Sonics H520 T/E User manual

Hand Held
Welders
Model H520 T/E
Model H530 T/E
Model H540 T/E
I N S T R U C T I O N M A N U A L

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Information contained in this manual is subject to change without notice. Sonics & Materials, Inc. is not responsible for any typographic errors.
© Sonics & Materials, Inc. 2012 Printed in U.S.A. Part No. 381-0035
Rev AC 03 8/12
I N S T R U C T I O N M A N U A L • H A N D H E L D W E L D E R S 1
TABLE OF CONTENTS
IMPORTANT SERVICE INFORMATION ...........................3
ImportantSafeguards ...................................3
Warnings .............................................3
Symbols .............................................4
SPECIFICATIONS ............................................5
IMPORTANT SERVICE LITERATURE ............................6
ManualChangeInformation ..............................6
UNPACKING AND INSPECTION ................................7
VisibleLossorDamage .................................7
ConcealedLossorDamage ..............................7
INTRODUCTION .............................................8
OVERVIEW OF ULTRASONIC PLASTICS ASSEMBLY ...............8
WhatisUltrasonics? ....................................8
Principal of Ultrasonic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . .8
Ultrasonic Hand Held Welders . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
GLOSSARY OF ULTRASONIC TERMS ..........................10
INSTALLATION AND SET UP ..................................11
Electrical Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .11
SettingUp ...........................................11
ElectricalConnections .................................11
CableConnections ....................................12
KeyComponents .....................................13
TipAssembly(CV53/55) ................................14
TipReplacement(CV53/55) .............................14
HornAssembly(CVG54Only)............................14
TipReplacement(CVG54)...............................15
TipSpecifications .....................................16
Options .............................................17
Corporate Headquarters
53 Church Hill Road • Newtown, CT 06470 USA
203.270.4600 • 800.745.1105 • 203.270.4610 fax
www.sonics.com • [email protected]
Sonics & Materials, Inc.

OPERATING PROCEDURES ..................................19
Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . .19
KeyinginParameters ..................................20
OperationalFeatures...................................21
StartinguptheWelder .................................21
TestFeature..........................................21
ReadyScreens .......................................22
Relationship of Time and Energy Settings . . . . . . . . . . . . . . . . . .23
TimeSettings ........................................24
EnergySettings .......................................25
Amplitude ...........................................25
FrequencyDisplay.....................................25
OverloadProtection ...................................26
KeypadSecurity ......................................27
APPLICATIONS – STAKING ...................................28
StandardFlaredStake .................................28
SphericalStake ......................................29
HollowStake .........................................29
KnurledStake ........................................29
FlushStake ..........................................30
APPLICATIONS – SPOT WELDING .............................31
OrderingInformation ...................................31
APPLICATIONS – ULTRASONIC INSERTION .....................32
MAINTENANCE .............................................34
CleaningInstructions ..................................34
Repairs/Service......................................34
WARRANTY ................................................35
LimitationofWarranty ..................................36
APPENDIX .................................................38
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I N S T R U C T I O N M A N U A L • H A N D H E L D W E L D E R S 3
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IMPORTANT AFEGUARD – READ BEFORE IN TALLING
OR U ING THE EQUIPMENT
Your Ultrasonic Equipment has been designed with safety in mind. However,
no design can completely protect against improper usage, which may result
in bodily injury and/or property damage. For your protection and equipment
safeguard, observe the following warnings at all times, read the operating
instructions carefully before operating the equipment, and retain this
instruction manual for future reference. If the Ultrasonic Equipment is used in
a manner contrary to that specified in this instruction manual, the protection
features designed into the unit may be impaired.
WARNING
• Make sure the Ultrasonic Power Supply is properly grounded via a 3-
prong outlet.
• High voltage is present in the power supply. Do not remove the cover.
Refer all servicing to qualified service personnel.
• Never operate the power supply unless it is connected to the hand gun.
• Never secure anything to the front driver, the tip or the horn.
• Never touch a vibrating horn.
• If air-cooling the converter, always use dry compressed air.
• Hearing protection is highly recommended. It is recommended that a
sound abating enclosure or ear protection be used when operating the
Ultrasonic Processor.
• Do not modify horn configurations.
• 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, U.S.
Department of Labor, or material supplier.
• 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 (converter) is on, be sure to isolate it from any/all
grounded surfaces (including machine frames) to avoid triggering an
overload condition as the system detects an alternate ground path.
IMPORTANT SAFETY INFORMATION

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YMBOL
Caution, risk of electric shock,
hazardous voltage
Caution, risk of danger.
Refer to User Manual.
WARNING or CAUTION
Where you see the alert symbols and/or WARNING or
CAUTION heading, strictly follow the
warning instructions to avoid personal injury
or equipment failure.

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I N S T R U C T I O N M A N U A L • H A N D H E L D W E L D E R S 5
Tip CV 55 & CV 53 CV 54
Dimensions Standard 1/2" diameter (12.7 mm) n/a
Materials Titanium Alloy Ti-6Al-4V
Environmental
Pollution Degree 2
Installation Category II
Operating Limits Temperature 41 - 104ºF (5 - 40ºC)
Relative Humidity 20 - 90% (Non Condensing)
Altitude 6,651 ft. (2000 m)
Shipping/Storage Temperature 35 -120ºF (2 - 49ºC)
Relative Humidity 10 - 95% (Non Condensing)
Ambient Pressure Extremes 40,000 ft. (12,192 m)
Restriction of
Hazardous
Substances (ROHS)
Relative humidity Maximum relative humidity 80% for temperatures up to 31ºC decreasing
linearly to 50% relative humidity to 40ºC
Other For indoor use only
Power Supply
Operational Input Voltage 115/230 V~ +/-10% @ 50/60 Hz
Rated Voltage/Current 115/230 V~, 5 A max.
Fuse Rating F6.3A 250V*
Weight 13 lbs. (5.9 Kg)
Dimensions 8.5"H x 13.5"W x 7.5"D
216 mm x 340 mm x 190 mm
Output Voltage 1000 V rms (max.)
Output Frequency 20 KHz (nom.), 30 kHz or 40 KHz
SPECIFICATIONS
*Only use IEC approved Fast acting fuses, Cooper Bussman series S500.
RoHS Compliant
Directive 2002/95/EC
Converter CV 55 & CV 53 CV 54
Weight 1.5 lbs. (0.68 Kg) 1.5 lbs. (0.68 Kg)
Dimensions 7.1" (CV55) or 6.3” L (CV53) x 1.9" Dia. 6.3" L x 1.9" Dia.
(180 or 160 mm x 48.3 mm) (with standard tip) (160 mm x 48.3 mm) (without horn)
Horn Materials Titanium Titanium or aluminum

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.
Please read carefully
before operating the
equipment, then
forward to your service
department.
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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
VI IBLE LO 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 LO 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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INTRODUCTION
Sonics’ hand held welders are portable 500 watt welders used for plastics
assembly that 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 26 for more information on these operations).
The model H520 is a 20 kHz power supply that comes with the CV55 hand
gun; the H530 is a 30 kHz power supply that comes with the CV53 hand gun.
The CV53/55 units are 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 CVG54 hand
gun. The CVG54 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 all models feature autotune circuitry.
OVERVIE OF ULTRASONIC PLASTICS
ASSEMBLY
WHAT I ULTRA ONIC ?
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 ULTRA ONIC A EMBLY
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).
ULTRA ONIC HAND HELD WELDER
“Sonics” ultrasonic hand held welders are generally composed of the
following major elements a power supply, hand gun (converter), and horn
(H540E 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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“ONIC ” ULTRA ONIC A EMBLY Y TEM
Generates ultrasonic electrical energy
(20/30/40 kHz)
50/60 Hz
Electrical power
Ultrasonic
electrical energy
Ultrasonic Vibrations
Transforms ultrasonic electrical energy
to ultrasonic mechanical vibrations
Contacts and transfers vibrational
energy to plastic part
Converter
Horn/Replaceable Tip
Ultrasonic Vibrations
Power Supply/Generator
Hand Gun
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GLOSSARY OF ULTRASONIC TERMS
POWER UPPLY/GENERATOR – The solid state power supply converts
standard 50/60 Hz electrical power to 20,000, 30,000 or 40,000 Hz (20/30/40
kHz) electrical energy.
CONVERTER – 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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INSTALLATION AND SET UP
ELECTRICAL POWER REQUIREMENT
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.)
ETTING 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 CONNECTION
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.
he line cord of the
controller/power supply
is equipped with a 3-
prong, grounding plug.
Do not, under any
circumstances, remove
the ground prong. he
plug must be plugged
into a mating 3-prong,
grounding type outlet.
If power supply is to be
run continuously, air
cooling of the converter
and horn is required.
Use clean, dry
compressed air filtered
down to 5 microns.
Do not plug the power
supply into an electrical
outlet until all other
connections have been
made.
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CABLE CONNECTION :
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 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. Foot switch jack – connects foot switch cable to enable remote actuation.
5. Fuses – 120V = 15A slo-blo
230V = 8A slo-blo
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.
Always turn off the
power supply before
installing or removing
the foot switch cable.
Do not use a damaged
or worn hand gun
cable. Never use the
cable and hand gun as
a rope; it is not rated
for pulling weight.
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❷
❹
❸
❺
❶

KEY COMPONENT
Pictured below is the power supply with hand gun options.
POWER SUPPLY
HAND GUN
TRIGGER SWITCH
CV53 / CV55*
CVG54
HORN
TIP
TIP
HAND GUN
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*CV55 shown

TIP ASSEMBLY (CV53 & CV55)
If he ip is no already assembled, follow he ins ruc ions below as
applicable (CV55 uni is shown below bu ins ruc ions also apply o CV53).
TIP REPLACEMENT (CV53 & CV55)
1. Clean he ma ing surfaces, as well as he hreaded s ud and hole. Check
ha he s ud is igh (see recommended orque requiremen s on page 13).
2. Hand assemble he ip o he i anium driver using open-ended wrenches
as shown below. Tigh en securely. Do not force or o ertighten.
HORN ASSEMBLY (CVG54 ONLY):
1. Clean he ma ing surfaces of he conver er and horn, as well as he
hreaded s ud and hole. Check ha he s ud is igh (see recommended
orque requiremen s on page 13).
2. Hand assemble he conver er and horn oge her using open-ended
wrenches as shown below. Tigh en securely. Do not force or
o ertighten.
NOTE: 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.
CVG54 / HORN
CV55 (shown) or
CV53 / 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.
14 INSTRUCTION MANUAL • HAND HELD WELDERS
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CVG54 /HORN / TIP
Thread
Frequency Component Size Foot-Lbs. Newton-Meters
20 / 30 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 REQUIREMENT
TIP REPLACEMENT (CVG54)
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 orce or overtighten.
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TIP PECIFICATION
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 26-31 for lists of standard threaded tips. For custom
tips, call our Sales Department at 203-270-4600.
STAKING
INSERTING
SPOT WELDING
FLAT KNURLED
16 INSTRUCTION MANUAL • HAND HELD WELDERS
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OPTION
The following options and accessories are available for the hand held
welding systems.
1. F T SWITCH for remote activation. (When foot switch actuation is
used, the trigger handle is removed from the hand gun housing.)
2. MANUAL ARB R 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.
I N S T R U C T I O N M A N U A L • H A N D H E L D W E L D E R S 17
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3.STAPLER with special pivoting mechanism. Ideal for sealing low
production rate clamshell packages (for 20 kHz Models only).
4. PIST L GRIP for more ergonomic handling of the hand gun in
specialized applications.
STAPLER
PISTOL GRIP
18 INSTRUCTION MANUAL • HAND HELD WELDERS
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OPERATING PROCEDURES
FRONT PANEL CONTROL AND INDICATOR
Located at the front of the power supply are the following controls
1. N/ FF switch which turns the power supply on and off. The switch
remains in a “latched state” even if power is interrupted or disconnected.
For example, if the unit is switched on and is then disconnected from the
power source, once it is reconnected to power, the unit will be on.
Likewise, if the unit is off and then disconnected, it will remain off when
reconnected to power until the ON switch is pressed.
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 welder (see #3 below).
3. L AD 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 21).
4. TIME key which allows selection and display of time settings and permits
adjustment of time duration in .01 second increments (from 00.00 to 99.99
seconds) for three time parameters as follows
a. Weld time
b. Time Limit Low
c. time Limit High
Do not operate the
power supply unless it
is connected to the
hand gun.
NOTE: he operating
range of amplitude is
20-100%
If ultrasonics are run
continuously (time
setting = 0), be sure to
air cool the converter.
1
2
3
4
5
7
6
8
9
10
3
11
4
12
I N S T R U C T I O N M A N U A L • H A N D H E L D W E L D E R S 19
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