Sonics T202WD User manual

Sonics & Materials, Inc.
53 Church Hill Road ◊Newtown, CT 06470 USA
203.270.4600 ◊203.270.4610 fax
[email protected] ◊www.sonics.com
Model T202WD
20 kHz
Ultrasonic
Pouch Sealer
Sonics&Materials,Inc.– Nov.2019
AllDataandInformationSubjecttoChangewithoutNotice
USER MANUAL

READ BEFORE INSTALLING OR USING THE EQUIPMENT
Our systems have been designed to assure maximum operator safety.
However, no design can completely protect against improper usage. For
maximum safety and equipment protection, observe the following warnings at
all times and read all applicable instruction manuals carefully before you
attempt to operate any equipment.
High voltage is present in the equipment. Disconnect electrical source before
servicing.
Make sure equipment is properly grounded. Before making electrical source
connection, test source outlet for proper earth grounding.
Never squeeze or grab the vibrating ultrasonic horn.
Do not modify horn configurations. Any machining done to an ultrasonic horn
will alter its resonance frequency and may render it unusable.
20 kHz, 30 kHz and 40 kHz ultrasonic welders operate above the
normal audible range for most people. Although it is typically not required,
some operators may choose to use hearing protection.
Do not affix any device to any portion of the horn.
Sonics&Materials,Inc.
53ChurchHillRoadNewtown,CT06470USA
203.270.4600800.745.1105203.270.4610fax
www.sonics.com[email protected]
Informationinthismanualissubjecttochangewithoutnotice.Sonics&Materials,Inc.isnotresponsibleforanytypographicerrors.
©Sonics&Materials,Inc.2019PrintedinU.S.A.
SAFETYPRECAUTIONS

TABLEOFCONTENTS
IMPORTANT SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . 1
Manual Change Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Visible Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Concealed Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
OVERVIEW OF ULTRASONIC PLASTIC ASSEMBLY . . . . . . . . . . 3
What is Ultrasonics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Principle of Ultrasonic Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Generator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Seal Head Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Booster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Sealing Anvil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Air and Cooling Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TOOLING SET-UP AND LEVELING . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Weld Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure (Force) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Initial Application Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ULTRASONIC STACK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 10
Recommended Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 10
PNEUMATIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

The system supplied with this instruction manual is constructed of the
finest
material and the workmanship meets the highest manufacturing stand ar ds. It has
been thoroughly tested and inspected before leaving the factory
and when used
in accordance with the procedures outlined in this manual,
will provide you with
many years of safe and dependable service.
MANUAL CHANGE INFORMA TION
We continually strive to be at the forefront of the latest e l e c t r o ni c developments
by adding circuit and component improvements to
our equipment as soon as they
are developed and
teste d.
Sometimes, due to printing and shipping requirements, we
c a nn o t incorporate
these changes immediately into printed manuals. Hence, your manual may
contain new change information. Change information, if any, is located in the
Appendix.
We reserve the right to make any changes in the design or construction
of our
equipment at any time, without incurring any obligation to make any change
whatsoever in units previously delivered.
The technical data and schematics in the manual are for
informational purposes
only and may not reflect the current configuration being
shipped from our factory.
Upon formal request, complete and up-to-date
information can be provided from
the factory free of charge.
1
NOTE: Please read this
manual carefully before
oper ating the equipment,
then forward to your service
depa
rtm ent.
IMPORTANTSERVICELITERATURE

Before unpacking the equipment, check the shipping carton for any visible damage.
If you see any, be sure to follow the procedures described
bel ow under “ V isi b l e Loss
or
Da m a g e . ” Otherwise, proceed to remove the equipment from the carton. Before
disposing of any packing material,
check it carefully for small parts. Then perform a
visual inspection of the
equipment to detect any evidence of damage which might
have occurred
during shipment. Check the following:
1. all components against the enclosed packing
list,
2. all module plug-in units,
3. all wire plug-in connections.
The equipment was carefully packed and thoroughly inspected befor e leaving
our factory. All units are tested and checked for problems prior
to shipping. It is
asked that when a problem does occur that all parts
and components be inspected
for damage (especially when the unit is not in working order when received).
Responsibility for safe delivery was assumed by the carrier upon acceptance of the
shipment. Claims for loss of damage sustained in transit must therefore be made upon
the carrier, as
follows:
VISIBLE LOSS OR DAMAGE
Any external evidence of loss or damage must be noted on the freight bill or shipment
receipt, and signed by the carrier’s agent. Failure to adequately describe such
external evidence of loss or damage may result in the carri
er’ s refusal to honor a
damage claim. The form required to file such a claim
will be supplied by the carrier.
CONCEALED LOSS OR DAMAGE
Concealed loss or damage means loss or damage which does not become apparent
until the merchandise has been unpacked. The contents
might have been damaged
in transit due to rough handling even though
the container may not show external
damage. When damage is
discovered upon unpacking, make a written request for
inspection by the carrier’s agent within 48 hours of the delivery date. Then file a claim
with the carrier since such damage is the carrier’s responsibility. The form required to
file such a claim will be supplied by the carrier. Do not destroy packing materials,
or move material from one location to another before the carrier makes their
inspection.
If the system or any unit is damaged, notify “Sonics.” “Sonics” will arrange for repair
or replacement of damaged equipment without waiting for
the claim against the
carrier to be settled, provided a new purchase order is issued to cover the repair or
replacement costs. Should any damage, shortage or discrepancy exist, please notify
us
immediately .
2
NOTE: We r
ecomme nd
keeping all carton(s) and
packing material in case
it
might be necessary to mov
e
the equipment, or to ship it
for repair.
UNPACKINGANDINSPECTION

WHAT IS ULTRASONICS?
Ultrasonics refers to vibrational waves with a frequency above the human audible range which is usually above
18,000 cycles per second (Hz).
PRINCIPLE OF ULTRASONIC WELDING
The basic principle of ultrasonic assembly involves conversion of high frequency electrical energy to high frequency
mechanical energy in the form of reciprocating motion which, when applied to a thermoplastic film, generates frictional
heat at the plastic-to-plastic interface. In ultrasonic welding, this frictional heat melts the plastic, allowing the two
surfaces to fuse together.
A. GENERATOR KIT – The solid state ultrasonic generator:
Note: Sonics’ kit style generators are intended to mount inside of a NEMA type electrical enclosure and be controlled
via a customer supplied PLC with related electronic components.
1) Converts the incoming single phase, 230VAC, 50/60 Hz electrical source to a high voltage, 20,000 Hz electrical
signal
2) Receives a 0-10VDC signal from the PLC to manipulate the vibrational amplitude
3) Provides output signals such as Run Frequency and Instantaneous Power
4) Provides error signals such as System Overload
B. SEAL HEAD ACTUATOR – The wash-down pneumatic actuator:
1) Provides compressive force on the seal jaws
2) Provides rigid mounting for the converter, booster, horn (stack) assembly and sealing anvil
3) Provides repeatable alignment and parallelism of the seal jaws
3
OVERVIEWOFULTRASONICPLASTICASSEMBLY


C. CONVERTER – The wash-down converter:
1) Is an electro-mechanical device that converts the high frequency electrical energy supplied by the generator into
mechanical vibrations through the use of piezo-electric ceramic crystals
2) Is sealed to allow spraying with CIP solutions
3) Contains air (in/out) ports for cooling
D. BOOSTER – The booster:
1) Is a tuned component of the system
2) Transmits and amplifies the mechanical vibrations from the converter to the Horn
3) Provides a non-vibrating, rigid clamping point to secure the vibrating components
E. HORN – The horn (Sonotrode):
1) Is a tuned component of the system
2) Transfers the ultrasonic vibrations from the booster to the pouch, creating frictional heat between the film layers
3) Further amplifies the vibrations to a level that will cause the film sealant layer to melt
4) May contain features on the face to enhance the seal quality and consistency
F. SEALING ANVIL – The sealing anvil:
1) Is a non-vibrating component of the system
2) Provides sufficient rigidity and mass to stop the ultrasonic vibrations, creating frictional heat between the film
layers
3) Provides a means of creating parallelism to the horn face (leveling)
4) May contain features on the face to enhance the seal quality and consistency
5) Contains connections for customer supplied cooling water
4
Seal Head Actuator
Generator Kit
SealingAnvil
Horn
Converter
OVERVIEWOFULTRASONICPLASTICASSEMBLY

ELECTRICAL POWER
The actuator is designed using air cylinders to provide the clamping force.
The solenoid that drives the pneumatic system is powered by the PLC
(24VDC signal, 3 watt max)
AIR SUPP L Y
The actuator requires a source of dry, filtered (5 micron), oil-free,
compr essed air capable of supplying a constant line pressure of up to 85
psig. (625 kPa / 6 bar) at a minimum capacity of 2 CFM.
The selected installation site should be near the electrical power and air
supply sources and away from any equipment that generates abnormally
high electrical transients. Observe the following additional instructions when
installing the system:
T202WD Installation and Setup Instructions
Mechanical Installation:
1. Mount the actuator such that the centerline of the tooling seal jaws (horn and anvil) are positioned at the centerline
of the required seal location on the pouch.
2. The actuator should be placed or attached to a sturdy structure or bench capable of supporting a minimum of 200
Lbs. (90 kg)
3. Allow at least 4 inches (100 mm) at the rear of theactuatorfor RF converter cable and compressed air line
connections.
5
Do not connect the actuator to
an air source
supplied by an air
compressor
lubricate d with
synthetic oils or oils containing
phosphate esters or
chlorinated
hydro- carbons.
This type
of lubricant may
cause the air filter to
malfunction, and the plastic
bowl to rupture.
Centerline
4"
(100mm)
INSTALLATION

Air and Cooling Installation:
1. Two regulated air supply lines are required (customer supplied).
(1) System seal pressure air should be dry, filtered to 5 microns and regulated between 20-100 psi.
Note that system seal pressure regulator should be easily accessible as seal force is a commonly
adjusted sealing parameter.
(1) Cooling air is connected to the port on the back of the converter and should be dry, filtered to 5 microns
and regulated between 10-30 psi. The air that exits the converter is then routed to additional cooling lines
on the system.
2. The actuator has two flow controls to adjust sealing jaw open and close speed. Rotate the respective flow control
clockwise to limit speed and counterclockwise to increase speed.
3. Customer supplied cooling water should be connected to the fittings on the anvil to prevent the tools from
overheating and keep the sealing process stable. Temperature and flow is dependent on the application
requirements.
6
Clean and dry air service is critical to equipment performance and operation. Routinely check the incoming air
regulator filter bowl for any moisture and/or condensation, and drain as necessary. Allowing any moisture to
enter the converter will damage electronic components and is not covered by warranty.
INSTALLATION
SystemSealPressure
Connection
ConverterAirCooling
Connection
StackAir
CoolingLine
HornFace
Cooling
AnvilWater
Cooling
Connection

1. The tooling opening can be adjusted for up to 2” (50.8 mm) of travel, 1” (25.4 mm) of horn travel and 1” (25.4 mm)
of anvil travel. Note: reducing the tooling travel can enhance the cycle rate.
2. Assemble the converter/booster/horn “stack” as shown below.
3. Open the hinged stack housing door and install the converter/booster/horn assembly into the stack housing.
Before fully tightening the door screws, rotationally align the horn face to match the sealing anvil.
4. Disconnect the system air pressure and manually close the seal jaws to ensure that the rotational alignment
between the horn and anvil is precise.
5. To self-level, re-connect air pressure and send a signal from the PLC to the pneumatic valve solenoid to close the
seal jaws without a pouch in place. Note that ultrasonic vibrations ARE NOT TO BE APPLIED at this time.
6. Adjust the seal pressure regulator to the required level. This will be determined by trial and error to optimize the
settings for each particular pouch. 30 PSI (2 Bar) is a good starting point.
7. With the jaws closed and the tools clamped under pressure, loosen the four leveling screws and four anvil tie-down
bolts on the back side of the anvil.
8. The anvil will pivot on the ball in the anvil mounting base and automatically become parallel with the horn face.
9. Next, lightly screw the Allen leveling screws inward until they make contact with the anvil mounting block.
10. To secure the anvil, tighten the four hex head anvil tie-down bolts to 25 ft-lb (35 Nm)
Once the horn and anvil are aligned, tighten the stack housing door screws to 5 ft-lb (7 Nm).
7
HousingDoor
DoorScrews
LevelingScrews (3)
AnvilTie‐DownBolts (4)
Converter/Booster/Horn"Stack"AnvilMount
Plate
TOOLINGSET‐UPANDLEVELING
SealAnvil

Once all electrical and air connections have been made, you are now ready
to power up the actuator and set your weld parameters.
WELD MODE
Sonics kit generators are capable of providing several methods to control the
weld process and monitor weld quality. Depending upon the sophistication of
the PLC programming the control modes can include time or energy based
weld modes.
Time is the duration of vibration being applied during the weld
cycle. Typical pouch sealing weld times are between 0.100 seconds and
1.000 seconds.
PRESSURE (FORCE)
The actuator air cylinder provides compressive weld force (in/lbs.) at a
mechanical advantage of approximately 4.9 times the actuator’s air
regulator setting (psig).
Pressure can be increased to produce welds in a shorter cycle time.
A weld pressure setting of 30 PSI is a recommended starting pressure.
AMPLITUDE
Amplitude is the microscopic distance that the face of the weld tool vibrates.
It should be set as a percentage of the available amplitude via the PLC
interface.
As with pressure, amplitude can be increased to produce welds in a shorter
cycle time.
A weld amplitude setting of 80% is a recommended starting point.
T202WD Sequence of Operation:
1. A filled pouch is indexed into position between the seal jaws and a pouch sensing device (customer supplied)
sends a signal to the PLC confirming the presence of a pouch between the tools.
2. Via customer supplied pneumatic valve, compressed air must then be provided to close the seal jaws.
3. The PLC then initiates the Ultrasonic Delay Time (typically 100-200 ms) which allows the pouch to be compressed
prior to the application of ultrasonic energy. The delay time may need to be adjusted for each particular application
and should be considered a frequently used setup parameter.
4. After the Ultrasonic Delay Time is complete, The PLC then initiates the Weld Time by sending a timed contact
closure (typically between 150-300 ms) to the generator kit to initiate ultrasonic vibration for the set duration. Note that
Weld Time will be the primary weld parameter that the operator will use to increase or decrease the degree of seal.
Weld Time may need to be adjusted often and should be considered a frequently used setup parameter.
5. After the Weld Time is complete, the PLC opens the contact to the generator and the ultrasonic vibrations cease.
8
NOTE: While increasing
p
ressure and/or amplitude can
reduce weld time, these
increases can also impede
ultrasonic vibration start and
cause an overload condition in
the system.
OPERATINGPROCEDURES

6. The PLC maintains the jaws in the closed position for the Hold Time to allow the pouch to cool (typically about 200
ms). Hold Time may need to be adjusted frequently and should be considered a frequently used setup parameter.
7. Via customer supplied pneumatic valve, compressed air should then be diverted to open the seal jaws.
Initial application setup:
1. To start, set the Air Pressure to 30 psi (less for pouches under 4” wide, more for pouches over 6” wide).
2. If less weld is desired, reduce Amplitude, Weld Time and/or Sealing Force.
3. If more weld is desired, increase Amplitude, Weld Time and/or Sealing Force.
4. If the seal is heavier on one side of the pouch than the other, re-level the tools as described above.
Electrical Installation:
1. Electrical connections to the generator are detailed in the separate Generator Kit manual that accompanied this
manual.
9
A pouch presence sensing device (typically optical) must be installed prior to running the pouch sealing system. It is
extremely important that the pouch presence sensor communicate with the PLC to prohibit activating the ultrasonic
energy when the tools are closed without a pouch in place. Activating the ultrasonic tools under pressure without a
pouch in place can cause severe damage to the converter, generator and tooling. Failures resulting from cycling the
system without a pouch in place are considered abuse and may not be covered under warranty.
OPERATINGPROCEDURES

If the converter, booster, and horn are not already assembled, follow these instructions:
1. Clean the mating surfaces of the converter and booster, as well as the threaded stud and hole. Check that the
stud is tight to the torque specification below.
2. Hand assembles the converter and booster together. Using spanner wrenches as shown below, tighten until
snug. Then, using a torque wrench, tighten to the torque specification below.
3. Clean the mating surfaces of the booster and horn, as well as the threaded stud and hole. Check that the stud is
tight to the torque specification below.
4. Hand assemble the horn to the booster. Using a spanner wrench for the booster and a wrench to secure the
horn, tighten until snug. Then, using a torque wrench, tighten to the torque specification below.
10
Component Foot-Lbs. Newton-Mete
r
s
Converter / Booster 50 70
Booster / Horn 50 70
Stud 10 15
RECOMMENDEDTORQUESPECIFICATIONS
Horn
Booster
Converter
SpannerWrench
SpannerWrench
ULTRASONICSTACKASSEMBLY

11
5
1
3
4
2
ANVIL
AIRCYLINDER
SOLENOID
VALVE
HORN
AIRCYLINDER
FILTER/REGULATOR
WITHPRESSUREGAUGE
PNEUMATICDIAGRAM
24VDC+/‐10%
3WATTS
22TO116PSI
10TO30VDC
MINLOAD4mA
MAXLOAD300mA
JUNCTIONBOX
SOLENOID (+)RED
(‐)BLACK
SEALJAWSCLOSED (‐)GREEN
(+)ORANGE
SEALJAWSOPEN (‐)BLUE
(+)BROWN
CABLE
SEALJAWSCLOSED
SEALJAWSOPEN
SOLENOID

NOTE: If packing unit
for return shipment, DO NOT use Styrofoam “pean uts.”
REPAIRS / SERVICE
If problems are encountered, contact our Service Department as follows:
Phone: [phone] • 1-203-270-4600 E xt. 343 or 366
Fax:
1-203-270-4610
E-Mail: [e-mail]
It is suggested that a system in need of repair be sent back to the factory , with a written description pertaining to
the nature of the
pr oblem.
Always
contact the factory for return authorization before shipping any instrument. Include date of purchase,
model number, and serial number. For units not covered by the warranty, a purchase order should be forwarded
to
avoid unnecessary delay. Care should be exercised to provide adequate packing to insure against possible damage
in shipment. The system must
be sent with all transportation charges prepaid and return method of shipment
indicated .
.
12
MAINTENANCE