Sonics GXC400-40 User manual

I N S T R U C T I O N M A N U A L
Sonics & Materials, Inc.
Model GXC / GC
Power Supply

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 1
ARNING
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 13 Rue Pre-de-la-Fontaine • CH - 1217 Meyrin/Satigny Switzerland
203.270.4600 • 800.745.1105 • 203.270.4610 fax (41) (0) 22/364 1520 • (41) (0) 22/364 2161
www.sonics.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. 2008 Printed in U.S.A. Rev 00 9/10

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 2
TABLE OF CONTENTS
IMPORTANT SERVICE LITERATURE ............................4
ManualChangeInformation ..............................4
UNPACKING AND INSPECTION ................................5
VisibleLossorDamage .................................5
ConcealedLossorDamage ..............................5
INTRODUCTION .............................................6
OVERVIEW OF ULTRASONIC PLASTICS ASSEMBLY ...............6
WhatisUltrasonics? ....................................6
Principal of Ultrasonic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .6
Ultrasonic Assembly Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
GLOSSARY OF ULTRASONIC TERMS ...........................8
INSTALLATION ..............................................9
Electrical Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SettingUp ............................................9
ElectricalConnections .................................10
Cable Connections
– For Models with 400 to 2200 Watts Power . .11
Cable Connections – For Models with 3500 or 4500 Watts Power .13
Available Converters For Power Supplies . . . . . . . . . . . . . . . . . . .15
OPERATING PROCEDURES ..................................16
Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . .16
KeyinginParameters ..................................17
OperationalFeatures...................................17
Starting Up the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . .18
InitialOperation .......................................18
ReadyScreen ........................................19
Amplitude ...........................................19
ADDITIONAL FEATURES AND FUNCTIONS .....................20
FrequencyDisplay.....................................20
OverloadProtection ...................................20
KEYPAD SECURITY .........................................21
MAINTENANCE .............................................22
General .............................................22
Repairs/Service ......................................22
WARRANTY ................................................23
LimitationofWarranty ..................................23

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 3
APPENDIX .................................................24
Drawings ............................................24
G-SeriesSwitches.....................................26

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 4
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
equip ent, then forward
to your service
depart ent.

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INSTRUCTION MANUAL • MODEL GXC / GC 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 reco end
keeping all carton(s) and
packing aterial in case
it ight be necessary to
ove the equip ent, or
to ship it for repair.

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 6
INTRODUCTION
The GXC / GC power supply is an ultrasonic generator with automatic
frequency tuning and a built-in Microprocessor that can be operated on a
continuous duty basis or pulsed via an outside 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 press or actuator or with a stand-alone converter.
OVERVIE 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 GXC / GC 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
Plastic part

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 8
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.

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.
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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 9
The line cord of the
controller/power supply
is equipped with a 3-
prong, grounding plug.
Do not, under any
circu stances, re ove
the ground prong. The
plug ust be plugged
into a ating 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 co pressed
air filtered down to 5
icrons (supplied to
converter fitting – see
page 11).
Power Rating/
Model Frequency 115 vac 230 vac
GXC400-40 400w - 40 kHz 15 amps 10 amps
GXC800-40 800w - 40 kHz 15 amps 10 amps
GXC1200-20 1200w - 20 kHz 15 amps 10 amps
GXC1700-20 1700w - 20 kHz N/A 20 amps
GXC2200-20 2200w - 20 kHz N/A 20 amps
GXC3500-20 3500w - 20 kHz N/A 30 amps
GXC2200-15 2200w - 15 kHz N/A 20 amps
GXC3500-15 3500w - 15 kHz N/A 30 amps
GXC4500-15 4500w - 15 kHz N/A 30 amps
Fuse Rating

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 10
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 (305 mm).
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 ade.

CABLE CONNECTIONS – For GXC Models with 400 to 2200
Watts Power:
Located at the rear of the power supply are the cable connections as
illustrated below. (The interconnecting cables will be supplied with your
system.)
❶J1 a round 12-pin RF cable that connects the welding press or
converter to the power supply.
❷J2 a control cable that connects the power supply to a trigger source
(press cable or external trigger source.) Refer to wiring diagrams in
Appendix.
❸The 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:
❹Optional J5 External I/O
❺Fuse (0.5 amp - internal low voltage)
➏Line fuse (based on requirements listed in “Power Specifications” table
page 9)
❼Line fuse (based on requirements listed in “Power Specifications” table
page 9)
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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 11
❷
❶
❸
❺
➏
❹
NOTE: Detailed wiring
diagra s are supplied in
the Appendix at the
back of this anual.
❼
Fan
NOTE: To see a list of
converters that can be
connected to the power
supply, see the table on
page 15.

CABLE CONNECTIONS – For GC Models with 400 to 2200
Watts Power:
Located at the rear of the power supply are the cable connections as
illustrated below. (The interconnecting cables will be supplied with your
system.)
❶J1 a round Lemo cable that connects the welding press or converter to
the power supply.
❷J2 a control cable that connects the power supply to a trigger source
(press cable or external trigger source.) Refer to wiring diagrams in
Appendix.
❸The 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:
❹Optional J5 External I/O
❺Fuse (0.5 amp - internal low voltage)
➏Line fuse (based on requirements listed in “Power Specifications” table
page 9)
❼Line fuse (based on requirements listed in “Power Specifications” table
page 9)
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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 12
❷
❶
❸
❺
➏
❹
NOTE: Detailed wiring
diagra s are supplied in
the Appendix at the
back of this anual.
❼
Fan
NOTE: To see a list of
converters that can be
connected to the power
supply, see the table on
page 15.

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 13
CABLE CONNECTIONS – For GC Models with 3 00 or 4 00
Watts Power:
Located at the rear of the power supply are the cable connections as
illustrated below. (The interconnecting cables will be supplied with your
system.)
❶J1 a round Lemo cable that connects the welding press or converter to
the power supply.
❷J2 an actuation cable that connects the power supply to a trigger source
(press cable or external trigger source.) Refer to wiring diagrams in
Appendix.
❸The 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:
NOTE: Detailed wiring
diagra s are supplied in
the Appendix at the
back of this anual.
NOTE: To see a list of
converters that can be
connected to the power
supply, see the table on
page 15.
❷❶
❸
❺
➏
❹
❹Optional J5 External I/O
❺Fuse (0.5 amp - internal low voltage)
➏Circuit breaker

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 14
CABLE CONNECTIONS – For GXC Models with 3 00 or
4 00 Watts Power:
Located at the rear of the power supply are the cable connections as
illustrated below. (The interconnecting cables will be supplied with your
system.)
❶J1 a round 12 pin RF cable that connects the welding press or converter
to the power supply.
❷J2 an actuation cable that connects the power supply to a trigger source
(press cable or external trigger source.) Refer to wiring diagrams in
Appendix.
❸The 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:
NOTE: Detailed wiring
diagra s are supplied in
the Appendix at the
back of this anual.
NOTE: To see a list of
converters that can be
connected to the power
supply, see the table on
the following page.
❷❶
❸
❺
➏
❹❼
❹Optional J5 External I/O
❺Fuse (0.5 amp - internal low
voltage)
➏Circuit breaker
❼J6 on 1595 only. Press motor
connector.

Item No. Description
CV00016 15 kHz with Button connector (O-ring mount)
CV00161 15 kHz with Lemo connector (O-ring mount)
CV00034 15 kHz with Button connector (O-ring mount)
CV00341 15 kHz with Lemo connector (O-ring mount)
CV00344 15 kHz with Lemo connector and fitting for air cooling (O-ring mount)
CV00015 20 kHz with Button connector (O-ring mount)
CVR0015 20 kHz with Button connector (rigid mount)
CV00151 20 kHz with Lemo connector (O-ring mount)
CVR0151 20 kHz with Lemo connector (rigid mount)
CV00154 20 kHz with Lemo connector and fitting for air cooling (O-ring mount)
CVR0154 20 kHz with Lemo connector and fitting for air cooling (rigid mount)
CV00157 20 kHz with Button connector and fitting for air cooling (O-ring mount)
CVR0157 20 kHz with Button connector and fitting for air cooling (rigid mount)
CV00159 20 kHz Hand Gun with handles and cables (O-ring mount)
CVR0159 20 kHz Hand Gun with handles and cables (rigid mount)
CV00029 20 kHz with Button connector (O-ring mount)
CV00291 20 kHz with Lemo connector (O-ring mount)
CV00294 20 kHz with Lemo connector and fitting for air cooling (O-ring mount)
CV00331 20 kHz with Fischer connector
CV00334 20 kHz with Fischer connector and fitting for air cooling
CVR0023 40 kHz with Button connector (rigid mount)
CVR0231 40 kHz with Lemo connector (rigid mount)
CVR0233 40 kHz with SHV connector side mounted (rigid mount)
CVR0234 40 kHz with Lemo connector and fitting for air cooling (rigid mount)
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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 15
AVAILABLE CONVERTERS FOR POWER SUPPLIES

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 16
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 keys which turn the unit on and off.
2. LCD SCREEN which displays various settings parameters and prompts
as detailed in the following pages. In addition during the weld process it
displays a load meter indicator showing the power level of ultrasonics that
is being delivered to the welding press (see #3 below).
3. LOAD METER SCALE from 0 to 100% which (in conjunction with
vertical line indicators on LCD display) shows the running power (bar
graph at bottom of display) and peak power (single vertical line at top of
display) during the weld. Peak power is reported as %Pmax after the cycle
(see page 18).
4. AMPLIT DE key which controls adjustment of the following amplitude
settings of the system’s high-frequency vibrations over the full operating
range. (Major adjustments of amplitude can be made through the use of
different boosters – consult your press manual for further information.)
a. Amplitude Setting
b. Amplitude Ramp (only on systems configured for more than 2200
watts)
5. FN key. Option not available on this model.
1
2
3
4
5
7
6
8
9
10
3

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 17
6. 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. Also functions as a frequency display.
7. O.L. RESET key which resets the power supply following an overload
condition. Red LED in upper left corner indicates an overload condition
exists.
8. ENTER/REVIEW key which Enters data into the system as keyed in with
the numerical keys and displayed on the LCD screen. In Review function
displays the alarm mode and cycle information.
9. CLEAR key which cancels a prior parameter value when a new value is to
be entered.
10. 0-9 N MERIC KEY PAD which allows input of numeric data or numeric
selection options by pressing the keys.
KEYING IN PARAMETERS
To make numeric entries into a cursor location that is displayed on a screen
menu use the numeric keypad. When the desired entry is displayed on the
LCD screen use the ENTER key to register the new value. Entries are made
left to right.
The CLEAR key will clear an existing value to 0 displayed as a series of
dashes and relocate the cursor to the extreme left-hand entry position ready
to accept entries again. As soon as a desired value is keyed in and displayed
pressing the ENTER key makes the system accept that entry. If a number
value is not “Entered ” then it will not be accepted by the system and the
parameter value will return to its former setting (before any numerical values
were changed).
OPERATIONAL FEATURES
– Information displays showing customer resettable counter (CRC) and
number of cycles
– Keypad security.
– Self-diagnostic input test.

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 18
STARTING UP THE POWER SUPPLY
Press the ON/OFF key to turn the power supply on. The LCD screen will
briefly display “Start Sequence” and show wattage and frequency
information. Then the LCD screen will show the following “ready” display:
INITIAL OPERATION
After the power supply is turned on (as described on previous page) 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 display. Make sure the bar graph indicator on the LCD
display (a series of vertical lines that register to the 0 to 100% load meter
scale – see example below) does not exceed 20%.
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.
A bar graph indicator reading of above 20% signals that there may be a
problem with the stack. Check your assembly and re-test.
3. The power supply is now ready for operation.
Frequency Display
The TEST key can also be used to display the running ultrasonic frequency
being used by the system. Refer to page 20 for more information.
NOTE: The TEST and
Load Meter check
should always be done
for all cold start-ups,
and for any start-up after
the syste has been idle
for 20 inutes or ore.
Ready
0045 Watts

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INSTRUCTION MANUAL • MODEL GXC / GC POWER SUPPLY 19
READY SCREEN
In addition to the start-up ready screen (shown on page 16) there is another
“ready” screen as shown below. The system must be displaying one of these
two ready screens in order for welding to commence. Welding cannot be
initiated from any other display.
Counter Screen
The Counter screen displays the number of cycles run to date and the
customer resettable counter (CRC). The resettable counter can be reset
whenever desired by pressing the Clear key when the counter screen is
displayed (the keypad must be unlocked).
AMPLITUDE
Fine adjustments of the following amplitude and pressure settings can be
made by using the Amplitude key. All settings range from 20% (minimum) to
100% (maximum).
Amplitude Ramp – (only on systems configured for more than 2200 watts)
Used primarily for 15 kHz systems to ensure a slow start-up when welding
with big horns.
Amplitude Setting – this setting is used to specify the vibrational amplitude.
Cycles: 00,004,678
CRC: 000,062
NOTE: Major
adjust ents of
a plitude is ade on
the press through the
use of boosters.