Ultrasonic Poultry Systems P100R Manual

ULTRASONICPOULTRYSYSTEMS.COM
3971 Hoover Rd. #291. Grove City, OH 43123
Operation &
Maintenance Manual
P100R
ULTRASONIC
WELDING
SYSTEM

ATTENTION: This manual and the engineering information it contains, is proprietary and is provided to
our customers for the sole purpose of operating and maintaining the Ultrasonic Poultry Systems equipment
it describes. This is not to be given or made available to anyone who might use this information to the
detriment of any entity of Ultrasonic Poultry Systems.
TABLE OF
CONTENTS
Table of Contents
Introduction
Overview of Ultrasonic Assembly
What is Ultrasonics?
Principles of Ultrasonic Assembly
Ultrasonic Hand-held Welders
Welder Specifications
Components and Use
Important Safeguards
Installation
Inspection
Electrical Requirements
Safety
Preperation for Use
Quick Start Instructions
Getting Started/How to Use
Troubleshooting
Component/Accessory Illustrations
P150R Travel Case (sold separately)
Warranty Information
Return Information
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INTRODUCTION
The model P100R is a portable 40
kHz, 100 watt hand held Ultrasonic
Welder used for plastics assembly. It
consists of an ultrasonic power supply
and a hand gun. These units are
designed specifically for welding,
staking, and spot welding applications.
OVERVIEW OF
ULTRASONIC
WELDING SYSTEM
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),
ULTRASONIC WELDING
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 overlapping belt interface.
In Ultrasonic Welding, this frictional heat melts
the plastic, allowing the two surfaces to fuse
together in ultrasonic staking the controlled flow
of molten plastic is used to capture or lock
another material in place.
ULTRASONIC HAND-HELD
WELDERS
Ultrasonic hand held welders are generally
composed of the following major elements: a
power supply, hand gun (transducer), and tip
(also referred to as a hom) 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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Power requirements
110-240 VAC
Output frequency
40 KHz
Amplitude Range
Adjustable by tip design
Dimensions
10.62” x 9.68” x 4.87”
(27 x 24.6 x 12.4 cm)
Power supply weight
6lbs (2.7Kg)
Handgun weight
8oz (0.25kg)
Cable length
6’ (1.8m)
Start button
Activates the ultrasonics
Nose cover
Always install nose cover before
using handgun
Tip
Wrench Flats
Nose Cover
Transducer
Backshell
Start Button
Cord Grip
Tip installation
Prior to installation, ensure the mating surfaces of the tip and transducer
are clean and free of debris . Make sure the M6x1.0 mm stud is tight in the
tip (30-35 in/lb). Always use open the end wrenches on the wrench ats.
Make sure the tip is tight to the transducer. Improperly tightened tips will
lead to incomplete welds and premature welder shuto.
Timer knob
(0-10 Seconds)
Handgun
receptacle
WELDER SPECIFICATIONS
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IMPORTANT
SAFEGUARDS
Read before installing or using the
equipment
Your Ultrasonic Welding system 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 safe-guard. 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 Welding System is used in
a manner contrary to that specified in
this instruction manual,the protection
features designed into the unit may be
impaired.
● High voltage is present in the power
supply. Do not remove the cover. Refer
all servicing to qualified service
personnel. Removing the cover may
void the warranty.
● Never operate the power supply unless
it is connected to the hand gun
(convener).
● Never secure anything to the tip
INSTALLATION
Inspection
Prior to installing the Ultrasonic Welding System,
perform a visual inspection to detect any evidence of
damage, which might have occurred during
shipment. Before disposing of any packaging
material, check it carefully for small items.
The Ultrasonic Welder System was carefully packed
and thoroughly inspected before leaving our factory.
The carrier, upon acceptance of the shipment,
assumed responsibility for its safe delivery. Claims
for loss or damage sustained in transit must be
submitted to the carrier.
If damage has occurred, contact your carrier within
48 hours of the delivery date. DO NOT OPERATE
DAMAGED EQUIPMENT. Retain all packing
materials for future shipment.
Electrical Requirements
The Ultrasonic Welder requires a fused, single
phase electrical outlet capable of supplying 60 Hz at
110 volts or 220 volts. Contact Ultrasonic Poultry
Systems for the right plug for your region.
Safety
Operating the equipment with voltages different from
those specified, or with voltages with high power
translents, will cause components within the power
supply to fail.
Preparation for Use
1. Connect the converter cable to the power supply.
2. Plug the electrical line cord into the electrical
outlet, and press the power button.
3. If the converter/tip assembly is not already
assembled; screw the tip into the converter and
secure with wrenches provided.
4. The following pages show standard tip.
Custom tip are available to suit your needs.
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DO NOT PRESS HARD!
Excess pressure will
result in a poor weld.
QUICK START
INSTRUCTIONS
Getting started/How to Use
1. Place the tip onto the belt to be welded and
apply light pressure.
2. Still applying light pressure, press the red
start button and hold light pressure for 1-2
seconds.
3. Release the switch and apply higher
pressure - hold for 1-2 seconds to allow weld
to cool.
TROUBLESHOOTING
A. System is not welding
I. Verify system is plugged in (110-240VAC)
II. Verify power switch is on is light
illuminated.
III. Confirm tip is properly tightened.
IV. Pressing too hard.
V. Check tip-is-tip worn?
VI. Allow tip to cool
If you are still having issues, please call
Technical support at 614.549.0627
3971 Hoover Rd. #291. Grove City, OH 43123

ACCESSORIES (included)
Two wrenches (9/16, 11/16)
STANDARD TIPS (Sold separately)
OPTION
P150 Travel
Case
1.6mm - 2.0mm
1.0mm to 1.5mm
H6
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WARRANTY
GUARANTEE
Ultrasonic Poultry Systems warrants its
products for a period of one year from the
date of shipment against any defect in
material or workmanship under normal
installation, use and maintenance as
described in the operating instructions.
Labor is provided under warranty for a
period of six months from the date of
purchase.
During the warranty period, Ultrasonic
Poultry Systems will, at its option either
repair or replace without charge for
material and labour, the part(s) which
prove upon our examination to be
defective, provided the defective unit is
returned to us properly packed with all
transportation charges prepaid. If the
purchaser describes Ultrasonic Poultry
Systems desires to come to their facility for
warranty work and/or production
debugging, the purchaser will be billed on
time and expense basis. Any alteration and
modification of the machine by the
customer without prior written approval by
Ultrasonic Poultry Systems will avoid all
warranties. Ultrasonic Poultry Systems will
not exceed the manufacturers warranty on
any purchased components.
All tooling and ultrasonic tips are warranted
for a period of one year. Ultrasonic Poultry
Systems will repair or replace cracked or
defective tips and tooling once without
charge, If the failure occurs during the
warranty period.
Note: The warranty will not cover normal
and expected wear on tooling and tips. Any
equipment judged by Ultrasonic Poultry
Systems personnel to have been worn out
by normal use, will not be replaced under
the warranty conditions.
Ultrasonic Poultry Systems reserves the right not to
warrant horns of unusual or experimental design
which in our judgment are likely to fail during use.
Ultrasonic Poultry Systems equipment is designed
for maximum operator safety and includes built-in
safety devices. Any modification of these devices
will void the warranty. Ultrasonic Poultry Systems
assumes no responsibility for damages or injuries
resulting from the modification of said safety
devices.
The warranty does not apply to equipment which
has been subjected to unauthorized repair, misuse.
Abuse, negligence or accident. Equipment that In
our judgment shows evidence of such damage will
be ineligible for service under this warranty.
Under no circumstances shall Ultrasonic Poultry
Systems be liable to the purchaser or to any other
person for any Incidental or consequential
damages or loss of profit or product resulting from
any malfunction or failure of this Ultrasonic Poultry.
Systems product. Due to the wide range of
machinery and equipment provided by and
produced by Ultrasonic Poultry systems, there are a
few exceptions to this warranty.These exceptions
will be handled on a case-by-case, based on the
merit of the exception and the conditions of the
operation of the machinery in question. To arrange
for an exception to the warranty, present all
information in writing to Ultrasonic Poultry Systems
and it will be taken Into consideration.
RETURN INFORMATION
An RMA number is required to return
equipment to Ultrasonic Poultry
Systems.
Contact Ultrasonic Poultry
Systems at:
3971 Hoover Rd. #291
Grove City, OH 43123
614.549.0627
UltrasonicPoultrySystems.com