RINCO ULTRASONICS AG Standard 3000 User manual

RINCO ULTRASONICS AG
Operating instructions
Translation of the original operating instructions (English)
Read the operating instructions before carrying out any work
Standard 3000
with ADG generator

These operating instructions are protected by
copyright and intended solely for internal purposes.
Transfer of the operating instructions to third
parties, reproduction of any kind - also in part - as
well as the use and/or disclosure of the contents
without the written consent of the manufacturer is
not permitted.
RINCO ULTRASONICS AG
Industriestrasse 4
CH-8590 Romanshorn
Switzerland
Tel. no.: [phone]
Fax no.: [phone]
www.rincoultrasonics.com
Year of construction: 2013
Date of issue: April 2013
Document version: 5.1

RINCO ULTRASONICS AG Contents
BA_Standard3000_GB_V5.1_36566 iii
Contents
1 General information 7
1.1 Information on these operating instructions 7
1.2 Explanation of symbols 8
1.3 Disclaimer 9
1.4 Warranty terms 10
1.5 Customer service and product monitoring 11
2 Safety requirements 12
2.1 Introduction 12
2.2 Responsibility of the operator 12
2.3 Personnel requirements 13
2.3.1 General personnel requirements 13
2.3.2 Qualifications 13
2.3.3 Unauthorised persons 14
2.4 Personal protective equipment 15
2.5 Residual risks 16
2.5.1 Hazards from electric energy 16
2.5.2 Mechanical hazards 17
2.5.3 Hazards at the operating site 18
2.5.4 Pneumatic hazards 18
2.6 Emergency shutdown 19
2.7 What to do in the event of dangers and accidents 19
2.7.1 Preventative measures 19
2.7.2 Measures in the event of accidents 19
2.8 Symbols/pictograms 20
2.9 Intended use 21
3 Machine description 23
3.1 Overview/assemblies 23
3.1.1 Complete system 23
3.1.2 Sound enclosure (optional) 24
3.1.3 Oscillator unit 25
3.2 Controls and indicators 27
3.2.1 Welding press 27
3.2.2 Generator/AUI control module 32
3.3 Menu tree 35
3.4 Connections 38
3.4.1 Electrical connection 38
3.4.2 Compressed air connection 39
3.5 Marking locations 40
3.6 Welding technology 41
3.6.1 Process 42

Contents RINCO ULTRASONICS AG
iv BA_Standard3000_GB_V5.1_36566
3.6.2 Programming an initial application 43
3.6.3 Welding modes 44
4 Transport, packaging and storage 46
4.1 Safety warnings for transport 46
4.2 Delivery (packaging/packages) 48
4.3 Transporting packages by forklift truck or lifting cart 49
4.4 Transporting the sound enclosure by forklift truck or lifting cart 50
4.5 Transporting by crane 51
4.6 Transport inspection 53
4.7 Storage and extended downtimes 54
4.8 Pictograms on the packages 55
5 Assembly and initial start-up 56
5.1 Safety instructions regarding the installation 56
5.2 Set-up location requirements 58
5.3 Setting up the machine 61
5.4 Connecting the machine 62
5.4.1 Electrical connections 62
5.4.2 Compressed air connection 64
5.4.3 Jumpers 64
6Operation 65
6.1 Safety 65
6.1.1 Hazards from electric energy 65
6.1.2 Hazards from incorrect operation 66
6.1.3 Hazards from vapours and particulate emissions 66
6.1.4 Hazards from noise emission 67
6.1.5 Hazards from materials 67
6.1.6 Mechanical hazards 68
6.2 Example application 69
6.2.1 ADG generator 69
6.2.2 ADG generator error signals 70
6.2.3 ADG generator and sound enclosure 71
6.2.4 ADG generator with special actuators (automatic start mode) 72
6.2.5 Switch data set function 73
6.3 Process programming 76
6.3.1 Setting up parameterization PIN 76
6.3.2 Advanced system operation 77
6.4 Data analysis 83
6.4.1 Statistics 83
6.4.2 Data string 84
6.4.3 Logging parameter data set via RS232 86
6.5 Setting up 87

RINCO ULTRASONICS AG Contents
BA_Standard3000_GB_V5.1_36566 v
6.5.1 Installing the oscillator system 87
6.5.2 Replacing the booster 88
6.5.3 Setting up the tool 88
6.5.4 Aligning the fixing plate 91
6.6 Steps prior to use 92
6.7 Starting the machine 92
6.8 Switching off 93
7Maintenance 94
7.1 Safety instructions 94
7.2 Maintenance schedule 95
7.2.1 Daily maintenance work on work finish 95
7.2.2 Semi-annual maintenance work 96
7.2.3 Annual maintenance work 96
7.3 Maintenance work 97
7.3.1 Cleaning the machine and surrounding area 97
7.3.2 Servicing the compressed air maintenance unit 99
7.4 Measures after completion of the maintenance work 99
8Faults 100
8.1 Safety 100
8.2 What to do in the event a fault poses a danger 101
8.3 Troubleshooting 101
8.3.1 General errors 101
8.3.2 Generator error LED1 101
8.3.3 Converter and application error LED2 102
8.3.4 Limit error LED3 103
8.4 Description of error range (error group) 104
8.5 Error tables 105
8.5.1 Generator errors 105
8.5.2 Press errors 107
8.5.3 Sound enclosure errors 107
8.5.4 Limit errors 109
8.5.5 Digital I/O errors 110
8.5.6 Hardware errors 110
8.5.7 Serial RS232 error 112
8.5.8 CANopen errors 113
8.5.9 Limit warnings 113
8.5.10 Parameter warnings 114
8.6 Troubleshooting measures after completion of work 115
9 Disassembly and disposal 116
9.1 Safety 116
9.1.1 Personnel 116

Contents RINCO ULTRASONICS AG
vi BA_Standard3000_GB_V5.1_36566
9.1.2 Personal protective equipment 116
9.1.3 Safety instructions 117
9.2 Measures before disassembly 118
9.3 Disassembly 118
9.4 Disposal 118
10 Technical data 119
10.1 General information 119
10.2 Dimensions and weights 119
10.3 Connected loads, limit values, electrical 121
10.4 Connected loads, pneumatic 121
10.5 Press 122
10.6 Base 122
10.7 Generator/control 123
10.7.1 Fuses 123
10.7.2 Analogue and digital inputs and outputs 124
10.8 Ultrasound 126
10.9 Emissions 126
10.10 Operating conditions 126
10.11 Pin assignments 127
10.11.1 Inputs at STO_2_1 (DSUB25) 127
10.11.2 Outputs at STO_2_2 (DSUB25) 128
10.11.3 Press at STO_3 129
10.11.4 Two-hand release at STO_5 130
11 Replacement parts 131
12 EC Declaration of Conformity for machines 132

RINCO ULTRASONICS AG General information | 1
BA_Standard3000_GB_V5.1_36566 7 / 137
General information
Information about these operating
instructions
We are pleased that you have decided to buy a RINCO product. We are con-
fident that by using this device you will achieve a high degree of efficiency
and product quality.
These instructions describe the ultrasonic welding systems Standard 3000
and Standard 3000 with sound enclosure SSK-H or SSK-K in operation with
the generators ADG 20-1000, ADG 20-1500, ADG 20-2000 and ADG
20-3000.
The purpose of this manual is to provide the customer and operator with all
the information necessary to handle, assemble, operate and maintain the
device. These operating instructions enable safe and efficient handling of the
machine. To ensure safe operation, it is essential that all the safety informati-
on and work instructions in this manual are observed.
Read and observe these operating instructions before unpacking and
starting the device. The device may only be used, maintained and repaired
by persons who are familiar with the operating instructions and the appli-
cable occupational safety and accident prevention regulations.
These instructions are part of the machine and must be stored easily acces-
sible for the personnel in the immediate vicinity of the machine.
In addition to the operating instructions, the signage on the machine applies.
Attach any technical modifications to these instructions. Furthermore, the
local accident prevention regulations and general safety regulations for the
application range of the machine apply.
The information contained in this publication is based on our current know-
ledge. However, it cannot be regarded as a guarantee of certain characteris-
tics or suitability for certain purposes of the products concerned. Our general
contract terms and conditions apply, also with regards to liability. No industri-
al property rights of any kind are granted to the user with the publication of
this information, nor any assurances made with regard to a licence. Separate
agreements must be made in this case. For certain applications, the suitabili-
ty of the products must be checked by our specialists. For the correctness of
the information, the German version of this publication is authoritative.
Illustrations in these instructions are provided for general understanding and
may differ from the actual design of the machine.
Order a replacement copy immediately if you lose these operating instruc-
tions. See the Legal Notice for contact details.
NOTE
Contact RINCO ULTRASONICS AG if you require telephone
support or training by skilled personnel.
1
1.1
Foreword
Legal force
Using these instructions
Reading obligation
Storage location
Applicable documents, regulations
and provisions.
Restriction
Illustrations in these instructions
Loss of the instructions

1 | General information RINCO ULTRASONICS AG
8 / 137 BA_Standard3000_GB_V5.1_36566
Explanation of symbols
Symbols are used to denote safety warnings in these instructions. Signal
words are found at the start of the safety warnings are used to express the
severity of the hazard.
Safety instructions must be observed and proper care must be taken to
avoid accidents or injury and damage to property.
DANGER
... indicates an imminent dangerous situation that will result in
death or serious injuries if not avoided.
WARNING
... indicates a potentially dangerous situation that could result
in death or serious injuries.
CAUTION
... indicates a potentially dangerous situation that could result
in minor injuries.
NOTICE
... indicates a potentially dangerous situation that could result
in damage to property.
NOTE
... indicates helpful advise and recommendations as well as
information for efficient and trouble-free operation.
1.2
Safety instructions
Tips and recommendations

RINCO ULTRASONICS AG General information | 1
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Disclaimer
The information and safety instructions in these operating instructions have
been composed with regard to the applicable standards, guidelines and
regulations, the state of technology and our years of experience.
The scope of delivery and the machine version may differ from the descrip-
tions and illustrations in these instructions due to the availability of optional
equipment, production of customised models or technical changes reflecting
technological improvements.
Beyond the contractually negotiated obligations, the General Terms & Condi-
tions and the manufacturer's delivery terms also apply. These are subject to
the applicable laws governing at the time the contract is signed.
The publication date of these operating instructions applies. We reserve the
right to make technical changes to the machine as part of developments to
improve its safety and functionality.
The manufacturer shall not be liable for damage and accidents related to the
following points:
▪ Non-intendeduseofthemachine
▪ Non-compliancewiththeinformationandwarningsgivenintheseopera-
ting instructions
▪ Workonorwiththemachinebyunqualifiedorunauthorisedpersonnel
▪ Installationofnon-originalreplacementparts
▪ Unauthorisedmodificationswithoutthewrittenapprovalofthemanufactu-
rer
▪ Useofnon-approvedoperatingmaterials
1.3
Information in these instructions
Delivery
Technical changes
Exclusion of liability in the case of
non-compliance

1 | General information RINCO ULTRASONICS AG
10 / 137 BA_Standard3000_GB_V5.1_36566
Terms of warranty
With the delivery of the machine, RINCO ULTRASONICS AG has assumed
a warranty obligation according to VSM (Swiss Machine Manufacturer
Association).
The following requirements must be met for RINCO ULTRASONICS AG to
fulfill its warranty obligations:
▪ Theusermusthaveknowledgeofthecontentoftheseoperatinginstruc-
tions.
▪ Theinstructionsandwarningsintheseoperatinginstructionsmustbe
observed.
▪ Unauthorisedconversionsormodificationstopartsofthedevice,the
oscillator system and the generator are not permitted.
The manufacturer will make final decisions on warranty claims following the
return or return shipment of all defective components, or following an on-site
inspection if necessary.
The replacement of defective parts does not extend the warranty of the
machine.
Modifications or significant repairs by the operator or third parties undertaken
without the written consent of the manufacturer void the warranty.
1.4
Location
Basic information

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Customer service and product monitoring
In the case of technical malfunctions and welding problems, the Technical
Customer Service of RINCO ULTRASONICS AG will be happy to help. See
the Legal Notice for contact details.
For requests concerning your ultrasonic welding machine Standard 3000
and the ADG generator, Customer Service will require the following informa-
tion:
▪ Adetaileddescriptionofthetechnicalfaultorweldingproblem
▪ Devicename
▪ Theexacttypecodeanddeviceserialnumber.
See chapter Marking locations [}40] for information on where the
type plates are located on the machine.
In our efforts to constantly improve our product, we in the Customer Service
department are interested in hearing about your experiences in working with
the machine.
Please inform us of any problems or errors that you may have encountered
while handling the machine.
Please notify the manufacturer of any accidents or hazardous incidents.
The design and wiring of this device are constantly being developed and
improved and are always state of the art.
1.5
Customer Service
Fig. 1: Type plates
Product monitoring
Advancement
BA

2 | Safety requirements RINCO ULTRASONICS AG
12 / 137 BA_Standard3000_GB_V5.1_36566
Safety requirements
Introduction
This section provides an overview of all key safety aspects for optimum
safety of the personnel, as well as safe and trouble-free operation.
Non-compliance with the instructions and safety warnings in these operating
instructions can result in considerable risks.
These operating instructions can only include the risks identified based on a
risk assessment. Risks that occur as a result of working conditions, the
location of the machine and the interfaces with external components must be
determined and the safety instructions amended accordingly.
Responsibility of the operator
Since the machine is intended for use in a commercial environment, the
machine operator is fundamentally subject to the statutory requirements for
safety at the workplace. In addition to the safety warnings in these operating
instructions, the safety, accident prevention and environmental protection
regulations governing the location where the machine is to be used are also
applicable.
The operator is obliged to inform himself about the applicable occupational
safety regulations and to carry out a risk assessment in order to identify
additional risks resulting from the specific working conditions at the location
of operation.
According to the results of the workplace risk assessment, the operator shall
issue, implement and document operating instructions. The operator is
responsible for ensuring that these operating instructions comply with the
applicable legal regulations for the entire operational life of the machine and
will amend them if necessary.
The operator manages who is responsible for working on or with the machi-
ne, including naming an agent to be responsible for the safe operation of the
machine and coordinating all tasks.
The operator ensures that all personnel who carry out work on or with the
machine have read and understood these operating instructions.
The operator must provide operating personnel with the necessary personal
protective equipment. The operator must make it compulsory that the
personal protective equipment be worn.
Where applicable, the operator must make sure before start up that the
machine where this product is to be installed or is a component corresponds
to the general safety requirements and stipulations of all relevant directives.
To keep the machine in a technically flawless condition at all times, opera-
tors will ensure that the maintenance intervals prescribed in these operating
instructions are followed. Operators will furthermore ensure that all necessa-
ry safety mechanisms are properly installed on the machine. They will check
these regularly for completeness and proper functioning.
2
2.1
2.2
Basic information
Risk assessment
Operating instructions
Responsibilities
Information flow
Personal protective equipment
Safety requirements
Technically flawless condition

RINCO ULTRASONICS AG Safety requirements | 2
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Personnel requirements
General personnel requirements
Authorised personnel are those who carry out their task reliably and whose
responses are not impaired by e.g. drugs, alcohol or medication.
When selecting personnel, observe the applicable job-specific age regulati-
ons applicable at the location of operation of the machine.
All transport, installation and start-up work must be carried out by qualified
and skilled personnel (IEC 364 and CENELEC HD 384 or DIN VDE 0100
and IEC report 664 or DIN VDE 0110 as well as national accident prevention
regulations must be observed).
According to this basic safety information, qualified and skilled personnel are
persons familiar with the installation, assembly, start-up and operation of the
product. Qualified and skilled personnel are properly qualified for their work.
Qualifications
WARNING
Insufficient qualification.
Risk of severe injuries and considerable damage to property!
• Have all work carried out by qualified personnel.
In the operating instructions, the qualifications for the various tasks are
specified as follows:
Skilled personnel have the technical education, know-how and experience
as well as the knowledge of applicable standards and regulations that allow
them to execute the work assigned to them and to independently recognise
and avoid potential dangers.
Qualified electricians have the technical education, know-how and experi-
ence as well as knowledge of applicable standards and regulations that
allow them to execute work on electrical equipment and to independently
recognise and avoid potential dangers.
Qualified electricians are trained for their specific site of work and know the
relevant directives, norms and specifications.
2.3
2.3.1
2.3.2
Skilled personnel
Qualified electricians

2 | Safety requirements RINCO ULTRASONICS AG
14 / 137 BA_Standard3000_GB_V5.1_36566
Unauthorised persons
WARNING
Unauthorised persons without knowledge of the dangers in
the working area.
Danger of severe injury!
• Unauthorised persons must be kept away from the working
area.
• In case of doubt, talk to the persons and instruct them to
leave the working area.
• Suspend work until the unauthorised persons have left the
working area.
2.3.3

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Personal protective equipment
Some tasks require personal protective equipment to be worn. To minimise
dangers to health, the mandatory personal protective equipment suitable for
the work must be worn. In addition to the personal protective equipment
specified in these operating instructions, also observe the attached warnings
in the working area.
The following personal protective equipment must be worn according to the
work to be carried out:
to protect against hearing damage.
are tight-fitting work clothes with a low tear threshold with tight-fitting sleeves
and no loose parts. Their primary purpose is to prevent being caught bet-
ween moving machine parts. Do not wear rings, chains or other jewellery.
to protect the respiratory tract from dust and other particulate matter.
to protect against slipping.
to protect hands against friction, abrasion, stabbing or deep wounds, as well
as contact with hot objects.
to protect eyes against flying parts.
The operator must make it compulsory that the personal protective equip-
ment be worn.
2.4
Hearing protection
Suitable protective clothes
Dust mask
Non-slip shoes
Protective gloves
Eye protecting glasses

2 | Safety requirements RINCO ULTRASONICS AG
16 / 137 BA_Standard3000_GB_V5.1_36566
Residual risks
The following section of these operating instructions indicates residual risks
that were identified in a risk assessment.
It is essential that you read these safety instructions and information in the
following chapters and take measures to avert dangers, reduce health
hazards and avoid dangerous situations.
Hazards from electric energies
DANGER
Damaged insulation or components.
Contact with live parts.
Risk of electrocution!
• In case of damaged insulation, disconnect the power supply
immediately and have it repaired.
• Before connecting the machine to the power supply,
compare the specifications in "Technical Data" with those of
the grid and only connect if they are identical.
Work on electrical equipment may only be performed by
electrically qualified persons.
• Never remove or insert the generator slide-in module when
connected to the power supply.
2.5
2.5.1

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Mechanical hazards
WARNING
Rotating and/or linearly moving components.
Danger of severe injury!
• Do not reach into or touch moving components during
operation.
• Do not open covers during operation.
• Observe the shut-down period: Before opening the covers,
make sure that no components are still moving.
If the machine is intended for automatic operation:
The systems manufacturer must provide a safety installati-
on or guard that must be kept closed for machine lifting
movements to be triggered.
2.5.2

2 | Safety requirements RINCO ULTRASONICS AG
18 / 137 BA_Standard3000_GB_V5.1_36566
Hazards at the operating site
WARNING
Insufficient lighting.
Safety hazards due to incorrect execution of work.
Danger of severe injury!
• Provide sufficient lighting at the workplace.
(The operator must provide sufficient lighting at the
machine's location according to regional occupational
safety regulations. The light intensity must be at least 300
lux at the workplace and in the immediate vicinity of the
operating area. Glare, reflections and shadows must be
avoided as far as possible).
• Have defective lamps replaced immediately.
WARNING
Edges, corners and sharp-edged materials.
Danger of severe injury!
• Proceed carefully when working close to sharp edges,
corners and sharp-edged materials and handling sharp-
edged materials.
• If in doubt wear protective gloves.
WARNING
You may slip and stumble on dirt and objects that are lying
around the machine.
Danger of severe injury!
• Always keep the working area clean.
• Remove objects that are no longer required.
• Use black/yellow tape to mark areas where there is a risk of
slipping or stumbling.
Pneumatic hazards
WARNING
High-pressure air leaking from damaged pneumatic compo-
nents.
Danger of severe injuries, e.g. to the eyes!
• Do not allow pressure settings to exceed the maximum
permitted values.
• If you suspect pneumatic components may be damaged,
shut down the machine immediately and have the compo-
nents repaired.
2.5.3
Insufficient lighting
Sharp edges, corners and sharp-
edged materials
Dirt and objects lying around
2.5.4

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Emergency shutdown
The machine must be shutdown immediately in the event of imminent
danger to the user or damage to the press.
– Press the EMERGENCY STOP button (1).
ðThe press returns to the start position.
ðThe system is switched off from the mains.
After the EMERGENCY STOP button has been pressed, turn or pull (depen-
ding on the model) the button to reset it so that the machine can be switched
on again.
WARNING
Uncontrolled switching on.
Danger of severe injury!
• Before switching on the machine again, make sure that the
cause of the EMERGENCY STOP has been rectified and
all the safety mechanisms are installed and functioning
properly.
• Only reset the EMERGENCY STOP button when there is
no more danger.
What to do in the event of danger or
accidents
Preventative measures
First-aid equipment (first-aid kits, blankets, etc.) and an adequate number of
suitable fire extinguishes must be kept within easy access.
▪ Familiarisepersonnelwiththeinternalemergencyplan.
Measures in the event of accidents
▪ SwitchoffthesystemwiththeEMERGENCYSTOPbutton.
▪ Turnoffthemainswitch.
▪ Notifyadoctor.
Perform first aid.
▪ SwitchoffthesystemwiththeEMERGENCYSTOPbutton.
▪ Turnoffthemainswitch.
▪ NotifytheTechnicalCustomerServiceofRINCOULTRASONICSAG.
▪ Extinguishfireusingasuitablefireextinguisher.
▪ Notifyworksorlocalfireservice.
▪ NotifytheTechnicalCustomerServiceofRINCOULTRASONICSAG.
2.6
Fig. 2: EMERGENCY STOP button
2.7
2.7.1
2.7.2
Electric shock
Smoking, unusual noises, unusual
heat build-up
Fire in the electrical unit

2 | Safety requirements RINCO ULTRASONICS AG
20 / 137 BA_Standard3000_GB_V5.1_36566
Symbols/pictograms
WARNING
Inability to recognise hazards due to illegible or missing
symbols/pictograms.
Danger of severe injury!
• Make sure that all safety instructions, warnings and opera-
ting instructions are always clearly legible.
• Immediately replace damaged/missing symbols and
pictograms.
• Never cover, block or remove symbols and pictograms.
Pictograms may be located on the machine if necessary. They relate to the
immediate vicinity around where they are attached and indicate hazards or
suitable measures to be taken.
In addition to pictograms that indicate obligatory personal protective equip-
ment (see chapter Personal protective equipment [}15]) the following
pictograms are on the machine:
This pictogram is affixed to live parts. They pose a risk of electrical shock.
2.8
Illegible symbols/pictograms
Warning of dangerous electric
voltages