User manual Ultrasonics Generator soniKKs digital K1-W
Contents
1. x soniKKSs ULTRASONICS TECHNOLOGY User manual Ultrasonics Generator soniKKs digital K1 W D 5 OUTPUT AS TEST ERROR lt gt NOMINAL GmbH SONIKKS ULTRASONICS TECHNOLOGY 2013 04 06 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 1 of 18 GW kke ULTRASONICS TECHNOLOGY Table of contents MOU CIO sou ipa sare tatattoarcariarcarntourtadies aad E E E 3 Se Neral I Ora Olt aa E uuniiedhasanaaanetihweunmleatnaneiie E 3 SOY ATE E EE E AE EN EE E A uid snes E N EE E E E E S 4 E COMVEMMON AI USE ae E E A E E E T 4 Ze O CUNY Mo O a E 5 DEAC PIO MONE aee E E E E 6 PECCI CONN S O a E EEE E A E E E 7 MSC TAA CAN Dal deea E EE E E 7 Connections on the backside Of the generator ccsscsscsecseccecceccececcecceccecceeceeceeceeceeceeceeseeceesetsetsetseteess 8 1 LEMO socket version for hand welding pistol ccccsecsecseeeceeeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeeseeseeseneess 9 2 Interface pin out Standard version csccscssssssssecseseeceesnscessussuseuseeesuseussuseessusussuseessessessessessessess 10 3 Interface signal description Standard version ccsecsecseeseeeeeeeeeeeeeeeseeeeeeeeeeeeeeseeseeeeeeeeneeseneags 12 CONE ONSan IG aA pay elemenl ia AE 13 k CED SS aU nd a O ernan a 13 DZ CONTO e E E E E E 13 TOUD NOON eee ee O 14 MalntenanCe ING CANS o E E E E T 16 N E E eer ere meee rn rer ee rere tre rere rere re 16 PELON Oh C ONOI i EE E 17 D2. 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 8 of 18 SoniKKS ULTRASONICS TECHNOLOGY 1 LEMO socket version for hand welding pistol s RF gr FS GND RF GND A BS f Switch on the pistol PE Ez GND RF Hot leg transducer Inner wire RG 174 RF GND Transducer ground Shield RG 174 PE Protective earth Green yellow GND Common ground Brown FS GND Remote on switch on pistol White Shield Shielding Outer shield 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 9 of 18 sSonikKKsS ULTRASONICS TECHNOLOGY 2 Interface pin out standard version nies 4 Common relay root for RF DA and ERROR relays GND Common ground FS ND Remote input active low link to ground to turn on the generator Optionally also remote with 24 V is available RF DA relay Relay output RF DA closed when ultrasonic voltage is emitted Error relay Relay output Error closes upon error normally open A extern Input 5 10 Volt for external adjustment of amplitude P out Output 0 10 Volt corresponds to the output power 0 100 15V 15 Volt supply voltage for external use max 100mA 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 10 of 18 SONIKKS aam Connection description Generator 8 pole Interface Error HF Relais DA Example of external connections 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 300
3. of the nominal generator amplitude Any voltage below 5V will clip the amplitude to 50 7 P Out On this pin there is a voltage proportional to the emitted ultrasonic power in the range of 0 10 volts This voltage corresponds to the nominal ultrasonic output power OV 0 10V 100 8 15V This output provides an auxiliary voltage of 15V for external use The maximum output current is 100mA 75mA permanent load and can be used as a supply voltage of the relay root RF DA amp Error on pin 1 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 12 of 18 sonikKKs ULTRASONICS TECHNOLOGY Controls and display elements SONIC ERROR lt gt NOMINAL OVERTEMP MENU MODE zs 1 lt gt Nominal Overtemp LED power gauge 2 Controls Test Button TEST LED status indicators Indicates that the generator is connected to the mains supply and the mains switch is switched on Indicates that ultrasonic power is emitted Indicates that there is a malfunction Indicates that a monitoring function has been set and the requested condition was not met during the last run Cleared automatically upon next start Monitoring functions can be set using the LCD display with rotary encoder operation When lit the generator is overheated and cannot be started When flashing the generator was shut down during the last welding
4. Below you can see all the warning and security symbols used in this manual Symbols in manual Immediate imminent danger health and live bad injuries or dead Attention hot surface Do not Touch Possible damage without danger for people Electrical voltage Symbols on device CE Conformity Symbol 1 Conventional use The generator was designed to be used for following applications gt Ultrasonic welding of plastic and metal gt Ultrasonic cutting gt Ultrasonic sieving Just operate with the generator when accessories from soniKKs are mounted such as transducer sonotrode and sieve If you use the generator with other components no functioning guarantee is furnished For other applications please obtain explicit written approval from the producer 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 4 of 18 SONIKKS a 2 Security instructions gt Operations of all ultrasonic equipment by trained staff only gt Do not use this unit in explosive environments without taking all necessary security measures gt Check the unit any time before operating gt The electromagnetic compatibility conforms to international standards For more details consult the Technical data section of this manual gt All necessary adjustments are either made by the manufacturer or are described in this manual In case of any trouble with the generator do contact our technica
5. process due to overtemperature If you start sonic again the LED disappears Indicates that the generator is set to stop after a predetermined condition has been reached The setting of these conditions can be done with the LCD Display with rotary encoder operation LED bargraph showing the effective ultrasonic power output in steps of 10 of the nominal power By pressing this button you can switch on the generator for testing purposes The button behavior can be configured using the LED Display with rotary encoder operation 2013 04 06 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 13 of 18 WG kke Troubleshooting The Error LED comes up right after the generator is started with the test button or a remote control signal Possible reasons gt Malfunction of the ultrasonic converter gt Malfunction of the cable to the transducer short circuit How to fix the problem 1 Disconnect the cable to the transducer 2 Switch on the generator with the test button Then what a The error still comes up generator faulty b The error does not come up again transducer or cable faulty The Error LED comes up with some delay after the generator is started with the test button or a remote control signal Possible reasons gt There is no ultrasonic converter connected gt The tool has a malfunction gt The ultrasonic converter is broken gt Malfunction of the connection cable or p
6. 0 2301D B page 11 of 18 GW kke a ULTRASONICS TECHNOLOGY 3 Interface signal description standard version 1 RF DA amp Error Common input output root of the internal relays RF DA and ERROR Relay input output signals have no reference to GND 2 GND Common reference point for input output signals except for the relay outputs 3 FS GND To switch the generator on connect this signal to GND pin 2 The behavior of this pin can be configured to be level or edge triggered A configuration is possible using LCD Display with rotary encoder operation 4 RF DA relay As soon as ultrasonic voltage is available on the RF output socket a relay contact closes and this pin 4 is linked via the relay to Pin 1 RF DA amp ERROR Normally open To use this function connect for instance 24V to pin 1 RF DA amp ERROR This voltage will then appear on this pin 4 as soon as the generator is turned on and an ultrasonic signal is available on the output socket 5 Error relay This pin is internally connected to the error relay contact root of the relay contact is pin 1 Normally open If there is any malfunction of the generator this relay contact will be closed 6 A extern The generator s amplitude can be controlled with an external voltage applied to this pin This function can be enabled on the LCD display Applying a voOltage between 5 and 10V the amplitude can be adjusted in a range of 50 100
7. 8 SONIKKS a In the following cases immediately disconnect the unit from mains and call a qualified service technician If cables or connectors are damaged If the housing is damaged If fluid came into the generator If the unit fell to the ground If the unit shows significant differences from normal operation VV VV WV Device Placement A running generator can heat up noticeably If the generator cannot dissipate the heat there is a possibility of an overheat condition An error message Overtemperature will appear if a display is connected and the OVERTEMP LED will light up See the error description Overtemperature for details If possible avoid operating the unit at ambient temperatures above 30 C 86 F Make sure that sufficient cool air can reach the generator for proper cooling Air conditioning helps in high temperature environment Always keep the cooling slots on the rear of the generator clear Do not place anything in front of the cooling slots Avoid heat sources close to the generator to avoid overheating Also avoid direct sunlight exposure Place the unit so that no humidity or fluid can come into the generator Lay the cables in a way that no one can stand on them or stumble over it Never carry the device holding it on the cable ATTENTION Place the unit in a way that no vapor water or other can get into the device Dusty or chemically contaminated air may cause long ter
8. ANE ee reste bantanaaunenedessiacasdcunetacsuasncticwpsnntesuparetecnaerasscboutcneeunenesncuss 18 2013 04 06 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 2 of 18 SONIKKS a Introduction Dear customer we would like to thank you for buying this product You have purchased a high quality product developed based on the latest technology standards developed and produced exclusively in Germany For your own safety please read this manual carefully before using this product and keep this manual in a place where it is accessible for all users ATTENTION Make sure that all electrical connections are only made by trained staff Only qualified service personnel may open or modify the device General information The ultrasonic generator soniKKs digital K1 W D is a device which is used normally for ultrasonic plastic and metal welding applications The main features are Autotuning circuit to tune automatically to the resonant frequency of the connected horn Fully digital frequency generation High speed microcontroller to control all functions of the generator LCD display with rotary encoder operation Constant adjustable amplitude 50 100 Vv Vv VV VV V WV Protected against a short circuit b idle run c overtemperature d overload 2013 04 06 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 3 of 18 GW kke ULTRASONICS TECHNOLOGY Safety
9. ator Keep the cooling slots clear at all times Warranty The period and extent of the warranty is part of the commercial terms and conditions Special agreements are part of the confirmation of the order Warranty exclusion applies in the following cases Damage due to wrong handling or tampering Damage due to wrong application Damage due to shock dirt or moisture Damage due to operation by nonqualified staff Damage due to nonobservance of safety regulations or accident prevention regulations Damage due to modifications to the operating manual VV VV V Y 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 16 of 18 GW kke a Declaration of Conformity We sonikKs Ultrasonics Technology GmbH declare in sole responsibility that the product Type Ultrasonic generator soniKKs digital K1 W D xxxx xxxx symbolizes the different power ratings Correspond to the following EEC directives EN 50081 1 EN 50082 2 EN 55022 EN 55014 EN 6055 EN 61000 The requirements of the low voltage directive are observed ATTENTION The device is not designed to be connected to the public utility AC power line Unauthorized modification of the device makes this declaration void Dobel 01 11 2008 Klaus Kern Managing Director 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 17 of 18 WG kke Imprint Purpose and use The operating instructions explain th
10. e construction and operation of the ultrasonic generator soniKKs K1 W D in connection with standard accessories for use in laboratories and the industry Please read especially the safety instructions carefully and observe them all time The operating instructions should always be at hand to help you to solve any questions and problems that may arise All rights reserved The manual has been prepared with all due care nevertheless faults and omissions cannot be fully precluded soniKKs GmbH reserves the right to make changes to the technical data and specifications during the curse of further development of the product Without given prior notice The warranty does not cover any malfunctions injuries and damages that result from such use or improper operation in use Address Editing soniKKs Ultrasonics Technology GmbH first edition August 2012 Neuenburgerstrabe 72 75335 Dobel Germany Phone 49 0 7083 92 48 360 Fax 49 0 7083 92 48 370 Mail info sonikks de www sonikks de www sonikks com 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 18 of 18
11. l service gt Never open the unit or in any way tamper with it This will void your warranty and may cause an electric shock gt For any cleaning or maintenance of the device please disconnect the mains supply gt All maintenance should be done by trained staff only gt Please pay attention at all warnings and hints in this manual and on the generator gt Take care of the mains supply voltage Over or undervoltage can cause malfunction or destroy the generator gt Always place the generator on a stable and flat surface gt Correct operations can only be guaranteed if the generator is used along with the recommended ultrasonic transducers gt Use only the recommended interface cables Do not coil up the RF cable or the line cord Coiling up these cables can cause overheating of the cables gt While using the generator with sonotrodes do not touch horn and sonotrode Caution could be very hot gt Never focus the connected transducer at people gt If you work with sonotrodes please wear an adequate ear protection or just operate in an acoustic noise protection box gt Please avoid the operation of the generator in presence of animals They have a more extended frequency range of audible sound than people ATTENTION Continuous operation will lead to hot surfaces of the horn and the Sonotrode They can heat up to 100 C 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 5 of 1
12. lug How to fix the problem 1 Check the transducer converter and sonotrode exchange them if necessary 2 Check cabling and connectors exchange them if necessary 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 14 of 18 GW kke Overtemp LED lights up or flashes If the generator gets overheated during sonification the Overtemp LED will light up and the generator switches off automatically When cooling down below the trip point the generator restarts automatically The Overtemp LED will flash to signalize this error until the generator is switched off with the test button or the remote control Possible reasons gt The cooling slots are obstructed gt Device is placed too close to another heat source gt Malfunction in the converter gt Malfunction of the fan How to fix the problem 1 Check the fan Check the cooling slots on the backside of the generator 3 Check device placement pay attention at the placement advice The generator starts and stops on its own How to fix the problem 1 Set the Timer value to zero 2 Verify that the MODE LED is off 3 Restart the generator 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 15 of 18 GW kke a Maintenance and care There is no need for special maintenance Please remove any dust and dirt with a damp woven fabric Do not use any chemicals to clean the gener
13. m corrosion of the device Avoid heat sources close to the generator to prevent overheating 2013 04 06 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 6 of 18 sSonikKKsS ULTRASONICS TECHNOLOGY Electrical connection N The generator may only be connected to a proper mains supply The allowed voltage is 230 Volt AC 50 60Hz eizspannung 210 250 V AC Linevoltage LtN PE 50 60 Hz Max 600 Watt 850 VA l Dauerleistung continuous power The mains supply must have a protective earth oo connection Care must be taken that the supply connection carries neither over nor undervoltage this may cause malfunction or even damage the unit Technical Data 260 x 85 x 200 mm approx 2 kg IP 20 IEC 60 529 EN 60 525 Depending on generator type 20 100 kHz 210 250 VAC 50 60Hz Depending on model up to 4 A Maximum 800 w 10 C through 40 C not condensing 2013 04 06 sonikKKs GmbH Ultrasonics Technology Doc nr 3000 2301D B page 7 of 18 GW kke a Connections on the backside of the generator Standard version om Connections from left to right gt Transducer connector gt Interface connector gt Mains switch gt Mains supply Version for the connection of a hand welding pistol with LEMO socket Connections from left to right gt Socket for the connection of the hand welding pistol gt Mains switch gt Mains supply
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