Sonics 4095 User manual

Models
4095 Press /
4096 Actuator
INSTRUCTION MANUAL
Sonics & Materials, Inc.

INSTRUCTION MANUAL • MODEL 4095/4096 1
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WARNING
SAFET PRECAUTIONS
READ BEFORE INSTALLING OR USING THE EQUIPMENT
Our systems have been designed to assure maximum operator safety.
However, no design can completely protect against improper usage. or
maximum safety and equipment protection, observe the following warnings at
all times and read all applicable instruction manuals carefully before you
attempt to operate any equipment.
– The equipment has safety devices that require both hands to be on the
palm buttons until the horn contacts the work piece. Do not defeat or
modify these safety devices.
– Do not use with foot switch unless alternate means of pinch-point
protection is provided.
– 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.
– High voltage potential may be present in the converter as a result of
temperature changes. Do not touch the converter contact unless you first
short both pins or the button to the converter case with an insulated tool.
– Never squeeze or grab a vibrating horn.
– Do not modify horn configurations.
– Ultrasonic welders operate above normal audibility for most people. Ear
protection is recommended.
– Do not affix any device to any portion of the horn.
onics & Materials, Inc.
Corporate Headquarters European Office
53 Church Hill Road • Newtown, CT 06470 USA 13, Rue Pre-de-la- ontaine • CH - 1217 Meryin/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.biz • inf[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. 2007 Printed in U.S.A. Part No. 381-0033
Rev 5/07

2 INSTRUCTION MANUAL • MODEL 4095/4096
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INSTRUCTION MANUAL • MODEL 4095/4096 3
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TABLE OF CONTENTS
IMPORTANT ERVICE LITERATURE ............................4
ManualChangeInformation ..............................4
UNPACKING AND IN PECTION ................................5
VisibleLossorDamage .................................5
ConcealedLossorDamage ..............................5
INTRODUCTION .............................................6
OVERVIEW OF ULTRA ONIC PLA TIC A EMBLY ..............6
WhatisUltrasonics? ....................................6
Principal of Ultrasonic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6
UltrasonicAssemblySystems .............................6
GLO ARY OF ULTRA ONIC TERM ...........................8
IN TALLATION ..............................................9
ElectricalPower .......................................9
AirSupply ............................................9
SettingUp ............................................9
KeyComponents .......................................9
Connections .........................................10
Options .............................................10
INITIAL EQUIPMENT ETUP ..................................11
Assembling and Mounting Converter, Booster and Horn . . . . . . .11
Hornand ixtureAlignment .............................13
PositiveStopAdjustment................................14
OPERATION ...............................................15
Actuation ............................................15
EmergencyStop ......................................15
FINE ADJU TMENT ........................................16
PressureSwitchAdjustment .............................16
UpperLimitSwitch ....................................17
BoosterSelection .....................................18
Pressure ............................................18
StrokeSpeedAdjustment ...............................19
Re-Establishing Proper Booster/Horn Interfaces . . . . . . . . . . . . .20
MAINTENANCE .............................................21
Repairs/Service......................................21
WARRANTY ................................................22
LimitationofWarranty ..................................22

4 INSTRUCTION MANUAL • MODEL 4095/4096
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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 the
equipment, then
forward to your service
department.

INSTRUCTION MANUAL • MODEL 4095/4096 5
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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 disposing of any packing material, check it carefully
for small parts. Then perform a visual inspection of the equipment to detect
any evidence of damage which might have occurred during shipment. Check
the following:
1. all components against the enclosed packing list,
2. all module plug-in units,
3. all wire plug-in connections.
The equipment was carefully packed and thoroughly inspected 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. ailure 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.

6 INSTRUCTION MANUAL • MODEL 4095/4096
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INTROD CTION
The models 4095 and 4096 are 40 kHz precision pneumatic actuators used
for ultrasonic plastics assembly. The 4095 is a tabletop version, whereas the
4096 can be mounted on a bridge or rigid structural member for use with
automated systems. Either can be supplied with the following GX-Series
power supplies:
■GXT . . . . . . .Weld by digital time
■GXE . . . . . .Weld by digital time and/or constant energy
■GXL . . . . . . .Weld by digital time, constant energy and/or distance*
*Requires optional linear encoder.
Both actuators are also compatible with E and Series power supplies.
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 ASSEMBL
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 ASSEMBL S STEMS
“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.

INSTRUCTION MANUAL • MODEL 4095/4096 7
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“SONICS” ULTRASONIC ASSEMBL S STEMS
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 upply/Generator
Actuator/Press
Holding Fixture

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GLOSSARY OF ULTRASONIC TERMS
POWER SUPPLY/GENERATOR – The solid state power supply onverts
standard 50/60 Hz ele tri al power to 15,000 Hz, 20,000 Hz, or 40,000 Hz
(15/20/40 kHz) ele tri al energy.
ACTUATOR/PRESS – The pneumati a tuator provides ompressive for e
and mounting for the onverter, booster, and horn assembly. The tabletop
press onsists of a base assembly, olumn and a tuator (head).
CONVERTER – The onverter hanges the high frequen y ele tri al energy
supplied by the power supply to high frequen y me hani al vibrations.
BOOSTER – Su essful ultrasoni welding often depends on having the right
amplitude at the horn fa e. Often it is not possible to design a horn whi h has
both the ne essary shape and required gain (ratios of input amplitude to
output amplitude). In su h ases, a booster is pla ed between the onverter
and the horn to either in rease or de rease the amplitude of the horn. In
addition to hanging/maintaining the amplitude, the booster provides support
and alignment in the welding system. (See page 18 for booster sele tion.)
HORN – The horn is a tuned omponent of the system whi h omes in
onta t with the parts to be assembled. The horn 1) transfers the ultrasoni
vibrations produ ed from the onverter to the parts being welded, and 2)
applies ne essary for e to the assembly while the material resolidifies.
HOLDING FIXTURE – The holding fixture or nest assures proper alignment
and support of the parts being assembled.
MODEL 4096 MODEL 4095

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INSTALLATION
ELECTRICAL POWER
The press is powered by the power supply. Consult your power supply
instruction manual to determine power specifications.
AIR SUPPL
The press requires a source of dry, filtered (5 micron), oil-free, compressed
air capable of supplying a constant line pressure of 85 psig. (586 kPa / 6 bar)
at a minimum capacity of 2 C M.
SETTING UP
The press 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
and air supply sources and away from any equipment that generates
abnormally high electrical transients. Observe the following additional
instructions when installing the press:
a. The press should be placed on a sturdy, level table or bench capable of
supporting a minimum of 500 pounds (227 kg).
b. Allow at least 6 inches (152.4mm) at the rear of the press for cable
connections.
KE COMPONENTS
Do not connect the press
to an air source supplied
by a compressor lubricated
with synthetic oils or oils
containing phosphate
esters or chlorinated
hydrocarbons. his type of
lubricant may cause the air
filter to malfunction, and
the plastic bowl to rupture.
NOTE: If the 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).
AIR
FILTER/REGULATOR
A EMBLY
CONVERTER HOU ING
with converter, booster &
horn (stack) assembly
PALM ACTIVATION
BUTTON
CONVERTER
HOU ING DOOR
PART HOLDING
FIXTURE
EMERGENCY TOP
BUTTON

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CONNECTIONS
When making the initial connections, make sure all power is disconnected.
1. Connect the air supply source to the press air filter located at the right, rear
of the press head, using a hose having a minimum inside diameter of 1/8
inch (6 mm).
2. Connect the R and base (actuating) cables of the press (4095 only) to the
power supply. (Consult your power supply instruction manual for details.)
3. Check with your electrician if you have any wiring questions.
OPTIONS
A Linear Encoder is available as an option for the 4095 and 4096 models. The
Linear Encoder allows distance-controlled welding in incremental and
absolute modes.
The Linear Encoder is supplied with a 9-pin male connector that connects to
a matching 9-pin female connector on the power supply (factory installed).
NOTE: 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 (304.8mm).
LINEAR ENCODER

INSTRUCTION MANUA • MODE 4095/4096 11
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INITIAL EQUIPMENT SETUP
ASSEMBLING AND MOUNTING CONVERTER, BOOSTER,
AND HORN
If the converter, booster, and horn are not already assembled, follow these
instructions:
1. Clean the mating surfaces of the converter and booster, as well as the
threaded stud and hole. Check that the stud is tight (see recommended
torque requirements on page 12).
2. Hand assemble the converter and booster together. Using open-ended
wrenches as shown below, tighten until snug. Then, using a torque wrench,
tighten to 25-35 foot-lbs.(34-47 newton-meters). Do not force or
overtighten.
3. Clean the mating surfaces of the booster and horn, as well as the threaded
stud and hole. Check that the stud is tight. (See recommended torque
requirements on next page.)
4. Hand assemble the horn to the booster. Using open-ended wrenches as
shown below, tighten securely. Then, using a torque wrench, tighten to 25-
35 foot-lbs. (34-47 newton-meters). Do not overtighten.
CONVERTER/BOOSTER
BOOSTER/HORN
Never tighten the horn to
the booster using the
housing door as the upper
wrench as this may cause
damage to the booster
and/or converter.

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Component Foot-Lbs. Newton-Meters
Converter / Booster 25 - 35 34-47
Booster / Horn 25 - 35 34-47
Stud 45 61
Tips 25 - 35 34-47
5. Using the 3/16” (4.7 mm) T-handle wrench provided, loosen (turn
counterclockwise) the two cap screws screws on the hinged converter
housing and open the door.
6. Place the converter / booster / horn assembly in the housing with the horn
facing down. Fit the male brass button connector on the top of converter
into the female brass connector in the bottom of the interior housing, and
gently push the assembly up and in so that the booster mounting ring rests
on the lower support ridge.
7. Close the converter housing door and tighten (turn clockwise) the two
socket head cap screws just until they are snug. Do not tighten the horn to
the booster using the door as the upper wrench. Hand-forcing the horn on
and off in this manner can twist wires and cause a failure. If the horn is not
in the correct position to make contact with your material, re-position the
converter.
RECOMMENDED TORQUE REQUIREMENTS
NOTE: I you do not close
the housing door once the
assembly is in place, the
assembly can all out.
Never tighten the horn to
the booster using the
housing door as the upper
wrench as this may cause
damage to the booster
and/or converter.
CONVERTER / BOOSTER
HORN ASSEMBLY
NOTE: When per orming
any o the operations
described on this page and
pages 13 and 14, DO NOT
turn on the power supply.

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HORN AND FIXTURE ALIGNMENT
For maximum productivity, the clearance between the horn and the part
should be at a minimum. However, adequate clearance should be provided to
enable easy loading and unloading of the part from the holding fixture. (The
maximum stroke distance is 3-1/2".) Ensure that the horn does not contact the
part when the head is close to the limit of its down travel distance. Otherwise,
the horn may not have sufficient distance to travel downwards to achieve a full
depth of weld. Set welding height as described below:
1. Position the holding fixture loosely on the base plate using 3/8-16 screws.
2. Place the part to be welded in the fixture.
3. Before loosening the column clamps, hold onto the head assembly firmly
as it can rise upwards rapidly once the clamps are released. While holding
the head assembly, loosen the two column clamps (counterclockwise) and
move the head up or down as required. Then tighten the column clamps.
4. Set the air pressure to zero by turning the PRESSURE regulator knob
(located at the top of air filter/regulator assembly) fully counterclockwise.
5. oosen the column clamps once again and manually lower the head until
the horn contacts the part. Tighten the clamps.
6. oosen the cap screws on the converter housing door and gently rotate the
head and horn as required to ensure proper horn-to-part alignment.
Support the head
be ore releasing the
column clamps so that
it cannot crash down or
ly up. Ignoring this
warning might result in
injury and/or damage to
the equipment and part
being welded.
When the air pressure
is decreased, the
converter housing can
drop down to its limit,
so be sure to either
support it or remove
anything in its path.
HEAD
ASSEMBLY
PRESSURE
REGULATOR
COLUMN CLAMPS

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7. ock the two column clamps, tighten the converter housing door screws,
and then tighten the fixture on the base plate.
8. Check for proper mating of fixture, parts, and horn. If the horn and part are
not in parallel contact, shim the fixture or adjust leveling screws as
required.
9. Set the PRESSURE regulator to a reading of 20 psig (140 kPa/1.4 bar) on
the pressure gauge. (Turn the PRESSURE knob clockwise.)
10. To check that the horn and parts are properly aligned, the horn needs to
be lowered. Read through the Operation instructions on the next page, and
then proceed to lower the horn as detailed. If the horn and parts are not
sufficiently aligned, then repeat steps 4 through 8 on the preceding page.
However, if you are working with small, delicate parts, then fine
adjustments can be made using the positive stop adjustment knob as
explained below.
POSITIVE STOP ADJUSTMENT
The positive stop is set to limit the downward travel of the horn to
approximately 75%. Readjustments may be required. Coarse adjustment of
the clearance between the face of the horn and part should be made using
the elevation control. Fine adjustment should be made using the positive stop.
The positive stop adjustment knob is located offset from the converter
housing. Turning the knob clockwise will decrease downward travel distance.
Turning the knob counterclockwise will increase the downward travel
distance. A set screw located on the left side of the housing locks the positive
stop adjustment in place. Use a 3/32 Allen wrench to lock and unlock this set
screw.
NOTE: For maximum
sa ety and productivity,
adjust the clearance
between the horn and
the part to a minimum
that will still allow ease
o loading and
unloading.
POSITIVE STOP
ADJUSTMENT
KNOB
Converter
Housing

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OPERATION
ACTUATION
The 4095 press is equipped with two maintained anti-repeat (non-tie-down)
palm buttons, one located on the left and one on the right side of the base of
the press. Both palm buttons must be pressed simultaneously to activate the
press to cycle the welder. To operate the press, follow these simple steps:
1. Depress both black palm buttons simultaneously.
2. Once the horn comes in contact with the part and the ultrasonics are
activated, release the palm buttons. If you release the buttons before
contact is made, the head will immediately return to its “home” position.
The operation of the 4096 actuator is controlled by the automated system. A
four-wire actuation cable is provided which ties into the output side of a P C,
or other system controlling device. Momentary two wire closure from a dry
source will initiate the welder’s cycle. For more information, refer to the power
supply manual and the included wiring diagrams.
EMERGENCY STOP
To abort the 4095 press during welding, simply press the red EMERGENCY
STOP button located at the front center of the press base.
Once the EMERGENCY STOP button has been depressed, the head will
retract and return to its “home” position, remaining there until the button is
released. Simply rotate the EMERGENCY STOP button to the right 1/4 turn
to release the press for further operation.
For the 4095 actuator, a four-wire actuation cable contains two normally
closed wires which control the emergency stop function. For more
information, refer to the power supply manual and the included wiring
diagrams.
NOTE: Power supply
cannot be shut o once
the weld cycle has
started. Termination o
cycle can only be
achieved by using the
EMERGENCY STOP
button.
The equipment has
sa ety devices that
require both hands to
be on the palm buttons
until the horn contacts
the workpiece. Do not
defe t or modify
these s fety devices.
Do not use with a
ootswitch unless
alternate means o
pinch-point protection is
provided.

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FINE ADJUSTMENTS
PRESSURE SWITCH ADJUSTMENT
For systems mounted in the normal vertical position with downward travel, no
adjustment should be necessary. The minimum trigger pressure is factory set
at 4-7 psig.
However, if the minimum trigger pressure requires recalibration or re-
adjustment, observe the following procedure:
1. Maintain air pressure and unplug the power supply from the electrical
source.
2. Remove the four screws holding the five-sided cover.
3. oosen the jam nut holding the 8-32 cap screw in place.
4. Rotate the cap screw counter-clockwise (up) until the Pressure Switch
closes.
5. Next rotate the cap screw clockwise (down) until the Pressure Switch
opens.
6. Rotate cap screw clockwise (down) 1/4 turn past the Pressure Switch
open position.
7. Tighten the jam nut to lock cap screw in position.
8. Replace the cover and four screws.
9. Plug the power supply into the electrical source.
10. Cycle the welder.
The press is now set to trigger at the minimum trigger pressure of 4-7 psig.
A press actuating in an upward or horizontal direction should be set to trigger
at a minimum of 8-10 psig. ower values may affect trigger performance
where false triggering may be observed.
PRESSURE SWITCH
Base of Air
Cylin er
Mount
Top of
Converter
Housing

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FINE ADJUSTMENTS
UPPER LIMIT SWITCH
The optional Upper imit Switch is used as a safety interlock in automation to
prevent the movement of material handling equipment (indexing) when the
horn is down. It also initiates the movement of material handling equipment
when the horn is up.
The Upper imit Switch is factory set and should be suitable for all
applications. If for some reason you need to readjust it, observe the following
procedure:
1. Maintain air pressure and unplug the power supply from the electrical
source.
2. Remove the four screws holding the five-sided cover.
3. oosen the jam nut holding the 8-32 cap screw in place.
4. Rotate the cap screw counter-clockwise (down) until the Upper imit
Switch closes.
5. Tighten the jam nut to lock cap screw in position.
6. Replace the cover and four screws.
The Upper imit Switch is now set.
UPPER LIMIT SWITCH

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BOOSTER SELECTION
The first step in optimizing welding conditions is to select a booster which will
provide the necessary amplitude. For parts one inch (25.4mm) in diameter or
greater, start with a moderately high amplitude booster such as a gold. For
smaller parts, start with a green booster. Determine optimum amplitude by
welding a few parts, and repeat the procedure with boosters giving higher or
lower amplitude. If there appears to be little or no difference, use the booster
giving the highest amplitude.
Six standard boosters, color coded or engraved for ease of identification, are
available either to increase or decrease the amplitude.
PRESSURE
During the welding process, sufficient pressure should be applied to the part
so that the mating surfaces contact each other. If the pressure is too low, the
process will run inefficiently causing unnecessarily long weld time cycles,
marking of the parts or poor welding. If the pressure is too high, the horn may
stop vibrating, the part(s) might fracture, or the power supply might overload.
BOOSTER
Color Part No. Gain Amplitu e Effect
Black BHN23TBK 2.50 Increase
Silver BHN23TSI 2.00 Increase
Gold BHN23GD 1.50 Increase
Brown BHN23BR 1.25 Increase
Green BHN23GR 0 No Change
Purple BHN23PU 0.75 Decrease
NOTE: Consult the
Applications Manual or
call our Applications
Lab or proper booster
selection.
High gain boosters,
such as silver and black
in combination with
high gain horns can
result in the horn
cracking or ailing.

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STROKE SPEED ADJUSTMENT
The velocity at which the horn descends and returns can be adjusted via the
speed controls. These controls are factory adjusted for average operating
conditions and should not require further adjustment. However, if a minor
adjustment is necessary, adjust in small degrees. Turn clockwise to slow the
extend speed, and counterclockwise to increase the return speed.
The speed controls are 2 small threaded screws located at the top of the
press and behind the air cylinder as shown below.
The top screw controls the extend speed – turn it clockwise to slow the
speed, counterclockwise to increase the speed. The bottom screw controls
the return speed – turn it clockwise to slow the speed, counterclockwise to
increase speed.
Excessive velocity may
be unnecessary and
harm ul to the system.
EXTEND
SPEED
CONTROL
RETURN SPEED
CONTROL