Sonics FM User manual

INSTRUCTION MANUAL
Sonics & Materials, Inc.
Model FM Power Supply

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INSTRUCTION MANUAL • MODEL FM POWER SUPPLY 1
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.
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.
© Sonics & Materials, Inc. 2001 Printed in U.S.A. Part No. 381-0039
Rev 00 8/01

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
Available Converters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . .13
OPERATIONAL SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Operational Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Starting up the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Initial Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
BASIC MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Time-Based Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Energy-Based Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Mode Codes Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
TIME-BASED MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Selecting and Setting Timers in a Time-Based Cycle . . . . . . . . .19
Selecting and Setting the Afterpulse Timer . . . . . . . . . . . . . . . . .20
Selecting and Setting Process Control Tolerance Limits
in a Time-based Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Selecting and Adjusting Variable Force Trigger Actuation
in a Time-Based Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
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2 INSTRUCTION MANUAL • MODEL FM POWER SUPPLY

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INSTRUCTION MANUAL • MODEL FM POWER SUPPLY 3
ENERGY-BASED MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Constant Energy-Based Cycle with Time Delay Triggering . . . . .23
Constant Energy-Based Cycle with Variable Force Triggering . . .24
Timer 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Selecting and Setting the Maximum Weld Time . . . . . . . . . . . . .24
OVERVIEW OF OPERATIONS AND LCD DISPLAYS . . . . . . . . . . . . . .25
OVERVIEW OF SET-UP PROCEDURES AND DISPLAYS . . . . . . . . . . .27
ADDITIONAL FEATURES AND FUNCTIONS . . . . . . . . . . . . . . . . . . . .29
Program Version Designation . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Cancel Number of Welds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Cancel Number of Rejects . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Job Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Job Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Cal Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
KEYPAD SECURITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
PRINTER INTERFACE AND OPERATION . . . . . . . . . . . . . . . . . . . . . . .34
Printer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Printout of the Weld Energy Curve . . . . . . . . . . . . . . . . . . . . . . .34
Printer Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Graph Header . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Reject Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
SYSTEM STATUS TESTS AND FUNCTIONS . . . . . . . . . . . . . . . . . . . .39
Power Supply Test and Display . . . . . . . . . . . . . . . . . . . . . . . . .39
Operation Sequence Display . . . . . . . . . . . . . . . . . . . . . . . . . . .39
System Status Tests and Miscellaneous Functions . . . . . . . . . . .39
Printer Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Coupling Force Measurement . . . . . . . . . . . . . . . . . . . . . . . . . .41
Clear Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
SYSTEM STATUS TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
System Status Tests and Miscellaneous Functions . . . . . . . . . . .42
Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Repairs / Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Limitation of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

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4 INSTRUCTION MANUAL • MODEL FM 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 FM 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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6 INSTRUCTION MANUAL • MODEL FM POWER SUPPLY
INTRODUCTION
The FM model power supply is an auto-tuned ultrasonic generator with a built-
in Microprocessor that allows time and energy-based control. The
Microprocessor is programmed with a multi-function keypad and information
is displayed on the back-lit liquid crystal display (LCD).This power supply can
be used with a pneumatic actuator or with a stand-alone converter.
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 FM POWER SUPPLY 7
“SONICS” ULTRASONIC ASSEMBLY SYSTEMS
Generates ultrasonic electrical 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
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
Ultrasonic Vibrations
Power Supply/Generator
Actuator/Press
Holding Fixture

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8 INSTRUCTION MANUAL • MODEL FM 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/WELDING PRESS – The pneumatic actuator provides com-
pressive 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.

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INSTRUCTION MANUAL • MODEL FM 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 12).
Model Power Rating 115 vac 230 vac
FM740 700w 15 amps 10 amps
FM1020 1000w 15 amps 10 amps
FM1520 1500w N/A 15 amps
FM2020 2000w N/A 20 amps

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1 INSTRUCTION MANUAL • MODEL FM 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.

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. J1, a round, 12-pin RF cable that connects the welding press or converter
to the power supply.
2. J2, 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. J3 Printer Output
5. fuse (based on requirements listed in “Power Specifications” table, p. 9),
6. J6 Rotary Table Output (see wiring diagrams in Appendix),
7. J7 I/O (see wiring diagrams in Appendix),
8. J8 I/O(see wiring diagrams in Appendix),
9. J9 Reject Output
10. fuse (based on requirements listed in “Power Specifications” table, p. 9),
11. fuse (fixed 0.5 amp),
12. fuse, not optional (based on requirements listed in “Power Specifications”
table, p. 9)
11
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INSTRUCTION MANUAL • MODEL FM POWER SUPPLY 11
❷
❶
❸❽
❺
➏
❼❹
NOTE: Detailed wiring
diagrams are supplied
in the Appendix at the
back of this manual.
❿
❾
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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12 INSTRUCTION MANUAL • MODEL FM 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 FM POWER SUPPLY 13
OPERATING PROCEDURES
FRONT PANEL CONTROLS AND INDICATORS
Located on the front panel of the power supply are the following controls and
indicators:
1. ON/OFF key which turns the unit on and off. Red LED in upper left corner
indicates unit is ON.
2. 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.)
3. LED LOAD METER which indicates the power level of ultrasonics that is
being delivered to the welding press.
4. LCD SCREEN which displays various settings, parameters and prompts
as detailed in the following pages.
5. TIMER key which selects and displays timer settings and permits
adjustment of timer duration in .01 second increments (from 0.00 to 9.99
seconds) for five timers as follows:
T1: Delay Timer (for normal delay triggering or pre-triggering).
T2: Weld Timer (in time-based operation).
T3: Hold Timer (in both time- and energy-based operation).
T4: Afterpulse Timer (to release assemblies adhering to horn).
T5: Abort Cycle Timer (limits maximum weld time permitted for an
assembly).
6. F-TRIGGER key which displays and permits adjustment of triggering
force as a percentage of maximum force. When used in conjunction with
Head Advance Control (1098 Model only) actual horn coupling force can
be displayed.
OUTPUT CONTROL
100
90
80
70
60
50
40
30
40 60 80 100200 MICROSONIC PROCESSOR™
+LIM
TIMER F
TRIGGER
REF
INFO PRT AUTO O.L.
RESET
0
1
4
7 8
5
2 3
6
9
ENTER
CE
TEST MAN
–LIM
3
2
4
14
15
16
17 1
5-13
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.

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14 INSTRUCTION MANUAL • MODEL FM POWER SUPPLY
7. REF key which displays energy in Watt Seconds (Ws) when the constant
energy mode has been selected, and permits adjustment of the set value
in .1 Ws increments. Green LED in the upper left corner indicates
completion of an acceptable process cycle.
8. +LIM / -LIM keys which display and establish upper and lower quality
control tolerance limits in time (sec.) when energy mode is selected and in
energy (Ws) when time mode is selected. Red LEDs in upper left corner
indicate when rejects occur because either time or energy is above or
below set limits.
9. TEST key which can be used to test ultrasonic operation and displays idle
losses of converter/booster/horn as a percentage of maximum power when
key is depressed.
10. INFO key which displays data (or parameters) on the LCD screen.Can be
pressed up to eight times to display the following data (in the order shown):
— Number of cycles
— Number of rejects
— Rated output power of system
— Mode Codes (functions selected)
— Length of Graph Time Axis when printed out on optional printer
— SAVE RECALL OTHER options
— Job Sequencing
— Calibration Pulse (activation or deactivation).
11. PRT key which permits display of parameters and dynamic process
conditions when optional CRT monitor or printer is used. Green LED in
upper left corner indicates when data is being transmitted to a peripheral
accessory.
12. MAN key which is only used with rotary table operation to select normal
single cycle indexing (the default mode).
13. AUTO key which is only used with rotary table operation to select
continuous cycling.
14. 0-9 Numeric key pad which allows input of numeric data or numeric
selection options by pressing the keys.
15. ENTER key which enters data into the system as keyed in with numerical
keys and displayed on the LCD screen.
16. CE key which cancels a prior parameter value when a new value is to be
entered. Red LED in upper left corner indicates key is functional and will
cancel a value displayed when depressed.
17. O.L. RESET key which resets the power supply following an overload
condition. Red LED in upper left corner indicates an overload condition
exists.

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INSTRUCTION MANUAL • MODEL FM POWER SUPPLY 15
OPERATIONAL SIGNALS
Valid parameter entries and/or selections are verified by an audible signal of
short duration. Invalid entries and/or selections (fault conditions) are signaled
by an audible signal of longer duration.
OPERATIONAL FEATURES
– Adjustable Afterpulse Timer to separate parts from horn.
– Adjustable tolerance limits in energy (Ws) or time (sec) with visual and
audible alarms.
– Information displays including: number of assemblies, number of rejects,
power supply rated output, Mode Codes (functions selected) and length of
time axis for optional power curve printout.
– Fault displays: CHECK PRESS, CHECK PRESSURE OR b8, FORCE
MISSING, PRESS VALVE FAILURE.
– Keypad security to prevent unauthorized adjustment of parameters.
– Self diagnostic input test.
– Display of coupling force measurement (Model 1098 only).
– Storage capabilities of up to 9 programs.
– Job sequence of up to 9 programs.
– Deactivation of calibration pulse (i.e., when utilizing vacuum horns).
– Variable weld time in constant energy mode.
– Printer/CRT monitor interface permits connection to an optional CRT
and/or printer or computer.
STARTING UP THE POWER SUPPLY
Press the ON/OFF key to turn the power supply on.The red LED will light up
indicating the unit is on.
The LCD screen will briefly display “Sonics & Materials.” If a printer or CRT is
not connected to the system, the following message will also be displayed
briefly:
Then the LCD screen will display “READY.”
* * * NO PRINTER! * * *

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16 INSTRUCTION MANUAL • MODEL FM POWER SUPPLY
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. Press and hold the TEST button. While depressing the TEST button,
check the LCD reading. Make sure the reading on the LCD display (see
example below) does not exceed 10%.
a) If the display is above 10%, contact Sonics immediately for further
instructions before proceeding.
b) If the display is below 10%, 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.
3. The power supply is now ready for operation.
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.
US-TEST = 05%

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INSTRUCTION MANUAL • MODEL FM POWER SUPPLY 17
BASIC MODES OF OPERATION
The FM power supply’s built-in microprocesor allows the use of either time-
based or energy-based cycles in four basic modes, as follows:
1. Time-based cycle with time delay triggering or pre-triggering.
2. Time-based cycle with variable force triggering.
3. Constant energy-based cycle with time delay triggering or pre-triggering.
4. Constant energy-based cycle with variable force triggering.
TIME-BASED MODES
In a Time-Based Cycle with Time Delay Triggering, the Weld and Hold
timers are actuated following the termination of a pre-determined delay
period. This delay period is initiated when the horn contacts the part to be
welded.
In a Time-Based Cycle with Variable ForceTriggering, the Weld and Hold
Timers are actuated after a pre-determined coupling force is exerted on the
components.
For both of these time-based modes of operation, upper and lower tolerance
limits in energy (Ws) can be adjusted.
ENERGY-BASED MODES
In a Constant Energy-Based Cycle with Time Delay Triggering, the weld
cycle follows the termination of a pre-determined delay period.The weld cycle
continues until a pre-selected amount of energy in Watt seconds (Ws) is
delivered to the components.The duration of the weld cycle may vary, but the
energy delivered is constant.
In a Constant Energy-Based Cycle with Variable Force Triggering, the
Weld cycle is initiated after a pre-selected Trigger Force is reached. Once
again, the duration of the weld cycle is dependent upon the pre-selected
amount of energy delivered to the components.
In the case of energy-based modes of operation, the upper and lower
tolerance limits are adjustable in time (seconds).

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18 INSTRUCTION MANUAL • MODEL FM POWER SUPPLY
MODE CODES DISPLAY
The power supply is shipped with blank programs, so all data and parameters
must be input by the customer. On initial start-up, the default mode selected
is the Time-Based cycle. Press the INFO key four times and the following
“Mode Codes” display will appear on the LCD screen:
DEFAULT SETTINGS
MODE CODES: FUNCTION ABBREVIATIONS
Following is a complete list of mode code abbreviations that will appear in
eight positions on the LCD display and their corresponding meanings.
1st Position T1 = Ultrasonics are turned on following termination of delay
time or pre-trigger
or
FT = Ultrasonics actuated when trigger force has been
reached
2nd Position ZT = Time-based welding
or
EN = Constant energy welding
3rd Position NB = Normal operation (no rotary table)
or
RT = Rotary table control and operation provided by
microprocessor
4th Position IS = Rotary table pulse control
or
DS = Rotary table continuous signal control with
acknowledgement
5th Position U = Afterpulse Timer (T4) operational (Not a default)
or
blank
6th Position 1 = Normal Timer operation
7th Position 48 = Baud rate of 4800 for optional printer
8th Position M = Manual, dual palm switch actuation
or
A = Automatic impulse actuation
FT ZT NB IS 1 48 M
Force
Triggering Time-Based
Welding Rotary Table Pulse Control Baud Rate of 4800 for Printer
Manual Palm
Button Start
Normal Timer
Operation
Normal
Operation

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INSTRUCTION MANUAL • MODEL FM POWER SUPPLY 19
TIME-BASED MODES
SELECTING AND SETTING TIMERS IN A TIME-BASED
CYCLE (with delay triggering)
As described on the previous pages, the default mode is the Time-Based
cycle. Pressing the INFO key four times would display the following codes on
the LCD Screen:
The mode code “ZT” would be displayed in the second position, indicating
time-based operation.
To change from Force Triggering (FT) to Time Delay Triggering (T1), press
numerical key 1.The following display will appear:
As mentioned previously, the five timers are:
Timer Timer Number (NR) Mode Code
Delay Timer = Timer 1 = T1
Weld Timer = Timer 2 = ZT
Hold Timer = Timer 3 = T3
Afterpulse Timer = Timer 4 = U
Abort Timer = Timer 5 =
Press the TIMER key and the following display will appear:
Press the appropriate numerical key to select a timer value to be displayed or
set; i.e., press key 1 to display the set-value of the Delay Timer (T1); key 2, to
display the set-value of the Weld Timer (T2); and so on.
Once a timer number has been selected, the red LED in the upper corner of
the CE key will light up, indicating that the CE key is functional and must be
depressed to enter a new time value, regardless of whether or not a
previously established value is displayed.After depressing the CE key, which
cancels the prior time value, key in a new value using the numeric keys and
press the ENTER key to set the value, or wait thirty seconds and the value
will be automatically accepted.
FT ZT NB IS 1 48 A
T1 ZT NB IS 1 48 A
NOTE: When the Time-
Based mode is in effect,
the percentage of
maximum power and
energy (Ws) used are
displayed on the LCD
immediately following
completion of the
process cycle.
TIMER NR = (1-5)
NOTE: If you do not
press the ENTER key
to enter in new data
within 30 seconds, the
new data will be
automatically entered in
by the system.