Models 2050 / 2055 Presses I N S T R U C T I O N M A N U A L Sonics & Materials, Inc.
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.
TABLE OF CONTENTS IMPORTANT SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Manual Change Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Visible Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Concealed Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 INTRODUCTION . . . . . . . . . . . . . . . . . . . . .
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. NOTE: Please read carefully before operating the equipment, then forward to your service department.
UNPACKING AND INSPECTION 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. 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.
INTRODUCTION The models 2050 and 2055 presses are 20 kHz precision benchtop pneumatic actuators/presses used for ultrasonic plastics assembly. The 2050 and 2055 presses 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* *Available with Model 2050 press only. Both presses are also compatible with E and F Series power supplies.
“SONICS” ULTRASONIC ASSEMBLY SYSTEMS 50/60 Hz Electrical power Power Supply/Generator Generates ultrasonic electrical energy (15/20/40 kHz) Ultrasonic electrical energy Actuator/Press Provides compressive force and mounting for Converter, Booster, Horn assembly (Stack) Converter Transforms ultrasonic electrical energy to ultrasonic mechanical vibrations Ultrasonic Vibrations Booster Increases or decreases amplitude Ultrasonic Vibrations Horn Contacts and transfers vibrational energy to plastic part Ultr
GLOSSARY OF ULTRASONIC TERMS POWER SUPPLY/GENERATOR – The solid state power supply converts standard 50/60 Hz electrical power to 15,000 Hz, 20,000 Hz, 30,000 Hz or 40,000 Hz (15/20/30/40 kHz) electrical energy (depending on frequency of model purchased). ACTUATOR/PRESS – The pneumatic actuator provides compressive force and mounting for the converter, booster, and horn assembly. The benchtop press consists of a base assembly, column and actuator (head).
INSTALLATION ELECTRICAL POWER The press is powered by the power supply. Consult your power supply instruction manual to determine power specifications. AIR SUPPLY 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 CFM.
CONNECTIONS When making the initial connections, make sure all electrical power is disconnected. 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). 1. Connect the air supply source to the press air connection located at the rear of the press head, using a hose having a minimum inside diameter of 1/8 inch (3 mm).
OPTIONS A Linear Encoder is available as an option on Model 2050 only. 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 FDL power supply (factory installed).
OPERATING PROCEDURES CONTROL PANEL (2050 PRESS) Located above the converter housing on the 2050 press are the following controls: ❶ ❷ ❸ 1. SPEED CONTROL knobs allow regulation of the velocity at which the horn descends and returns (stroke speed). These controls are factory adjusted for average operating conditions. When minor adjustments are necessary, be sure to adjust in small degrees. Excessive velocity may be unnecessary and harmful to the system.
CONTROLS (2055 PRESS) Located at the top rear of the 2055 press are the following controls: 1. PRESSURE REGULATOR with corresponding gauge that allows regulation of the (air) pressure with which the horn contacts the part(s). Pull the knob to make adjustments, and then push in to lock setting when desired pressure is displayed on the gauge. Once pulled, turning the knob clockwise increases pressure, and turning it counterclockwise decreases pressure.
2. SPEED CONTROLS The velocity at which the horn descends and returns can be adjusted via the two small threaded screws located at the top of the press as shown below. These controls are factory adjusted for average operating conditions. If a minor adjustment is necessary, adjust in small degrees. Excessive velocity may be unnecessary and harmful to the system. Turn the Descend Speed Control screw clockwise to slow the descend speed, counterclockwise to increase the speed.
INITIAL EQUIPMENT SETUP ASSEMBLING AND MOUNTING CONVERTER, BOOSTER, AND HORN If the converter, booster, and horn are not already assembled, follow these instructions: 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. 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 15). 2.
5. Using the 3/16" (4.7 mm) T-handle wrench provided, loosen (turn counterclockwise) the two cap screws on the hinged converter housing and open the door. NOTE: When performing any of the operations described on this page and pages 16-17, DO NOT turn on the power supply. 6. Place the converter / booster / horn assembly (stack) in the housing with the horn facing down.
HORN AND FIXTURE ALIGNMENT Support the head before releasing the column clamps so that it cannot crash down or fly up. Ignoring this warning might result in injury and/or damage to the equipment and part being welded. 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 4" (101.6 mm).
5. Lock the two column clamps, tighten the converter housing door screws, and then tighten the fixture on the base plate. 6. 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. 7. Set the PRESSURE regulator to a reading of 20 psig (140 kPa/1.4 bar) on the pressure gauge. (Turn the PRESSURE knob clockwise.
OPERATION ACTUATION The equipment has safety devices that require both hands to be on the palm buttons until the horn contacts the workpiece. Do not defeat or modify these safety devices. Each 2050 and 2055 press is equipped with two maintained anti-repeat (nontie-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.
FINE ADJUSTMENTS BOOSTER SELECTION NOTE: Consult the Applications Manual or call our Applications Lab for proper 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.
RE-ESTABLISHING PROPER BOOSTER / HORN INTERFACES To re-establish proper interfaces, follow these instructions: NOTE: Contact between the booster and horn should be parallel. When encountering symptoms such as loud noises or tuning difficulties, examine the booster / horn interfaces for parallelism, corrosion, galling or foreign deposits. Also check the integrity and tightness of the stud. 1. Using open-ended wrenches, separate the booster from the horn.
MAINTENANCE REPAIRS / SERVICE If problems are encountered, contact our Service Department as follows: Phone: 1-800-745-1105 • 1-203-270-4600 ext. 343 or 366 Fax: NOTE: If packing unit for return shipment, DO NOT use styrofoam “peanuts.” 1-203-270-4610 E-Mail: service@sonics.biz It is suggested that a system in need of repair be sent back to the factory, with a written description pertaining to the nature of the problem. Always contact the factory for return authorization before shipping any instrument.
COVER REMOVAL MODEL 2050 COVER REMOVAL Always disconnect the power supply from the electrical source before removing covers. To remove the side panel cover: a. Maintain air pressure and unplug the power supply from the electrical source. b. Loosen and remove the 2 Phillips pan head screws on the back of the cover. c. Loosen and remove the 2 socket head cap screws at the bottom of the cover. d. Loosen column clamps. e. Raise head as shown below to bottom of column cap.
To remove the pinch point cover: a. Loosen and remove the cover’s 4 screws - 2 on each side of the cover. PINCH POINT COVER SCREWS b. Pull the cover to the front and then pull it down and off as shown below. MODEL 2055 COVER REMOVAL To remove the side panel cover: a. Maintain air pressure and unplug the power supply from the electrical source. Always disconnect the power supply from the electrical source before removing covers. b.
PAN HEAD SCREWS Do not operate press without covers in place. PRESSURE SWITCH ADJUSTMENT NOTE: Pressure switch is factory set and should not be adjusted unless authorized by Sonics Service Department. 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 readjustment, the pressure switch can be accessed and adjusted.
3. Next rotate the cap screw down until the Pressure Switch opens. 4. Rotate cap screw down one turn past the Pressure Switch open position. 5. Tighten the jam nut to lock cap screw in position. 6. Replace pinch point cover and the side panel cover and position securely. 7. Plug the power supply into the electrical source. 8. Cycle the welder. The press is now set to trigger at the minimum trigger pressure of 4-7 psig.
WARRANTY Sonics & Materials, Inc., hereinafter referred to as "Sonics", warrants its products for a period of one year from the date of original shipment against defects in materials and workmanship under normal installation, use and maintenance as described in the operating instructions which accompany such equipment.
For components and parts not manufactured by Sonics but included in Sonics manufactured equipment, this warranty shall be limited to the warranty as given to Sonics by said original component or part manufacturer. Ultrasonic horns supplied by Sonics are manufactured to exacting specifications and are tuned to vibrate at a specific frequency. Using an out-of-tune horn will cause damage to the equipment and may result in warranty nullification.
APPENDIX 2050 LAYOUT FRONT VIEW Dimensions are shown in inches and millimeters, i.e., 11/2 (38.1) signifies 11/2" (38.
APPENDIX 2050 LAYOUT SIDEVIEW Dimensions are shown in inches and millimeters, i.e., 11/2 (38.1) signifies 11/2" (38.
APPENDIX 2050 EXPLODED ASSEMBLY DRAWING • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • I N S T RU C T I O N M A N UA L • M O D E L 2 0 5 0 / 2 0 5 5 30
APPENDIX 2055 LAYOUT FRONT VIEW Dimensions are shown in inches and millimeters, i.e., 11/2 (38.1) signifies 11/2" (38.
APPENDIX 2055 LAYOUT SIDEVIEW Dimensions are shown in inches and millimeters, i.e., 11/2 (38.1) signifies 11/2" (38.
APPENDIX 2055 EXPLODED ASSEMBLY DRAWING • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • I N S T RU C T I O N M A N UA L • M O D E L 2 0 5 0 / 2 0 5 5 33
APPENDIX BASE LAYOUT Dimensions are shown in inches and millimeters, i.e., 11/2 (38.1) signifies 11/2" (38.
APPENDIX OPTIONAL STAND-ALONE MOUNTING HUB LAYOUT Dimensions are shown in inches and millimeters, i.e., 11/2 (38.1) signifies 11/2" (38.
