Hand Held Welders - Sonics & Materials, Inc.
Contents
1. and 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 000000 J O 10 20 30 40 50 60 70 80 90 10096 This display shows the last weld information weld time energy on E models only and power After power down and subsequent power up values are cleared to zero TEST FEATURE After the press 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 0 10 20 30 40 50 60 70 80 90 10096 During the testing process keep in mind that the ultrasonics are only activated as long as the TEST button is depressed once you release the TEST button ultrasonics is terminated A bar graph indicator reading of above 2096 signals that there may be a problem with the stack If this occurs check your assembly and re test INSTRUCTION MANUAL HAND HELD WELDERS 21 Frequency Display The TEST key can also be used to display the running ultrasonic frequency Refer to page 23 for mo2. If ultrasonics are run 4 TIME key which allows selection and display of time settings and permits continuously time adjustment of time duration in 01 second increments from 00 00 to 99 99 setting 0 be sure to seconds for three time parameters as follows air cool the converter a Weld time b Time Limit Low c time Limit High INSTRUCTION MANUAL HAND HELD WELDERS 19 For a complete explanation of these parameters refer to page 22 5 ENERGY key active on E models only which allows selection and display of the following energy settings and permits adjustment of the energy parameters a through c below in 1 joule increments from to 999 999 joules a Energy Setting b Energy Limit Low c Energy Limit High For a complete explanation of these parameters refer to page 23 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 bar graph 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 o
3. an any all grounded alternate ground path The overload protection circuits will prevent damage surfaces including to internal system components Depending upon the type of condition that machine frames to caused the overload the situation is resolved by different methods avoid triggering an overload condition as the system detects an alternate ground path 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 ultrasonic overload condition exists simply press the O L Reset key to reset the system If an overload condition persists contact our Service Department at 1 800 745 1105 di SONICS 26 INSTRUCTION MANUAL HAND HELD WELDERS Go To Top Of Document KEYPAD SECURITY The keypad can be locked so that no new parameters or commands can be entered via the keyboard thereby preventing unauthorized cancellation or adjustment To activate the security feature press and hold the numeral 7 key on power up When the keypad is secured i
4. any changes in the design or construction of our equipment at any time without incurring any obligation to make any change whatsoever in units previously delivered The technical data and schematics in the manual are for informational purposes only and may not reflect the current configuration being shipped from our factory Upon formal request complete and up to date information can be provided from the factory free of charge if SONICS 6 INSTRUCTION MANUAL HAND HELD WELDERS a UNPRCKING AND INSPECTION 2 NOTE We recommend keeping all carton s and packing material in case it might be necessary to move the equipment or to ship it for repair Before unpacking the equipment check the shipping carton for any visible damage If you see any be sure to follow the procedures described below under Visible Loss or Damage Otherwise proceed to remove the equipment from the carton Before disposing of any packing material check it carefully for small parts Then perform a visual inspection of the equipment to detect any evidence of damage which might have occurred during shipment Check the following 1 all components against the enclosed packing list 2 all module plug in units 3 all wire plug in connections The equipment was carefully packed and thoroughly inspected before leaving our factory All units are tested and checked for problems prior to shipping It is asked that when a problem does occur that
5. e e e Hand Held Welders Model H520 T E Model H530 T E o o 6 6 9 9 9 Model H540 TIE SONICS 5 5 SONICS amp MATERIALS INC TRBLE OF CONTENTS IMPORTANT SERVICE INFORMATION 3 Important Safeguards 3 Warnings Reece a eke EX e RU ONUS ae ee 3 oymbols ox ese xe EX Ga Nae eRe ae d 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 10 INSTALLATION AND SET 11 Electrical Power Requirements 11 Seng UP a CT mE 11 Electrical Connections 11 Cable Connections 12 Key Components xxu exem Orisa aed bet
6. 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 converter is on be sure to isolate it from any all grounded surfaces including machine frames to avoid triggering an overload condition as the system detects an alternate ground path INSTRUCTION MANUAL HAND HELD WELDERS 3 SYMBOLS Caution risk of electric shock hazardous voltage Caution risk of danger Refer to User Manual E INSTRUCTION MANUAL HAND HELD WELDERS SPECIFICRTIONS Power Supply Operational Input Voltage 115 230 V 10 50 60 Hz Rated Voltage Current 115 230 V 5 A max Fuse Rating F6 3A 250V Weight 13 Ibs 5 9 Kg Dimensions 8 5 H 13 5 W x 7 5 D 216 mm x 340 mm x 190 mm Output Voltage 1000 V rms max Output Frequency 20 KHz nom 30 kHz or 40 KHz Converter CV 55 amp CV 53 CV 54 Weight 1 5 Ibs 0 68 Kg 1 5 Ibs 0 68 Kg Dimensions 7 1 CV55 or 6 3 L CV53 x 1 9 Dia 6 3 L x 1 9 Dia 180 or 160 mm x 48 3 mm with standard tip 160 mm x 48 3 mm without horn CV 55 amp CV 53 Dimensions Standard 1 2 diameter 12 7 mm Environmental Pollution Degree Operating Limits Temperature 41 104 F 5 40 Relative Humidity 20 Altitude 6 651 ft 2000 m Shipping Storage Temper
7. 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 BEFORE SONICS e8 INSTRUCTION MANUAL e HAND HELD WELDERS Go To Top Of Document 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 component 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 reco
8. CONNECTIONS DIAGRAM Sadana QISA 03501250 TYAS DNOLANGO Ni 5 saing Si 2 TING ONY NOUWRMCIN SIINYA IOL 9Nid NDININ WHO 8NId 10uN02 3anungwv H313AOLIN310d SNISN NO 9 Nid OL 433 X8 b 30A 9 9 BOYNOS 39vVL 0A O3NddNs YINOLSNI SNid680 gt WHO ee UNId 680 TWNUGLN Nid 1 ay 9 CVNH31NI 30N313334 AUS 6 amaw 8 3oN30Y3dI WHO 591 1 1 1 1 SLIVM 01 JOA 0 5 2 ndino SLYM S1ndino MOLSISNVMHL YOLOSTIOD AWS SLIVM 9 ONNDHI 9 CHDNVOSORLSOHAOS WHO AS 4 4N3YNND 9NDINIS Pugparc 9gAac 1 NOLIVOIONI TO 2 LOVINOD MO HOUMS 779 9 WE ANIS SOND ASL I3S34 YO 2GA8C LOVINOD AY MO HOLIMS 2 i Il SNOILO3NNOO 041 H3AO1Sn2 SNOUZ3NNOO Nid S310N30 SINN 3ON3H3 3M TN L 680 SALON vuis L MNIS SOND ASL 1 15 SOINOS N 9 2 INSTRUCTION MANUAL e HAND HELD WELDERS
9. The ability to specify Time and Energy affords maximum control of the weld process However when entering your specifications in the various menus described below keep in mind that the settings from previous use remain in effect until you make a change and use the Enter key to register a new value This means that if you want to achieve a weld time of 2 seconds for example you will need to ensure that other entries in the Energy menu will allow a 2 second weld before an Energy setting is reached and ultrasonics are terminated INSTRUCTION MANUAL e HAND HELD WELDERS 23 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 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 fo
10. al 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 the following major elements a power supply hand gun converter and horn H540E 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 HAND HELD WELDERS Go To Top Of Document SONICS ULTRASONIC ASSEMBLY SYSTEMS 50 60 Hz Electrical power Power Supply Generator Generates ultrasonic electrical energy 20 30 40 kHz Ultrasonic electrical energy Transforms ultrasonic electrical energy to ultrasonic mechanical vibrations Horn Re
11. all parts and components be inspected for damage especially when the unit is not in working order when received Responsibility for safe delivery was assumed by the carrier upon acceptance of the shipment Claims for loss of damage sustained in transit must therefore be made upon the carrier as follows VISIBLE LOSS OR DAMAGE Any external evidence of loss or damage must be noted on the freight bill or express receipt and signed by the carrier s agent Failure to adequately describe such external evidence of loss or damage may result in the carrier s refusal to honor a damage claim The form required to file such a claim will be supplied by the carrier CONCEALED LOSS OR DAMAGE Concealed loss or damage means loss or damage which does not become apparent until the merchandise has been unpacked The contents might have been damaged in transit due to rough handling even though the container may not show external damage When the damage is discovered upon unpacking make a written request for inspection by the carrier s agent within 48 hours of the delivery date Then file a claim with the carrier since such damage is the carrier s responsibility The form required to file such a claim will be supplied by the carrier Do not destroy packing materials or move material from one location to another before the carrier makes their inspection If the system or any unit is damaged notify Sonics Sonics will arrange for repair or replacem
12. ate packing to insure against possible damage in shipment The system should be sent with all transportation charges prepaid and return method of shipment indicated SONICS INSTRUCTION MANUAL e HAND HELD WELDERS o _ Top Of Document WARRANTY Sonics amp Materials Inc hereinafter referred to as Sonics warrants its products for a period of one year from the date of original shipment against defects in materials and workmanship under normal installation use and maintenance as described in the operating instructions which accompany such equipment During the warranty period Sonics will at its option as the exclusive remedy either repair or replace without charge for material and labor the part s which prove upon our examination to be defective provided the defective unit is returned to us properly packed with all transportation charges F O B Sonics dock Newtown CT Warranty period on equipment rentals that are converted to purchase are deemed to have commenced on the date of original rental equipment shipment Ultrasonic plastics welding horns constructed of titanium or aluminum are guaranteed against defects for a period of one year from date of shipment Sonics will repair or replace a cracked or defective horn once without charge if failure occurs within the warranty period Ultrasonic plastics welding horns constructed of steel are guaranteed against defects for a period of ninety days from date of s
13. ature 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 kaa awa er INSTRUCTION MANUAL HAND HELD WELDERS 5 IMPORTRNT SERVICE LITERRTURE The system supplied with this instruction manual is constructed of the finest material and the workmanship meets the highest manufacturing standards It has been thoroughly tested and inspected before leaving the factory and when used in accordance with the procedures outlined in this manual will provide you with many years of safe and dependable service Please read carefully before operating the MANUAL CHANGE INFORMATION equipment then forward to your service department 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
14. d the weld cycle occurred within the designated energy limits Energy Limit High sets the high energy alarm examination point see Limit Low above An energy alarm will be triggered if the actual weld energy is greater than this value The energy high alarm will show on the Alarm Screen display and will be indicated by a flashing LED on the Energy 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 INSTRUCTION MANUAL HAND HELD WELDERS eb 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 When the hand gun voltage or current or a loose or failed horn tip The welding cycle will also be converter is on be automatically terminated if the hand gun contacts a grounded surface while sure to isolate it from the power is on the power supply will overload because it detects
15. el oad 13 Tip Assembly CV53 55 14 Tip Replacement CV53 55 14 Horn Assembly CVG54 14 Tip Replacement 54 15 Tip Specifications 16 ODUGNS xd per exp Vois 17 Sonics amp Materials Inc Corporate Headquarters 53 Church Hill Road e Newtown CT 06470 USA 203 270 4600 800 745 1105 203 270 4610 fax www sonics com e info sonics com 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 2012 Printed in U S A Part No 381 0035 Rev AC 03 8 12 INSTRUCTION MANUAL HAND HELD WELDERS 1 OPERATING PROCEDURES 19 Front Panel Controls and Indicators 19 Keying in Parameters 20 Operational 21 Starting up the Welder 21 Test Feature RR kee CIR EXE GU EEG E 21 Ready Screens 22 Relationship of Time and Energy Settings 23 Time Settings iiec xem me x rus AE RS 24 Energy Settings s e EA dia a dhe Erba 25 Amplitude
16. ent 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 INSTRUCTION MANUAL HAND HELD WELDERS 7 INTRODUCTION Sonics hand held welders are portable 500 watt welders used for plastics assembly that 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 H520 is a 20 kHz power supply that comes with the CV55 hand gun the H530 is a 30 kHz power supply that comes with the CV53 hand gun The CV53 55 units are 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 H540 is a 40 kHz power supply that comes with the CVG54 hand gun The CVG54 hand gun is supplied with a 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 all models feature autotune circuitry OVERVIEW OF ULTRRSONIC PLRSTICS RSSEMBLY WHAT IS ULTRASONICS Ultrasonics refers to vibration
17. exe eR eioi ce Vania Hea e wr e Rr s 25 Frequency 25 Overload Protection 26 Keypad Security 2 aka heu kk ERO RE Eee 27 APPLICATIONS STAKING 28 Standard Flared Stake 28 Spherical Stake ta tee ae dua x dehet 29 Hollow Stake uk x eka EXE X TES ae eR Eee S 29 Knurled Stake s sexe PC E Pie mE a 29 FIUSH Stake oes ee be UAE ace 30 APPLICATIONS SPOT WELDING 31 Ordering Information 31 APPLICATIONS ULTRASONIC INSERTION 32 MAINTENANCE 34 Cleaning Instructions 34 Repairs ServICe iex ote ERA CAU XO RC KW ROGER 34 WARRANTY m RIA Rem ck wee mm 35 Limitation of Warranty 36 APPENDIX 2 1 kw ga emos ees XR Ed eee 38 PV aaa F1 SONICS e INSTRUCTION MANUAL e HAND HELD WELDERS Go To Top Of Document IMPORTRNT SAFETY INFORMRTION 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 resul
18. g open ended wrenches as this may cause as shown below Tighten securely Do not force or overtighten damage to the booster and or converter N y CV55 shown or CV53 TIP RE NOTE Before using wrenches to assemble HORN ASSEMBLY CVG54 ONLY as shown you should 1 Clean the mating surfaces of the converter and horn as well as the be able to seat the threaded stud and hole Check that the stud is tight see recommended horn or tip without torque requirements on page 13 encountering 2 Hand assemble the converter and horn together using open ended wrenches as shown below Tighten securely Do not force or overtighten resistance in the mating threads AY CVG54 HORN SONICS 14 INSTRUCTION MANUAL HAND HELD WELDERS Go To Top Of Document TIP 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 TIP i E RECOMMENDED TORQUE REQUIREMENTS Thread Frequency Component Size Foot Lbs Newton Meters 20 30kHz Converter 1 4 28 25 35 34 47 40 kHz Converter Horn 8 25 35 34 47 40 kHz Horn Tip 1 4 28 25 35 34 47 INSTRUCTION MANUAL HAND HELD WELDERS 15 TIP SPECIFICATIONS A variet
19. hipment 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 Ultrasonic metal welding horns constructed of titanium or steel are guaranteed against defects for a period of one year from date of shipment Sonics will repair or replace a cracked or defective horn once without charge if failure occurs within the warranty period Sonics warrants its ultrasonic converters for a period of one year from date of shipment with a one time replacement if a converter proves to be non repairable When customer site service is required all travel living and related expenses will be billed at cost In warranty service labor time including travel time at the customers facility is provided Monday through Friday excluding holidays from 8 00 am to 5 00 pm Any in warranty service time requested outside of these days and hours will be billed at 15096 of Sonics current rate per hour for such site service work INSTRUCTION MANUAL HAND HELD WELDERS 35 LIMITATION OF WARRANTY This warranty does not apply to items subject to normal wear and tear or to equipment or tooling which has been subject to unauthorized repair misuse abuse negligence or accident Misuse includes operation of equipment with tooling that is not qualified for the equipment or tooling not properly installed on the equipment Equipment which in our judgment shows e
20. l Thickness TIP CODE LETTER 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 INSTRUCTION MANUAL HAND HELD WELDERS 31 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 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 fab
21. mmended for use with a hand held ultrasonic spot welder Knurled tips are available in a variety of fine medium and course configurations BEFORE INSTRUCTION MANUAL HAND HELD WELDERS 29 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 Diameter Flare Head Conical Boss Spherical Head High Profile Tip Size Stud Height inches Low Profile Tip Size Stud Height High Low Profile Profile 30 INSTRUCTION MANUAL HAND HELD WELDERS SONICS Go To Top Of Document 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 formation 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 Materia
22. n this manner any attempt to change or enter parameters will result in the following message being displayed on the LCD screen KEYBOARD LOCKED 10 20 30 40 50 60 70 80 90 10096 INSTRUCTION MANUAL HAND HELD WELDERS 27 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 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
23. n to 5 microns Do not plug the power supply into an electrical outlet until all other connections have been made 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 between 95 135 volts or 190 265 volts respectively SETTING UP The power supply is a free standing assembly It should be installed in a clear uncluttered location that is free from excessive dirt dust corrosive fumes and temperature and humidity extremes The selected installation site should be near the electrical power source and away from equipment that generates abnormally high electrical transients Observe the following additional instructions when installing the equipment a Allow at least 6 inches 152 4mm at the rear of the power supply for cable connections b Position the power supply so that the front panel controls are visible and readily accessible c The power supply is air cooled allow sufficient space around the assembly to ensure adequate ventilation If the power supply must be housed in a confined space forced air cooling may be necessary to keep surrounding air within acceptable ambient temperature limits Periodically check the ventilation grille and clean as necessary ELECTRICAL CONNECTIONS When making the i
24. nd gun in specialized applications PISTOL GRIP F1 SONICS 18 INSTRUCTION MANUAL e HAND HELD WELDERS Go To Top Of Document OPERRTING 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 1 ON OFF switch which turns the power supply on and off The switch range of amplitude is remains in a latched state even if power is interrupted or disconnected 20 100 For 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 reconnected to power until the ON switch is pressed 2 LCD SCREEN which displays various settings parameters and prompts as detailed in the following pages In addition during the weld process it displays a load meter indicator showing the power level of ultrasonics that is being delivered to the 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 Pmax after the cycle see page 21
25. nitial electrical connections make sure the power is disconnected and follow these precautions 1 Do not strain or kink the cables When going around corners allow as wide a bend as possible Do not run the cables parallel to any power line within a distance of less than 1 foot 305mm 2 To prevent the possibility of an electrical shock ensure that the power supply line cord is properly grounded Also make sure that the voltage rating of the electrical power source matches the power supply requirement 3 Check with your electrician if you have any wiring questions INSTRUCTION MANUAL e HAND HELD WELDERS 11 CABLE CONNECTIONS Located at the rear of the power supply are the cable connections as illustrated below The interconnecting cables will be supplied with your System Make sure the ON OFF switch is in the OFF position and the power 1 A round 4 pin cable with red locator dot that connects the hand gun to the power supply supply line cord is not 2 standard DB9 I O connector that can interface with automated plugged in before machines via a PLC See drawing in the Appendix at the back of this making any cable manual connections 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 operation Always turn off the po
26. o ultrasonic plastics welding equipment horns or fixtures where metal to metal tooling contact time is in excess of 250 milliseconds This warranty does not apply to used or re built equipment This warranty is non transferable SONICS 36 INSTRUCTION MANUAL HAND HELD WELDERS Go To Top Of Document Data supplied in Sonics instruction manuals has been verified and validated and is believed adequate for the intended use of the equipment If the equipment or procedures are used for purposes other than those specified herein confirmation of their validity and suitability should be obtained in writing from Sonics Otherwise Sonics does not guarantee results and assumes no obligation or liability This warranty is in lieu of any other warranties either express implied or statutory Sonics neither assumes nor authorizes any person to assume for it any other obligation or liability in connection with the sale of its products Sonics hereby disclaims any warranty or merchantability or fitness for a particular purpose No person or company is authorized to change modify or amend the terms of this warranty in any manner or fashion whatsoever Under no circumstances shall Sonics be liable to the purchaser or to any other person for any incidental or consequential damages or loss of profit or product resulting from any malfunction or failure of this Sonics product INSTRUCTION MANUAL HAND HELD WELDERS 37 RPPENDIX DB9 I O
27. placeable Tip Contacts and transfers vibrational energy to plastic part Ultrasonic Vibrations Ultrasonic Vibrations INSTRUCTION MANUAL HAND HELD WELDERS 9 GLOSSRRY OF ULTRRSONIC TERMS POWER SUPPLY GENERATOR The solid state power supply converts standard 50 60 Hz electrical power to 20 000 30 000 or 40 000 Hz 20 30 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 parts 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 of a horn at its output face SONICS 10 INSTRUCTION MANUAL HAND HELD WELDERS Go To Top Of Document The line cord of the controller power supply is equipped with a 3 prong grounding plug Do not under any circumstances remove the ground prong The plug must be plugged into a mating 3 prong grounding type outlet If power supply is to be run continuously air cooling of the converter and horn is required Use clean dry compressed air filtered dow
28. r this limit and the Time Limit High a weld 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 LED on the Time key SONICS 24 INSTRUCTION MANUAL e HAND HELD WELDERS Lnd Go To Top Of Document ENERGY SETTINGS ON E MODELS ONLY There are 3 energy parameters that can be specified These are accessed by pressing the Energy key which allows specification of the following parameters The first menu display will show the following Energy Setting sets the amount of energy in joules to be delivered to the parts being assembled Press the Energy key again and successively after each menu display to advance to these next screen displays Energy Limit Low sets the low energy alarm examination point as a process control tolerance limit An energy alarm will be triggered if the actual weld energy is less than this value The energy low alarm will show on the Alarm Screen display and will be indicated by a flashing LED on the Energy key By specifying values for this limit and the Energy Limit High a weld energy window can be created in which a good weld can occur If no alarms are triggere
29. re 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 Alarms 10 20 30 40 50 60 70 80 90 10096 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 whether alarms occurred in Time or Energy on E models only If there are no alarms dashes will display If there are alarms an 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 by the applicable mode time or energy Once another new cycle is begun the system will automatically clear the current alarm Counter Screen Cycles 00 004 678 CRC 000 062 RAC 0 000 O 10 20 30 40 50 60 70 80 90 10096 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 m
30. rication costs and increased productivity as a result of reduced mold cycle times SONICS INSTRUCTION MANUAL HAND HELD WELDERS Go To Top Of Document 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 3x 0 5 3 5 x 0 6 4 x 0 7 5x0 8 6x1 8 x 1 25 INSTRUCTION MANUAL HAND HELD WELDERS 33 MRINTENRNCE CLEANING INSTRUCTIONS 2 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 NOTE If packing unit REPAIRS SERVICE for return shipment DO NOT use styrofoam peanuts Phone 1 800 745 1105 e 1 203 270 4600 If problems are encountered contact our Service Department as follows Fax 1 203 270 4610 E Mail service sonics 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 adequ
31. t 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 e Make sure the Ultrasonic Power Supply is properly grounded via a 3 prong outlet e High voltage is present in 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 e Never touch a vibrating horn e f air cooling the converter always use dry compressed air Hearing protection is highly recommended It is recommended that sound abating enclosure or ear protection be used when operating the Ultrasonic Processor Do not modify horn configurations Do not affix any device to any portion of the horn e 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
32. ust be unlocked SONICS ee INSTRUCTION MANUAL e HAND HELD WELDERS Go To Top Of Document RELATIONSHIP OF TIME AND ENERGY SETTINGS ON E MODELS ONLY Parameters can be set in the time and energy menus The settings in both of these menus should be taken into account when you are setting up a job since they do not function independently of each other and a parameter in one menu can impact the effect of a parameter in another menu For example if you specify a weld time of 2 seconds and an energy setting of 2 000 joules the weld cycle will be terminated by whichever of the 2 settings Weld Time or Energy Setting is reached first that is either when ultrasonics have been applied for 2 seconds or when energy equivalent to 2 000 joules has been delivered to the parts being assembled If 2 seconds is reached before 2 000 joules have been delivered the weld cycle will terminate regardless of the amount of energy delivered and vice versa The start up ready screen which shows the last weld information will show a flashing sec or J to indicate which setting was achieved first and thereby terminated the weld cycle In the example above if the weld time of 2 seconds is reached before 2000 joules have been delivered the ready screen will display 02 00 sec with the sec flashing along with whatever energy was delivered The peak power delivered 96Pmax will be displayed as a percent of the supply rating
33. verload 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 on a screen menu use the numeric keypad When the desired entry is displayed on the LCD screen use the ENTER key to register the new value Entries are made left to right The CLEAR key will clear an existing value to 0 displayed as a series of dashes and relocate the cursor to the extreme left hand entry position ready to accept entries again As soon as a desired value is keyed in and displayed pressing the ENTER key makes the system accept that entry If 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 SONICS 20 INSTRUCTION MANUAL HAND HELD WELDERS Go To Top Of Document The TEST and Load Meter check should always be done for all cold start ups and for any start up after the system has been idle for 20 minutes or more OPERATIONAL FEATURES Adjustable tolerance limits in energy Ws for E models only
34. vidence of having been used in violation of operating instructions or which has had the serial number altered or removed will be ineligible for service under this warranty For components and parts not manufactured by Sonics but included in Sonics manufactured equipment this warranty shall be limited to the warranty as given to Sonics by said original component or part manufacturer Ultrasonic horns supplied by Sonics are manufactured to exacting specifications and are tuned to vibrate at a specific frequency Using an out of tune horn will cause damage to the equipment and may result in warranty nullification Sonics assumes no responsibility for converters horns or fixtures not supplied by Sonics or for consequential damages resulting from their usage Ultrasonic converters showing signs of excessive heat or contamination such as but not limited to oils and moisture are not covered by this warranty Warranty does not apply to ultrasonic horns quoted as prototype experimental or of unusual design which in our judgment are more likely to fail in use Warranty does not apply to re sharpening of ultrasonic blade type cutting or slitting horns Warranty does not apply to knurl pattern wear on ultrasonic plastics and metal welding horns and tips Warranty does not apply to ultrasonic horn or tip face wear when used with plastics that are molded with fillers such as but not limited to glass or talc This warranty does not apply t
35. wer supply before installing or removing the foot switch cable e SQUE SA MATERNAL NS OUTPUT 0 C MODEL H 20 SERIAL p ndang KOKO VOLTS 120 VAC S0 60Hz NOM C FUSE SIZE 16 AMPS SLO BLO Do not use a damaged or worn hand gun Also located at the rear of the power supply are the following cable Never use the cable and hand gun as 4 Foot switch jack connects foot switch cable to enable remote actuation a rope it is not rated 5 Fuses 120V 15A slo blo for pulling weight 230V 8A slo blo S SONICS 12 INSTRUCTION MANUAL HAND HELD WELDERS uus _ Go To Top Of Document KEY COMPONENTS Pictured below is the power supply with hand gun options POWER SUPPLY HAND GUN CV53 CV55 CV55 shown ln cc TIP TRIGGER SWITCH HAND GUN HORN CVG54 TIP er INSTRUCTION MANUAL HAND HELD WELDERS 13 TIP ASSEMBLY CV53 amp CV55 Z If the tip is not already assembled follow the instructions below as applicable CV55 unit is shown below but instructions also apply to CV53 NOTE Never remove TIP REPLACEMENT CV53 amp CV55 or install a tip by 1 Clean the mating surfaces as well as the threaded stud and hole Check holding the hand gun h d 13 case or rotating the tip that the stud is tight see recommended torque requirements on page 13 with only one wrench 2 Hand assemble the tip to the titanium driver usin
36. y 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 w 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 SONICS 16 INSTRUCTION MANUAL HAND HELD WELDERS Go To Top Of Document Always turn off the power supply before installing or removing the foot switch cable OPTIONS The following options and accessories are available for the hand held welding systems 1 FOOT SWITCH for remote activation When foot switch actuation is used the trigger handle is removed from the hand gun housing 2 MANUAL ARBOR PRESS available with foot switch or cam actuation 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 assemblies MANUAL PRESS INSTRUCTION MANUAL HAND HELD WELDERS 17 3 STAPLER with special pivoting mechanism Ideal for sealing low production rate clamshell packages for 20 kHz Models only STAPLER 4 PISTOL GRIP for more ergonomic handling of the ha
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