Sonics & Materials, Inc.
Contents
1. 19 Front Panel Controls and Indicators 19 Keying in Parameters 20 Operational Features 21 Starting up the Welder 21 Test Sad uen 21 Ready Screens siririn oa 945525 vies 22 8 siu Eg dem ER s DER S 23 Armplitude ee eel eer 23 Frequency Display 23 Overload Protection 24 Keypad Security 24 APPLICATIONS STAKING 25 Standard Flared Stake 25 Spherical Stake 26 Hollow Stake Nm eee 26 Knurled Stake 26 Fl sh Stake ce eee ee E 27 APPLICATIONS SPOT WELDING 28 OrderingdlInformation 28 APPLICATIONS ULTRASONIC 29 MAINTENANCE 31 Cleaning Instructions 31 Repairs 31 32 Limit2. 10 INSTALLATION AND 11 Electrical Power Requirements 11 sl ME PL ERES 11 Electrical Connections 11 Cable Connections 12 Rey Components uis ER RR 13 Tip Assembly CV55 14 Tip Replacement 55 14 Horn Assembly CVG54 14 Tip Replacement 54 15 Tip Specifications 16 ODUGNS CUT 17 4 SONICS world wide leader in ultrasonic technology HUM ARAN Qoovia Corporation Hong Kong Limited Hong Kong Office 15B Granville House 41C Granville Road T S T Kowloon Hong Kong Tel 86 00852 61717217 amp 81463719 Fax 86 00852 81479859 Dongguan Office 6 Hang No 17 Heng Xin Road Heng Gang Tou Xin An Qu Chang An Dongguan Guangdong China 523882 Tel 86 0769 8532 0321 Fex 86 0769 8532 0145 Information contained in this manual is subject to change without notice Sonics amp Materials Inc is not responsible for any typographic errors Sonics amp Materials Inc 2009 Printed in U S A Part No 381 0035T Rev 00 11 09 F1 SONIC E INSTRUCTION MANUAL 3 MODEL H520T H540T 1 info qoovia hk com www qoovia hk com TRBLE CONTENTS OPERATING PROCEDURES
3. 20 100 remains in latched state even if power is interrupted or disconnected or example if the unit is switched on and is then disconnected from the power source once it is reconnected to power the unit will be on Likewise if the unit is off and then disconnected it will remain off when NN reconnected to power until the ON switch is pressed 2 LCD SCREEN which displays various settings parameters and prompts as detailed the following pages In addition during the weld process it displays a load meter indicator showing the power level of ultrasonics that is being delivered to the welder see 3 below 3 LOAD METER SCALE from 0 to 100 which in conjunction with vertical line indicators on LCD display shows the running power bar graph at bottom of display and peak power single vertical line at top of display during the weld Peak power is reported as after the cycle see page 21 If ultrasonics are run continuously time 4 TIME key which allows selection and display of time settings and permits setting 0 be sure to adjustment of time duration in 01 second increments from 00 00 to 99 99 air cool the converter seconds for three time parameters as follows a Weld time b Time Limit Low time Limit High F1 EORI E INSTRUCTION MANUAL e MODEL H520T H540T 19 info qoovia hk com www qoovia hk com For a complete explanation of these parameters refer to page 22 5 E
4. fastened together With staking tight assemblies are possible because mating parts are clamped under pressure of the horn until the rivet head solidifies There is no elastic recovery as is the case with heat staking or cold forming A major advantage of ultrasonic staking over heat staking is that the ultrasonic staking tip remains relatively cool during the process forming a clean head with no sticking or stringing during assembly STANDARD FLARED STAKE The standard flared stake satisfies the requirements of most applications This stake is recommended for bosses with an O D of 1 16 inch 1 6 mm or larger and is ideally suited for low density nonabrasive amorphous plastics BEFORE HIGH PROFILE 48 HORN BEFORE LOW PROFILE HORN METAL PLASTIC ASTIC INSTRUCTION MANUAL MODEL H520T H540T eb info qoovia hk com www qoovia hk com SPHERICAL STAKE The spherical stake is preferred for bosses with an O D less than 1 16 inch 1 6 mm It is also recommended for rigid crystalline plastics with sharp highly defined melting temperatures for plastics with abrasive fillers and for materials that degrade easily BEFORE HIGH PROFILE HOLLOW STAKE Bosses with an O D in excess of 5 32 inch 4 mm should be made hollow Staking a hollow boss produces a large strong head without having to melt a large amount of material Also the hollow stake avoids sink marks on the opposite side of the co
5. so that no new parameters or commands be entered via the keyboard thereby preventing unauthorized cancellation or adjustment To activate the security feature press and hold the numeral 7 key on power up When the keypad is secured in this manner any attempt to change or enter parameters will result in the following message being displayed on the LCD screen KEYBOARD LOCKED 0 10 20 30 40 50 60 70 80 90 100 SONICS INSTRUCTION MANUAL MODEL H520T H540T info qoovia hk com www qoovia hk com APPLICATIONS STAKING Ultrasonic staking also referred to as ultrasonic heading or riveting controls the flow of the molten plastic used to capture or retain another component in place Ultrasonic staking provides an alternative to welding when the two parts consist of dissimilar materials that cannot be welded or when simple mechanical retention of one part relative to another is inadequate i e as distinct from molecular bonding A common application is the attachment of plastic to metal Typically a metal part with location holes is placed over a plastic part with molded bosses The horn tip is then pressed against the plastic boss and the vibratory motion creates friction and localized heating As the boss melts the light pressure from the horn forms a head to a shape determined by the horn tip configuration When the vibrations stop the plastic material solidifies and the dissimilar materials are
6. time alarm will be triggered if the actual weld time is less than this value The time low alarm will show on the Alarm Screen display and will be indicated by a flashing LED on the Time key By specifying values for this limit and the Time Limit High aweld time window is created that defines a good weld If no alarms are triggered the weld cycle occurred within the designated time limits Time Limit High sets the high time alarm examination point A time alarm will be triggered if the actual weld time is greater than this value The time high alarm will show on the Alarm Screen display and will be indicated by a flashing EED on the Time key AMPLITUDE The Amplitude Setting is used to make fine adjustments to vibrational amplitude from 2096 minimum to 10096 maximum FREQUENCY DISPLAY The TEST key can also be used to display the running frequency Press and hold the TEST key for 3 seconds The information on the display will change to include a frequency counter display Hz After this switch the power is captured no longer updated and the frequency display will update every second This information can help diagnose problems with the hand gun F1 docu INSTRUCTION MANUAL MODEL H520T H540T e3 info qoovia hk com www qoovia hk com When the hand gun is on be sure to isolate it from any grounded surface to avoid triggering an overload condition as the system detects an alternate gr
7. 2 INSTRUCTION MANUAL 3 MODEL H520T H540T info qoovia hk com www qoovia hk com 5 Pictured below is the power supply with 2 hand gun options 20 kHz CV55 and 40 kHz CVG54 POWER SUPPLY NN HAND GUN A TRIGGER SWITCH CVG54 lnc HORN INSTRUCTION MANUAL MODEL H520T H540T 13 info qoovia hk com www qoovia hk com ASSEMBLY CV55 hy If the tip is not already assembled follow the instructions below as LE applicable TIP REPLACEMENT CV55 NOTE Never remove or install a tip by holding the hand gun case or rotating the tip 2 Hand assemble the tip to the titanium driver using open ended wrenches 1 Clean the mating surfaces as well as the threaded stud and hole Check that the stud is tight see recommended torque requirements on page 13 with only one wrench as this may cause damage to the booster and or converter 2 55 as shown below Tighten securely Do not force or overtighten NOTE Before using HORN ASSEMBLY CVG54 ONLY as shown you should be able to seat the 1 Clean the mating surfaces of the converter and horn as well as the horn or tip without threaded stud and hole Check that the stud is tight see recommended encountering torque requirements on page 13 resistance in the 2 Hand assemble the converter and horn together using open ended mating threads wrenches as sho
8. N OFF switch is in the OFF position and the power supply line cord is not plugged in before making any cable connections Always turn off the power supply before installing or removing the foot switch cable Do not use a damaged or worn hand gun cable Never use the cable and hand gun as a rope it is not rated for pulling weight CABLE CONNECTIONS Located at the rear of the power supply are the cable connections as illustrated below The interconnecting cables will be supplied with your System 1 A round 4 pin cable with red locator dot that connects the hand gun to the power supply 2 standard DB9 I O connector that can interface with automated machines via a PLC See drawing in the Appendix at the back of this manual 3 3 prong inlet to connect the power supply with the appropriate electrical outlet Do not make this connection until the hand gun is connected to the power supply Once these connections have been made the power supply is ready for aa BURCH HALAS MENTOR Ct vo Port OUTPUT MODEL W 620 SERIAL NO 222228 POWER 500 WATTS 45 G8 FREQ 20 kHz VOLTS 120 VAC S0 S0Hz NOM C FUSE SIZE 16 AMPS SLO BLO operation Also located at the rear of the power supply are the following 4 Foot switch jack connects foot switch cable to enable remote actuation 5 Fuses 120V 15A slo blo 230V 8A slo blo SONICS 1
9. NERGY key Option not available on this model 6 AMPLITUDE key which controls adjustment of the amplitude setting relating to the system s high frequency vibrations over the full operating range Refer to page 23 for more information 7 FN KEY Option not available on this model 8 TEST key which can be used to test the actual power output watts When this key is pressed the ultrasonics are activated and will remain on cycle for 5 seconds The number of watts will be displayed on the LCD screen and a line will display along the bafgraph on the bottom of the LCD screen which will reflect the percentage of power output 9 O L RESET key which resets the power supply following an overload condition Red LED in upper left corner indicates an overload condition exists Refer to page 24 for complete information 10 0 9 NUMERIC KEYPAD which allows input of numeric data by pressing the keys 11 CLEAR key which clears the preceding entry when pressed 12 ENTER REVIEW key which serves to enter data into the system and or to display data or parameters on the LCD screen KEYING IN PARAMETERS To make numeric entries into a cursor location that is displayed a screen menu use the numeric keypad When the desired entry is displayed on the LCD screen use the ENTER key to register the new value Entries are made left to right The CLEAR key will clear an existing value to 0 displayed as a series of dashes and relocate the curs
10. Sonics amp Materials Inc 295254 Models 9999 nor Hs4T eee eS Hand Held Pe Weve Welders ay ABR ZS Qoovia Corporation Hong Kong Limited Hong Kong Office 158 Granville House 41C Granville Road T S T Kowloon Hong Kong Tel 86 00852 61717217 amp 81463719 Fax 86 00852 81479859 Dongguan Office 6 Hang No 17 Heng Xin Road Heng Gang Tou Xin An Qu Chang An Dongguan Guangdong China 523882 Tel 86 0769 8532 0321 Fex 86 0769 8532 0145 info qoovia hk com www qoovia hk com TRBLE CONTENTS IMPORTANT SERVICE INFORMATION 3 Important Safeguards 3 Watnlrigs ek rr Ro 3 SYMBOLS vex ee ub RSS Ru SERRE 4 SPECIFICATIONS 5 IMPORTANT SERVICE LITERATURE 6 Manual Change Information 6 UNPACKING AND INSPECTION 7 Visible Loss or Damage 7 Concealed Loss or Damage 7 INTRODUCTION 8 OVERVIEW OF ULTRASONIC PLASTICS ASSEMBLY 8 What is Ultrasonics 8 Principal of Ultrasonic Assembly 8 Ultrasonic Hand Held Welders 8 GLOSSARY OF ULTRASONIC TERMS
11. Vi1N3Q4NO2 5328v83 01 NDWININ NHO 8Nid 101N02 3anundwv 0 H313AOUN310d SNISN NO A SNId680 WHO LNId 680 TWNUGLN t Nid 12 CVNH31NI 30343334 AUS 6 9 Nid OL 333 x88 1 8 XVM OWL 2gA 324005 39vVL 0A 0309975 43401502 SLIVM X001 0 JOA 0967 28 2114110 SLIVM panos 8 3oNa v3dHI WHO 51791010 5 5 401221102 340 AWS SLIVM s ANNOYS 32405 WHO 4 AN3HBh2 9NDINIS XVN NOLINOIONI TO LOVINOO AVT3H XO HOLIMS 2 5 SOND ASL 13539 TO 12 1 02 YO HOLIMS a SNOILO3NNOO 0 1 1 5 4 Nid wwe L 5 SOND ASL 1891 SOINOS SNOLLONN4S 680 SNOLLOSNNOD M3NO15n2 SALONA SINN 031002 NONMOO 3Sn 3ON3M3J3H TW L S310N 9 2 0 INSTRUCTION MANUAL MODEL H520T H540T 34 info qoovia hk com www qoovia hk com
12. ation of Warranty 32 BPPENDIX cce eon d erm Rake cie Ra e Ex er pn s 34 INSTRUCTION MANUAL MODEL H520T H540T info qoovia hk com www qoovia hk com IMPORTANT SAFETY INFORMATION IMPORTANT SAFEGUARDS READ BEFORE INSTALLING OR USING THE EQUIPMENT Your Ultrasonic Equipment has been designed with safety in mind However no design can completely protect against improper usage which may result in bodily injury and or property damage For your protection and equipment safeguard observe the following warnings at all times read the operating instructions carefully before operating the equipment and retain this instruction manual for future reference If the Ultrasonic Equipment is used in a manner contrary to that specified in this instruction manual the protection features designed into the unit may be impaired WARNINGS Make sure the Ultrasonic Power Supply is properly grounded via a 3 prong outlet High voltage is present the power supply Do not remove the cover Refer all servicing to qualified service personnel Never operate the power supply unless it is connected to the hand gun Never secure anything to the front driver the tip or the horn Neverdouch a vibrating horn f air cooling the converter always use dry compressed air e Hearing protection is highly recommended It is recommended that a sound abating enclosure or ear protection be used when ope
13. com www qoovia hk com 5 The following options and accessories are available for the H520T H540T systems 1 FOOT SWITCH for remote activation When foot switch actuation is Always HT Om used the trigger handle is removed from the hand gun housing power supply before installing Or removing 2 MANUAL ARBOR PRESS available with foot switch or cam actuation the foot switch cable is designed for assembling parts where production volume does not justify automated equipment The press provides a more controlled motion of the welder than is possible by just holding the hand gun resulting in more consistent assemb N S MANUAL PRESS F1 OS sas INSTRUCTION MANUAL MODEL H520T H540T 17 info qoovia hk com www qoovia hk com 3 STAPLER with special pivoting mechanism ldeal for sealing low production rate clamshell packages 4 PISTOL GRIP for more ergonomic handling of the hand gun in specialized applications X PISTOL GRIP 18 INSTRUCTION MANUAL MODEL H520T H540T info qoovia hk com www qoovia hk com OPERATING PROCEDURES FRONT PANEL CONTROLS AND INDICATORS Located at the front of the power supply are the following controls Do not operate the power supply unless it is connected to the hand gun 2 000 NOTE The operating range of amplitude is 1 ON switch which turns the power supply on and off The switch
14. ctions b Position the power supply so that the front panel controls are visible and readily accessible c The power supply is air cooled allow sufficient space around the assembly to ensure adequate ventilation If the power supply must be housed confined space forced air cooling may be necessary to keep surrounding air within acceptable ambient temperature limits Periodically Check the ventilation grille and clean as necessary If power supply is to be run continuously air cooling of the converter and horn is required l di EA ELECTRICAL CONNECTIONS compressed air filtered down to 5 microns When making the initial electrical connections make sure the power is disconnected and follow these precautions 1 Do not strain or kink the cables When going around corners allow as wide a bend as possible Do not run the cables parallel to any power line within a distance of less than 1 foot 305mm 2 To prevent the possibility of an electrical shock ensure that the power supply line cord is properly grounded Also make sure that the voltage Do not plug the power rating of the electrical power source matches the power supply supply into an requirement electrical outlet until all other connections have been made 3 Check with your electrician if you have any wiring questions F1 US INSTRUCTION MANUAL MODEL H520T H540T 11 info qoovia hk com www qoovia hk com sure the O
15. e to rough handling even though the container may not show external damage When the damage is discovered upon unpacking make a written request for inspection by the carrier s agent within 48 hours of the delivery date Then file a claim with the carrier since such damage is the carrier s responsibility The form required to file such a claim will be supplied by the carrier Do not destroy packing materials or move material from one location to another before the carrier makes their inspection If the system or any unit is damaged notify Sonics Sonics will arrange for repair or replacement of damaged equipment without waiting for the claim against the carrier to be settled provided a new purchase order is issued to cover the repair or replacement costs Should any damage shortage or discrepancy exist please notify us immediately F1 EUNDI IG ED INSTRUCTION MANUAL MODEL H520T H540T 7 info qoovia hk com www qoovia hk com INTRODUCTION The models H520T and H540T are portable 500 watt hand held ultrasonic welders used for plastics assembly Both models consist of an ultrasonic power supply and a hand gun These units are designed specifically for welding staking inserting and spot welding applications refer to the Applications section of this manual beginning on page 26 for more information on these operations The model H520T is a 20 kHz power supply that comes with the CV55 hand gun The CV55 hand gun i
16. f operating instructions or which has had the serial number altered or removed will be ineligible for service under this warranty No liability is assumed for expenses or damages resulting from interruptions in operation of the product or damages to material in process Sonics equipment is designed for maximum operator safety and incorporates built in safety devices Any modifications to these safety features will void the warranty Sonics assumes no responsibilities for consequential damages incurred due to modifications to the said equipment SONICS INSTRUCTION MANUAL 3 MODEL H520T H540T info qoovia hk com www qoovia hk com Sonics reserves the right not to warrant horns of unusual or experimental design which in our judgment are more likely to fail in use This warranty does not cover equipment used for applications requiring metal to metal contact with weld time in excess of 1 second Data supplied in the instruction manual has been verified and validated and is believed adequate for the intended use of the equipment If the equipment or procedures are used for purposes other than those specified herein confirmation of their validity and suitability should be obtained in writing from Sonics INSTRUCTION MANUAL MODEL H520T H540T 33 info qoovia hk com www qoovia hk com RPPENDIX DB9 I O CONNECTIONS DIAGRAM WdaLanens S Qr FINI ONY NOLLVASOANI 2
17. he following major elements a power supply hand gun converter and horn H540T only as detailed in the diagram on the next page A review of this diagram will help you understand the basic elements involved in the assembly process and their relation to each other SONICS 8 INSTRUCTION MANUAL e MODEL H520T H540T info qoovia hk com www qoovia hk com SONICS ULTRASONIC ASSEMBLY SYSTEMS 50 60 Hz Electrical power Power Supply Generator Generates ultrasonic electrical energy 20 40 kHz Ultrasonic electrical energy ai Transforms ultrasonic electrical energy to ultrasonic mechanical vibrations Horn Replaceable Contacts and transfers vibrational energy to plastic part Ultrasonic Vibrations Ultrasonic Vibrations F1 SONICS M INSTRUCTION MANUAL MODEL H520T H540T 9 info qoovia hk com www qoovia hk com GLOSSARY OF ULTRASONIC TERMS POWER SUPPLY GENERATOR The solid state power supply converts standard 50 60 Hz electrical power to 20 000 Hz or 40 000 Hz 20 40 kHz electrical energy CONVERTER The converter changes the high frequency electrical energy supplied by the power supply to high frequency mechanical vibrations TIP HORN The tip horn is a tuned component of the system which comes in contact with the pa
18. hould O 10 20 30 40 50 60 70 80 90 10096 always be done for all cold start ups and for any start up after the system has been idle for 20 minutes or more A bar graph indicator reading of above 2096 signals that there may be a problem with the hand gun If this occurs check your assembly and re test During the testing process keep in mind that the ultrasonics are only activated as long as the TEST button is depressed once you release the TEST button ultrasonics is terminated F1 INSTRUCTION MANUAL MODEL H520T H540T 21 info qoovia hk com www qoovia hk com Frequency Display The TEST key can also be used to display the running ultrasonic frequency Refer to page 23 for more information READY SCREENS In addition to the start up ready screen shown on page 20 there are 2 other ready screens The power supply must be displaying one of the 3 ready Screens in order for welding to commence Welding cannot be initiated from any other display All 3 ready screens can be accessed by pressing the ENTER REVIEW key The other 2 ready screens are as follows 0 10 20 30740 50 60 70 80 90 100 Alarm Screen The Alarm screen displays information about the alarm s that have been triggered by the system encountering parameters outside of the specified tolerance limits The screen will indicate an alarm that occurs in Time If there alarms dashes will display If there are alarms a
19. ion around the weld Simultaneously the molten plastic displaced from the second sheet flows into the preheated area and forms a permanent molecular bond Large thermoplastic parts and applications with hard to reach joining surfaces can easily be welded together using an ultrasonic spot welder and standard replaceable tips BEFORE STANDARD THREADED TIPS FOR SPOT WELDING SPOT WELDING Material Thickness inches ORDERING INFORMATION Specify tip required using code letter Example Spot weld tip SA indicates a tip used for spot welding 1 32 thick material SONICS 28 INSTRUCTION MANUAL 3 MODEL H520T H540T info qoovia hk com www qoovia hk com APPLICATIONS ULTRASONIC INSERTION Ultrasonic insertion involves a metal insert to be placed in a cored or drilled hole that is slightly smaller than the insert This hole provides a certain degree of interference and also serves to guide the insert into place The vibrating ultrasonic horn contacts the insert and the ultrasonic vibrations travel through the insert to the interface of the metal and plastic Heat generated by the insert vibrating against the plastic causes the plastic to melt and as the horn advances the insert is embedded into the component The molten plastic flows into the serrations flutes or undercuts of the inserts and when the vibrations terminate the plastic resolidifies and the insert is securely encapsulated in
20. mponent and enables the parts to be reassembled with self taping Screws should repair and disassembly be necessary BEFORE KNURLED STAKE The knurled stake is used in applications where appearance and strength are not critical Since alignment is not an important consideration the knurled stake is ideally suited for high volume production and is often recommended for use with a hand held ultrasonic spot welder Knurled tips are available in a variety of fine medium and course configurations BEFORE 2B INSTRUCTION MANUAL MODEL H520T H540T info qoovia hk com www qoovia hk com FLUSH STAKE The flush stake is used for applications requiring a flush surface The flush stake requires that the retained piece has sufficient thickness for a chamfer or counterbore STANDARD THREADED TIPS FOR STAKING STAKING TIP CODE LETTER Plastic Boss Solid Boss Conical Boss Diameter Flare Head Spherical Head High Profile Low Profile High Low Tip Size Stud Height Tip Size StudHeight Profile Profile inches INSTRUCTION MANUAL 3 MODEL H520T H540T 7 info qoovia hk com www qoovia hk com RPPLICRTIONS SPOT WELDING During spot welding the horn tip penetrates through the top sheet and enters the bottom sheet to a depth of one half the top sheet thickness The displaced molten plastic is shaped by a cavity in the tip to create an annular format
21. n L for Low limit indicating that the low limit was violated and or an H for High limit indicating that the high limit was violated will display Once another new cycle is begun the system will automatically clear the current alarm Counter Screen Cycles 00 004 678 CRC 000 062 0 000 EN NE 0 10 20 30 40 50 60 70 80 90 100 The Counter screen displays information about the job number the number of cycles run to date the customer resettable counter CRC and the resettable alarm counter RAC The 2 resettable counters can be reset whenever desired by pressing the Clear key when the counter screen is displayed the keypad must be unlocked see page 25 SONICS INSTRUCTION MANUAL MODEL H520T H540T info qoovia hk com www qoovia hk com TIME SETTINGS There are 3 time parameters or timers that can be set They are accessed by pressing the Time key which allows specification of the following time parameters The first menu display will show the following Weld Time sets the duration of time for which ultrasonic vibrations are applied to the parts If the time value is cleared zero or dashes displayed on screen then ultrasonics will be activated when the hand gun trigger switch is depressed Press the Time key again and successively after each menu display to advance to these next screen displays Time Limit Low sets the low time alarm examination point as a tolerance limit A
22. n this manual will provide you with many years of safe and dependable service MANUAL CHANGE INFORMATION We continually strive to be at the forefront of the latest electronic developments by adding circuit and component improvements to our equipment as soon as they are developed and tested Sometimes due to printing and shipping requirements we cannot incorporate these changes immediately into printed manuals Hence your manual may contain new change information Change information if any is located in the Appendix We reserve the right to make any changes in the design or construction of our equipment at any time without incurring any obligation to make any change whatsoever in units previously delivered The technical data schematics in the manual are for informational purposes only and may not reflect the current configuration being shipped from our factory Upon formal request complete and up to date information can be provided from the factory free of charge SONICS INSTRUCTION MANUAL MODEL H520T H540T info qoovia hk com www qoovia hk com UNPACKING AND INSPECTION Before unpacking the equipment check the shipping carton for any visible damage If you see be sure to follow the procedures described below 2 under Visible Loss or Damage Otherwise proceed to remove the equipment from the carton Before disposing of any packing material check it carefully for small parts Then perf
23. or to the extreme left hand entry position ready to accept entries again As soon as a desired value is keyed in and displayed pressing the ENTER key makes the system accept that entry If a number value is not Entered then it will not be accepted by the system and the parameter value will return to its former setting before any numerical values were changed SONICS INSTRUCTION MANUAL 3 MODEL H520T H540T info qoovia hk com www qoovia hk com OPERATIONAL FEATURES Adjustable tolerance limits in time sec with visual alarms Information displays including number of assemblies number of rejects and number of cycles Fault displays Keypad security STARTING UP THE WELDER Press the ON OFF button to turn the welder on The LCD screen will display the model number wattage and frequency information Then the LCD screen will show the following ready display 00 00 sec 00 10 420 30 40 50 60 70 80 90 100 This display shows the last weld information weld time and power After power down and subsequent power up values are cleared to zero TEST FEATURE After the power supply is turned on press and hold the TEST button While depressing the TEST button check the display Make sure the bar graph indicator on the display a series of vertical lines that register to the O to 10096 load meter scale see example below does not exceed 20 The TEST and Load Meter check s
24. orm a visual inspection of the equipment NOTE We to detect any evidence of damage which might have occurred during recommend keeping shipment Check the following all carton s ang 1 all components against the enclosed packing list packing material in case it might be 2 all module plug in units necessary to move the 3 all wire plug in connections equipment or to ship it for repair The equipment was carefully packed thoroughly inspected before leaving our factory All units are tested and checked for problems prior to shipping It is asked that when a problem does occur that all parts and components be inspected for damage especially when the unit is not in working order when received Responsibility for safe delivery was assumed by the carrier upon acceptance of the shipment Claims for loss of damage sustained in transit must therefore be made upon the carrier as follows VISIBLE LOSS OR DAMAGE Any external evidence of loss or damage must be noted on the freight bill or express receipt and signed by the carriers agent Failure to adequately describe such external evidence of loss or damage may result in the carrier s refusal to honor a damage claim The form required to file such a claim will be supplied by the carrier CONCEALED LOSS OR DAMAGE Concealed loss or damage means loss or damage which does not become apparent until the merchandise has been unpacked The contents might have been damaged in transit du
25. ound path OVERLOAD PROTECTION There are two overload protection circuits one for the power supply and one for the hand gun which will terminate the welding cycle when the System is operated under adverse conditions such as excessive wattage voltage or current or a loose or failed horn tip The welding cycle will also be automatically terminated if the hand gun contacts a grounded surface while the power is on the power supply will overload because it detects an alternate ground path The overload protection circuits will prevent damage to internal system components Depending upon the type of condition that caused the overload the situation is resolved by different methods If an ultrasonic overload condition exists simply press the O L Reset key to reset the system If a shock protection condition caused the overload the system cannot be reset with the O L Reset key The system must be powered down using the ON OFF switch and the cable hand gun connection problem s fixed before turning the power supply back on There is a ground fault circuit for shock protection which monitors currents in the hand gun cable and the earth ground If a wire breaks or an alternate ground path is detected which changes the currents the unit will go into a latched Off state to protect the operator If an overload condition persists contact our Service Department at 1 800 745 1105 KEYPAD SECURITY The keypad can be locked
26. place Inserts can be ultrasonically installed in most thermoplastics Ultrasonic insertion provides the high performance strength values of a molded in insert while retaining all of the advantages of post molded installation Some of the advantages of ultrasonic insertion over other methods include rapid installation minimal residual stresses in the component following insertion elimination of potential mold damage reduced mold fabrication costs and increased productivity as a result of reduced mold cycle times INSTRUCTION MANUAL MODEL H520T H540T info qoovia hk com www qoovia hk com STANDARD THREADED TIPS FOR INSERTION INSERTING Insert Inside Diameter Pilot Diameter Size of Insert Of Tip SAE 4 40 6 32 8 32 10 24 10 32 1 4 20 1 4 28 5 16 18 METRIC 2 5 x 0 45 3 x 0 5 3 5 X 0 6 4 x 0 7 5x0 8 6x1 8 x 1 25 INSTRUCTION MANUAL MODEL H520T H540T rs info qoovia hk com www qoovia hk com 2 NOTE If packing unit for return shipment DO NOT use styrofoam peanuts F1 SONICS CLEANING INSTRUCTIONS The power supply and converter may be cleaned using a solvent free cleaning solution i e glass cleaner Horns and probes should be cleaned using isopropyl alcohol Titanium horns can be autoclaved REPAIRS SERVICE If problems are encountered contact our Service Department a
27. put Frequency 20 KHz nom or 40 KHz Converter CV 55 CV 54 Weight 1 5 Ibs 0 68 Kg 1 5 Ibs 0 68 Kg Dimensions 7 6 L x 1 9 Dia 6 3 L x 1 9 Dia 93 mm x 48 3 mm with standard tip 160 mm x 48 3 mm without horn Horn Materials Titanium Titanium or aluminum Tip CV 55 Dimensions Standard 1 2 diameter 12 7 mm Environmental Pollution Degree Operating Limits Temperature 41 104 F 5 40 C Relative Humidity 20 Hs Non odas Altitude 6 651 ft 2000 m Shipping Storage Temperature 35 120 F 2 49 C Relative Humidity 10 9596 Non Condensing Ambient Pressure Extremes 40 000 ft 12 192 m Restriction of Hazardous RoHS Compliant Substances ROHS Directive 2002 95 EC Relative humidity Maximum relative humidity 8096 for temperatures up to 31 C decreasing linearly to 5096 relative humidity to 40 Only use IEC approved Fast acting fuses Cooper Bussman series S500 F1 GCUNII E UAE INSTRUCTION MANUAL MODEL H520T H540T 5 info qoovia hk com www qoovia hk com IMPORTRNT SERVICE LITERRTURE Please read carefully before operating the equipment then forward to your service department The system supplied with this instruction manual is constructed of the finest material and the workmanship meets the highest manufacturing standards It has been thoroughly tested and inspected before leaving the factory and when used in accordance with the procedures outlined i
28. rating the Ultrasonic Processor Do not modify horn configurations Do not affix any device to any portion of the horn Certain plastic materials when ultrasonically welded may emit fumes and or gases hazardous to an operator s health Where such materials are processed proper ventilation of the work station should be provided If in doubt about the toxicity of your plastic material contact OSHA U S Department of Labor or material supplier Maintenance should be performed only by a qualified electronic technician Always turn off the power supply before installing or removing the optional foot switch cable When the hand gun is on be sure to isolate it from any grounded surface to avoid triggering an overload condition as the system detects an alternate ground path F1 E EMI MGE INSTRUCTION MANUAL MODEL H520T H540T 3 info qoovia hk com www qoovia hk com SYMBOLS Caution Risk of electric shock Hazardous voltage Caution Risk of danger Refer to User Manual A INSTRUCTION MANUAL 3 MODEL H520T H540T info qoovia hk com www qoovia hk com SPECIFICRTIONS Power Supply Operational Input Voltage 115 230 V 10 50 60 Hz Rated Voltage Current 115 230 5 A max Fuse Rating F6 3A 250V Weight 3 Ibs 5 9 Kg Dimensions 8 5 H x 13 5 W x 7 5 D 216 mm x 340 mm x 190 mm Output Voltage 1000 V rms max Out
29. rts to be assembled The tip horn 1 transfers the ultrasonic vibrations produced from the converter to the parts being welded and 2 applies necessary force to the assembly while the material resolidifies AMPLITUDE The peak to peak excursion horn at its output face SONICS 10 INSTRUCTION MANUAL MODEL H520T H540T info qoovia hk com www qoovia hk com INSTRLLRTION RND SET UP ELECTRICAL POWER REQUIREMENTS The power supply requires a fused single phase standard 3 terminal grounding type receptacle capable of supplying the requisite voltage and current Standard 120 volts or optional 220 volts 50 60 Hz regulated The line cord of the between 95 135 volts or 190 265 volts respectively controller power supply is equipped with a SETTING UP 3 prong grounding plug Do not under any circumstances remove the ground prong The plug must be plugged into a mating 3 prong grounding type outlet The power supply is a free standing assembly It should be installed in a clear uncluttered location that is free from excessive dirt dust corrosive fumes and temperature and humidity extremes The selected installation site should be near the electrical power away from equipment that generates abnormally high electrical transients Observe the following additional instructions when installing the equipment a Allow at least 6 inches 152 4mm at the rear of the power supply for cable conne
30. ructed of titanium or aluminum are guaranteed against defects for a period of one year from date of shipment Sonics will repair or replace a cracked or defective horn once without charge if failure occurs within the warranty period Ultrasonic welding horns constructed of steel are guaranteed against defects for a period of ninety days from date of shipment Sonics will repair or replace a cracked or defective steel horn once at a charge of 5096 of the original purchase price if failure occurs within the warranty period LIMITATION OF WARRANTY This warranty is in lieu of any other warranties either express implied or statutory Sonics neither assumes nor authorizes any person to assume for it any other obligation or liability in connection with the sale of its products Sonics hereby disclaims any warranty or merchantability or fitness for a particular purpose No person or company is authorized to change modify or amend the terms of this warranty in any manner or fashion whatsoever Under no circumstances shall Sonics be liable to the purchaser or to any other person for any incidental or consequential damages or loss of profit or product resulting from any malfunction or failure of this Sonics product This warranty does not apply to equipment which has been subject to unauthorized repair misuse abuse negligence or accident Equipment which in our judgment shows evidence of having been used in violation o
31. s follows Phone 1 800 745 1105 1 203 270 4600 Fax 1 203 270 4610 E Mail service8sonicsandmaterials com It is suggested that a system in need of repair be sent back to the factory with a written description pertaining to the nature of the problem Always contact the factory for return authorization before shipping any instrument Include date of purchase model number and serial number For units not covered by the warranty a purchase order should be forwarded to avoid unnecessary delay Care should be exercised to provide adequate packing to insure against possible damage in shipment The system should be sent with all transportation charges prepaid and return method of shipment indicated INSTRUCTION MANUAL MODEL H520T H540T 31 info qoovia hk com www qoovia hk com WARRANTY Sonics amp Materials Inc hereinafter referred to as Sonics warrants its products for a period of one year from the date of shipment against defect in material and workmanship under normal installation use and maintenance as described in the operating instructions which accompany such equipment During the warranty period Sonics will at its option as the exclusive remedy either repair or replace without charge for material and labor the part s which prove upon our examination to be defective provided the defective unit is returned to us properly packed with all transportation charges prepaid Ultrasonic welding horns const
32. s supplied with an integral 1 2 12 7mm diameter titanium front driver with a replaceable flat face tip Other standard or custom tips are available The model H540T is a 40 kHz power supply that comes with the CVG54 hand gun The CVG54 hand gun is supplied with removable horn designed specifically for each customer s requirements The higher frequency and lower amplitude of the 40 kHz system makes it ideal for welding small assemblies that require gentler action The power supplies of both models feature autotune circuitry OVERVIEW OF ULTRRSONIC PLRSTICS RSSEMBLY 15 ULTRASONICS Ultrasonics refers to vibrational waves with a frequency above the human audible range which is usually above 18 000 cycles per second Hz PRINCIPLE OF ULTRASONIC ASSEMBLY The basic principle of ultrasonic assembly involves conversion of high frequency electrical energy to high frequency mechanical energy in the form of reciprocating vertical motion which when applied to a thermoplastic generates frictional heat at the plastic plastic or plastic metal interface In ultrasonic welding this frictional heat melts the plastic allowing the two surfaces to fuse together in ultrasonic staking or insertion the controlled flow of molten plastic is used to capture or lock another material in place staking or encapsulate a metal insert insertion ULTRASONIC HAND HELD WELDERS Sonics ultrasonic hand held welders are generally composed of t
33. wn below Tighten securely Do not force or overtighten CVG54 HORN gt 14 INSTRUCTION MANUAL MODEL H520T H540T info qoovia hk com www qoovia hk com REPLACEMENT CVG54 1 Clean the mating surfaces as well as the threaded stud and hole Check that the stud is tight See recommended torque requirements below 2 Hand assemble the tip to the horn using open ended wrenches as shown below and tighten securely Do not force or overtighten CVG54 HORN E RECOMMENDED TORQUE REQUIREMENTS Thread Frequency Component Size Foot Lbs Newton Meters 20 2 Converter Tip 1 4 28 25 35 34 47 40 kHz Converter Horn 8 mm 25 35 34 47 40 kHz Horn Tip 1 4 28 25 35 34 47 E N INSTRUCTION MANUAL MODEL H520T H540T 15 info qoovia hk com www qoovia hk com 5 5 A variety of replaceable tips both custom and standard are available for the hand held welding systems Upon request special carbide faced wear resistant flat knurled and custom faced tips are available INSERTING STAKING SPOT WELDING 2 3 v at 4 e lt 4 FLAT KNURLED Refer to the various tables under staking spot welding and insertion descriptions on pages 26 31 for lists of standard threaded tips For custom tips call our Sales Department at 203 270 4600 16 INSTRUCTION MANUAL MODEL H520T H540T 757 info qoovia hk
Download Pdf Manuals
Related Search