Sonics Fc User manual

INSTRUCTION MANUAL

Sonics & Materials, Inc.

Model FC Power Supply

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

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WARNING

SAFETY PRECAUTIONS

READ BEFORE INSTALLING OR USING THE EQUIPMENT

This system has 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 the instruction manual carefully before you attempt to

operate the equipment.

– High voltage is present in the equipment. Disconnect plug before removing

cover or servicing.

– Make sure equipment is properly grounded with a 3-prong plug. Before

plugging in equipment, test outlet for proper earth grounding.

– Ultrasonic welders operate above normal audibility for most people. Ear

protection is recommended. Consult the Appendix for a list of

manufacturers of ear protectors

Sonics & Materials, Inc.

Corporate Headquarters European Office

53 Church Hill Road • Newtown, CT 06470 USA 22 ch du Vernay • CH - 1196 Gland, Switzerland

203.270.4600 • 800.745.1105 • 203.270.4610 fax (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax

www.sonicsandmaterials.com • [email protected] [email protected]

Information contained in this manual is subject to change without notice. Sonics & Materials, Inc. is not responsible for any typographic errors.

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

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TABLE OF CONTENTS

IMPORTANT SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Manual Change Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Visible Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Concealed Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

OVERVIEW OF ULTRASONIC PLASTICS ASSEMBLY . . . . . . . . . . . . . .6

What is Ultrasonics? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Principal of Ultrasonic Assembly . . . . . . . . . . . . . . . . . . . . . . . . .6

Ultrasonic Assembly Systems . . . . . . . . . . . . . . . . . . . . . . . . . . .6

GLOSSARY OF ULTRASONIC TERMS . . . . . . . . . . . . . . . . . . . . . . . . . .8

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Electrical Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Front Panel Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Starting up the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Repairs / Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Limitation of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

IMPORTANT SERVICE LITERATURE

The system supplied with this instruction manual is constructed of the finest

material and the workmanship meets the highest manufacturing standards. 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 INFORMATION

We continually strive to be at the forefront of the latest electronic

developments by adding circuit and component improvements to our

equipment as soon as they are developed and tested.

Sometimes, due to printing and shipping requirements, we cannot 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.

NOTE: Please read

carefully before

operating the

equipment, then

forward to your service

department.

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

5

UNPACKING AND INSPECTION

Before unpacking the equipment, check the shipping carton for any visible

damage. If you see any, be sure to follow the procedures described below

under “Visible Loss or Damage.” Otherwise, proceed to remove the equipment

from the carton. Before storing 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 before 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

express receipt, and signed by the carrier’s agent. Failure to adequately

describe such external evidence of loss or damage may result in the carrier’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 the 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.

NOTE: We recommend

keeping all carton(s)

and packing material in

case it might be

necessary to move the

equipment, or to ship it

for repair.

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

INTRODUCTION

The FC model power supply is an auto-tuned ultrasonic generator that can be

operated on a continuous basis, or pulsed via an outside control. This power

supply can be used with a stand-alone converter, or with a pneumatic

actuator. The FC does not offer time or energy-based control.

OVERVIEW OF ULTRASONIC PLASTICS

ASSEMBLY

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 ASSEMBLY

The basic principle of ultrasonic assembly involves conversion of high

frequency electrical energy to high frequency mechanical energy in the form

of reciprocating vertical motion which, when applied to a thermoplastic,

generates frictional heat at the plastic/plastic or plastic/metal interface. In

ultrasonic welding, this frictional heat melts the plastic, allowing the two

surfaces to fuse together; in ultrasonic staking or insertion, the controlled flow

of molten plastic is used to capture or lock another material in place (staking)

or encapsulate a metal insert (insertion).

ULTRASONIC ASSEMBLY SYSTEMS

“Sonics” ultrasonic assembly systems are generally composed of the

following major elements: a power supply, converter, booster, horn, pneumatic

press and holding fixture, as detailed in the diagram on the next page. A

review of this diagram will help you understand the basic elements involved in

the assembly process and their relation to each other.

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

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“SONICS” ULTRASONIC ASSEMBLY SYSTEMS

Generates ultrasonic electric energy

(15/20/40 kHz)

50/60 Hz

Electrical power

Ultrasonic

electrical energy

Ultrasonic Vibrations

Provides compressive force

and mounting for Converter,

Booster, Horn assembly

Aligns and supports part

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@@g

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Transforms ultrasonic electrical energy

to ultrasonic mechanical vibrations

Increases or decreases amplitude

Contacts and transfers vibrational

energy to plastic part

Converter

Booster

Horn

Ultrasonic Vibrations

Power Supply/Generator

Actuator/Press

Holding Fixture

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

GLOSSARY OF ULTRASONIC TERMS

POWER SUPPLY/GENERATOR – The solid state power supply converts

standard 50/60 Hz electrical energy to 15,000 Hz, 20,000 Hz or 40,000 Hz

(15/20/40 kHz) electrical energy.

ACTUATOR/PRESS – The pneumatic actuator provides compressive force

and mounting for the converter, booster and horn assembly. The tabletop

press consists of a base assembly, column and actuator (head).

CONVERTER – The converter changes the high frequency electrical energy

supplied by the power supply to high frequency mechanical vibrations.

BOOSTER – Successful ultrasonic welding often depends on having the right

amplitude at the horn face. Often it is not possible to design a horn which has

both the necessary shape and required gain (ratios of input amplitude to

output amplitude). In such cases, a booster is placed between the converter

and the horn to either increase or decrease the amplitude of the horn. In

addition to changing/maintaining the amplitude, the booster provides support

and alignment in the welding system.

HORN – The horn is a tuned component of the system which comes in

contact with the parts to be assembled. The horn 1) transfers the ultrasonic

vibrations produced from the converter to the parts being welded, and 2)

applies necessary force to the assembly while the material resolidifies.

HOLDING FIXTURE – The holding fixture or nest assures proper alignment

and support of the parts being assembled.

NOTE: For additional

information on set-up

and adjustment of the

converter / booster /

horn / holding fixture,

refer to the Welding

Press Instruction

Manual.

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

9

INSTALLATION

ELECTRICAL POWER REQUIREMENTS

The power supply requires a fused, single-phase, standard 3-terminal

grounding type receptacle capable of supplying the requisite voltage and

current. Refer to the table below for power specification.

SETTING UP

The power supply is a free-standing assembly. It should be installed in a clear,

uncluttered location that is free from excessive dirt, dust, corrosive fumes, and

temperature and humidity extremes. The selected installation site should be

near the electrical power source and away from equipment that generates

abnormally high electrical transients. Observe the following additional

instructions when installing the equipment:

a. Allow at least 6 inches (152.4mm) at the rear of the power supply for cable

connections.

b. Position the power supply so that the front panel controls are visible and

readily accessible.

c. The power supply is air cooled; allow sufficient space around the assembly

to ensure adequate ventilation. If the power supply must be housed in a

confined space, forced air cooling may be necessary to keep surrounding

air within acceptable ambient temperature limits. Periodically check the

ventilation grille and clean as necessary.

The line cord of the

controller/power supply is

equipped with a 3-prong,

grounding plug. Do not,

under any circumstances,

remove the ground prong.

The plug must be plugged

into a mating 3-prong,

grounding type outlet.

POWER SPECIFICATIONS

NOTE: If power supply is

to be run continuously, air

cooling of the converter

and horn is required. Use

clean, dry compressed air

filtered down to 5 microns

(supplied to converter

fitting – see page 11).

Model Power Rating 115 vac 230 vac

FC740 700w 15 amps 10 amps

FC1020 1000w 15 amps 10 amps

FC1520 1500w N/A 15 amps

FC2020 2000w N/A 20 amps

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

ELECTRICAL CONNECTIONS

The standard cable supplied with a “Sonics” press is 10 feet. Optional

extension cables are available up to 15 feet without modification.

When making the initial electrical connections, make sure the power is

disconnected and follow these precautions.

1. Do not strain or kink the cables. When going around corners, allow as wide

a bend as possible. Do not run the cables parallel to any power line within

a distance of less than 1 foot (305mm).

2. To prevent the possibility of an electrical shock, ensure that the power

supply line cord is properly grounded. Also make sure that the voltage

rating of the electrical power source matches the power supply

requirement (refer to the “Power Specifications” table on preceding page).

3. Check with your electrician if you have any wiring questions.

NOTE: Do not plug

the power supply into

an electrical outlet

until all other

connections have

been made.

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

11

CABLE CONNECTIONS:

Located at the rear of the power supply are the cable connections as

illustrated below. (The interconnecting cables will be supplied with your

system.)

1. A round, 12-pin RF cable that connects the welding press or converter to

the power supply.

2. An actuation cable that connects the power supply to a trigger source (refer

to wiring diagrams in Appendix).

3. The power line cord that plugs into the appropriate electrical outlet.

Once these connections have been made, the power supply is ready for

operation. If applicable, be sure to consult your welding press instruction

manual to insure that all connections on the press side are correct, and that

the press is ready for operation.

Also located at the rear of the power supply are the following:

4. fuses (fixed 0.5 amp),

5. fuses (based on requirements listed in “Power Specifications” table, p. 8),

6. fuses (based on requirements listed in “Power Specifications” table, p. 8),

7. outputs J7 (see wiring diagrams in Appendix),

8. outputs J8 (see wiring diagrams in Appendix),

9-12. optional.

❷

❶

❸

❹

❺

➏

❼❽

NOTE: Detailed wiring

diagrams are supplied

in the Appendix at the

back of this manual.

❿

❾

11

12

Fan

NOTE: To see a list of

converters that can be

connected to the power

supply, see the table on

the following page.

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

AVAILABLE CONVERTERS

Item No. Description

CV00015 20 kHz with Button connector

CV00151 20 kHz with Lemo connector

CV00154 20 kHz with Lemo connector and fitting for

air cooling

CV00157 20 kHz with Button connector and fitting for

air cooling

CV00158 20 kHz Hand Gun with handles and cables

CV00331 20 kHz with Fischer connector

CV00334 20 kHz with Fischer connector and fitting for

air cooling

CV00023 40 kHz with Button connector

CV00231 40 kHz with Lemo connector

CV00232 40 kHz with SHV connector side mounted

CV00234 40 kHz with Lemo connector and fitting for

air cooling

CV00238 40 kHz Hand Gun with trigger switch and

cable

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

13

OPERATING PROCEDURES

FRONT PANEL CONTROLS

Located on the front panel of the power supply are the following controls:

1. Red POWER button which turns the unit on and off.

2. Yellow RESET button which resets the power supply following an overload

condition. If an overload condition exists, the button lights up. In addition,

the RESET button must be depressed after the unit is first turned on

before any operation can proceed.

3. Green TEST button which can be used to test ultrasonic operation

(pressing it only manually activates the ultrasonics).

4. OUTPUT CONTROL DIAL which controls fine adjustment of the ampli-

tude of the system’s high-frequency vibrations over the full operating range.

(Major adjustments of amplitude are made through the use of different

boosters – consult your press manual for further information.)

5. LED LOAD METER which indicates the level of ultrasonics that is being

transmitted to the welding press.

RESET POWER

TEST

OUTPUT CONTROL

100

90

80

70

60

50

40

30

40 60 80 100200

The RESET button is a

built-in safety feature. When

the power supply is

connected to a press, be

sure the press head

actuation signals are not

activated (or closed). If they

are activated, the press

head will descend

immediately when the

RESET button is

depressed.

❷❶❸❹

❺

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

STARTING UP THE POWER SUPPLY

Press the red POWER button to turn the power supply on. The POWER

button will light up. The yellow RESET button will also come on and will

remain lit.

INITIAL OPERATION

After the power supply is turned on (as described above), follow these steps:

1. Make sure that all necessary preparations have been made with regard to

the ultrasonic system and tooling, and that the items to be welded are in

position.

2. Before pressing the RESET button, make sure the press head actuation

(cycle start) signals are not activated (or closed). Then, press the RESET

button to activate power supply operation.

3. Press the TEST button. While depressing the TEST button, check the

LED Load Meter reading to make sure that it does not exceed 20%.

a) If the meter reading is above 20%, contact Sonics immediately for further

instructions before proceeding.

b) If the meter reading is below 20%, you can proceed with operation.

During the testing process, keep in mind that the ultrasonics are only

activated as long as the TEST button is depressed – once you release the

TEST button, ultrasonics is terminated.

4. The power supply is now in ready mode.

NOTE: The TEST and

Load Meter check

should always be done

for all cold start-ups,

and for any start-up

after the system has

been idle for 20 minutes

or more.

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

15

OVERLOAD PROTECTION

The overload protection circuit will terminate the welding cycle when the

system is operated under adverse conditions, i.e., improper tuning, excessive

power supply loading, loose or failed horn or booster, thereby protecting the

power supply and other system components. When an overload condition

exists, the RESET button will illuminate and remain lit until the condition has

been corrected and the button is pressed. If the condition is not corrected, the

RESET button will remain lit. If a repeated overload condition exists, resolve

the problem before a failure of the power supply occurs.

If an overload condition exists, try the following:

— decrease horn force

— decrease amplitude (change booster or decrease output control)

— decrease downspeed

— check for loose or broken studs

— check the coupling surfaces between horn/booster and booster/converter

— check for cracked horn or booster

— check to see if the load meter exceeds 100% during weld process (if so, a

higher powered unit is needed)

If you cannot remedy the situation, contact Sonics.

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

MAINTENANCE

GENERAL

1. Always make sure the power supply has adequate ventilation by keeping

sufficient space around the assembly.

2. Periodically check the ventilation grilles and clean as necessary.

If problems are encountered, contact our Service Department at 1-800-745-

1105.

REPAIRS / SERVICE

If problems are encountered, contact our Service Department at 1-800-745-

1105.

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 problem.

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 should

be sent with all transportation charges prepaid and return method of shipment

indicated.

NOTE: If packing unit

for return shipment,

DO NOT use

styrofoam “peanuts.”

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

17

WARRANTY

Sonics & Materials, Inc., hereinafter referred to as “Sonics,” warrants its

products for a period of one year from the date of shipment against defect in

material and workmanship under normal installation, use, and maintenance

as described in the operating instructions which accompany such equipment.

During the warranty period, “Sonics” will, at its option, as the exclusive

remedy, either repair or replace without charge for material and labor, the

part(s) which prove upon our examination to be defective, provided the

defective unit is returned to us properly packed with all transportation charges

prepaid.

LIMITATION OF WARRANTY

This warranty is in lieu of any other warranties, either express, implied, or

statutory. “Sonics” neither assumes nor authorizes any person to assume for

it any other obligation or liability in connection with the sale of its products.

“Sonics” hereby disclaims any warranty or merchantability or fitness for a

particular purpose. No person or company is authorized to change, modify,

or amend the terms of this warranty in any manner or fashion whatsoever.

Under no circumstances shall “Sonics” be liable to the purchaser or to any

other person for any incidental or consequential damages or loss of profit or

product resulting from any malfunction or failure of this “Sonics” product.

This warranty does not apply to equipment which has been subject to

unauthorized repair, misuse, abuse, negligence or accident. Equipment

which, in our judgment, shows evidence of having been used in violation of

operating instructions, or which has had the serial number altered or

removed, will be ineligible for service under this warranty.

No liability is assumed for expenses or damages resulting from interruptions

in operation of the product or damages to material in process.

“Sonics” equipment is designed for maximum operator safety and

incorporates built-in safety devices. Any modifications to these safety features

will void the warranty. “Sonics” assumes no responsibilities for consequential

damages incurred due to modifications to the said equipment.

“Sonics” reserves the right not to warrant horns of unusual or experimental

design which in our judgment are more likely to fail in use.

Data supplied in the instruction manual has been verified and validated and

is believed adequate for the intended use of the equipment. If the equipment

or procedures are used for purposes other than those specified herein,

confirmation of their validity and suitability should be obtained in writing from

“Sonics.”

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18

INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

Model Actuation J2 I/O J7 I/O J8

FC E2962 E-3014 E-3013

Drawing Part No. Description

E-2962*/2962-1* 201-0179 FC continuous duty cable

E-3013* 201-0206 F-Series general I/O

E-3014* 201-0207 F-Series General I/O

APPENDIX

EQUIPMENT WIRING DIAGRAMS AND ASSOCIATED I/O

*See drawing on following pages.

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INSTRUCTION MANUAL • MODEL FC POWER SUPPLY

19

APPENDIX

Sonics FC User manual

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