User Guide Display and Firmware Generator model “W“ with touch
Contents
1. soniKKs ULTRASONICS TECHNOLOGY User Guide Display and Firmware Generator model W with touch screen SAAS _____ _eL_ILTRASONICS TECHNOLO GY 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 1 of 33 soni lt kKe ULTRASONICS TECHNOLOGY Table of contents TDC Or CONE N ere E EEE EE EE 2 Calibration OF the TOUE I SC CCA ste ce atie cect artes aectuctnrsts isinna 4 Parameters security scan ceacenaacaasenencnsantanaesraeesensun oeneane cannes ouarauanautansaeaaneninnavaeoutsauanerneteantan 4 SESLE OLS D a D e rte E E A A E E ete cw chet O E A E E E E AE A A 5 Navigation CNAN aseran EA A A 6 Menu iteme aa Oper eene A ENANA A A EAEN AAO ONENA 8 1 Frequency display Start screen cissercventeesannternvaes insane cnet eieee een 8 De VIO E E eee eee 9 2 AP boll Oe nee ne ener ee ee ne ree ee ae 9 Bale 2p POS oe nt vcs tn AEE ens ete E RA 10 Duc Cle VS ING PE E T E E E E sates A eee 11 5 3 717018 UI reer 11 3 4 F Start Start frequency cccsssessssseccccuusursesseccecuususseseecausursussesaecausursessesas 12 3 5 MONILO aeee E ees ee 13 3 6 NOMINA isee E E E E EEA 14 3 7 OO aE EENE EE E EE E A AE EEN 15 38 EE E aerate E S E E E AE 16 3 9 Eno LOD EE E E E E E 16 3 10 EEN i a E tacts eee cee eee en eee camer eee E E E 17 FI BI Ea T E EE E EE E E E E E 17 3 12 Date TIMO eera AE OEE N A EE AEI EA AE EEEE e 18 3 13 SOLE cen eee eee ee ee 18 3 14 Testbutton2. An additional screen makes it possible to visualize all the presets and to handle the memory the generator It is reachable through the PRESET button on the top left corner 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 28 of 33 soha ULTRASONICS TECHNOLOGY 2 Presets Screen This screen allows having an overview of the presets stored in memory The 32 preset slots contents only welding time and welding energy though can be visualized here thanks to the arrows on the right of the screen In addition this screen allows clearing the slots storing the current parameters in different slots or recalling a preset without having to go through all of them These actions can be done by touching a line of the array A pop up will then appear asking you to choose an action As you can see on the write the selected preset is then highlighted in the background Note that CLEAR will clear the slot 0 and this preset will no longer be available when cycling with the handgun s double click feature As shown on the screenshot on the right the actions are different depending on the slot you select Touching an empty slot will only propose you to store the parameters in it for instance As for clearing several slots at once this can be done by touching the first column of the array i e the slot indexes When selecting a first preset the latter will be highlighted but no pop up will
3. gt ON the generator is set to stop after a predetermined condition is Mode LED reached These conditions are time or energy gt Blinking one or more welding cycle parameter is set Indicates the effective ultrasonic power in steps of 10 of the wn t t Of 4 3 Output o gauge nominal power SONIC ERROR lt gt NOMINAL OVERTEMP MODE 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 5 of 33 sonikKKs ULTRASONICS TECHNOLOGY Navigation chart Your logo Hello Tak Touchscreen calibration l Menu items Overview Frequency display Start screen Amplitude F Start a On Ti rasi Start i ma Adjust Adjust Screen otme amplitude Start frequency Energy Time me A Min offsets E Analog Digital LSEM g Digi A Max offsets P Out Security levels Load or save Shows logged SNE function adjustments errors POES on of Contrast A Show adjust Adjust the Backlight i date and time menu items Beep Testb Rem bevels Err relay ri HF relay Shows data Mixed omore HF relay mode IXe levels 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 6 of 33 N sonikKKs ULTRASONICS TECHNOLOGY Window Security levels Without password Level 2 Level 3 Mixed levels 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 7 of
4. 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 14 of 33 N sonikKKs ULTRASONICS TECHNOLOGY 3 7 Offsets ATTENTION You must consult the manufacturer before you change these values Danger of damaging the transducer system As explained in the Overview screen description page 19 the amplitude of the vibrations of the sonotrode is adjustable from 50 to 100 Those percentages correspond to two physical values Amin and Amax expressed in um which are respectively the minimum and maximum amplitude This screen allows you to tune those two values by adding offsets to them These offsets are called A min offset and A max offset They are given in the form of signed percentages of the maximal amplitude Amax adjusted in factory On the graph below this value is called Amax f where f stands for factory In this example the user sets Amin offset to 40 and Amax offset to 20 In this case as shown on the graph the minimum amplitude will be decreased by 40 of Amax f while the maximum amplitude will be decreased by 20 of Amax f Amplitude Hm AMAX f PEARS PA ATIF Original operating range Amax offset Amax APA nnn ss Tuned operating range AMIN f KAAPS AARRE A Amin Amplitude 50 100 AMin offs and AMax offs Proceed as usual to activate the adjustment mode and change the settings
5. 3 16 Handheld mode The generator features a special mode for hand welding applications which allows the user to scroll through the different presets by double clicking with the handgun s trigger Handh Mode 5 This screen allows activating deactivating this mode See the Handheld Mode section for more details 3 17 Sensorics This screen displays various pieces of information gathered by the sensors present in the generator In case your generator does not feature one of them no value will be displayed at the corresponding line see Ext Temp on the right Ext Voltage Generator Teme Ext Teme gt Ext Voltage voltage applied to the interface pin 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 20 of 33 ULTRASONICS TECHNOLOGY gt Generator temperature gt Ext Temp temperature measured by the external temperature sensor The EXIT button leads back to the settings menu 3 18 Info Here you can readout following data of the generator Front front firmware version Silicon processor version Engine generator firmware version Datecode date of manufacture Serial number of the generator Runtime Bus address if the Profibus option is available VV VV VV Y The EXIT button leads back to the settings menu 3 19 Window The monitor function page 13 enables you to set windows fo
6. gt Power am e You can define windows that are bounded by threshold values If one of the operating values exceeds its window the lt gt Nominal LED will turn on You can also configure the device to signal an error see Window menu item This function can especially be used to detect if no transducer is connected to the generator In this case the power and energy at the end of the run will be null You can detect this anomaly by setting an energy and or power minimum threshold to a value higher than zero This screen enables you to modify the limits of the windows Note that the min max values constrain each other i e a minimum value can never be higher than a maximum value The generator will automatically adapt the peer value if necessary Tap the value of your choice to modify it The adjustment of the values in every Data input screen is done the same way 6 example values are arranged in an array where the bottom left value is the minimum and the top right value the maximum The arrow keys on the right side allow for coarse tuning double arrows and fine tuning simple arrow v T Min E Min und P Min set the lower limit v T Max E Max und P Max set the higher limit v The monitoring function controls now whether the operating values correspond to the windows or not Time T Min and T Max 0 0005 valid values 600 4 800 i 6 000 0 000 1200
7. 2400 3 single arrow 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 13 of 33 GW kke ULTRASONICS TECHNOLOGY Energy E Min and E Max e000 i 3333 aka i so 4 2000 4000 i 1 Joule The EXIT button leads back to the settings menu 3 6 Nominal In this menu item you can configure whether the nominal amplitude is tuned via an external voltage analogically or over the communication buses digitally v If the Analog mode is selected the amplitude can no longer be adjusted via the digitally It is instead set re via an external voltage 5 10V standard or rather 0 Digital 10V user specific adjustment corresponding to 50 100 amplitude If you tap the Amplitude area in the Start screen or in the Overview screen in analog mode the Nominal screen pops up You can then modify the nominal source If you enter the Amplitude screen in the settings menu the device displays Parameter not available Before you can adjust the amplitude you have to change the mode to Digital v If the Digital mode is chosen the amplitude can be adjusted via the touchscreen in the Amplitude screen or over the communication buses Select the mode by tapping the corresponding area or using the arrows on the right The selected option appears above the array The EXIT button leads back to the settings menu
8. The EXIT button leads back to the single arrow steps of 1 settings menu aa yealid intarnysi AN Of tna LOR OL ke l if L5 A 2 TU O LU TAJI 0 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 15 of 33 sonikKKs ULTRASONICS TECHNOLOGY 3 8 Presets The generator offers the possibility to save one or more sets of parameters in order for them to be restored easily Therefore 32 preset memory slots are available 0 31 The following parameters are saved Amplitude Starting frequency Modes Energy Timer Controls Monitoring Amin Amax Offsets VV VV V At first you select one of the preset memory slots by tapping it or using the arrows on the right The single arrow moves the cursor one step further with each touch whereas the double arrow gives five steps Now you have the possibility to delete the memory slot with CLEAR if there is a preset With STORE you save the current adjustments in the selected slot With RECALL you restore the adjustments present in this slot The EXIT button leads you back to the settings menu NB This screen is only available in the menu if the handheld mode is disabled see Handheld mode section 3 9 Error Log The generator features a time stamped event log that logs errors and unusual system events to the non volatile memory Log Entry 1 a of the device cd iae deta ls i o Ho p This screen all
9. Trivver Regarding the Testbutton 4 modes are available Off E ae Push Push Latch and Trigger v off the testbutton is disabled v Push as long as you hold the button the generator is on v Latch tapping the virtual testbutton switches the generator on tapping it again switches the generator back off v Trigger this option is only recommended when at least one of the special operation modes Timer or Energy is used A short pulse starts the generator Then the device automatically switches off when the predetermined time or energy is reached Tap the mode of your choice to select it The now selected adjustment appears as a heading above the touch icons With the arrows on the right side the mode can also be modified In doing so single and double arrow have the same function Different remote options are settable Latch Static and i generator Trigger off SER E 1 f Latch v Latch activating the remote switches the generator on y y K remote dinni off activating it again switches the generator back off gt Storage function m v Static the generator directly switches on or off if there ganora is a remote signal gt No storage function n SUG v Trigger this option is only recommended when at least _ ranpe Sgn one of the special operation modes Timer or Energy is Time Energy used A short pu
10. is done the same way 6 example values are arranged in an array where the bottom left value is the minimum and the top right value the maximum The arrow keys on the right side allow for coarse tuning double arrows and alic g interv higl igh fine tuning simple arrow steps of 1 Concerning the adjustment of the double arrow Backlight you have the choice between the adjustments Dim On and Auto v If you want the backlight to be active every time select On v If you want the backlight to turn off automatically after some time select Auto v To turn the backlight to a lower level select Dim 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 17 of 33 ULTRASONICS TECHNOLOGY Just touch the icon showing your desired mode to select it The now selected adjustment appears as a heading above the touch icons With the arrows on the right side the mode can also be modified In doing so single and double arrow have the same function Concerning the adjustment of the beeper there is the choice between the adjustments On and Off Just touch the icon showing your desired mode to select it The now selected adjustment appears as a heading above the touch icons With the arrows on the right side the mode can also be modified In doing so single and double arrow have the same function The EXIT button leads back to the settings menu
11. 3 12 Date Time This screen displays the current date and time set in the generator 20 O8 20 1 2 It is recommended to set date and time because it is used 12 47 05 for the error log and can simplify the diagnosis To adjust date and time touch the arrows to increase decrease the desired number day month year hour minute When you have finished settings these parameters press the exit area to leave this screen The EXIT button leads you back to the settings menu 3 13 Screens In this screen you can selectively disable or enable menu Or Modes 2 Amelitude items F start J Monitor You enable or disable the individual menu items by touching Adee He niiata OF 15 gt ecurit the text or the check box of the belonging menu Testb sRem Pelavs Handh Mode sSensorics Setup v If there is a cross in the box the menu item is shown ee ee in the settings menu v If there is no cross the menu item is hidden You can change the adjustments every time and thus modulate the settings menu to your exercise The EXIT button leads back to the settings menu 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 18 of 33 ff N sonikKKsS ULTRASONICS TECHNOLOGY 3 14 Testbutton Remote In this screen you can set the operation modes of the virtual testbutton and the remote signal You can navigate via the tabs between Testb Remote Latch
12. 33 i N sonikKKs ULTRASONICS TECHNOLOGY Menu items and operation The navigation is operated by a resistive touchscreen All inputs are done via pictured buttons which the user simply has to tap Hereby you profit from a comfortable handling simplifying the input and navigation It often can be helpful to use a pencil for input and confirmation as the buttons are sometimes rather small However you must pay attention that the pencil is not too sharp We recommend special touch pencils or ball pens out of plastic with plugged in needle Ball pens out of metal can scratch the display and thus are not recommended Moreover the use of a pencil plumb or a felt pen is disadvantageous because they often leave color 1 Frequency display Start screen The Start screen displays the current working frequency in big digits If the generator is not delivering any sonic then the starting frequency is displayed 60 70 By touching the frequency value you enter the F start menu item in which you can adjust the starting frequency as d MPL 602 MIR described in chapter 3 4 OVERVIEW leads to the Overview screen gt see chapter 2 MENU opens the settings menu gt see chapter 3 The lock symbol shows if the passwords are active or not An open padlock indicates that the passwords are inactive whereas a closed padlock indicates that the passwords are active For more information gt see chapt
13. appear Instead you will have to select a second index All the presets in between will then be selected and the CLEAR button will pop up In the screenshot on the right indexes 0 and 2 or the other way around have been selected MHENU ENERGY OVERVIEW 20 0003 6 6005 E 0003 OVERVIEW BO ia ES OVERVIEW TIME Note that you can leave the pop up without doing any action For this you just need to touch somewhere else 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 29 of 33 sonikKKs ULTRASONICS TECHNOLOGY Fault report and fault clearance OVERCURRENT PROTECTION F touch 4 OVERTEMP 79 C t check fans 4 NO VOLTAGE ON OUTPUT k touch 4 NO RESONANCE P touch 4 OVERLOAD P touch 4 2015 01 28 soniKKs GmbH Ultrasonics Technology Transducer broken Short circuit at RF cable Error of the generator Start frequency too close to resonance frequency Fan broken Error of the generator Transducer broken Error of the generator Transducer not connected or broken Cable broken Generator overloaded Doc rr Replace transducer Replace RF cable Contact sonikKKs Select a higher value for the start frequency Check if fan works Contact sonikKKs Replace transducer Contact sonikKKs Connect or replace transducer Replace cable Reduce compacting power Use generator with more power 3010 2300 C
14. mode Setting it to Latch or Trigger mode will deactivate the handheld mode 1 Start Screen When the handheld mode is active the home screen changes to the one on the right PRESETS MENU 1 lee 41 00kHz It contains among others Power OW an overview of the current parameters of the Time 2 OOE generator 1 Energy an indicator of the currently active preset 2 i a SAVE button 3 to overwrite the active preset with the current parameters The parameters stored in this mode are the Start Frequency first line the welding time third line and the welding energy fourth line You can modify each of them by touching the corresponding line Once you have modified them the SAVE button allows you to store them in the indicated preset memory here preset 0 After pressing it note that the SAVE button will be disabled PRESETS i MENU see screenshot on the right meaning that the current gate 41 00kHz parameters have been saved It will be re enabled if you stems ain modify the parameters again Time 5 0005 DESET Energy SOOJ 0 The preset indicator area has a second function It can be fd AMPL coz Mets used to cycle through the presets as one would do with by erines double clicking the handgun s trigger By touching the area the next preset will be recalled ATTENTION Make sure to save any modification before cycling to the next preset All unsaved changes will be lost
15. page 30 of 33 aati ULTRASONICS TECHNOLOGY Change history Generator firmware revision 1 12 395 3233 The end of the welding cycle is now notified by an acoustic signal if the beeper is enabled 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 31 of 33 soni lt kKs ULTRASONICS TECHNOLOGY 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 generator 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 The warranty does not cover any malfunctions injuries and damages that result from such use or improper operation in use 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 WV 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 32 of 33 soni lt kKe ULTRASONICS TECHNOLOGY Imprint Purpose and use The operating instructions explain the handling and operation of the software
16. EE A ENEAS 30 cnan de NI TON araa E A E E E EO EE 31 Maintenance and Caf ssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nananana nnno 32 AE EIEE EPE E E E E E P A T 32 ADAIN era E EEE EA EEEE EA EEE 33 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 3 of 33 i N sonikKKs ULTRASONICS TECHNOLOGY Calibration of the touchscreen To re calibrate the touchscreen power cycle the generator while you keep the touchscreen pressed On the display appears the message calibration mode touch to start Just follow the on screen instructions and touch the markers on the screen If the process is finished the display shows calibration complete touch to start the application Answer the question whether you want to use a rotary encoder or not with No It may be necessary to repeat the process to get satisfactory results Parameters security To protect the device and consequently the production flow the unit features a unique three level security concept based on numeric passwords Every user can perform basic operations like setting the display s contrast However a password must be entered for the process relevant parameters to be modified The passwords can also be disabled for a better ease of use There are three distinct password levels gt Level 1 User settings gt Level 2 Advanced settings gt Le
17. Remote cee tcercerrtrsetsarea cesta rete eete wre tence ween ewe sew cenee escent sereeneemereeeen 19 Cm hs RCI AY e EN E EE E A EE EE 20 3 16 TEENE ean r A A A E A E F 20 Cae DB CIISOMCS acosanceannsesensest diss NE EN E EE ENE E ETT 20 3 18 NiE ZEE A EEEN E EENEN A E EE EE E 21 3 19 WUT GOW ENEN N EEEE NEE AEE E EE EES EE E E EREE 21 3 20 SSID AE EE E E E E E E E 21 3 21 FACTORY aeee EEEE EEEE EES 22 IGE d e e N E EEEE E E E EEE E E E F 22 4 1 Weld User MOO nassyusauanineteamneentanii steven iriure ausu rs aRar asiasia 23 4 2 Ha U Ar MOG seanetues tune tens cana reee ye AEE EEE EAEE EEEE 24 Cycle welding MOQO sae upsssavesccisseunavessn thence utsesrncdesttacenen tte ugeseteeacencdanuanccedscenitevenssttaenentteregent 25 E Papo Or WS TES cca ctccece sete ererepeeettte E E 25 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 2 of 33 K sokka ULTRASONICS TECHNOLOGY Pe eS LEDS aaa E E E EEST 25 S TEPUNG ranna AEAEE EEEE L EDERA 26 EC E eee tie E E E nem E E E E an asesacce acess 26 5 Parameters of the welding CyCle ccccsescsecseccsecsecesecnecusncuecusneneensuensensuesecuseeuenseestensas 26 i aE ES pE g E E E EE FE EEEE EOE EEE EEEE 27 Handheld mode ssssssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 28 e SC T OE EEEE EEEE EEEE EEEE ER 28 De Pe oeo E a E EEEE EEEIEE EEEE 29 Faut repot and TAU EG Cal QC pereira irren N EE
18. alues in every Data input screen is done the same way 6 example values are arranged in an array where the bottom left value is the minimum and the top right value the maximum The arrow keys on the right side allow for coarse tuning double arrows and fine tuning simple arrow On Timer and Off Timer Energy single arrow steps of 1 single arrow 1 Joule The EXIT button leads back to the settings menu 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 10 of 33 S sonikKs ULTRASONICS TECHNOLOGY 3 2 Cycle Welding If your generator is configured as a cycle welding one this jim Sane screen will replace the Op Modes screen Here you will be ie TA pas able to configure the timings of your welding cycle Moreover WelaTvE note that the welding on energy mode is also available Hold Htterh gt Delay the time between the user s start PRS E co request remote activation and the moment the generator starts welding gt Weld T E welding time On Timer and welding energy see Op Modes section gt Hold a delay after the generator has stopped emitting The press then holds the parts together to let the weld cool down gt Afterburst the duration of an additional HF burst optional This final burst is used to clean the sonotrode Tap the value of your choice to modify it Please refer to the Welding cycle mode se
19. ction for further information especially the timing chart 3 3 Amplitude In this menu item you can adjust the desired amplitude The adjustment of the values in every Data input screen is done the same way 6 example values are arranged in an array where the bottom left value is the minimum and the top right value the maximum The arrow keys on the right side allow for coarse tuning double arrows and fine tuning simple arrow enk Aal Amelhtude Amplitude single arrow steps of 1 The EXIT button leads back to the settings menu 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 11 of 33 sorka ULTRASONICS TECHNOLOGY 3 4 F start Start frequency ATTENTION The start frequency should be modified by experienced personnel only An incorrect adjustment could damage the generator Make sure to follow the advice given in this section First let us be clear about what the Start frequency Resonant Start frequency represents When the generator is turned on it starts frequency emitting ultrasonic power at a certain frequency the start frequency hence its name Then the generator endeavors to tune the operating frequency to the resonant frequency of the connected transducer system This auto tuning function works downwards only which means that the generator will be scanning a limited range of frequencies below the start frequency The graph on th
20. e right shows the behavior of the impedance of a transducer in function of the excitation frequency yellow curve The resonant frequency is reached at the point of lowest impedance max 0 5kHz Setting the start frequency too close to the resonant frequency of the system might cause the error amplitude protection active In this case please set the start frequency to a higher value see also Troubleshooting On the other hand setting the start frequency too high could cause the generator not to find the resonant frequency since the scan range is limited In this case the generator could emit at a wrong operating frequency which could be harmful to the equipment Ideally it should always be set to 0 5kHz higher than the resonant frequency of the transducer system If the latter is unknown use the originally set start frequency depending on model Starting frequency f start valid interva Depending on model F Start 60 70kHz single arrow steps of 10 Hz 61 00 62 00 6300 53 00 60 00 double arrow The EXIT button leads you back to the settings menu 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 12 of 33 S sonikKKs ULTRASONICS TECHNOLOGY 3 5 Monitor The generator features monitoring functions With those it is possible to control a welding process on Time 0 000 0 000 Eneray ip 07 Ime gt Energy P Out 0 100
21. er 3 10 The AMPL xx label indicates the current amplitude Touching this area will open the Amplitude menu item gt chapter 3 2 for adjusting the amplitude 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 8 of 33 sortie Ke ULTRASONICS TECHNOLOGY 2 Overview The Overview screen gives the following parameters EIG FREQ BIGFREG MENU 4 l Fr Ey Bil plt kHz 3 gt The current working frequency or the start frequency POLE rill if no sonic is being emitted gt F start Time a aaas TEST gt The current emitted power Ener q CJ gt The elapsed time gt Op Modes ci ALe N ci ALe N en gt The emitted energy gt Op Modes Touching frequency timer or energy yields to the input screens of the corresponding nominal values An on screen testbutton allows testing the current configuration and starting the generator manually The test button can be configured or disabled using the menu item The top left area BIG FREQ leads back to the main screen The other buttons MENU LOCK AMPL xx behave the same way as they do in the Start screen 3 Settings MENU The menu shows all currently activated menu items The selection is carried out by tapping a menu item The EXIT button allows getting back to the Start screen The gt gt and lt lt buttons allow scrolling through the different pages of the men
22. for the linear amplifier 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 sonikKKs 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 Address Editing soniKKs Ultrasonics Technology GmbH first edition August 2012 NeuenburgerstraBe 72 second edition March 2014 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 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 33 of 33
23. hether the Welding Cycle feature is enabled or not The generator will emit ultrasonic power as long as the testbutton signal is active see the Testbutton Remote section page 17 It cannot be used to start a cycle for instance Of course the testbutton will be ignored during the welding cycles 4 Beeper When ON the beeper will notify the user of the end of the welding cycles with a short signal 5 Parameters of the welding cycle The welding cycle can include up to four steps whose durations can be tuned by the user The different times of the welding cycle are v Delay the delay between the moments the remote input is activated and the generator starts welding v Weld Time Energy the generator emits ultrasonic power until the specified time energy threshold is reached If both thresholds are set the generator stops as soon as one of the two is reached v Hold Time a delay time after the generator has stopped emitting ultrasonic power This phase enables the press to hold the pieces while the weld cools down v Afterburst the time during which the generator will emit ultrasonic power at the end of the cycle The afterburst is used to remove the residues of material from the sonotrode In addition the user can also configure the Sonic output relay to act as a cycle status as explained on page 19 The output will then be active during the whole cycle i e from the start of the delay phase to the end of the afterburst
24. in addition to the previous chapters 1 Purpose of the feature The cycle mode has been designed to be used together with ultrasonic welding presses that do not feature a built in controller Controllers are commonly used in welding chains to make them more efficient and to improve their cadence In order to do this the controller makes sure that the ultrasonic energy is automatically delivered to the sonotrode at specific periods of the welding cycle during the welding time when the pieces are pressed against each other and optionally during an afterburst Therefore the welding cycles can be completed faster without any waste of time Thanks to this helpful feature the sonikKKs Welding Generator can replace such a controller giving your ultrasonic presses the intelligence they are lacking 2 Status LEDs The behaviors and meaning of the status LEDs of the generator are globally the same as described on page 5 The only changes concern the Error LED and the Mode LED which will work as follows e Welding Cycle mode disabled ON the generator is set to a timer or energy mode Mode LED e Welding Cycle mode enabled ON a welding cycle is ongoing 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 25 of 33 soni lt kKs ULTRASONICS TECHNOLOGY 3 Testbutton function Please note that the virtual testbutton in the Overview screen will keep the same function w
25. ki NB The user mode is not available on cycle weldin S y g Envlish Deutsch generators In this case the User mode tab will not be displayed in this screen as shown on the right 3 21 Factory In this screen you have the possibility to set the generator to the factory settings For this you need the level 3 password Reset to factory settings 4 User Mode You can activate the User Mode through the Setup menu item which you find in the settings menu Tap the User Mode tab so that the User Mode selection screen appears screenshot on the right Ott As you can see there are two different modes that are Weld and Lab They offer different behaviours as explained in the following chapters The device enters the user mode as soon as you select one of the two modes Once you exit the menu you will notice that the Start screen has changed to the screen on the right Note that the layout OP MODE of this screen is the same in both Weld and Lab modes POWER ENERGY ELAPSED TA Gla A 0DOS You can only exit the User Mode by tapping the bottom corners 10 times alternately left right left right This will lead you to the settings menu where you will be able to turn the user mode off 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 22 of 33 N sonikKKs ULTRASONICS TECHNOLOGY 4 1 Weld user mode The User Mode 1 pro
26. lse starts the generator The device t ow automatically switches off when the predetermined time or energy is reached Trigger Just touch the icon showing your desired mode to select it The sr now selected adjustment appears as a heading above the touch icons With the arrows on the right side the mode can also be modified In this case single and double arrows have the same function The EXIT button leads back to the settings menu 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 19 of 33 soha ULTRASONICS TECHNOLOGY 3 15 Relays The generator features two internal relays that drive the fraser error and HF outputs In this screen you can configure these N d output relays to act as a normally closed or normally open orm Close contactor gt Normally closed the output is low active gt Normally open the output is high active If your generator is configured as a cycle welding generator Err Rel FHF Rel etanarr ne a third parameter called HF relay mode will be available in HE Status this screen see screenshot on the right It allows configuring the behavior of the HF output gt HF status the HF output is active as long as ultrasonic power is being emitted gt Cycle the HF output is active as long as a welding cycle is ongoing NB if your generator is not a cycle welding generator it will come with the default setting i e HF status
27. ottom left value is the minimum and the top right value the maximum The arrow keys on the right side allow for coarse tuning double arrows and fine tuning simple arrow Timer P3600 i 4 00 BoD Off 2 1200 24 00 Steps of 1 sec 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 23 of 33 GW kke ULTRASONICS TECHNOLOGY v E nergy 6000 000 3393 S000 4000 Single arrow Steps of 1 Joule Cycle 6 000 000 10 000 3 H i OFF i E000 i 4 000 3 eae Cycle Value Cycle Value Example for Timer 1 min and Cycle 10 000 s Timein s 4 2 Lab user mode This second User Mode provides the following functions gt Operation in automatic mode with pre set amplitude gt Operation on pre set time gt Switching the generator on and off with the virtual testbutton On the left side in the middle there is the icon TIMER The Timer corresponds to the time function in the normal mode the On Time The generator emits power until the predetermined time value is reached If a timer is set the MODE LED will light up Proceed as usual to set this parameter Foes r Timer Steps of 1 sec 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 24 of 33 GW kke ULTRASONICS TECHNOLOGY Cycle welding mode If your generator is configured for cycle welding please take into consideration the following section
28. ows for easy access of the last 100 entries into a l 41 EE nET this memory each one having a timestamp and an error ae Se label or a numeric error code Use the arrows or the scroll handle to the right of the screen to page through up to 100 errors The EXIT button leads you back to the settings menu 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 16 of 33 K sonii lt kKs ULTRASONICS TECHNOLOGY 3 10 Security Here you can change the security settings e g switching the password function on and off Passwords If the password function is set to Off the screen looks like the picture on the right To activate the password function tap Off A confirmation message will pop up for you to confirm abort the process Once you have confirmed two additional parameters appear as shown on the right The level 1 and level 2 passwords can now be adjusted By tapping the corresponding area a menu will open in which a numeric password for the chosen level is defined To disable the password function tap the On area Confirm the action by tapping Yes in the pop up The EXIT button leads you back to the settings menu 3 11 Display Here you can change the display s settings You can navigate via three tabs between Contrast Backlight and Beep and modify the settings The adjustment of the values in every Data input screen
29. phase interface 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 26 of 33 sonii lt kKe ULTRASONICS TECHNOLOGY 6 Timing chart The graph below illustrates the welding cycle and its timings Delay Weld Hold _ J Afterburst OP On Off i l Time On i i i a R Ultrasonic Power Output off Time Active 3 3 E HF Relay Output HF Status Inactive Time Active Inactive 7 i Time On Mode LED Off 7 7 Time 3 j Error LED Off TE Time Start of Time Energy ene o ne the cycle threshold se aaa reached This behavior only applies in the case when a Weld Time and a Weld Energy are both set and the Weld Time expires before the Weld Energy is reached 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 27 of 33 ULTRASONICS TECHNOLOGY Handheld mode This mode has been especially developed for hand welding applications It allows the user to browse through the presets of the generator by simply double clicking the handgun s trigger By doing so the next preset found in memory will be recalled All the user has to do then is to configure the different sets of parameters that he wants to use beforehand This mode can be activated deactivated in the settings menu see page 19 Note that the remote is automatically set to Static mode when the activating the handheld
30. r time energy and power In case one of these operating values exceeds its window you can choose to be notified with an error by activating the window error in this screen Please note that the error will only occur when the generator is operated remotely 3 20 Setup Here you can configure the Language used by the device and enable disable the User Mode see below Concerning the adjustment of the language you can choose between four possibilities English German French and Polish Select the language of your choice by tapping the corresponding area or using the arrows on the right The now selected language appears as heading above the touch icons 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C WS NS ULETE Oxso0s EA oen go 1 2230 23 10 2011 Serial number 001 04 6 0 01700 Front Silicon Enang Datecode Pari time 10 7 7 03hr Eus address Window errors Polski Deutsch Fransais Ensvlish page 21 of 33 i sonikKKs ULTRASONICS TECHNOLOGY Concerning the tab User Mode you have the possibility to activate or deactivate this mode You can choose between two modes Weld and Lab The User Mode is only recommended for advanced users It allows simplifying the use of the generator by hiding unessential parameters For more information gt see chapter 4 The EXIT button leads back to the settings menu English Francais Pols
31. u Op Modes Amplitude Presets Error log esth Rem Relays F start Monitor Security Display Nominal Offsets DateTime Screens A Setup Factory 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 9 of 33 GW kke ULTRASONICS TECHNOLOGY yole Weld Amplitude Please note that the Operation Modes screen is replaced by the Cycle welding screen if your generator is configured for cycle welding 3 1 Op Modes The generator features two special operating modes g P P J Tin Timek lt gt Welding on time gt Welding on energy 60 000 180 000 99 999 Off 220 000 40 000 Both operating modes can be used simultaneously and are indicated by the Mode LED In this menu item you can navigate through three tabs On Timer Off Timer and Energy and determine your desired values v On Timer defines the time after which the generator stops emitting ultrasonic power v The activation of the Off Timer is optional It puts the generator in pulse operation on off on off With this parameter you set the time after which the generator turns back on v Energy activates the welding on energy mode If the here predetermined energy value is reached the generator turns off automatically If a Timer and an Energy values are both set the generator turns off as soon as one of these values has been reached The adjustment of the v
32. vel 3 Reseller settings The level 3 password cannot be disabled or modified via the touchscreen Indeed it is reserved to the reseller and thus not known by end users If any problems occur please contact our service Which passwords are required for which parameter is depicted in the navigation chart see chapter Navigation chart Once an access to a security level has been granted it remains unlocked for 60 seconds from the last input recognizable thanks to the lock symbol Of course higher level securities are still active After this period the device locks itself against unauthorized manipulation If you want to lock the device instantly touch the lock symbol in the bottom left corner of the Start screen See chapter 3 10 for more information 2015 01 28 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2300 C page 4 of 33 ULTRASONICS TECHNOLOGY Status LEDs Sonic LED ON ultrasonic power is active Error LED ON there is a malfunction of the generator ON a monitoring function has been set and the requested condition lt gt Nominal LED was not met during the last run Conditions are power time or energy windows ON the generator is overheating and the over temperature fuse has shut off the generator Overtemp LED gt Blinking the generator was shut down during the last welding process due to over temperature The LED turns off if you start the generator again
33. vides the following functions gt Operation in automatic mode with preset amplitude gt Operation with preset energy timer and or cycle timer gt Switching the sonic on and off with the testbutton On the left side in the middle there is the icon OP Mode The generator provides several modes gt Operation on preset energy gt Operation on preset time or cycle time You can use these modes simultaneously If one mode is set the MODE LED will blink In this display you can navigate between three tabs Timer Cycle and Energy and adjust the desired values v Timer during this time the generator emits ultrasonic power If the preset time is elapsed the generator automatically shuts off v The use of the Cycle timer is optional If this mode is chosen the generator is operating in a cycle mode on off on off The cycle time is adjustable with the arrows on the right side of the display Attention the cycle value has to be set to a time less than the timer v Choosing Energy the generator operates in energy mode If an energy is set the generator turns off automatically when this energy is reached e g during a welding process If also a time is set with the timer the generator turn off automatically either he has reached the time or the energy The adjustment of the values in every Data input screen is done the same way 6 example values are arranged in an array where the b
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