the unit always make sure it is in a closed and safe condition Only use dry compressed airfor operation If necessary install an upstream water trap 2 6 Operation Never open generator converter housing while the Multipress is in operation There is a high voltage inside the units risk of injury Avoid any potentially unsafe working practices Only operate the Multipress when protective equip ment and safetyrelated apparatus e g detachable protectors EMERGENCY STOP buttons soundproo fing etc are in place and in working order Failure by customers to order and use safety precautions such as the sound booth shall exemptthe manufacturer from all liability for damage which could have been avoided by using the safety devices provided Before switching on the Multipress make sure that no one is endangered by the starting up of the machine In normal operation the two hand trigger button must be operated by the same person u
20. Trigger Hold Time Amplitude En max En min Energy Travel Time Parts Required Rejects Delaytime US Pulse Power Peak Power Loss Horn Fixture Booster 1 Pressure Speed 7 5 9 Parameters of the Absolute 2 TRAVEL Operating Mode Weld depth Ultrasonic trigger Hold time Amplitude Maximum energy Minimum energy Current energy value Current travel value Current time Part counter Required part count Rejected part counter Impulse delay time Delayed impulse Maximum power Power loss Horn number Fixture number Size of the booster System pressure Flow control valve performance 00 00 99 99 mm 00 00 99 99 mm 0 000 9 999 s 0 10 000 Ws 0 10 000 Ws 0 000 1 999 s 0 000 1 999 s 1 Parameter 60 70 80 90 100 Parameter Parameter Parameter Parameter Limit Limit Measured value Measured value Measured value Measured value Limits Measured value Parameter Parameter Measured value Measured value Info Info Info Info Info Directly influences the welding result The parameters can be changed Limits limit is exceeded an error message is output The values can be changed Measured Value Measured values The values can be read but not changed Info These values are only for information The values can be changed The amplitude cannot be adjusted for the PCS 1 The ampli tude is always at 100 MP202PCSV20 GB N 1831
21. damaged i The horn must befastened with a tightening torque of 30 40 Nm 8 4 Fixture The fixture serves a variety of purposes holds the welding object in the same position throughout the welding operation It simplifies the assembly process laying up of various parts It has a positive effect on the acoustic process of the ultrasonic welding It prevents damage to the welding object surface The degree of success and the level of quality depend in many ways on the design of the fixture It is therefore vitally important for the fixture and the horn to be produced by the same manufacturer He knows the requirements to be met by the application SN MP202PCSV20 GB N 1831 18569 Elements A CREST GROUP COMPANY T9 MP202PCSV20 GB N 1831 18569 8 5 Elements ULTRASONICS A CREST GROUP COMPANY T9 8 6 MP202PCSV20 GB N 1831 18569 RINO A CREST GROUP COMPANY Application examples 9 Application examples 9 1 The weld The typical profile for an ultrasonic weld serves two functions It is designed as a tongue and groove joint in order to facilitate the lay up of work guide the two halves of the workpiece precisely during the processing operation p The energy director integrated in the contact zone acts as an energy concentrator and at the same time it supplies the neces sary molten mass for an optimum joint The weld profi
22. directly so it is amplified by a booster 25 The efficiency of a piezoelectric converter is extremely high The small losses which occur during the conversion are noticeable in a rise in temperature of the converter Residual heat is dissipated by natural convection thanks to the special design of the converter Special applications require dissipation of heat by additional ventilation optional The converter must not be warmed up to more than 60 C at the contact point Converter booster horn and generator may be damaged by overheating The converter must be fastened with a tightening torque of 30 40 Nm MP202PCSV20 GB N 1831 18569 Elements ULTRASONICS A CREST GROUP COMPANY 8 2 Booster The correct amplitude atthe hornis Example E one of the most important factors for ultrasonics welding Converter Su Booster 1 2 10u The geometrical form of the horn must match to the welding object Horn 1 3 30u Finding the correct amplitude for the application is often difficult The booster intensifies the ampli tude of the converter in a given ratio 1 2 in our example The factor of reinforcement at tenuationis given inthe correspom ding ratio The ratio is designated with a colour code and a numerical value A see table The booster must be fastened with a tightening torque of 30 40 Nm Booster 1 2 10um Horn 1 3 30um Ultrasonic welders of the 20 series are available wit
23. displayed Energy too low If the energy limit is not reached the error message Energy too low is displayed Possible causes are System pressure too low Amplitude too small Object to be welded not in the fixture Object to be welded defective Travel A Specified travel value Time Energy minimum maximum energy energy Travel A Specified travel Time Energy minimum maximum energy energy MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation Travel Time Energy minimum maximum energy energy Energy too high Ifthe energy used rises beyond the upper energy limit the error mes sage Energy too high is display ed Possible causes are Travel value cannot be rea ched System pressure too high Amplitude too high Object to be welded defective Time overflow If the time limit is exceeded the error message Time overflow is displayed Possible causes are Travel value cannot be reached maximum weld time too short System pressure too low Amplitude too low Noobject to be welded in fixture Object to be welded defective MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY 7 5 4 Overview of Functions for the Differential TRAVEL MODE TRAVEL MODE Differential Travel 02 00mm Trigger 2 0 TRAVEL MODE Differential Travel 02 00mm Trigger 2 0
24. is determined by means of its design For the production of horns it is vital to have a knowledge of the load capacity of various materials 8 3 1 Horn materials Horns are manufactured exclusively from specifically high strength materials namely high strength aluminium titanium and steel alloys The choice of material depends largely on the intended applica tion Various factors are crucial for choosing the material 1 The strength of the horn material in conjunction with the amplitude to be attained 2 The surface condition of the material and its related surface finishing characteristics 3 The ultrasonic transmission characteristics 4 The heat conducting characteristics of the horn material MP202PCSV20 GB N 1831 18569 8 3 Elements ULTRASONICS A CREST GROUP COMPANY Allowance must also be made for the fact that horns are subject to immense mechanical loads It is extremely important therefore to design the horn in such a 4 way as to enable the plastic to be joined under optimal conditions The horn surface may have a coating for abrasive plastics for longer service life RINCO has a long record and a lot of experience in horn manufacture Horns that are manufactured without the necessary theoretical and practical experience are bound to lead to unsatisfactory and poor welding results and hence to inferior product quality In some cases vibration system and generator may be
25. keep track of adjustment steps 6 9 Switching off 1 Switch off the generator with the ON OFF key 2 Move the compressed air lever to the vertical position closed 6 8 MP202PCSV20 GB N 1831 18569 ULTRASONICS Initial start up A CREST GROUP COMPANY T9 MP202PCSV20 GB N 1831 18569 6 9 Initial start up A CREST GROUP COMPANY T9 6 10 MP202PCSV20 GB N 1831 18569 Operation sn 1 T 1 Ll Solenoid valve Lo d LT o LL Safety switch Home position Weld time Lo dne Wu Hold time Option after pulse L Brake Lo po LP LL o riger POC Time t Stroke Time quick gentle Weld time Hold time quick t down touchdown return Operation The welding operati on sequence Weld cycle MP202PCSV20 GB N 1831 18569 Operation RINCO A CREST GROUP COMPANY 7 1 2 Work cycle 1 Press both start buttons within 0 3 seconds to start the cycle The power loss of the vibration system is measured over a period of 0 3 seconds system test The solenoid valve is activa ted and the feed drops down 2 Keep the start buttons actuated until safety switch is reached or until hold time is ended i If start buttons are released too early the actuator moves back to the home position An error mes sage appears Welding is actuated by the TRIGGER As soon as the welding and hold
26. new booster in the converter housing n 12 Close the converter housing 7 and tighten the fastening screw 8 13 Screw the converter 24 into the booster and tighten with the special wrench A 14 Re open the converter housing 7 15 Take the converter 24 with the atta ched booster 25 out of the converter housing and turn round the other way 16 Insert the RF plug in the RF socket 23 17 With the converter 24 on top re insert the booster 25 in the converter housing 10 2 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Retooling 18 Close the converter housing 7 and tighten the fastening screw 8 19 Screw the horn 9 back into the booster and tighten it with the special wrench A MP202PCSV20 GB N 1831 18569 10 3 Retooling ULTRASONICS A CREST GROUP COMPANY T9 10 4 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Cleaning and maintenance 11 Cleaning and maintenance 11 1 General maintenance jobs Cleaning and maintenance jobs may only be carried out by specially trained staff Before beginning maintenance jobs make sure all energy sources such as the power and compres sed air supply are disconnected Attention Never clean the keypad or plastic sheeting of the generator with caustic agents The Multipress and Generator require no special maintenance Howeve
27. ofthe energy mode are explained starting on page 7 12 Service 5 O TEST Time 1 Energy 1 MP202PCSV20 GB N 1831 18569 Controls and indicators A CREST GROUP COMPANY 41 The Gauge Key The Gauge key activates the travel mode The possible functions of the travel mode are explained starting on page 7 18 Gauge 42 The Check Key 4 Using the Check key you can place the cursor the begin ning of the current menu Using the Check key you can reset the error relay Check 38 The CLR Key 4 4 Using the CLR key you can reset and clear error messages reset input values select fixed input values CLR MP202PCSV20 GB N 1831 18569 5 7 Controls and indicators ULTRASONICS A CREST GROUP COMPANY 49 The System Test Key The vibration system currently connected can be tested using the System Test key The vibration system must be connected System Test Do not touch the sonotrode Offset of the A D converter 3 SYSTEM TEST Converter voltage Offset 0021Bin Voltage 0530Bin c Converter power loss Power Loss 1 m 47 TheFKey The parameter menu is activated using the F key After entering a code you can adjust the machine parameters F m 48 The Data Bank Key The databank administration functions are activated using the Data Bank key Welding data can be stored selected deleted or printed out The possible functions of the data bank mode are
28. out after the weld has been completed by pressing the Enter key Time Scale The appropriate time scale for the time axis must be selected according to the weld time The value for the scaling can be changed by pressing the CLR key Baud Rate The baud rate of the RS 232 interface can be selected Different values for the baud rate can be selected by pressing the CLRkey Output format 8bit no parity 1 stop bit Print Interval If a printout is not to be sent to the printer after each weld a print interval can be set The data for faulty welds are always printed out If the print gap is set to 0000 only the data for faulty welds is printed out Output The output can be sentto a serial printer or transferred to an SPC program The value can be changed by pressing the CLR key MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY 7 7 The DATA BANK Function 7 7 1 Possibilities of the DATA BANK Function In actual applications the same ultrasonic equipment is often used for welding several diffe rent types of materials in alter nating operating modes The DATA BANK function of fers a useful extension of the PCS system in this case All of the most important set tings and specified values can be stored There are 40 storage locations available for storing data The individual databanks can also be optionally selected over the RS 232 interface only for the PCS Il Operatio
29. rectly the message Data sa ved appears in the display By pressing the Check key you return to the initial position MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY 7 7 3 Loading Data After you have switched to the ad justment level 1 press the Data Bank key The display now shows the first databank function Save Data 2 Using the cursor keys select the Load Data function 3 Press the Enter key The number of the last occupied storage location then appears in the display 4 Enter the number of the desired storage location and confirm the entry by pressing the Enter key If the desired storage location is empty the message No Data appears Select a valid number and confirm the number by pressing the Enter key After pressing the Enter key the contents of the desired storage lo cation appear in the display By pressing the Check key you return to the initial position Adjustment level Check cxi Check cxi Check cxi 9 Data i Bank Service cxt CR DATA BANK z Service Save Data RE DATA BANK Load Data Service cai CR o DATA BANK Number 05N Enter CLR TIME MODE Weld Time H 111s Service CLR Hold Time 2 221s Trigger 2 0 i i MP202PCSV20 GB N 1831 18569 A CREST GROUP
30. sos 2 2 2 6 Operation 2 2 2 6 1 Noise emissions pp 2 3 2 7 EMERGENCY STOP button aaa Data aa Da ta a ct a d daca aa aaa at ada 2 3 3 Product information site tatea aaa al a ma ai iat aia itemi aaa dai n aaa acalmie degli 3 1 3 1 Prod ctoVerviGW cere ite prre neos ae da ataman ca aaa ata a a dacs a Deo nie pee d 3 1 3 14 1 Multipress u ue terrere a at an a an ta la e eee Bea ta n dau aa 3 1 2 1 2 Vibration System ice aaa ee aa ee diee ee Roe Re e Ree ER des 3 2 3 1 3 Ultrasonic 3 2 3 2 Comparative examiple siii pite iter d eta d Goi ERR DR aaa EA a EE ERRARE eue a ta 3 3 3 3 Use of ultrasonics in the plastics industry sssee nee 3 3 34 Fundamentals and advantages of ultrasonic 3 3 3 5 Mode of operation and characteristics of the Ultrasonic 3 4 3 6 Warranty Statement 3 4 37 Technical data of the Multipress sssesesesesseseeeeeenerrnrrtnrnnrnstnsstrtststtttttrtntnnnnn nnen nnnnnn teet rEnn 3 6 3 7 1 ACIUGtO iena a eat ices ar d a aaa Ra a ae E aie 3 7 3 2 sn LEES 3 7 373 BASEL EEUU 3 7 3 7 4 3 7 3 7 D DIMENSIONS ic eere e ada da a Pt do a aula aaa ia des 3 7 3 7 6 Wagi asane a ous dee aaa Hd 3 7 3 8 Technical d
31. 0W STO1 STO2 STO3 STO4 STO6 ST6 N O A WD N a O iN IR List of unit sockets General order No RINCO order No Appliance socket 14 pole AMP 0 182641 1 Appliance socket 7 pole AMP 0 211398 1 Appliance socket SUB D 15 pole 77 SDA15S Appliance socket Lemo 2 ERA 2S 408 CTL Appliance socket 250V 8A STO6 Appliance socket SUB D 25 pol 77SD B25S 5040 List of connection plugs General order No RINCO order No Plug 14 pole AMP 0 182649 1 Plug 7 pole AMP 0 211400 1 Plug SUB D 15 pole 77 SD A15P Plug Lemo 2 FFA 28 408 CTAC52 Mains cable 250V DEDIMUS on country 13 4 MP202PCSV20 GB N 1831 18569 RINCO A CREST GROUP COMPANY Electrical diagrams 13 4 Fuses Generator 1000W 1500W Fuses are to be found in the following assem blies Power socket PCS Module F12 9 Generator module I F4 F5 LJ i All fuse dimensions 5 x 20 mm MP202PCSV20 GB N 1831 18569 13 5 Electrical diagrams ULTRASONICS A CREST GROUP COMPANY 13 5 Fuses Generator 2000 3000W Fuses areto be found inthe following assem blies Power socket PCS Module Generator module 13 i All fuse dimensions 5 x 20 mm 14 13 6 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Electrical diagrams 13 6 List of fuses Generator 1000 1500W Generator Power socket
32. 18569 A CREST GROUP COMPANY Operation Travel This parameter specifies the depth of the weld The weld depth is calculated starting after the triggering Trigger This parameter adjusts the triggering of the ultrasonic horn The higher the value the higher the pressure on the object to be welded Hold Time After the welding time has run out the holding time starts The object welded can harden under pressure during the hold time Amplitude The output amplitude can be set to one of five levels from 100 down to 60 The values are changed using the CLR button The amplitude cannot be changed for the PCS The ampli tude is always at 100 Maximum Energy If the amount of energy output is higher than the specified value the error message Energy too high is displayed Minimum Energy If the amount of energy output is smaller than the specified value the error message Energy too low is displayed Energy Effective measured energy Travel Effective measured depth Time Effective measured time Part Counter Counts the number of fault free welded parts The Part Counter can be reset using the CLR key Required Part Count After reaching the specified part count the message Part count reached is displayed Is only active if F 4729 has been initialized to ON Reject Counter Counts the number of incorrectly welded parts The Reject Counter can be reset using the C
33. 31 18569 A CREST GROUP COMPANY Controls and indicators RINCO ULTRASONICS SWITZERLAND PCS II V9 6 HP IEI OOQ 2290 O 2 Enter EI OW OW 5 4 Description of the Display and Keyboard 31 The Display After turning on the machine the control unit carries out a self test The manufacturer s address and the software version are displayed After 3 seconds the control is switched to the current welding mode The welding parameters messages and machine settings are displayed The display is equipped with a background light To increase the life span of the light it is automatically turned off 5 minutes after the last key has been pressed The light switches back on again as soon as any key is pressed 37 The Numerical Keyboard Using the 0 9 Enter and CLR keys certain welding data can be changed depending on the operating mode selected When the Enter key is pressed the value entered is checked and stored If the value lies outside of the valid range for the value then the previous value is redisplayed 44 The Cursor Keys Using the and lt cursor keys a certain value within a numerical range can be selected The border values are automatically set by the number of digits Using the and J cursor keys you can jump to a differentline As the number of lines in the display is limited to 4 lines the lowest line in the display is overwritten each time a new line of data is displayed Al
34. 415 yellow Aluminium 1 2 Titanium Titanium Titanium 3 7 3 Base Ribbed steel construction Tool clamping plate with tee slot and parallel alignment mecha nism Dual safety switch with emergency stop button 3 7 4 Compressed air Dry compressed air 7 bar max 105 PSI 3 7 5 Dimensions see fig page 3 6 3 7 6 Weight MP202PCSV20 GB N 1831 18569 3 7 Product information ULTRASONICS A CREST GROUP COMPANY 3 8 Technical data of the Ultrasonic Gene amp rator m OA Weight 1 000 1 500 W 260 11 kg 2 000 3 000 W 300 15 kg Dimensions in mm 3 8 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Product information 3 9 PCS Control 3 9 1 Concept Flexible modular system with various insertable modules 3 9 2 Display 4 line alohanumeric LCD display 3 9 3 Data Entry Keyboard with numerical keys and 14 function keys 3 9 4 Operating Modes Time Energy Travel 3 9 5 Time Mode Constant Time with energy limits 3 9 6 Energy Mode Constant energy with time limits 3 9 7 Travel Mode Constant travel distance with energy limits 3 9 8 Ultrasonic Actuation Using a trigger sensor or through the travel mode 3 9 9 System Test Can be selected to be carried out before or after each weld 3 9 10 Control Voltage 24V DC 3 9 11 Menus Menus can be selected to appear in German English French Italian or in Spanish
35. 5 11 11 999999 T 2 0 1 000s 100 1000 Ws Error 1 O O O es 2 Energy Mode Date Time Piece Mode Trigger Weld Time Power Energy Errors 11 11 95 11 11 999999 E 2 0 1 000s 100 1000 Ws Error 1 O O O a 107 B 3 Differential Travel Mode Date Time Piece Mode Travel Weld Time Power Energy Errors 11 11 95 11 11 999999 D 99 99 mm 1 000s 100 1000 Ws Error 1 20 EI O O O I 7 34 MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY O O 4 Absolute 1 Travel Mode 2 Date Time Piece Mode Travel Weld Time Power Energy Errors 11 11 95 11 11 999999 A1 99 99 mm 1 000s 100 1000 Ws Error 1 l J O C 5 Absolute 2 Travel Mode l l l O l l Date Time Piece Mode Travel Weld Time Power Energy Errors l l O 11 11 95 11 11 999999 A2 99 99 mm 1 000s 100 1000 Ws Error1 O px 1 7 6 3 Printout of the Welding Diagram 29 Power 100 2000W Time hh mm 15 27 Date dd mm yy 11 12 95 120 100 50 0 16s 0 32s 0 48s 0 64s 0 80s 0 96s 1 12s 1 28s 1 44s Power Loss 15 Weld Time 1 000s MP202PCSV20 GB N 1831 18569 Operation 7 6 4 Overview of Functions Operational level n Q QQ Q Adjustment level Check ci Check KI Check KI Check KD
36. COMPANY Operation BANK Check DATA Save Datall cxi Check Ci Check CR DATA BANK Check Number 05 Data deleted 7 7 4 Deleting Data After you have switched to the adjustment level 1 press the Data Bank key The display now shows the first databank function Save Data 2 Using the cursor keys select the Delete Data function 3 Press the Enter key The number of the last occupied storage location then appears in the display 4 Enter the number of the desired stora ge location and confirm the entry by pressing the Enter key If the desired storage location is empty the message No Data appears Select a valid number and confirm the num ber by pressing the Enter key The data in the desired location is deleted The message Data deleted appears in the display By pressing the Check key you return to the initial position MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation 7 7 5 Print Data i Before you print data make sure thata printer is connectedtothe serial port and thatthe printer is Adjustment level ready O To print saved data switch to the adjust Bark se CLR ment level ui 1 Press the Service key 2 Enter the code 23 DATA BANK Check Save Datall 3 Confirm the entry by pressing the Enter key
37. Generator module F1 F2 4 5 GM20 1000 6 3 A T 6 3 A T 6 3 A T 100 mA T GM20 1500 8 A T 8 A T 8 A T 100 mA T 13 7 List of fuses Generator 2000 3000W Generator Power socket Generator module F1 F2 F3 F4 F6 F5 PIM 20 2000 10AT 10 AT 10AT 10AT 10AT 400 mA T PIM 20 3000 16 AT 16 AT 16AT 16AT 16AT 400 mA T 13 8 List of fuses PCS Module PCS Module F7 F8 F9 50 mA T 400 mA T 400 mA T 400 mA T 1 25 A T 400 mA T MP202PCSV20 GB N 1831 18569 Electrical diagrams ULTRASONICS A CREST GROUP COMPANY T9 13 8 MP202PCSV20 GB N 1831 18569
38. Key 7 8 1 System Initialization To prepare the Multipress and the Generator for the diverse tasks accorded them the individual press functions are initialized depending onthe application by the generator controller The hardware and software para meters of the welding machine are changed using the F key F Code 4711 Software parameters F Code 4729 Hardware parameters Operational level 2 00 n E A CREST GROUP COMPANY Adjustment level SYSTEM INIT 4095 Bin 2000W 100 1478W Loss max 25 SYSTEM INIT 4095 Bin 2000W 100 1478w Loss max 25 SYSTEM INIT 4095 Bin 2000W 100 1500W Loss max 25 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation 7 8 2 Code 4729 Parameter Display SYSTEM INIT 4095 Bin 2000 3125 100 1000 1500 2000 3000 Loss max 10 40 Voltage 1000 Bin Travel Mode on off Encoder 1 1 1 09132 Start Manual Impulse Automatic Homeposition on off Required on off Loss Test before after Reset on off US Stop on off Trigger before after 7 8 3 Parameter Adjustment Using Code 4729 4095 see table 100767 Generator power see ratings plate Loss max If this value is exceeded during the self test a vibration system error is output Standard Setting Ne 25 Travel Mode If the press is equipped with a travel m
39. LR key The Reject Counter is automatically reset when the Part Counter is reset MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation Delay Time The impulse delay time starts after the hold time has run out US Pulse After the impulse delay time has run out the ultrasonic pulse is activated Using the us pulse an object sticking to the sonotrode can be shaken off Power Peak The setting for the maximum power is displayed Power Loss The power loss of the vibration system is displayed Horn Number The part number of the sonotrode can be noted for informati on purposes Fixture Number The part number of the fixture can be noted for information purposes Booster 1 The size of the booster can be noted for information purpo ses Pressure The pressure of the press system can be noted for informati on purposes Speed The flow control performance of the press can be noted for information purposes MP202PCSV20 GB N 1831 18569 RINCO A CREST GROUP COMPANY Operation 7 6 The PRINT Function 7 6 1 Possible Selections in the Print Menu Welding data and welding diagrams can be sent out over the serial interface to a printer for printout with the PCS The welding data can also be transferred to an SPC software program only for the PCS Il 7 6 2 Printing the Welding Data 1 Time Mode Date Time Piece Mode Trigger Weld Time Power Energy Errors 11 11 9
40. OMPANY T9 5 10 MP202PCSV20 GB N 1831 18569 ULTRASONICS A CREST GROUP COMPANY Initial start up 1200 UL 8 Q CS 6 Initial start up 6 1 Selecting a location Choose a location that fits the follo wing criteria Clean surroundings Alevel and solid standing surface Vibration free seating for the electronic units Ambient temperature in operation 10 45 for adjustments 20 C 6 2 Space requirement The location chosen for the press should provide enough room for carrying out maintenance and re pair jobs Minimum dimensions for the place of installation see Fig 1 6 3 Work station The sketch shows an example of how a work station can be arran ged MP202PCSV20 GB N 1831 18569 Initial start up A CREST GROUP COMPANY 6 4 Assembling and connecting up the units To prepare the units for operation El carry out the following steps 1 Anchor the work bench and screw the Multipress to the rear as shown in Fig 2 2 Connect up the cables between the press and generator Be sure to fit the power connection with a groun ded connector 3 Plug the unit plugs in the Sockets of the Generator STO1 Actuator STO2 Start optional STOS Interface optional STO4 Converter connec tion WK GW N STO5 Power connection STO6 RS 232 Option ST6 Mains cable i
41. Operating Manual English Ultrasonic Welder for Plastics Multipress MP202 with Generator PCS al aa ae RINCO ULTRASONICS AG Industriestrasse 4 CH 8590 Romanshorn Switzerland 7 41 71 466 41 00 41 71 466 41 01 www rincoultrasonics com vu SUCCES info rincoultrasonics com Version 2 0 MP202PCS N 1831 Note ULTRASONICS A CREST GROUP COMPANY Note Read this operating manual and study it carefully before unpacking and putting the machine into operation The machine may only be used maintai ned and repaired by persons who are familiar with the operating manual and the applicable regulations concerning working safety and accident prevention Machine specification e er OF e ev Multipress Generator Representative Copyright by RINCO ULTRASONICS AG Switzerland MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY List of contents 1 Explanation of symbols and signs eeeeesseseeeeeeeeeeeeee rennen 1 1 2 Safety inforrn ali OI Mec M 2 1 21 General E 2 1 2 2 Jlntended PURPOSE eee epe eee teen bao i ge ERE ERE E ehe Fue 2 1 2 3 Special points to note 2 1 24 Choosing staff ceto as et E te E ancien ed ul e ure uaa ic eee 2 1 25 Installing the units
42. SV20 GB N 1831 18569 11 3 Cleaning and maintenance ULTRASONICS A CREST GROUP COMPANY T9 11 4 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Error messages and trouble shooting 12 Error messages and trouble shooting Troubleshooting may only be carried out by specially trained staff In case of doubt contact the service centre or the manufacturer directly see appendix 12 1 Error messages corrective action switching on Possible cause Corrective action Generator cannot be switched no voltage supply insert mains plug on EMERGENCY STOP button release EMERGENCY pressed STOP button fuse faulty test fuses F1 F5 module not in its housing insert module and bolt toge ther 12 2 Error messages corrective action set up and welding Possible cause Corrective action Horn is lowered but ultrasonics Trigger set too high set trigger lower fail to start Trigger faulty replace trigger The parts are not welded clo stop is set too low set stop higher ser together despite an increased welding time Press returns without welding safety switch not reached press start keys until safety switch is reached or hold time has run out MP202PCSV20 GB N 1831 18569 12 1 Error messages and trouble shooting ULTRASONICS A CREST GROUP COMPANY 12 3 Generator error messages during operation OVERLOAD Trigger set too high maximum weld
43. T9 MP202PCSV20 GB N 1831 18569 12 3 Error messages and trouble shooting ULTRASONICS A CREST GROUP COMPANY T9 12 4 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Electrical diagrams dual safety i actuator switch box input safety switch i 3 i E input trigger 4 output solenoid valve lt wy Emergency stop 12 input emergency stop lt 24V 13 input start 1 4 14 input start 2 G 13 Electrical Diagrams 13 1 Electrical Diagrams for the PCS Generator 13 1 1 Actuator STO1 CE MP202PCSV20 GB N 1831 18569 Electrical diagrams ULTRASONICS A CREST GROUP COMPANY 13 1 2 RS 232 STO6 RS 232 Cable The other pins are not connected 25 poles D Sub 25 poles D Sub Plug Plug 2 em MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Electrical diagrams 13 1 3 Interface STO3 NC NC NC NC a NC o NC NC 00 NC 9 Error 24V 0 5A Open if error Ready max 24V 0 5A Open if not ready N Z O I Z O gt 2 O MP202PCSV20 GB N 1831 18569 13 3 Electrical diagrams ULTRASONICS A CREST GROUP COMPANY 13 2 Generator rear panel 1000 1500W STO1 STO2 STO3 STO4 STO5 STO6 O O KR C DHS a A WIG 0 N 13 3 Generator rear panel 2000 300
44. an be shaken off Power Peak The setting for the maximum power is displayed Power Loss The power loss of the vibration system is displayed Horn Number The part number of the sonotrode can be noted for informati on purposes Fixture Number The part number of the fixture can be noted for information purposes Booster 1 The size of the booster can be noted for information purpo ses Pressure The pressure of the press system can be noted for informati on purposes Speed The flow control performance of the press can be noted for information purposes MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY 7 5 8 Overview of Functions for the Absolute 2 TRAVEL MODE Operation level Adjustment level Bru TRAVEL MODE Differential Travel 02 00mm Trigger 2 0 TRAVEL MODE Absolute 1i Travel 02 00mm TRAVEL MODE Absolute 21 Travel 02 00mm Trigger 10 00mm o 2 CRE o CRE CLR Trigger 2 0 TRAVEL MODE Absolute 2 Travel 02 00mm Trigger 10 00mm Check Service ci CLR Enter TRAVEL MODE Absolute 2 Travel 05 00mm Trigger 10 00mm Check Service cr CR TRAVEL MODE Absolute 2 Check Travel 05 00mm Service Trigger 10 00mm cxi cD CR MP202PCSV20 GB N 1831 18569 RING A CREST GROUP COMPANY Operation Display Absolute 2 Travel
45. asured value Delaytime Impulse delay time 0 000 1 999 s Parameter US Pulse Delayed impulse 0 000 1 999 s Parameter Power Peak Maximum power Measured value Power Loss Power loss Measured value Horn Horn number Info Fixture Fixture number Info Booster 1 Size of the booster Info Pressure System pressure Info Speed Flow control valve Info performance 1 Parameter Directly influences the welding result The parameters can be changed Limits limit is exceeded an error message is output The values can be changed Measured Value Measured values The values can be read but not changed Info These values are only for information The values can be changed The amplitude cannot be adjusted for the PCS I The ampli tude is always at 100 MP202PCSV20 GB N 1831 18569 7 15 A CREST GROUP COMPANY Operation Energy This parameter sets the energy level Trigger This parameter adjusts the triggering of the ultrasonic generator The higher the value the higher the pressure on the object to be welded Hold Time After the welding time has run out the holding time starts The object welded can harden under pressure during the hold time Amplitude The output amplitude can be set to one of five levels from 10096 down to 6090 The values are changed using the CLR button The amplitude cannot be changed for the PCS The ampli tude is always at 100 Maximum Weld Time
46. ata of the Ultrasonic Generator nana nana 3 8 39 PCS Control cs pere cae nm ata cl to Date m ati ati nula dl ata Ri Ea a ai ta e a 3 9 3 91 CONCEP EUER 3 9 S922 DIa Lm 3 9 393 Data Entry RE 3 9 3 9 4 Operating 3 9 3 9 55 Time MOG 5 rr rere t rame anal dou eee rk dati d aaa lao Ve 3 9 396 Energy Mode cessive nula ala aia da ca cach ha i Elite Ra ape En ra a 3 9 397 Travel cei a oaze seat tt ua da a ata o aa a ata a a E i a aaa 3 9 3 9 8 Ultrasonic Actuation sseeseeesseeenentnennseeestttttttttttt tnr Enn netan rttr EEEE EEE EEnES Ennn arer EEEE EEEE EEEE 3 9 399 System Test uendere edere aaa de aa e a la ee a i ul 3 9 3 9 10 Control VolagG siriisrariieairiaisiianninneka ianiai ndi a iiaa aaan aia i 3 9 3 911 CRUEL 3 9 Menus can be selected to appear in German English French Italian or in Spanish 3 9 3 912 Databank ste au dee baie aud ae a li ip PE PRIN aaa EDI PTT AUDIT au 3 10 3 9 13 Interface esses sins nn 3 10 3 9 14 Generator Modules Available pp 3 10 3 9 15 Connected loadS pp 3 10 3 9 16 DIMENSIONS diria tio eren ag e a daca e a aia aaa DUREE ER e NH 3 10 4 Transportation e P 4 1 4 1 Unpacking receiving inspection nenea nenea anna anna mana mana aaa 4 1 4 2 Damage during trast save oaia dean atare at a R 4 1 4 9 P
47. d weld solidifying again immediately after the welding operation This means that the workpiece is able to withstand loads and to betransported and further processed straight afterthe operation No additional work is required An ultrasonic weld is produced with the material s inherent structure i e without the addition of foreign agents such as adhesives solvents etc This characteristic makes for an as sembly process with a high level of automation convenience and productivity The energy requirement per welding operation is minimal The efficiency ofthis modern ultrasonic welding system is approxima tively 9596 3 5 Mode of operation and characteristics of the Ultrasonic Multipress The system created with the Multipress and the generator com bines mechanical precision and strength with immense versatili ty At the same time we have been concerned to keep the unit as simple as possible in its operation and application The press can be adjusted in height by means of a handwheel height adjustment mechanism and can be moved precisely ina dovetail guide The clamping table is aligned parallel to the horn face by means of an adjusting mechanism 3 6 Warranty statement With the delivery of this system RINCO ULTRASONICS AG acknowledges its warranty obligation in accordance with VSM Association of Swiss Machine Builders Fulfilment of the terms of this warranty by RINCO ULTRASO NICS AG shall be conditional however on a
48. e noted for informati on purposes Speed The flow control performance of the press can be noted for information purposes MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY 7 5 6 Overview of Functions for the Absolute 1 TRAVEL MODE Operation level TB Gg C Adjustment level Gauge Service CLR TRAVEL MODE Absolute 20 GR Travel 02 00mm Trigger 10 00mm TRAVEL MODE TRAVEL MODE Absolute 10 Differential Travel 02 00mm Travel 02 00mm CLR Trigger 2 0 Trigger 2 0 o CRE TRAVEL MODE Absolute 1 Check Travel 02 00mm Trigger 2 0 Trigger 2 0 TRAVEL MODE Check Absolute 1 Travel 05 00mm TRAVEL MODE Absolute 1 Travel 05 00mm Trigger 2 0 Check cxi MP202PCSV20 GB N 1831 18569 RING A CREST GROUP COMPANY Operation Display Absolute 1 Travel Trigger Hold Time Amplitude En max En min Max time Energy Travel Time Parts Required Rejects Delaytime US Pulse Power Peak Power Loss Horn Fixture Booster 1 Pressure Speed 7 5 7 Parameters of the Absolute 1 TRAVEL Operating Mode Weld depth Ultrasonic trigger Hold time Amplitude Maximum energy Minimum energy Maximum time Current energy value Current travel value Current time Part counter Required part count Rejected part counter Impulse delay time
49. e noted for information purpo ses Pressure The pressure of the press system can be noted for informa tional purposes Speed The flow control performance of the press can be noted for information purposes MP202PCSV20 GB N 1831 18569 7 17 Operation A CREST GROUP COMPANY 7 18 7 5 The TRAVEL Opera ting Mode There are three different TRAVEL operating modes available 1 Differential TRAVEL MODE 2 Absolute 1 TRAVEL MODE 3 Absolute 2 TRAVEL MODE The TRAVEL MODE is activated by pressing the GAUGE button 7 5 1 Differential TRAVEL MODE With this operating mode the exa ct same amount of material is to be melted for each weld The weld depth DEPTH has the highest priority The advantage of the differential method is that differences in the size and density ofthe objects to be welded are continually compensa ted for Cycle After reachingthe TRIGGER Sen Sor the welding process is activa ted After activation the objects are welded until the DEPTH S is rea ched The current travel value is measu red at the end of the holding time An energy range and a maximum weld time can be set as limits 41 SY 14 ni Depth US Stop MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation 7 5 2 Absolute 1 TRAVEL MODE 16 With this operating mode the same final size is to be achieved after each weld The final size of the welded part has the highest pri
50. easurement system this must be initialized to ON Change the setting by pressing the CLR key MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY Encoder Must be initialized to 0 9312 Change the setting by pressing the CLR key Start Must be initialized to MANUAL Change the setting by pressing the CLR key Homeposition If the press is not equipped with a final upper position switch then this must be initialized to OFF Change the setting by pressing the CLR key Standard Seng eee cota a ao aa ta teras ON Required If the required piece count is not to be monitered then this must be initialized to OFF Change the setting by pressing the CLR key Standard settng erret ea ON Loss Test The self test can be run either BEFORE or AFTER the weld is completed If AFTER has been selected then a system test is run after turning the machine on After that the system test is run after the delay time has run out If the delay time is set to 0 000s a system test is not conducted It is better to run the machine with the system test if possible Change the setting by pressing the CLR key Standard setting BEFORE Reset Must be initialized to OFF Change the setting by pressing the CLR key US Stop The differential travel mode can be run with a stop switch using an optional adapter box If a stop switch is used this para
51. elect operation in German English French Italian or Spanish Change the setting by pressing the CLR key Data Bank A databank can be selected over the RS 232 interface if set to ON Change the setting by pressing the CLR key Standard setting OFF Time Current time Date Current date Generator Generator power i only for the PCS Il MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY T9 MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY T9 MP202PCSV20 GB N 1831 18569 RING A CREST GROUP COMPANY Elements 24 K1 25 Elements Converter The converter is a sensitive instrument Please handle with great care The converter 24 is the core of every ultrasonic welder Atype C20 12 converter is usedforthe Ultrasonic Welding Press It belongs to the category of piezo electric converters Piezoelectric converters consist of several ceramic disks that change their size when an electric voltage is applied In the case of the ultrasonic welding converter an alternating voltage with the nominal frequency e g 20 kHz is applied This electric signal is converted by the piezoelectric elements into a mechanical vibration of identical frequency Amechanical vibration in the axial direction is thus available at the front end K1 of the converter 24 The amplitude is usually too small to be used
52. explained starting on page 7 38 Data Bank 40 50 The Print Key The Print key activates the print menu Welding data can be printed out The possible functions ofthe print mode are explained starting on page 7 34 O Print only for the PCS Il 5 8 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Controls and indicators TIME MODE Weld Time 2 333s Hold Time 2 221s Trigger 2 0 Service Code TIME MODE Weld Time 2 333S Hold Time 2 221s Trigger 2 0 ADJUSTING WU 5 4 1 Important Information To protect the welding parameter settings from unwanted chan ges all of the important key functions should be locked after turning on the machine After turning the machine on the display shows the operating mode which will be used during actual welding 5 4 2 Releasing the Keyboard Lock EH 1 Press the Service key The display switches to the code input request mode 2 Enter the number 23 using the numerical keyboard and confirm the data entered by pressing the Enter key The display then returns to the previous operating mode display The keyboard is now unlocked and can be used to enter data 5 4 3 Activating the Keyboard Lock 5b 1 Press the Service key again Display 2 Press the CLR key The keyboard is now locked again MP202PCSV20 GB N 1831 18569 Controls and indicators ULTRASONICS A CREST GROUP C
53. for information purposes Booster 1 The size of the booster can be noted for information purpo ses Pressure The pressure of the press system can be noted for informati on purposes Speed The flow control setting of the press can be noted for infor mation purposes MP202PCSV20 GB N 1831 18569 7 11 A CREST GROUP COMPANY Operation 7 4 The ENERGY Opera ting Mode The amount of energy output is held constant in the energy mode A miminum and a maximum wel ding time can be set as limits The length of the welding time can vary within the limits of a certain range The range is affected by the tolerances of the parts to be wel ded By holding the energy con stant certain variations can be eli minated 7 4 1 The Time Window in the ENERGY Mode Correct welding The welding energy must remain within the set limits If these limits are exceeded an error message is displayed Specified Energy Level Time minimum maximum time time 7 12 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation Power Specified Energy Level Specified Energy Level minimum time minimum time maximum time maximum time Time Time Time underflow If the minimum time limit is not reached then the error message Time underflow is displayed Possible causes are minimum welding time too long system pressure too high amplitude to
54. h the following boo ster types Reducing Color Booster Color Booster 1 0 5 blue Aluminium 1 1 green Aluminium 1 0 6 violet Aluminium 1 1 5 yellow Aluminium 1 2 Titanium other ratios on request 2 Titanium Titanium 8 2 MP202PCSV20 GB N 1831 18569 Elements RING A CREST GROUP COMPANY 8 3 Horn Any changes to the metallic body of the horn will affect its vibration characteristics and should not be performed without consulting the manufacturer The hornis the tool that transfers the ultrasonic energy produced by the converter to the welding object in the form of an intensive vibration Since workpieces come in a variety of forms horns have to be adapted to the specific requirements The horn is an acoustic body tuned to the resonance frequency This accounts for restricted shaping possibilities The geometrical form of the hom should be kept as simple as possible Other important factors in addition to the geometrical shape of a horn are 1 The horn must be tuned to the resonance frequency of 20 000 Hz 50 Hz at 20 C During operation a tolerance of 150 Hz 250 Hz is permitted 9 2 For the horn to vibrate correctly it must be designed as far as possible to move in an axial direction at its transmission surface The aim is to produce pulses on the horn face that act as far as possible in an axial direction and which can be transmitted to the welding object 3 The amplitude of the horn
55. hapter Operation Contains notes and warnings Explains the sequence and opera concerning the operation of the tion of a welding cycle welding system Chapter Elements Product information Describes the various exchangea Contains all the general informati ble elements on concerning function design and mode of Chapter Application examples operation Describes the different possibilities technical data of welding applications warranty Chapter Retooling Transportation Describes how to change a horn Contains necessary information on or booster the transportation and receipt of the press Chapter Cleaning and maintenance Contains instructions and notes Operating and display elements concerning the care and upkeep Describes the operating elements of the press Initial start up Chapter Error messages and corrective Provides important notes and action instructions concerning the instal Describes possible errors their lation connection and start up of likely sources and suggestions for the device corrective action Includes all the information and Other chapters Diagrams and drawings procedures necessary for the safe and efficient handling of the Multipress MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Important Important Please quote the exacttype designation and theunitserial numbers in all enquiries conce ring your Multipress and your Generator You will find this data on the rating plate
56. ing pressure too high generator output too low for intended application vibration system faulty TIME OVERFLOW 2 all of the energy has not yet flowed into the part after having reached the maximum welding time TIME UNDERFLOW 3 allofthe energy has flowed intothe partbefore the maximum welding time has been reached ENERGY TOO LOW 4 the minimum desired amount of energy has not been transferred to the part ENERGY TO HIGH the maximum allowable amount of energy has been exceeded VIBRATION SYSTEM faulty sonotrode or sonotrode incorrectly tuned faulty booster faulty converter faulty HF cable or HF cable not connected faulty generator frequency change due to coupling with the fixture NO RF SIGNAL generator module incorrectly plugged in faulty generator module ABORT start button released before safety switch was reached or before hold time has run out HARDWARE faulty valve in actuator faulty pressure monitoring switch in actuator faulty safety switch faulty home position switch home position switch not adjusted stroke smaller than 6 mm fault in generator fault in dual safety switch An error is acknowledged by pressing the CLR button By pressing the Check button you enter the current menu The HARDWARE error can only be canceled by switching the unit off 12 2 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Error messages and trouble shooting
57. ket wrench supplied 15 First tighten both sides slightly checking to see if the centering is still correct then tighten fully 16 Move press to upper neutral position using the dual safety switch MP202PCSV20 GB N 1831 18569 ULTRASONICS A CREST GROUP COMPANY Initial start up 20 P TIME MODE Weld Time 2 333s Hold Time 2 221s Trigger 2 0 Make changes CLR WU 17 18 19 20 21 Release knurled screw 6 1 and raise 18 depth control stop by the approximate weld depth S by turning to the left Lock the stop with knurled screw 6 1 When the press is lowered again the 19 centering of the is checked Attention the horn should not touch the fixture when the press is lowered if there is no workpiece in place You display the current welding mode 20 by pressing Check key The welding parameters can now be adju sted After having successfully determined the welding parameters you should lock the control panel again This is done by pressing the Service key followed by pressing the CLR key The welding paramters cannot be changed anymore after these keys have been pressed MP202PCSV20 GB N 1831 18569 6 7 A CREST GROUP COMPANY Initial start up 6 7 Aligning the clamping table Theclamping table 13 was aligned parallelto the hornface in the factory Should the clamping
58. l numerical data is entered as follows unless stated otherwise 1 Place the cursor on the desired parameter line using the T and J keys 2 Enter the value desired using the numerical keyboard 3 Finally press the Enter key MP202PCSV20 GB N 1831 18569 Controls and indicators ULTRASONICS A CREST GROUP COMPANY 45 The Service Key After pressing the Service key you are requested to enter a code Code 23 releases the machine so you can adjust the settings unlock The welding parameters can now be changed To activate the feed without ultrasonics the Service key must be pressed a second time The feed can then be dropped down by pressing the dual safety switch As soon as the activation mark is passed over the switch can be released Pressing the start key after that will return the feed back to its original position The setup operation is ended by pressing the CLR key lock 46 The US TEST Key The current sonotrode frequency and its power loss can be displayed using the US TEST key The key must be pressed until the value in the display does not change anymore The US Test is automatically stopped after 5 seconds The vibration system must be connected Do not touch the sonotrode 39 The Time Key The Time key activates the time mode The possible functions ofthe time mode are explained starting on page 7 6 40 The Energy Key The Energy key activates the energy mode The possible functions
59. lastification takes place at this point The resulting rivetheadis given enough time to harden underthe action offorce from the press Multiple tools are often used for riveting operations in orderto rivet parts at various points simultaneously MP202PCSV20 GB N 1831 18569 9 1 Application examples ULTRASONICS A CREST GROUP COMPANY 9 3 Spot welding Spotweldingis called for for example wherever large thermopla stic parts cannot be loaded under a welding press for practical reasons In these cases the welding head is taken to the object to be welded The weld is then performed with a welding gun either manually or by robot The advantage of ultrasonic spot welding is that the parts do not require any special preparations at their welding points an energy director is not essential Even deep drawn parts can thus be processed without difficulty The ultrasonic tool is designed to generate a relatively high amplitude The tip of the horn is specially formed so that the advancing tip penetrates the half to be welded and the displaced material is caught and positively shaped in an outer ring S m SESS 94 Embedding of metal parts Preformed openings to be firmly plugged by a threaded insert pin connector or the like The sontrode makes contact with the foreign and sets it vibrating the high intensity of its movement causing the plastic A GZ body to pla
60. le 27 1 PCS module handle with model designation 28 PCS module 31 LCD Display 32 Generator module 33 Generator module handle 33 1 Generator module handle with model designation 34 Keyboard 3 2 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Product information 3 2 Comparative example Electricity Fuel Generator Driver Converter Engine Booster Gearbox Sonotrode Trans mission Ready for welding Off you go 3 3 Use of ultrasonics in the plastics indu stry As you know thermoplastics are available today in a large number of types and forms can be found in the most diverse products The use of ultrasonic welding is therefore equally diversified It covers all ima ginable technical fields where pla stic materials are processed in one way or another or where they find application as components 3 4 Fundamentals and advantages of ultra sonic welding Ultrasonic welding is an assembly process for the mass production of quality articles Its greatadvantage is its economic efficiency MP202PCSV20 GB N 1831 18569 3 3 Produ ct information ULTRASONICS A CREST GROUP COMPANY Ultrasonics works without pollution and without foreign agents Ultrasonic welding can therefore be recommended for use in sterile rooms because there can be no pollution of surroundings by any additives A typical ultrasonics work cycle takes just a fraction of a second with the melte
61. le is adapted to the particular case of application i e there are several variations Machine set up parameters such as welding force and amplitude are calculated to enable the top half of the workpiece to move in phase with the horn The bottom halflies in the fixture andis passive This brings about a phase shift in the movement between the two halves of the workpiece resulting in friction at the point of contact This highly intensive ultrasonic oscillation causes the point of contact between the two halves of the workpiece to meltinstantly The simultaneous input of force from the press which lasts longer than the ultrasonic pulse holds the welding halves of the workpie ce until the molten plastic solidifies 9 2 Rivet joints Rivet joints are used among other things to join injection moulded plastic parts to parts made of a different material Moulded NS N spigots on the injection moulded part penetrate the foreign part that is to be riveted to it The section projecting above the foreign part is then deformed into a rivet head using a pre formed horn The cavity in the horn tip must be designed to take up the volume of the displaced material The amplitude of the horn must be set to result in complete decoupling between the workpiece and the horn surface This results in the generation of direct frictional heat at the point of contact between the plastic part and the metallic surface of the horn Instant p
62. meter must be initialized to ON The welding process is activated by the trigger and a signal on the input of the adapter box ends the welding process If no signal is sent the weld time parameter setting serves to control the weld time A time overflow error is output Using the ultrasonic us pulse you can weld after the weld time is up Change the setting by pressing the CLR key Standard Setting OFF Trigger The trigger only becomes active after the safety switch if set to The trigger is active during the entire stroke if set to BEFO RE This is necessary if the welding distance is larger than 6 mm Standard setting dete ga ete eti rege AFTER MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation Operational level TE Gg C Adjustment level CLR Check LANGUAGE Check m English cx m Cx Check c DATA BANK RS 232 0 l CLR CLR al DATA BANK Servii CLR Check RS 232 0n ervice MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY 7 8 4 F Code 4711 Parameter Display SYSTEM INIT Language Deutsch English Francais Italiano Espanol DATA BANK RS 232 on off HH MM 11 11 DATE DD MM YY 11 11 95 GENERATOR Power 2000W 7 8 5 Parameter Settings for Code 4711 Language The user can s
63. nal level APE o Service Adjustment level Check ci Check Dat Bank DATA BANK Save Datall Ea DATA BANK Load DATA BANK Delete Data DATA BANK Print Datall Service o E EE Service cx CR Service cxi CR Service Q Re Service CLR MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation Operational level B Gu C Adjustment level O Data CLR Bank DATA BANK Check Save Data ee Enter DATA BANK Check Number 21 Service Data saved i 7 7 2 Saving Data To save the data entered go into the adjustment level 1 Press the Service key 2 Enter the code 23 3 Confirm the entry by pressing the Enter key After you have changed to the adjustment level 4 press the Data Bank key The display shows the first da tabank function Save Data 5 Press the Enter key The number of the next location available for storing data now appears in the display You can select this number or enter a different number 6 Confirm the entry by pressing the Enter key Ifthe desired storage location is invalid or is already in use a message will appear in the dis play If data has been saved cor
64. number of require ments for example The user must be familiar with the contents of this Operating Manual The instructions and warnings contained in this Ope rating Manual must be observed Unauthorized conversions or modifications to parts of the press and generator are prohibited RINCO ULTRASONICS AG shall be glad to clarify any unlcear points on the phone or to provide instruction by capable specia lists MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Product information T9 MP202PCSV20 GB N 1831 18569 3 5 Product information ULTRASONICS A CREST GROUP COMPANY 3 7 Technical data of the Multipress E 1040 1320 Dimensions in mm Weight incl PCS Generator 103 kg 3 6 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Product information other ratios on request 3 7 4 Actuator Force at o ede eed ennt 3 000 N Travel measuring system optional Adjustable depth control stop with vernier Precision cross roller guide on the feed slide Depth stop with vernier and scale Double acting cylinder damping possible in every position Switch for cylinder home position Dynamic sensor to trigger ultrasonics adjustable according to force Piezoelectric converter Threaded coupling for horn M12 3 7 2 Booster Reducmg Color Booster Color Booster 1 0 5 blue Aluminium 1 1 green Aluminium 1 0 6 violet Aluminium 1
65. o high object to be welded is defective Time overflow fthe maximum time limit is excee ded then the error message Time overflow is displayed Possible causes are maximum welding time too short system pressure too low amplitude too low no object in the fixture object to be welded is defective MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY 7 4 2 Overview of the ENERGY Mode Functions i End each entry of new data by pressing the Enter key Operation level O Service 2 3 Enter Adjustment level Check cxi ENERGY MODE Energy 03500Ws Trigger 2 0 Hold Time 2 221s ENERGY MODE Energy 05000Ws Trigger 2 0 Hold Time 2 221s ENERGY MODE Energy 05000Ws Trigger 2 0 Hold Time 2 221s MP202PCSV20 GB N 1831 18569 RING A CREST GROUP COMPANY Operation 7 4 3 Parameters of the ENERGY Operating Mode Display Energy Energy 0 10 000 Ws Parameter Trigger Ultrasonic trigger 0 0 9 9 Parameter Hold Time Hold time 0 000 9 999 s Parameter Amplitude Amplitude 60 70 80 90 100 Parameter Time max Maximum weld time 0 000 9 999 s Limit Time min Minimum weld time 0 000 9 999 s Limit Energy Current energy value Measured value Time Current time Measured value Parts Part counter Measured value Required Required part count Limit Rejects Rejected part counter Me
66. oce aaa e Pei ale ea a eie nues ere aa a da a D 11 1 11 4 Lubrication System sssssrisriinriiriririnrerinicisinaniniinininnu id kuidai kaiii daianuiid dadanan aiaiai iiaii 11 1 11 5 Generator ea 11 1 116 Vibration System inec aie a aa ga a a tt n ii i i a aia Di 11 2 11 7 Threaded coupling ce retea aaa a aa ta ra a a i er au a i 11 2 12 Error messages and trouble 12 1 12 1 Error messages corrective action switching On pp 12 1 12 2 Error messages corrective action set up and welding 12 1 12 3 Generator error messages during operation ppp 12 2 13 Electrical Diagrams X 13 1 13 1 Electrical Diagrams for the PCS 13 1 13 1 1 Actuator STOT ie rii caiac eite aaa a niei ec nate ane il tle ee 13 1 19 12 RS 232 STOO tetro Fa a e i it deer an rc da e 13 2 13 1 3 Interface S TOQ9 d nit oa ni e ia a aa a dee Pea a a e dr de SR gud ee re RR 13 3 13 2 Generator rear panel 1000 1500W 13 4 13 3 Generator rear panel 2000 3000W ssssssssnssnssnsssesseesstettttnrrtnnrnnnnnnssnnsntttnttttnttnnn tennen nnna 13 4 13 4 Fuses Generator 1000W 1500W ssssssssssssrirssseserrrssstirrrsstttrtnsstttinnnssstttnunnanteennnnnstennnanneenn 13 5 13 5 Fuses Generator 2000 3000
67. on The speed of the return stroke is not adjustable 6 Vernier screw for the depth stop The distance between the horn face and the fixture can be continuously adjusted by means of the depth stop with scale 0 1mm increments 7 Converter housing The converter housing contains the vibration system with the electrical supply leads 9 Horn Neveraltertuned horns by machining This can cause subsequent damage to the vibration system and to the generator The horn is the actual welding tool it has been tuned to the resonance frequency by the manufacturer 13 Clamping table The integrated T slot enables rapid centering and fastening ofthe workpiece mount with the supplied clamps 14 Parallel adjusting nuts The parallel adjusting nuts allow an extremely exact alignment of the clamping table 13 and hence the alignment of the fixture in relation to the horn face MP202PCSV20 GB N 1831 18569 Controls and indicators ULTRASONICS A CREST GROUP COMPANY 15 Dual safety switch The welding cycle is triggered manually by pressing the two buttons simultaneously The two buttons must be actuated within 0 3 s of each other This ensures that the operator is unable to reach into the area of the tool during the welding operation This precaution serves the interests of safe operation and may not be removed or modified in its construction Observe any statutory safety regulations in force in
68. ori ly Cycle After reaching the TRIGGER Sen Sor the welding process is activa ted After activation the objects are welded until the DEPTH S is rea ched The value of the DEPTH S is calculated starting from the up per home position The current travel value is measu red at the end of the holding time An energy range and a maximum weld time can be set as limits Depth 0 Home position t t i 1 1 L Depth US Stop Final position Trigger US Start 7 5 3 Absolute 2 TRAVEL 17 Withthis operating mode the same final size is to be achieved after each weld The final size of the welded part has the highest priori ly Depth 0 Home position Cycle After reaching the TRIGGER S1 Travel the welding process is ac tivated After activation the objects og are welded until the DEPTH S2 is Trigger US Start Depth US Stop reached The value of the DEPTH Final position S2 is calculated starting from the upper home position The current travel value is measu red at the end of the holding time An energy range and a maximum weld time can be set as limits MP202PCSV20 GB N 1831 18569 7 19 Operation RINCO A CREST GROUP COMPANY Correct welding The weld depth must be reached before the end of the maximum weld time and mustuse an amount ofenergy which is within the energy range otherwise an error message is
69. ositioning the plant cae tact i aa a ea arta i a td Aa 4 1 MP202PCSV20 GB N 1831 18569 IEEE List of contents ULTRASONICS A CREST GROUP COMPANY 5 Controls and indicators 5 1 5 1 cc 5 1 5 2 Ultrasonic Generator ende dee vtae vp vu 5 3 5 3 Elements of the Operator s Panel ee nmn nnne nennen nennen nnn 5 4 5 4 Description of the Display and Keyboard ssssesssssssrssssssrrrsstttrrrstttrrnsssttnrnssttttnnsssttnnnnnnrenn n 5 5 5 4 1 Important Information 4 anna nana aaa 5 9 5 4 2 Releasing the Keyboard 10 nenea eee nana nana nana aaa 5 9 5 4 3 Activating the Keyboard 5 9 6 Initial start up ee 6 1 6 1 Selecting a location uiii aa aaa cea reiecit teer reae a ee nbn ine vee e a 6 1 6 2 Space requirement pp 6 1 6 3 Workstation iti cace ocara aa a ce ta ea da a a E ada a 6 ci aaa ac i a da d 6 1 64 Assembling and connecting up the units seeseeeeeeeeeeeeeeeerrrssseetrrtsteterrusssttnnnnnntttnuntntennnnnseeen nn 6 2 6 5 Installing the vibration System nn 6 3 6 6 SEtUNg UP c 6 4 6 7 Aligning the clamping table iieri eniin ci aaa ca aa n aa ta 6 8 6 8 Determining the welding data eee eee nenea eee 6 8 0 9 Switehing Off aa ar a ca ea er a d aia a 6 8 SG ANN v
70. ount Limits Rejects Rejected part counter Measured value Delaytime Impulse delay time 0 000 1 999 s Parameter US Pulse Delayed impulse 0 000 1 999 s Parameter Power Peak Maximum power Measured value Power Loss Power loss Measured value Horn Horn number Info Fixture Fixture number Info Booster 1 Size of the booster Info Pressure System pressure Info Speed Flow control valve Info performance 1 Parameter Directly influences the welding result The parameters can be changed Limits limit is exceeded an error message is output The values can be changed Measured Value Measured values The values can be read but not changed Info These values are only for information The values can be changed The amplitude cannot be adjusted for the PCS I The ampli tude is always at 100 MP202PCSV20 GB N 1831 18569 7 9 A CREST GROUP COMPANY Operation Weld Time This parameter sets the welding time Trigger This parameter adjusts the triggering of the ultrasonic generator The higher the value the higher the pressure on the object to be welded Hold Time After the welding time has run out the holding time starts The object welded can harden under pressure during the hold time Amplitude The output amplitude can be set to one of five levels from 10096 down to 6090 The values are changed using the CLR button The amplitude cannot be changed for the PCS The ampli
71. ount of energy output is smaller than the specified value the error message Energy too low is displayed Energy Effective measured energy Travel Effective measured depth Time Effective measured time Part Counter Counts the number of fault free welded parts The Part Counter can be reset using the CLR key Required Part Count After reaching the specified part count the message Part count reached is displayed Is only active if F 4729 has been initialized to ON Reject Counter Counts the number of incorrectly welded parts The Reject Counter can be reset using the CLR key The Reject Counter is automatically reset when the Part Counter is reset MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation Delay Time The impulse delay time starts after the hold time has run out US Pulse After the impulse delay time has run out the ultrasonic pulse is activated Using the us pulse an object sticking to the sonotrode can be shaken off Power Peak The setting for the maximum power is displayed Power Loss The power loss of the vibration system is displayed Horn Number The part number of the sonotrode can be noted for informati on purposes Fixture Number The part number of the fixture can be noted for information purposes Booster 1 The size of the booster can be noted for information purpo ses Pressure The pressure of the press system can b
72. perience obtai ned while welding in this operating mode can be applied and expanded to the other opera ting modes The Applications Technology Laboratory of the RINCO company is available for any questions you may have MP202PCSV20 GB N 1831 18569 7 5 A CREST GROUP COMPANY Operation 73 The TIME Operating Mode The time operating mode is the traditional operating mode for ultra sonic welding equipment The welding time is held constant in this operating mode A minimum and a maximum ener limit can be set Theamountofenergy made availa ble for welding can vary within the limits ofa certain range The rangeis affected by the tolerances of the parts to be welded It may happen that small variations can be found on the welded parts 7 3 1 The Energy Range in the TIME Mode 6 Correct welding The welding energy must remain within the set limits If these limits Travel are exceeded an error message is A displayed Time Energy minimum maximum energy energy 7 6 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation Travel Time Energy minimum maximum energy energy Travel Time Energy minimum maximum energy energy Energy is too low Ifthe minimum amount of energy is not reached then the error messa ge Energy too low is displayed Possible causes are welding time is too short system pressure is too low amplitude too low objec
73. r regular cleaning of actuator clamping table 13 fixture 11 horn 9 booster 25 converter 24 converter housing 7 is essential for a long and trouble free operation of the press system 11 2 Clamping table Clean clamping table 13 daily 11 3 Pneumatic unit When work is completed move compressed air valve to the vertical position In this way no maintenance will be required 11 4 Lubrication system Maintenance free 11 5 Generator Maintenance free MP202PCSV20 GB N 1831 18569 Cleaning and maintenance ULTRASONICS A CREST GROUP COMPANY Avoid contact with RF socket 23 of the converter 11 6 Vibration system Work may only be carried out on thevibration system and converter housing when the mains voltage is switched off High voltage Never connect any measuring in struments to the RF socket of the converter The converter is electrically char ged even after switching off the generator 11 7 Threaded coupling The converter 24 booster 25 and horn 9 are joined together by threading couplings i Tightening torque 30 40 Nm 24 Black marks on the surface of the booster 25 or horn 9 are easy to remove 1 Lay out a polishing cloth on a level 25 surface 2 Draw the blackened area over the polishing cloth MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Cleaning and maintenance T9 MP202PC
74. sing both hands Bypassing this button by means ofathird party or any other conceivable practice shall exempt the manufac turer from all liability for injury to persons or damage to materials Correct operation and careful handling of the units and their associated tools during operation will keep the system ready for service prolong its useful life and reduce stoppage times to a minimum MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Safety information 2 6 1 Noise emissions Limit values according to current information ultra sonics are harmless provided maximum level is below 140 dB and the mean level on an 8h day basis is below linear 110 dB Attention mustbe paidtothe subharmonic i e audible vibrations which fluctuate widely according to the application and can have a very harmful and damaging effect The limiting range is the energy equivalent continuous sound level Leg in relation to a representative working period min 8 h day max 2000 h year of 85 87 dB A From this limit value upwards staff the work station must be issued with ear protection or a machine specific sound proofing device is necessa ry Data according to SUVA Information No 86048 d 4 94 2 7 EMERGENCY STOP button If there is an imminent risk of injury to the user or damage to the press Push the EMERGENCY STOP button 16 The press stops instantly and is disconnected from the mains
75. sticize at the point of contact The penetrating movement executed simultaneously by the wel ding press displaces the now ductile material into the specially provided backtapers and cavities in the inserted part When the displaced material solidifies the embedded partremains firmly trapped It is thus invested with high tensile and torsional strength 1 2 Advantage The assembly operation can take place subsequently at a less costly workstation It is possible therefore possible for the injection moulding operation to take place fully automatically whereas with the traditional insert moulding process it is always interrupted Expensive plants can thus be put to optimum use 9 2 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Application examples 9 5 Designing of joint zones The precise and expert design of joint zones ensures a correct layout of the parts and hence perfect and flawless welded products Design guidelines covering the entire spectrum of ultrasonic welding have been compiled and drawn up by RINCO Ultrasonics AG Please ask for relevant data sheets To ensure the correct layout of your parts the RINCO team of specialists will be glad to assist by providing technical advice on the design of joint zones 9 6 Approximate amplitude values for near field ultrasonic welding Approximate amplitude values for near field ultrasonic welding
76. t to be welded is not in the fixture object to be welded is defective Energy too high If the amount of energy exceeds the maximum energy limit then the error message Energy too high is displayed Possible causes are welding time too long system pressure too high amplitude too high object to be welded is defective MP202PCSV20 GB N 1831 18569 7 7 Operation A CREST GROUP COMPANY 7 3 2 Overview of the TIME Mode Functions End each entry of new data by pressing the Enter key Operation level O Service 2 3 Enter em Adjustment level Check cxi TIME MODE Weld Time 2 333s Trigger 2 0 Hold Time 2 221s TIME MODE Weld Time 0 500s Trigger 2 0 Hold Time 2 221s TIME MODE Weld Time 0 500s Trigger 2 0 Hold Time 2 221s Service CLR MP202PCSV20 GB N 1831 18569 RING A CREST GROUP COMPANY Operation 7 3 3 Parameters of the TIME Operating Mode Display Weld Time Welding time 0 010 9 999 s Parameter Trigger Ultrasonic trigger 0 0 9 9 Parameter Hold Time Hold time 0 000 9 999 s Parameter Amplitude Amplitude 60 70 80 90 100 Parameter En max Maximum energy 0 10 000 Ws Limit En min Minimum energy 0 10 000 Ws Limit Energy Current energy value Measured value Time Current time Measured value Parts Part counter Measured value Required Required part c
77. table need readjusting however it can be aligned using the four parallel adjusting nuts 14 Parallel adjustment 1 Release setscrews 22 using socket wrench A 2 Set parallel adjusting nuts 14 according to requirements as shown in the illustration 3 When the adjustments are completed re tighten the setscrews 22 6 8 Determining the welding data Ultrasonic welding requires a knowledge ofthe interrelationships between the individual functions Since the functions of the various elements interact it is important for them to be exactly coordinated Objects which require welding vary so muchin their properties in the geometry of their parts in their materials and in their surface conditions that it would be quite inadequate to determine the welding parameters once only These need to be determined anew for each object to be welded The mostimportant variable settings ofthe ultrasonic welding unit are Amplitude Contact force Welding time Triggering Lowering speed It is quite possible to achieve identical welding results with different settings e g high contact pressure and short welding time or long welding time and low contact pressure Recommendation To be able to achieve successful results repeatedly note the established setting parameters in a set up log Do not change several settings simultaneously because they will influence each other This makes it more difficult to
78. time have run out the actuator moves back to the home position Options US STOP AFTER PULSE MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation 7 1 3 Optimization To optimize the welding operation only ever change one setting at a time assess the welding results after each changed setting Never change several settings simultaneously When several settings are changed simultaneously it is very difficult to establish which changes have actually affected the welding results MP202PCSV20 GB N 1831 18569 Operation A CREST GROUP COMPANY T9 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation 7 2 Operating the PCS Controller 7 2 1 The Operating Modes A PCS controlled ultrasonic welding machi ne offers a high degree of flexibility with respect to its use for welding plastic parts There are basically three different operating modes for the PCS controller which can be selected by pressing a button constant time b constantenergy C constant travel Ci The press must be equipped witha travel measuring system The choice of the operating mode is highly dependent on the welding application For a new user to become more familiar with the various operating modes it is easiest to start with the time operating mode It is also advantageous to test the welding procedure on new parts while operating in this operating mode The ex
79. tude can be set to one of five levels from 100 down to 60 The values are changed using the CLR button The amplitude cannot be changed for the PCS The ampli tude is always at 100 Maximum Energy If the amount of energy output is higher than the specified value the error message Energy too high is displayed Minimum Energy If the amount of energy output is smaller than the specified value the error message Energy too low is displayed Maximum time Error message Time exceeded will be issued if the maxi mum time limit is exceeded Energy Effective measured energy Travel Effective measured depth Time Effective measured time Part Counter Counts the number of fault free welded parts The Part Counter can be reset using the CLR key MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Operation Required Part Count After reaching the specified part count the message Part count reached is displayed Is only active if F 4729 has been initialized to ON Reject Counter Counts the number of incorrectly welded parts The Reject Counter can be reset using the CLR key The Reject Counter is automatically reset when the Part Counter is reset Delay Time The impulse delay time starts after the hold time has run out US Pulse After the impulse delay time has run out the ultrasonic pulse is activated Using the us pulse an object sticking to the sonotrode c
80. voltage MP202PCSV20 GB N 1831 18569 2 3 Safety information ULTRASONICS A CREST GROUP COMPANY T9 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Product information LOC OC DOO DOO OO COOC ES O COCC 17 18 18 1 19 20 19 21 3 1 3 1 1 WK N 10 11 12 13 14 15 16 17 18 18 1 19 20 21 22 o Product information Product overview Multipress Metal panelling Front panel Pressure gauge System pressure control ler Speed throttle Vernier for depth stop Clamping screw Converter housing Fastening screw for converter housing Horn Rectangular column Fixture Clamps Clamping table Adjusting nuts for parallel alignment Dual safety switch EMERGENCY STOP button Name plate Scale for feed Trigger marking Clamping levers for fixing the press head Handwheel for rough fixing of the press head Compressed air hose tap and air hose with connec ting branch Clamping screws for clamping plate Generator Base Brief operating instructions MP202PCSV20 GB N 1831 18569 Product information ULTRASONICS A CREST GROUP COMPANY 3 1 2 Vibration system 9 Horn E 23 23 gt socket 24 Converter 25 Booster 25 1 Type designation 25 2 Booster designation 24 25 25 1 25 2 3 1 3 Ultrasonic generator 26 Fastening screws 27 PCS module hand
81. your country Failure to observe these regulations will exempt the manufacturer from all liability for injury to persons or damage to materials 16 EMERGENCY STOP button Pressing the EMERGENCY STOP button stops the press imme diately The complete power supply is interrupted After pressing the EMERGENCY STOP button it remains lok ked To unlock the EMERGENCY STOP button Pull the head of the button upwards into its initial positi on 18 Scale for feed Scale for reading and setting the actuator 18 1 Trigger marking Ifthe trigger marking is passed the safety switch is activated The cycle now continues automatically without the dual safety switch being held in 19 Clamping levers for fixing the press head Clamping device for fixing the press head after rough adjustment 20 Handwheel for height adjustment The handwheelis used to adjust the height of the press head The handle of the handwheel can be swung in 21 Compressed air connection valve Connection valve for joining up the unit s compressed air system to the local compressed air network The valve serves to separate the energy between the local compressed air network and the unit s compressed air system 22 Clamping screws for clamping plate Socket setscrews for releasing and fastening the clamping table for parallel alignment 5 2 MP202PCSV20 GB N 1831 18569 A CREST GROUP COMPANY Controls and indicators

Multipress MP202 Generator PCS

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