Sonics H520 T/E User manual

Models
H520 and H540
Hand Held
Welders
I N S T R U C T I O N M A N U A L
Sonics & Materials, Inc.

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INSTR CTION MAN AL • MODEL H520/H540 1
WARNING
SAFETY 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. For
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.
– 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.
– Never squeeze or grab a vibrating horn.
– Do not modify horn configurations.
– ltrasonic welders operate above normal audibility for most people. Ear
protection is recommended.
– Do not affix any device to any portion of the horn.
– Certain plastic materials, when ultrasonically welded, may emit fumes
and/or gases hazardous to an operator’s health. Where such materials are
processed, proper ventilation of the work station should be provided. If in
doubt about the toxicity of your plastic material, contact OSHA, .S.
Department of Labor, or material supplier.
– Do not operate the power supply unless it is connected to the hand gun.
– Maintenance should be performed only by a qualified electronic technician.
– Always turn off the power supply before installing or removing the optional
foot switch cable.
– When the hand gun is on, be sure to isolate it from any grounded surface
to avoid triggering an overload condition as the system detects an alternate
ground path.
Sonics & Materials, Inc.
Corporate Headquarters European Office
53 Church Hill Road • Newtown, CT 06470 USA 13, Rue Pre-de-la-Fontaine • 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.com • [email protected] euro [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 .S.A. Part No. 381-0035
Rev 00 8/07

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2 INSTRUCTION MANUAL • MODEL H520/H540

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INSTRUCTION MANUAL • MODEL H520/H540 3
TABLE OF CONTENTS
IMPORTANT SERVICE LITERATURE ............................4
ManualChangeInformation ..............................4
UNPACKING AND INSPECTION ................................5
VisibleLossorDamage .................................5
ConcealedLossorDamage ..............................5
INTRODUCTION .............................................6
OVERVIEW OF ULTRASONIC PLASTICS ASSEMBL ..............6
WhatisUltrasonics? ....................................6
Principal of Ultrasonic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Ultrasonic Hand Held Welders . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
GLOSSAR OF ULTRASONIC TERMS ...........................8
INSTALLATION AND SET UP ...................................9
Electrical Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
SettingUp ............................................9
ElectricalConnections...................................9
CableConnections ....................................10
KeyComponents ......................................11
TipAssembly(CV52) ..................................12
TipReplacement(CV52)................................12
HornAssembly(CV54Only) .............................12
TipReplacement(CV54)................................13
TipSpecifications .....................................14
Options .............................................15
OPERATING PROCEDURES ..................................17
ront Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . .17
InitialOperation .......................................19
OverloadProtection....................................21
APPLICATIONS – STAKING ...................................22
Standard laredStake .................................22
SphericalStake ......................................23
HollowStake .........................................23
KnurledStake ........................................23
lushStake ..........................................24
APPLICATIONS – SPOT WELDING .............................25
OrderingInformation ...................................25
APPLICATIONS – ULTRASONIC INSERTION .....................26
MAINTENANCE .............................................28
Repairs/Service......................................28
WARRANT ................................................29
LimitationofWarranty ..................................29

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4 INSTRUCTION MANUAL • MODEL H520/H540
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 H520/H540 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 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:
ISIBLE 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.

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6 INSTRUCTION MANUAL • MODEL H520/H540
INTRODUCTION
The models H520 and H540 are portable 500 watt, hand held ultrasonic
welders used for plastics assembly. Both models consist of an ultrasonic
power supply and a hand gun. These units are designed specifically for
welding, staking, inserting and spot welding applications (refer to the
Applications section of this manual beginning on page 22 for more information
on these operations).
The model H520 is a 20 kHz power supply that comes with the CV52 hand
gun. The CV52 hand gun is supplied with an integral 1/2" (12.7mm) diameter
titanium front driver with a replaceable flat face tip. (Other standard or custom
tips are available.)
The model H540 is a 40 kHz power supply that comes with the CV54 hand
gun. The CV54 hand gun is supplied with a removable horn designed
specifically for each customer’s requirements. The higher frequency and lower
amplitude of the 40 kHz system makes it ideal for welding small assemblies
that require gentler action.
The power supplies of both models feature autotune circuitry.
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 HAND HELD WELDERS
“Sonics” ultrasonic hand held welders are generally composed of the following
major elements: a power supply, hand gun (converter), and horn (H540 only)
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 H520/H540 7
“SONICS” ULTRASONIC ASSEMBLY SYSTEMS
Generates ultrasonic electrical energy
(20/40 kHz)
50/60 Hz
Electrical power
ltrasonic
electrical energy
ltrasonic Vibrations
Transforms ultrasonic electrical energy
to ultrasonic mechanical vibrations
Contacts and transfers vibrational
energy to plastic part
Converter
Horn/Replaceable Tip
ltrasonic Vibrations
Power Supply/Generator
Hand Gun

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8 INSTRUCTION MANUAL • MODEL H520/H540
GLOSSARY OF ULTRASONIC TERMS
POWER SUPPLY/GENERATOR – The solid state power supply converts
standard 50/60 Hz electrical power to 20,000 Hz or 40,000 Hz (20/40 kHz)
electrical energy.
CON ERTER – The converter changes the high frequency electrical energy
supplied by the power supply to high frequency mechanical vibrations.
TIP/HORN – The tip/horn is a tuned component of the system which comes
in contact with the parts to be assembled. The tip/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.
AMPLITUDE – The peak to peak excursion of a horn at its output face.

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INSTRUCTION MANUAL • MODEL H520/H540 9
INSTALLATION AND SET UP
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. (Standard 120 volts or optional 220 volts, 50/60 Hz, regulated
between 95-135 volts or 190-265 volts, respectively.)
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.
ELECTRICAL CONNECTIONS
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.
3. Check with your electrician if you have any wiring questions.
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.
NOTE: If power supply is
to be run continuously, air
cooling of the converter
and horn is required. se
clean, dry compressed air
filtered down to 5 microns.
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. A round, 4-pin cable (with red locator dot) that connects the hand gun to
the power supply.
2. A standard DB9 I/O connector that can interface with automated machines
via a PC or PLC. (See drawing in the Appendix at the back of this manual.)
3. 3-prong inlet to connect the power supply with the appropriate electrical
outlet. Do not make this connection until the hand gun is connected to the
power supply.
Once these connections have been made, the power supply is ready for
operation.
Also located at the rear of the power supply are the following:
4. oot switch jack – connects foot switch cable to enable remote actuation.
5. uses – 120V = 15A slo-blo
230V = 8A slo-blo
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10 INSTRUCTION MANUAL • MODEL H520/H540
15 15
FOOTSWITCH
NW
SONICS & MATERIALS, INC.
50 CHURCH HILL RD. NEWTOWN, CT USA
OUTPUT
Make sure the
ON/OFF switch is in
the OFF position and
the power supply line
cord is not plugged in
before making any
cable connections.
❷
❹
❸
❺
❶
Always turn off the
power supply before
installing or removing
the foot switch cable.

KEY COMPONENTS
Pictured below is the power supply with 2 hand gun options, 20 kHz (CV52)
and 40 kHz (CV54).
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INSTRUCTION MANUAL • MODEL H520/H540 11
POWER SUPPL
HAND GUN
TRIGGER SWITCH
CV52
CV54 HORN
TIP
TIP
HAND GUN

TIP ASSEMBLY (C 52)
If the tip is not already assembled, follow the instructions below as applicable.
TIP REPLACEMENT (C 52)
1. Clean the mating surfaces, as well as the threaded stud and hole. Check
that the stud is tight (see recommended torque requirements on page 13).
2. Hand assemble the tip to the titanium driver using open-ended wrenches
as shown below. Tighten securely. Do not force or overtighten.
HORN ASSEMBLY (C 54 ONLY):
1. Clean the mating surfaces of the converter and horn, as well as the
threaded stud and hole. Check that the stud is tight (see recommended
torque requirements on page 13).
2. Hand assemble the converter and horn together using open-ended
wrenches as shown below. Tighten securely. Do not force or overtighten.
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12 INSTRUCTION MANUAL • MODEL H520/H540
Never remove or install
a tip by holding the
hand gun case or
rotating the tip with
only one wrench as
this may cause
damage to the booster
and/or converter.
CV54 / HORN
CV52 / TIP
NOTE: Before using
wrenches to assemble
as shown, you should
be able to seat the
horn or tip without
encountering
resistance in the
mating threads.

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INSTRUCTION MANUAL • MODEL H520/H540 13
CV54 /HORN / TIP
Thread
Frequency Component Size Foot-Lbs. Newton-Meters
20 kHz Converter / Tip 1/4-28 25-35 34-47
40 kHz Converter / Horn 8 mm 25-35 34-47
40 kHz Horn / Tip 1/4-28 25-35 34-47
RECOMMENDED TORQUE REQUIREMENTS
TIP REPLACEMENT (C 54)
1. Clean the mating surfaces, as well as the threaded stud and hole. Check
that the stud is tight. (See recommended torque requirements below.)
2. Hand assemble the tip to the horn using open-ended wrenches as shown
below and tighten securely. Do not force or overtighten.

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14 INSTRUCTION MANUAL • MODEL H520/H540
TIP SPECIFICATIONS
A variety of replaceable tips – both custom and standard – are available for
the hand held welding systems. Upon request, special carbide faced, wear
resistant, flat, knurled, and custom faced tips are available.
Refer to the various tables under staking, spot welding and insertion
descriptions on pages 24-27 for lists of standard threaded tips. or custom
tips, call our Sales Department at 203-270-4600.
STAKING
INSERTING
SPOT WELDING
FLAT KNURLED

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INSTRUCTION MANUAL • MODEL H520/H540 15
OPTIONS
The following options and accessories are available for the H520 and H540
systems.
1. FOOT SWITCH for remote activation. (When foot switch actuation is
used, the trigger handle is removed from the hand gun housing.)
2. MANUAL ARBOR PRESS, available with foot switch or cam actuation,
is designed for assembling parts where production volume does not justify
automated equipment. The press provides a more controlled motion of the
welder than is possible by just holding the hand gun, resulting in more
consistent assemblies.
MANUAL PRESS
Always turn off the
power supply before
installing or removing
the foot switch cable.

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16 INSTRUCTION MANUAL • MODEL H520/H540
3. STAPLER with special pivoting mechanism. Ideal for sealing low
production rate clamshell packages.
4. PISTOL GRIP for more ergonomic handling of the hand gun in
specialized applications.
STAPLER
PISTOL GRIP

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INSTRUCTION MANUAL • MODEL H520/H540 17
OPERATING PROCEDURES
FRONT PANEL CONTROLS AND INDICATORS
Located at the front of the power supply are the following controls:
1. ON/OFF switch which turns the unit on and off.
2. AMPLITUDE dial which controls adjustment of the amplitude of the
system’s high-frequency vibrations over the full operating range. Turning
the dial clockwise increases amplitude, while turning it counterclockwise
decreases the amplitude.
3. 0-9 NUMERIC KEYPAD which allows input of numeric data by pressing
the keys.
4. CLEAR key which clears the preceding entry when pressed.
5. ENTER/REVIEW key which serves to enter data into the system and/or
to display data (or parameters) on the LCD screen.
6. TIMER key which, when used with the numeric keys, controls the duration
of the ultrasonics. The minimum time setting is 0.1 seconds and the
maximum is 9.9 seconds. At a time setting of 0, the ultrasonics will run
continuously when the hand gun trigger switch is depressed.
❶❷
❻
❼
❺
❹
❽
❸
Do not operate the
power supply unless it
is connected to the
hand gun.
NOTE: The operating
range of amplitude is
20-100%
NOTE: If ultrasonics
are run continuously
(time setting = 0), be
sure to air cool the
converter.

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18 INSTRUCTION MANUAL • MODEL H520/H540
7. TEST key which can be used to test the actual power output (watts). When
this key is pressed, the ultrasonics are activated and will remain on (cycle)
for 5 seconds. The red LED in the upper left corner lights up accordingly
during the cycle. The number of watts will be displayed on the LCD screen
and a line will display along the bar graph on the bottom of the LCD screen
which will reflect the percentage of power output.
8. LCD SCREEN which displays various settings, parameters and prompts
as detailed on the following pages.

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INSTRUCTION MANUAL • MODEL H520/H540 19
INITIAL OPERATION
1. When all cable connections have been made, and the hand gun is
connected to the power supply, turn the ON/OFF switch to the ON
position.
The LCD screen will briefly display the model number (in these examples,
the H520), wattage and frequency as follows:
This display will be immediately followed by the SET UP screen, like the
example below, that shows the Time and Amplitude parameters:
2. The TIMER parameter controls the amount of time the ultrasonics will be
activated. To enter the welding time value, press the TIMER key. The
current time setting, such as the example below, will be displayed:
Use the numeric keypad to enter the number of seconds desired (a value
between 0.1 and 9.9 seconds). To enter the keyed-in time value into the
system, press the ENTER/REVIEW key.
3. Adjust the amplitude by turning the AMPLITUDE dial. Turning the dial
clockwise to its limit will yield 100%, providing maximum amplitude. Turning
the dial counterclockwise to its limit will yield approximately 20% amplitude.
4. Once the time parameter has been entered and the amplitude adjusted,
the ultrasonics are ready to be tested. Make sure the tip is not in contact
with anything.
SONICS & MATERIALS
MODEL H520 500W20 KHZ
H520 SET UP
TIME 1.5 SECONDS AMPL 90%
TIME 1.5 SEC