Model FC Power Supply 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 This system has 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 the instruction manual carefully before you attempt to operate the equipment. – High voltage is present in the equipment. Disconnect plug before removing cover or servicing.
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TABLE OF CONTENTS IMPORTANT SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Manual Change Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Visible Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Concealed Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 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 storing any packing material, check it carefully for small parts.
INTRODUCTION The FC model power supply is an auto-tuned ultrasonic generator that can be operated on a continuous basis, or pulsed via an outside control. This power supply can be used with a stand-alone converter, or with a pneumatic actuator. The FC does not offer time or energy-based control. OVERVIEW 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).
“SONICS” ULTRASONIC ASSEMBLY SYSTEMS 50/60 Hz Electrical power Power Supply/Generator Generates ultrasonic electric energy (15/20/40 kHz) Ultrasonic electrical energy Actuator/Press Provides compressive force and mounting for Converter, Booster, Horn assembly @@@@@@@@e? @@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e?@@@@@@@@?e@@@@@@@@e? @@@@@@@@
GLOSSARY OF ULTRASONIC TERMS POWER SUPPLY/GENERATOR – The solid state power supply converts standard 50/60 Hz electrical energy to 15,000 Hz, 20,000 Hz or 40,000 Hz (15/20/40 kHz) electrical energy. ACTUATOR/PRESS – The pneumatic actuator provides compressive force and mounting for the converter, booster and horn assembly. The tabletop press consists of a base assembly, column and actuator (head).
INSTALLATION 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. Refer to the table below for power specification. 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.
ELECTRICAL CONNECTIONS The standard cable supplied with a “Sonics” press is 10 feet. Optional extension cables are available up to 15 feet without modification. NOTE: Do not plug the power supply into an electrical outlet until all other connections have been made. 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.
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.) NOTE: Detailed wiring diagrams are supplied in the Appendix at the back of this manual. 1. A round, 12-pin RF cable that connects the welding press or converter to the power supply. 2. An actuation cable that connects the power supply to a trigger source (refer to wiring diagrams in Appendix). 3.
AVAILABLE CONVERTERS Item No.
OPERATING PROCEDURES FRONT PANEL CONTROLS Located on the front panel of the power supply are the following controls: ❺ 60 0 20 40 60 80 100 70 50 80 40 90 30 100 TEST RESET POWER ❸ ❷ ❶ OUTPUT CONTROL ❹ 1. Red POWER button which turns the unit on and off. The RESET button is a built-in safety feature. When the power supply is connected to a press, be sure the press head actuation signals are not activated (or closed).
STARTING UP THE POWER SUPPLY Press the red POWER button to turn the power supply on. The POWER button will light up. The yellow RESET button will also come on and will remain lit. INITIAL OPERATION After the power supply is turned on (as described above), follow these steps: 1. Make sure that all necessary preparations have been made with regard to the ultrasonic system and tooling, and that the items to be welded are in position. 2.
OVERLOAD PROTECTION The overload protection circuit will terminate the welding cycle when the system is operated under adverse conditions, i.e., improper tuning, excessive power supply loading, loose or failed horn or booster, thereby protecting the power supply and other system components. When an overload condition exists, the RESET button will illuminate and remain lit until the condition has been corrected and the button is pressed. If the condition is not corrected, the RESET button will remain lit.
MAINTENANCE GENERAL 1. Always make sure the power supply has adequate ventilation by keeping sufficient space around the assembly. 2. Periodically check the ventilation grilles and clean as necessary. If problems are encountered, contact our Service Department at 1-800-7451105. REPAIRS / SERVICE If problems are encountered, contact our Service Department at 1-800-7451105.
WARRANTY Sonics & Materials, Inc., hereinafter referred to as “Sonics,” warrants its products for a period of one year from the date of shipment against defect in material and workmanship under normal installation, use, and maintenance as described in the operating instructions which accompany such equipment.
APPENDIX EQUIPMENT WIRING DIAGRAMS AND ASSOCIATED I/O Model Actuation J2 I/O J7 I/O J8 FC E2962 E-3014 E-3013 Drawing Part No. Description E-2962*/2962-1* 201-0179 FC continuous duty cable E-3013* 201-0206 F-Series general I/O E-3014* 201-0207 F-Series General I/O *See drawing on following pages.
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APPENDIX • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 22 I N S T R U C T I O N M A N U A L • M O D E L F C P O W E R S U P P LY
Sonics & Materials, Inc. Corporate Headquarters European Office 53 Church Hill Road • Newtown, CT 06470 USA 203.270.4600 • 800.745.1105 • 203.270.4610 fax www.sonicsandmaterials.com • info@sonicsandmaterials.com 22 ch du Vernay • CH - 1196 Gland, Switzerland (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax europe@sonicsandmaterials.
