Sonics GXL User manual

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

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I N S T R U C T I O N M A N U A L • M O D E L G XLP O W E R S U P P LY
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W A R N I N G
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 fax
www.sonics.com • [e-mail] eur[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. 2010 Printed in U.S Rev 01, 9/10

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INSTRUCTION MANUAL • MODEL GXL 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 700 to 2200 Watts Power . . .11
Cable Connections – For Models with 3000 to 4000 Watts Power . .12
AvailableConverters ...................................13
OPERATING PROCEDURES ..................................14
Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . .14
KeyinginParameters ..................................16
OperationalFeatures...................................17
Starting up the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
InitialOperation .......................................18
ReadyScreens .......................................18
Relationship of Time Distance and Energy Settings . . . . . . . . . .19
TimeSettings ........................................20
DistanceSettings .....................................21
EnergySettings .......................................23
Amplitude/Pressure...................................24
Trigger ..............................................25
ADDITIONAL FEATURES AND FUNCTIONS .....................26
JobStorage..........................................26
FrequencyDisplay.....................................27
OverloadProtection ...................................27
KEYPAD SECURITY .........................................28
PRINT LINE OUTPUT ........................................29

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INSTRUCTION MANUAL • MODEL GXL POWER SUPPLY 3
AUTOMATION INTERFACE & I/O CONTROLS ....................31
ExternalJobAddressLines .............................33
MAINTENANCE .............................................34
General .............................................34
Repairs/Service ......................................34
WARRANTY ................................................35
LimitationofWarranty ..................................35
APPENDIX .................................................36
Print Line Output Data Items . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Automation Interface & I/O Controls . . . . . . . . . . . . . . . . . . . . . . .39
Source/Sink Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . .39
Source/Sink Digital I/O Configuration . . . . . . . . . . . . . . . . . . . . . .40
Sinking Output to PLC Input Diagram . . . . . . . . . . . . . . . . . . . . .41
PLC Output to Sinking Input Diagram . . . . . . . . . . . . . . . . . . . . .41
PLC Output to Sourcing Input Diagram . . . . . . . . . . . . . . . . . . . .41
TwoIsolatedLoopSupplies .............................42
I/O Timing Diagram – Automated Controls . . . . . . . . . . . . . . . . . .42
PLCSampleCode ....................................43
Drawings ............................................45
GXLSwitches ........................................53

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INSTRUCTION MANUAL • MODEL GXL POWER SUPPLY 4
IMPORTANT SERVICE LITERAT RE
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 t e
equipment, t en
forward to your
service department.

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INSTRUCTION MANUAL • MODEL GXL POWER SUPPLY 5
NPACKING 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 mig t be
necessary to move
t e equipment, or to
s ip it for repair.

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INSTRUCTION MANUAL • MODEL GXL POWER SUPPLY 6
INTROD CTION
The GXL power supply is an ultrasonic generator with automatic frequency
tuning and a built-in Microprocessor that features time energy and distance
controls. 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. (Note: Distance controls are not available with a
stand-alone converter.)
OVERVIEW OF LTRASONIC 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 GXL 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 GXL POWER SUPPLY 8
GLOSSARY OF LTRASONIC 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 GXL POWER SUPPLY 9
T e line cord of t e
controller/power
supply is equipped
wit a 3-prong,
grounding plug. Do
not, under any
circumstances,
remove t e ground
prong. T e plug must
be plugged into a
mating 3-prong,
grounding type outlet.
NOTE: If power
supply is to be run
continuously, air
cooling of t e
converter and orn is
required. Use clean,
dry compressed air
filtered down to 5
microns (supplied to
converter fitting – see
page 13).
POWER SPECIFICATIONS
Power Rating/
Model Frequency 115 vac 230 vac
GXL400-40 400w - 40 kHz 15 amps 10 amps
GXL800-40 800w - 40 kHz 15 amps 10 ampL
GXL1200-20 1200w - 20 kHz 15 amps 10 amps
GXL1700-20 1700w - 20 kHz N/A 20 amps
GXL2200-20 2200w - 20 kHz N/A 20 amps
GXL3500-20 3500w - 20 kHz N/A 30 amps
GXL2200-15 2200w - 15 kHz N/A 20 amps
GXL3500-15 3500w - 15 kHz N/A 30 amps
GXL4500-15 4500w - 15 kHz N/A 30 amps