Home

Operating Instructions

1. Caution N Denotes a danger warning Ignoring this warning can lead to severe injury or damage to parts of the unit Danger A Denotes a severe danger warning Ignoring this warning can lead to death or severe injury 1 2 Safety information General The construction of this unit represents the latest state Of technology and is safe in operation The individual components as vvell as the complete unit have been checked by our quality control department prior to delivery Intended purpose A The welding unit is intended exclusively for the ultrasonic welding of the plastics for which it is sui ted Different use or use beyond that does not count as intended use The producer does not accept any liability for damage caused by unintended use The user bears sole responsibility This system is intended for industrial use Unintended use e Using the system with insufficient knowledge of how to operate maintain or care for the system e Altering the welding system and the generator with for example attachments or conversions that could influence the safety without the approval of RINCO ULTRASONICS e Making modification in the control software e Using unsuitable working materials e Opening the generator housing during operation e Handling the converter while energised e Allowing a second person to operate the two hand start button Important note Before putting the machine into operation carefully re
2. 2 2 2 3 2 4 Unpacking receiving inspection Damage during transportation Placing the unit Site location and work place creation 3 Product information 3 1 The entire system 3 2 Press 3 3 Oscillator unit 3 4 Booster 3 5 Generator control 3 5 1 Generator SL 3 5 2 Generator RL 4 Initial operation 4 1 4 2 Power supply and connections Operation and display elements 4 2 1 Welding press 4 2 2 Generator 4 2 2 1 Generator SL 4 2 2 2 Generator RL 5 Starting up the system 5 1 5 2 5 3 Welding operation Starting up the generator 5 2 1 Generator SL 5 2 1 1 Parameter setup 5 2 1 2 Description of setting parameters 5 2 2 Generator RL 5 2 2 1 Detailed description of functions from the program selector switch 5 2 2 2 Process programming Adjustment CON O 10 10 10 10 11 12 12 12 13 13 14 14 14 15 15 16 16 18 18 19 21 21 21 21 22 23 23 24 25 6 Maintenance and service 6 1 Cleaning the machine 6 2 H ses 6 2 1 Generator SL 6 2 2 Generator RL 7 Service Addresses 27 27 29 29 30 31 Important When you make enquiries about your machine we ask you to state the exact type of designation and serial number of the unit You will find these details on the type plates A and B on the side of the press as well as on the back of the generator ABW35 Press with 745 N max force The construction and electric installation of these devices are subject of co
3. a regulated pressure of approx 1 bar can be set on a typical section with a welded seam of 2mm x 10mm Throttle 14 The throttle has two functions e Speed of the machine stroke e The temporal power structure when the sonotrode has touched down on the workpiece Stroke limitation 11 With this screw the stroke limitation is to be set at a safety distance of 6mm A The stroke must be delimited on max 6mm This ensu res that the operator can not reach in the tool range during the welding operation This precaution serves the operational safety and must not be removed or altered structurally 13 14 17 4 2 2 Generator 4 2 2 1 Generator SL 30 Handle for generator module This handle is used to withdraw the generator module when required The fixing screws 31 for the opening of the generator module are located above and below the bar of the handle A Never attempt to withdraw or insert the generator module while it is connected to the mains network High voltage Do not touch the printed circuit board the capacitor carries high voltage 32 LED bars This display indicates the output provided during the welding process With no load on the horn free oscillation in the air the display should not indicate more than 25 lf the 100 mark is exceeded an error
4. message appears After the welding process a flashing LED indicates the maximum output peak 36 2 line LCD display The LCD display indicates e welding parameters e error messages and e Operating states 37 Kevboard These kevboard can be used to e activate the generator functions change welding parameters change the programme welding operation move to the next programme line move to the previous programme line move the digit selection to the left move the digit selection to the right reduce numeric value increase numeric value 2 AO F amp F b set value to zero 31 34 US TEST key Key for activating the ultrasonic test The display will indicate the current horn frequency If the key is activated for more than 5 seconds an error message appears Do not touch the horn 35 LED e US ON ultrasonic active e VALVE electrovalve active e ERROR error exit active 38 ON OFF key 33 POWER LED Operating mode display 31 Fixing screws During operation the fixing screws must be fitted properly 4 2 2 2 Generator RL 30 Handle for generator module This handle is used to withdraw the generator module when required The fixing screws 31 for the opening of the generator module are located above and below the bar of the handle A Never attempt to withdraw or insert the generator module while it is connected to the mains network High voltage Do not touch t
5. surfaces need to be replaced A If heat production is too high greater than 50 C the converter needs to be cooled with compressed air Converter 5 Booster 1 2 gt 10 um Horn 1 3 gt 30 um Converter 5 um Booster 1 2 gt 10 um ili IV Horn 1 3 30um 13 3 5 Generator control 3 5 1 Generator SL Technical data e Dimensions WxLxH e Power classes e Connected loads e Connection e Display e Weight 3 5 2 Generator RL Technical data e Dimensions WxLxH e Power classes e Connected loads e Connection e Display e Weight 14 130 x 450 x 300 mm 400 600 W 230 V 50 60 Hz Mono pashased Power supply Power bars and status LED 7 kg 130 x 450 x 300 mm 400 600 W 230 V 50 60 Hz Mono pashased Power supply Power bars and status LED 7 kg 4 Initial operation 4 1 Power supply and connections Take the following steps to put the equipment into Operating condition 1 Anchor the work table and screw on the press on the back side 2 Connect the cables between the press and the generator A Danger Only use an earthed electrical connection 3 Insert the unit plug into the socket on the generator 21 STO1 Actuator 22 STO2 Start 23 STO3 Interface 24 STO4 Converter connection 25 STO5 Power electrical supply Only on the RL generator the power switch is on the back board The generator SL is switched at the front A Compressed air conne
6. 9999999 Welding time WELDTIME Duration of welding Setting range 0 00 9 99 s Standard setting 1 00 s This parameter is operative only if the function IWELDTIME TIMERI is operative in the SYSTEM INIT Hold time HOLDTIME Upon exipation of the welding time the horn keeps exerting pressure on the welding object for the HOLD TIME Setting range 0 00 9 99 s Standard setting 1 00 s 22 5 2 2 Generator RL The RL generator can be started up through the power switch 25 on the back At the startup of the device a system test will be executed With this the efficiency of the oscillator system will be verified With the US Test button the function system test can be repeated 5 2 2 1 Detailed description of functions from the program selector switch Ultrasonic devices are used in a wide range of fields today so that users have a variety of different control requirements A welding installation needs to be able to be connected to the available peripheral devices For this reason a number of programmes have been created to suit the most common peripheral require ments These programmes are permanently installed in an integrated computer and can be preselected via rotary switches The program selector switch is deliberately located on the card module see fig inside the housing in order to prevent unauthorised changes to the program Before a program modification 1 Dis
7. CE a Disclaimer The information in this brochure corresponds to our current state of knovvledge Hovvever it is not to be understood as a vvarranty for certain characteristics or for suitability of the products for certain applications Our general contractual terms appiy in this regard and reference should also be made to these terms with regard to liability No industrial property rights of any kind are granted to the user along vvith this brochure nor are any assurances made vvith regard to a licence Corresponding separate agreements vvould be necessary for this purpose The suitability of the products for particular appli cations may only be checked with our own specialists The German version of the brochure is binding with regard to accuracy of the information given Copyright by RINCO ULTRASONICS AG Switzerland Version 1 0 gb Art No 39034 Operating instructions established with ABW35 SL35 600 RL35 400 Creation date 06 11 2009 Notes Read and precisely follow the information in this operating manual before unpacking the unit and putting it into operationi The unit may only be used maintained and repai red by people who are familiar with the operating manual and the applicable regulations on work safety and accident prevention Representative Content 1 Safety 1 1 1 2 1 3 Explanation of symbols and signs Safety information Noise emissions 2 Transportation 2 1
8. ad the operating manual in hand The operating manual is to be kept near the welding system where it can be accessed Choosing stuff Only trained and instructed personnel should perform work with the cutting unit The responsibility of the personnel to operate set up maintain and repair the equipment is to be clearly defined by the operating company The operating company must make sure that only authorised person nel use the welding unit Work on the electrical equip ment of the welding unit may only be carried out by trained electricians according to electrical regulations Work on the pneumatic equipment may only be car ried out by trained personnel who are qualified and experience in the field of pneumatics Installation A Dangerl Do not attempt to hook up the equipment when it is plugged ini The electrical connection is to be earthed in all casesi Country specific statutory safetv mea sures must be followed during installation If these regulations are not respected the producer refuses to accept any liability for personal and property damages The equipment must be put in a closed and secure state each time before it is put into operation Only use dry compressed air for operation If necessary an air service unit can be added Operation ZN Caution Under no circumstances should the generator or the converter housing be opened during operation of the welding system Danger High voltage preva
9. cillator system from the front in the converter housing 5 Close again the cover plate 9 of the converter housing and thighten the two screws with the allen key SW 6 mm lt should be possible to turn the oscillator system with little effort 6 Align the horn 6 parallel to the anvil 3 then mode rately tighten the screws of the cover plate 9 Pay attention to uniform distribution of gabs between converter housing and cover plate 25 A Caution If the horn is not precisely aligned the micro switch 10 can get damage Hold the actuator and loosen the 4 attachement screws 12 with a socket wrench SW 10 mm Push the actuator completely to the top and fasten it by means of the screws Loosen the screws of the limit plate 15 and after move the limit plate completely back Put the adjustment caliber on the anvil 3 10 Loosen the screws 12 and carefully place the 11 actuator on the adjustment caliber lightly press it down and thighten all 4 screws equally If the wel ding image becomes unequal during the welding process if necessary the parallelism between horn and anvil has to be readjusted point 7 10 Loosen the counternut of the stroke limitation 11 and turn counterclockwise until the horn 6 can be put on the anvil 3 Clamp the feeler gauge 0 2 mm between horn and anvil and turn the stroke limitation clockwise until resistance is felt Tighten the counternut Check the resulti
10. connect the unit from the power supply 2 Unscrew the 4 fastening screws 31 3 Take out the generator module by pulling the insert grips 30 23 The program selector svvitch has 10 adiustable modes For this application we choos program 8 automatic is selected 5 2 2 2 Process programming The welding and holding time as well as the soft start time can be parameterized 40 Welding time With this button the welding time can be changed e ncreas digit value e Decrease digit value Hz With the initialization of the internal programm switch level 9 the welding time will increas by ten times 99 9s 41 Hold time With this button the hold time can be changed e ncreas digit value e Decrease digit value 24 31 30 33 5 3 Adjustment Installing the oscillator system A Caution Always switch off the power supply to the generator before installing the oscillator system Power OFF The setting takes place in an unpres surized state pressure regulator 0 bar and without cover 1 Screw on the horn 6 with the provided special spanner A a flatspanner SW 18 mm or a adjus table spanner to the oscillator system 4 5 and tighten the screw carefully Tightening force 15 20 Nm The oscillator system is ready for operation 2 Open the cover plate 9 of the converter housing 3 Plug in the RF plug at the RF connector 7 of the converter 4 Insert the os
11. ction 7 bar maximum 105 psi 4 Connect the compressed air hose 21a to the available compressed air mains 15 4 2 Operation and display elements 4 2 1 Welding press 1 Converter housing 8 The oscillator system together with the electrical sup ply line is located in the converter housing 2 Horn 6 The horn is the actual welding tool It is tuned to the resonant frequency by the producer A Warning Never alter the tuned horn by making mechanical changes This can cause damage to the oscillator system and the generator Anvil 3 Rapid centering and fastening of the anvil with the supplied attachment screws Attachment screws actuator 12 The attachment screws of the actuator allows most accurate alignment of the anvil 3 and thus also the alignment to the horn face 6 Microswitch 10 By the exert of the microswitch the welding cycle will be activated N Warning Country specific statutory safety regulations must be followed during installation Note If these statutory regulations are not adhered to the producer refuses to accept any and all liability for personal and property damagesi 12 10 19 b s 2 x Pressure regulator 13 The pressure regulator holds the air pressure on the top side of the piston constant and is set to a height which depends on the size of the piece and the length of the weld joint as well as on the material to be wel ded As a point of reference
12. g descriptions of work place creation is a proposal and derived from the valid international norms for industrial work places 11 3 Product information 3 1 The entire system The entire system consists of Press Generator control Anvil Converter Booster Horn 09 O FW NY 3 2 Press Drive Double acting cylinder diameter 40 mm e Tool stroke maximum 6mm e Power at 6 bar 745 N e Throat depth 66 mm e Precision ball track on the sliding actuator carriage e Switch for upper cylinder position Ultrasonic Working frequency 35 kHz Energy e dry compressed air maximum 7 bar 105 PSI Weight e Weight 11 2 kg without generator and oscillator unit 12 3 3 Oscillator unit 4 Converter 5 Booster 6 Horn 7 RF socket Lemo 1 Amplitude gain The amplitude can be correspondingly amplified by various booster and horn designs The individual elements are mechanically connected by means of a screw thread The tightening torque for 35 kHz systems comes to 15 25 Nm We recommend using the RINCO tool wrench The allowable operating temperature lies between 10 C and 50 C 3 4 Booster For RINCO 35 kHz welding units the following booster types are available Booster colour material 1 1 titanium 1 1 5 titanium 1 2 white titanium Connection screw thread e On the converter Mg e On the horn M8 Before mounting the coupling surfaces have to be cleaned Parts with damaged coupling
13. he printed circuit board the capacitor carries high voltage 32 LED bars This display indicates the output provided during the welding process With no load on the horn free oscillation in the air the display should not indicate more than 25 lf the 100 mark is exceeded an error message appears After the welding process a flashing LED indicates the maximum output peak 33 POWER LED Operating mode display 31 19 34 US TEST key Key for activating the ultrasonic test The display will indicate the current horn frequency If the key is activated for more than 5 seconds an error message appears Do not touch the horn 35 LED e US ON ultrasonic active e VALVE electrovalve active e ERROR error exit active 40 Welding time With this key the welding time can be changed With the initialization at the internal program switch level 9 the welding time can be increased by the decuple 99 9s 41 Hold time With these buttons the hold time can be changed 31 Fixing screws During operation the fixing screws must be fitted properly 20 5 Starting up the system 5 1 Welding operation Through the activation of the micro switch the wel ding cycle will be activated The actuator pulls out and the ultrasonic starts immediately The ultrasonic stops according to the parametrized time After the parametrized hold time the actuator goes back to the resting position 5 2 Start
14. ils inside the device risk of injury e Refrain from any and all possible methods of work which may put safety at risk e Only operate the welding system when all protec tion and safety equipment e g detachable pro tection equipment emergency stop button noise insulation are present and functional e f safety measures such as sound proof cabins are not ordered and used by the customer the manu facturer accepts no responsibility for any damage which could have been avoided had such equip ment been used e Before switching on the welding press make sure that no one can be harmed by the starting press Danger During normal operation the two hand start buttons are to be actuated by one person using both hands The manufacturer accepts no liability for any personal injury or damage to property caused if the dual safety switch is operated with the help of another person or in any other way other than the correct way e maintain the operational readiness e increase the life of the device and e reduce down time to a minimum 1 3 Noise emissions A Caution Limit value according to current understanding ultrasonic causes no damage when the maximum level remains below 140 dB and the median level referring to 8 hrs day remains under a linear 110 dB Pay attention to the sub harmonic i e audible pulsa tions that depending on use fluctuate greatly and have an annoying and harmful effect Here the sta
15. ltrasonics com 31 9JON ul UOS194 YHOM JNO PoLLIEJ 21eq 32 310N buseu ul UOS194 YHOM JNO PoLLIEJ 21eq 33
16. n dard measure is the equivalent sound level Leq over a representative working period at least 8 hrs day max 2000 hrs year with a maximum level of 85 87 db A When welding special materials the 70 dB A sound level may be exceeded Counter measures e Wear ear protection e Install a sound hood optional e Operate with sound enclosure Information according to SUVA the Swiss Accident Insurance Fund no 86048 d 4 94 For more measured values see Sound Measuring Protocol in the RINCO supplements no 920 3903 1 95 Guarantee RINCO ULTRASONICS delivers the system with a guarantee that corresponds to VSM Swiss Association of Machinery Manufacturers The conditions for RINCO ULTRASONICS fulfilling its guarantee are among other things the following e The user possesses knowledge of the contents of this operating manual e The instructions and warnings in this operating manual are followed e The operating company is not permitted to under taken any changes or conversions of the individual parts of the press the oscillator system or the generator of its own accord ULTRASONICS is happy to explain any possible ambiguities or to provide instructions by our qualified staff via telephone 2 Transportation AN Equipment may only be transported by suitably trai ned personnel Please note the transport advice on the packaging The press and the generator should be tran
17. ng air gap The air gap should be 0 2 mm 12 Adjust the limit plate 15 to the desired welding 26 distance 3 10 mm and tighten the screws 10 12 6 Maintenance and service 6 1 Cleaning the machine A Caution Cleaning and maintenance work may only be carried out by trained personnel Before beginning the main tenance work make sure that all power sources such as electrical power and compressed air are disconnected Never clean the keyboard or the display with acidic cleaners The multipress and the generator do not require any special main tenance However regularly cleaning the e Press 1 e Generator control 2 e Anvil 3 Horn 6 guarantees a long and problem free operation of the press system Pneumatic unit After work disconnect the compressed air supply Lubrication system Maintenance free Generator Alwavs keep the generator displav clean 2 Oscillator system AN Dangerl Work on the oscillator system and converter housing only if the supply voltage is switched off High vol tage Avoid contact with the RF socket of the converter Do not connect any measuring device to the RF socket of the converter The converter contains an electrical charge even after the generator has been switched off Screw connection Converter 4 booster 5 and horn 6 are screwed to each other Tightening torque 15 20 Nm Black spots on the surfaces of the boos
18. ntinuous development and improvement and represents the latest state of tech nology RINCO ULTRASONICS AG Romanshorn Switzerland Preface We are very pleased that you chose to buy a RINCO product We are convinced that you will achieve a maximum degree of economy of operation and pro duct quality when using this unit The purpose of this manual is to give the purchaser and the user all the information they need in terms of the handling assembly operation and care of the welding press To ensure that your system is always in an operational state you should take note of and follow all the tips and instructions contained within this manual IE These instructions describes the ultrasonic welding machine ABW35 in operation with a generator SL35 400 600 and RL35 400 600 CAUTION ATTENTION x tir 725 l min in Secdcertand br 7 hic ULTf AS EE I Az thom 1 Safety 1 1 Explanation of symbols and signs A system of symbols indicates dangerous behaviour as well as correct behaviour The symbols are used in the operating manual All danger and note symbols describe conditions during which people things or the environ ment could be put at risk if these symbols are ignored Danger symbols in the operating manual are structured according to a unified schema Structure of the danger warnings Note Especially important information or operating notes for problem free operation
19. sported separately 2 1 Unpacking receiving inspection The transport container for machines and equipment can withstand normal wear and tear resulting from road rail and air transport Upon receipt of the delivery you should check for completeness of all parts listed on the packing list and that there is no visible damage If there is any damage you should immediately contact your transport company and retain the packaging as evidence 2 2 Damage during transportation Any damage that has been caused during transportis the responsibility of the haulier In order to substantiate the claim a complete report with an accurate description of the damage must be submitted to the haulier as a basis for the claim Any damage or loss of goods provided by ourselves is to be reported to us immediately sending a copy of the above report as confirmation If the delivery from RINCO ULTRASONICS AG was free house or CIF the damaged delivery will be replaced and the appropriate claim made under the relevant transport insurance provided the respective conditions are met 2 3 Placing the unit The ABW ultrasonic welding machine is designed for a e Placement on a table e Mounting on a table e Mounting on a wall For the mounting of the unit there are provided four mounting holes 2 A Site location and vvork place creation The ultrasonic welding machine ABW35 is designed for a normal clean industrial environment The followin
20. ter 5 and the horn 6 can be easily removed 1 Lay a polishing rag on an flat surface 2 Draw the black spots over the polishing rag 28 6 2 Fuses 6 2 1 Generator SL The following components are fitted with fuses Mains socket Bus print F1 F2 F3 F4 Generator module F5 Dimensions of all fuses 5 x 20 mm Ne 6 2 1 1 230 volt fuses Generator Mains socke Busprint Generator module FI F2 F3 FA F5 GM35 400 AA T 400mA T AA T 100mA T GM35 600 4A T 400mA T AA T 100mA T 29 6 2 2 Generator RL The following components are fitted with fuses Mains socket Bus print Generator module Dimensions of all fuses 5 x 20 mm 6 2 2 1 230 volt fuses Generator Mains socke Busprint Generator module ee e FA F5 UGF3 35 250 3 15 A T 400 mA T 3 15 A T 100 mA T UGF3 35 400 400 mA T 100 mA T UGF3 35 600 400 mA T 100 mA T 30 7 Service Addresses The RINCO ULTRASONICS AG technical service agents are happy to answer any questions you may have concerning any technical malfunctions or welding pro blems which may occur For an efficient response our Customer Service requires the following information Aprecise description of the technical fault or cutting problem Our address RINCO ULTRASONICS AG Industriestrasse 4 CH 8590 Romanshorn Switzerland Tel 41 71 466 41 00 Fax 41 71 466 41 01 www rincoultrasonics com info rincou
21. up of the generator 5 2 1 Generator SL The following standard settings are reccomended for this application e Start Automatic e Trigger Off e Welding Timer e Valve On e End switch Off e Afterpulse Off application dependent for dieing away On e Soft start 7 Language German Country dependent e Amplitude Intern SDF Off Earned limit Off 5 2 1 1 Parameter setup According to the initialization of the generator there are parameter settings available They can be changed if required For activating the parameter setup see following page Adjustable parameter Setting ADJUSTING 4 Part counter PART Welding time WELDTIME Hold time HOLDTIME Trigger TRIGGER 1 After pulse AFTERPULSE Amplitude AMPLITUDE 1 Performance limits PERFORMANCE MIN PERFORMANCE MAX After impuls AFTERPULS It is advisable to record the respective changes in a setup log in in order to be able to return to existing settings whenever necessary 21 5 2 1 2 Description of setting parameters Setting ADJUSTING 41 Press both start buttons within 0 3 seconds to lower the actuator Keep the start buttons actuated until the safety switch is reached Press the start buttons again to move the actuator back to the home position Part counter PART The part counter steps up by one after each sound welding Press CLR key to reset part counter Maximum display

Operating Instructions

Contents

Download Pdf Manuals

Related Search

Related Contents