Weber Ultrasonics SONIC DIGITAL HS MD User manual

Operating manual - part no.: M21201WUGB
Date of operating manual: 19.01.2015
Version of operating manual: 005
Operating manual EN
Ultrasonic DIN rail generator
SONIC DIGITAL HS
Versions MD/MFD
MULTI PURPOSE

All rights reserved. This documentation is protected by copyright. WEBER Ultrasonics reserves all
rights not expressly granted. This documentation may not be duplicated, distributed or made pub-
licly available in any other way without prior written consent or in legally permitted cases.
We reserve the right to make changes without giving prior notice. The original document was published in
German (the official language of the manufacturer). All translations are copies of the original document.
Copyright 2015 by WEBER Ultrasonics, Karlsbad-Ittersbach (D)
Production, sales and service:
WEBER Ultrasonics GmbH Phone: [phone] / 92 07-0
Im Hinteracker 7 Fax: [phone] / 92 07-11
76307 Karlsbad-Ittersbach [email protected]
Germany www.weber-ultrasonics.de

I
Table of contents
1Introduction....................................................................................................................................1
1.1 About WEBER Ultrasonics.........................................................................................................1
Success through customer-oriented ultrasonic solutions .....................................................1
1.2 About the device ........................................................................................................................2
1.3 Purpose of the ultrasonic welding generator..............................................................................2
1.4 Validity of the operating manual.................................................................................................3
1.4.1 Type HS MD/MFD ................................................................................................................3
1.5 About this document ..................................................................................................................5
1.5.1 Purpose ................................................................................................................................5
1.5.2 Target groups .......................................................................................................................5
1.5.3 General structure..................................................................................................................5
1.5.4 Abbreviations used...............................................................................................................6
1.5.5 Signal words used ................................................................................................................6
1.5.6 Pictograms and safety instructions.......................................................................................6
2Safety.............................................................................................................................................. 7
2.1 Personnel requirements.............................................................................................................7
2.2Operating conditions..................................................................................................................8
2.3 Safety concept of the manufacturer ...........................................................................................8
2.3.1 Conversions or modifications................................................................................................8
2.4 Responsibilities of the operator..................................................................................................9
2.5 Responsibilities of operating personnel ...................................................................................10
2.6 Environmental protection and emissions .................................................................................11
3Warranty.......................................................................................................................................12
3.1 Exclusion of warranty...............................................................................................................12
4EU Declaration of Conformity ....................................................................................................13
5Generator description.................................................................................................................14
5.1 Housing....................................................................................................................................15
5.1.1 Housing of the HS MD / MFD .............................................................................................15
5.2 Connectors...............................................................................................................................16
5.2.1 Model HS MD / MFD...........................................................................................................16
5.2.2 PIN assignment, mains connection ....................................................................................17
5.2.3 PIN assignment, converter connection...............................................................................17
5.2.4 Assignment of the 15-pole interface socket........................................................................18
5.2.5 PIN assignment, hardware tooling interface.......................................................................21
5.2.6 RS-485 Interface (optional).................................................................................................23
6Installation and connection........................................................................................................24
6.1 Installation................................................................................................................................25
6.2 Installation with angled adapter................................................................................................26
6.3 Mains connection.....................................................................................................................27
6.3.1 Supply ratings.....................................................................................................................27
6.3.2 Cable quality and cable routing ..........................................................................................27
7Operation....................................................................................................................................... 28
7.1 Control and display elements...................................................................................................28
7.1.1 Generator HS MD / MFD....................................................................................................28
7.2 Switching on.............................................................................................................................29
7.3 Switching off.............................................................................................................................30
7.4 Setting up, programming and controlling the ultrasonic generator...........................................30

II
8Specifications..............................................................................................................................31
8.1 Generator HS MD /MFD...........................................................................................................31
8.1.1Rating plate.........................................................................................................................31
9Troubleshooting ..........................................................................................................................32
9.1 Resetting malfunctions.............................................................................................................32
9.2 Eliminating malfunctions ..........................................................................................................32
10 Quality assurance........................................................................................................................ 36
11 General maintenance instructions............................................................................................. 37
11.1 Safety.......................................................................................................................................37
11.2 Care and maintenance.............................................................................................................37
11.3 Maintenance and inspection list...............................................................................................38
11.4 Maintenance.............................................................................................................................39
11.5 Repair work..............................................................................................................................39
12 Life cycle......................................................................................................................................40
12.1 Transport..................................................................................................................................40
12.1.1 Safety..................................................................................................................................40
12.1.2 Packaging...........................................................................................................................40
12.2 Positioning and installing..........................................................................................................41
12.2.1 Unpacking and cleaning .....................................................................................................41
12.2.2 Checking the delivery for completeness.............................................................................41
12.2.3 Place of installation.............................................................................................................42
12.2.4 Installing and assembling ...................................................................................................43
12.3 Supply and installation.............................................................................................................44
12.3.1 Mains connections..............................................................................................................44
12.3.2 Ultrasound supply...............................................................................................................44
12.3.3 Control cables.....................................................................................................................44
12.4 Commissioning.........................................................................................................................44
12.5 Temporary non-use..................................................................................................................45
12.6 Decommissioning.....................................................................................................................45
12.7 Disposal ...................................................................................................................................46
12.7.1 Dismantling.........................................................................................................................46
SERVICE.......................................................................................................................................................47

SONIC DIGITAL HS MD/MFD Introduction
1
1 Introduction
This chapter provides information on the manufacturer, the equipment and these
operating manual.
1.1 About WEBER Ultrasonics
Success through customer-oriented ultrasonic solutions
The WEBER Ultrasonics brand sets new standards in the development and manu-
facture of high-quality ultrasonic components. The company was founded in 1998
by Dieter Weber and stands for innovation, high quality and customer proximity.
Thanks to our innovative portfolio of high-grade products for ultrasonic cleaning, ul-
trasonic welding and special applications, we have become one of the world's tech-
nological leaders in the space of just a few years.
We offer our customers new technical solutions that make economic sense. With
our products and services, as well as our knowledge and experience, we create
competitive advantages for you that can help you achieve market success.
Made by WEBER Ultrasonics –quality you should never go without.
Fig. 1: WEBER Ultrasonics in Karlsbad-Ittersbach, Germany

Introduction SONIC DIGITAL HS MD/MFD
2
1.2 About the device
The ultrasonic generators have been designed to perform flexible tasks in the fields
of:
Thermal forming
Separating and cutting
Gluing, riveting and welding
The ultrasonic generators offer the following benefits:
Space-saving design
High efficiency at low heat build-up rates
Easy operation, power output steplessly adjustable
between 50% and 100%
Application-based frequency selection
Control via an external control unit
Interface for monitoring and controlling
process-relevant functions
Overload protection for the power electronics and intelligent cooling system
LEDs as status displays
Service-friendly connections and assembly
A high degree of process stability, consistent welding quality and cutting
performance thanks to electronic amplitude control and optimised software.
1.3 Purpose of the ultrasonic welding
generator
The ultrasonic generator generates and regulates the energy required to operate
piezoceramic ultrasonic transducers (converters). The control system allows various
processing sequences to be defined. The corresponding ultrasonic transducers
generate the ultrasound.
The ultrasonic generator is used in connection with an ultrasonic transducer in a
transducer system and, where required, an ultrasonic welding device for thermal
processing of thermoplastic workpieces by means of
thermal forming
Separating and cutting
gluing, riveting and welding
Alongside applications in the field of welding technology, special applications such
as screening, dispersing or atomising are also possible.

SONIC DIGITAL HS MD/MFD Introduction
3
NOTE
§
Only those transducer systems and ultrasonic welding devices
intended for this use in terms of their frequency, power output and
dimensions may be operated on the generator.
The operator bears sole responsibility for any damage caused by not
using the equipment in accordance with its intended use!
WEBER Ultrasonics accepts no liability for material damage and
bodily injury caused by improper use of the equipment.
1.4 Validity of the operating manual
NOTE
§
This operating manual refers exclusively to the specific product(s)
with which it was supplied.
No claims of any kind with regard to other products purchased may
be derived from it or its contents.
These operating instructions are valid for
Type HS MD/MFD
1.4.1 Type HS MD/MFD
The Sonic Digital HS MD is an ultrasonic generator for device-specific piezoelectric
ultrasonic transducers.
Suitable for DIN rail installation
Supply voltage 230 V AC +/- 10%
Switching power supply and integrated mains filter
Microcontroller control
Electronic amplitude control
Matched to the transducer-based welding frequency
Intelligent fan control
Protection against short-circuit, no-load operation and overload
Control via an external control unit with graphical display
Interface for control and monitoring
LED status display
All connectors pluggable

Introduction SONIC DIGITAL HS MD/MFD
4
With the following power outputs:
400 to 2000 Watt
With the following options:
20, 30, 35, 36 and 40 kHz
Standard software (MD) or
SONIC FULL DIGITAL software, welding version (MFD)

SONIC DIGITAL HS MD/MFD Introduction
5
1.5 About this document
1.5.1 Purpose
This operating manual provides a basic introduction to the design, method of func-
tioning and intended operation of the equipment supplied. You can also find im-
portant notes on safe handling and proper maintenance.
In the interests of its customers, WEBER Ultrasonics continually develops and re-
fines its equipment. For this reason, WEBER Ultrasonics reserves the right to make
technical modifications without prior notice that may deviate from the information
stated in this operating manual.
1.5.2 Target groups
This operating manual is aimed at:
Assembly staff
Operating staff
Maintenance staff
NOTE
§
Read the safety instructions and the entire operating manual before
assembling and commissioning the equipment!
Please store the operating manual in a place where it is accessible to
all users at any time.
The operating manual must be complete and kept in a perfectly read-
able state at all times.
1.5.3 General structure
The instructions comprise:
Objective
Prerequisites, if applicable
1. Step 1
2. Step 2
3. Further steps
Interim result, if applicable.
4. Further steps
Result of steps performed
Instructions

Introduction SONIC DIGITAL HS MD/MFD
6
1.5.4 Abbreviations used
HF = high frequency, operating frequency of the generator
HF connection = transducer connection, transducer system connection
US = ultrasound/ultrasonic
1.5.5 Signal words used
Immediate danger of serious injury or death.
Potentially dangerous situation with the risk of serious injury or death.
Potential risk resulting in minor injuries.
Risk of material damage to equipment and products, as well as harm to the
environment.
Important information, failure to comply results in loss of warranty or guarantee.
Additional information to aid understanding.
1.5.6 Pictograms and safety instructions
Please observe all safety instructions on the equipment itself and all safety instruc-
tions in this document.
Warning sign
Meaning
Warning sign
Meaning
General warning re-
garding a hazardous
location or situation
Danger from
electric current
Warning regarding
hot surfaces or heat
Warning regarding
hot liquids
Wear ear protection
Table 1: Pictograms used for identifying hazards
DANGER!
WARNING!
CAUTION!
ATTENTION!
PLEASE NOTE!
INFO
Safety instructions