Model FM 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.
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 . . . . . . . . . . . . . . . . . . . . . . . . . .
ENERGY-BASED MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Constant Energy-Based Cycle with Time Delay Triggering . . Constant Energy-Based Cycle with Variable Force Triggering Timer 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting and Setting the Maximum Weld Time . . . . . . . . . . . . . . . . . . . . .23 .23 .24 .24 .24 OVERVIEW OF OPERATIONS AND LCD DISPLAYS . . . . . . . . . . . . . .25 OVERVIEW OF SET-UP PROCEDURES AND DISPLAYS .
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 FM model power supply is an auto-tuned ultrasonic generator with a builtin Microprocessor that allows time and energy-based control. The Microprocessor is programmed with a multi-function keypad and information is displayed on the back-lit liquid crystal display (LCD). This power supply can be used with a pneumatic actuator or with a stand-alone converter.
“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 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 Ultrasonic V
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/WELDING 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. J1, a round, 12-pin RF cable that connects the welding press or converter to the power supply. 2. J2, 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 AND INDICATORS Located on the front panel of the power supply are the following controls and indicators: 4 3 70 60 0 20 40 60 80 100 MICROSONIC PROCESSOR™ 50 80 40 90 30 100 OUTPUT CONTROL 2 7 8 9 4 5 6 1 2 3 ENTER CE TIMER F TRIGGER REF +LIM –LIM 0 TEST INFO PRT MAN AUTO O.L. RESET 5-13 17 14 16 15 1 1. ON/OFF key which turns the unit on and off. Red LED in upper left corner indicates unit is ON.
7. REF key which displays energy in Watt Seconds (Ws) when the constant energy mode has been selected, and permits adjustment of the set value in .1 Ws increments. Green LED in the upper left corner indicates completion of an acceptable process cycle. 8. +LIM / -LIM keys which display and establish upper and lower quality control tolerance limits in time (sec.) when energy mode is selected and in energy (Ws) when time mode is selected.
OPERATIONAL SIGNALS Valid parameter entries and/or selections are verified by an audible signal of short duration. Invalid entries and/or selections (fault conditions) are signaled by an audible signal of longer duration. OPERATIONAL FEATURES – Adjustable Afterpulse Timer to separate parts from horn. – Adjustable tolerance limits in energy (Ws) or time (sec) with visual and audible alarms.
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. Press and hold the TEST button. While depressing the TEST button, check the LCD reading. Make sure the reading on the LCD display (see example below) does not exceed 10%.
BASIC MODES OF OPERATION The FM power supply’s built-in microprocesor allows the use of either timebased or energy-based cycles in four basic modes, as follows: 1. Time-based cycle with time delay triggering or pre-triggering. 2. Time-based cycle with variable force triggering. 3. Constant energy-based cycle with time delay triggering or pre-triggering. 4. Constant energy-based cycle with variable force triggering.
MODE CODES DISPLAY The power supply is shipped with blank programs, so all data and parameters must be input by the customer. On initial start-up, the default mode selected is the Time-Based cycle.
TIME-BASED MODES SELECTING AND SETTING TIMERS IN A TIME-BASED CYCLE (with delay triggering) As described on the previous pages, the default mode is the Time-Based cycle. Pressing the INFO key four times would display the following codes on the LCD Screen: NOTE: When the TimeBased mode is in effect, the percentage of maximum power and energy (Ws) used are displayed on the LCD immediately following completion of the process cycle.
Pre-triggering is accomplished by setting T1 to 0.00 sec, thus continuing the calibration pulse until T2 is actuated by the horn contacting the workpiece. NOTE: T1 should be selected and set at 0.00 seconds only when pretriggering is required. Pretriggering during normal welding operations can result in surface marking. The Delay Timer (T1) can only be set or changed when Delay Timer Triggering (T1) has been selected.
key to activate and cancel the Afterpulse function.) When the Afterpulse Timer is cancelled, the function letter “U” will no longer appear in the Mode Codes display. SELECTING AND SETTING PROCESS CONTROL TOLERANCE LIMITS IN A TIME-BASED CYCLE The process control tolerance limits are established in energy (Ws) when the Time-Based mode (ZT) is in effect. If tolerance reject limits have not previously been set, or if all parameters have been cleared, the system will automatically display the default limits.
Press the ENTER key or any other key to enter the new Force Trigger set value, or wait 30 seconds for automatic acceptance. The Force Trigger (FT) value can only be set or changed when the Force Triggering (FT) mode is in effect. It is not operational when the Time Delay Triggering function (T1) has been selected. Attempts to access FT by depressing the F Trigger Key when the Time Delay Triggering (T1) function is in effect will result in this display: FORCE-TRIG.
ENERGY-BASED MODES CONSTANT ENERGY-BASED CYCLE WITH TIME DELAY TRIGGERING When the CONSTANT ENERGY function (EN) has been selected, the weld cycle follows the termination of a predetermined delay period (T1) and continues until a pre-selected amount of energy (Ws) has been delivered to the components being assembled. When the Constant Energy function is in effect, the percentage of maximum power used and actual weld cycle duration are displayed on the LCD immediately following completion of the cycle.
CONSTANT ENERGY-BASED CYCLE WITH VARIABLE FORCE TRIGGERING (Refer to page 27 for keystroke sequence guide.) This mode of operation utilizes both the Force Trigger (FT) and Constant Energy (EN) functions to assure consistent triggering and energy delivery. To change from Time-based operation, press the INFO key four times to display the current Mode Codes, i.e., T1 ZT NB IS 1 48 A. Press the numerical keys 1 and 2 to select the alternate functions FT and EN.
OVERVIEW OF OPERATIONS AND LCD DISPLAYS MICROSONIC PROCESSOR™ OPERATING INSTRUCTIONS DISPLAY BEFORE FUNCTION START-UP Start power supply and Microsonic Processor™ KEY OPERATION SEQUENCE — DISPLAY AFTER SONICS AND MATERIALS •••• NO PRINTER •••• READY TEST Test for idle losses in air READY TEST US - TEST = 5% TIMER Select Timer Function READY TIMER TIMER NR = (1-5)? Select Timer ex: Delay Trigger Timer TIMER NR = (1-5)? 1 TIMER 1 = 0.00 sec Set Timer 1 ex: 0.25 sec. TIMER 1 = 0.
FUNCTION AFTERPULSE TRIGGER FORCE REF SECURITY DISPLAY BEFORE KEY OPERATION SEQUENCE Select Afterpulse Timer (T4) or cancel Afterpulse Timer (T4). T1 ZT NB IS 1 48 M Select Trigger Force READY TRIGGER Set Trigger Force ex: 25% TRIGGER (F) = 1% CE Enter set value TRIGGER (F) = 25% ENTER Select and clear energy (REF) set value READY REF CE Set REF value ex: 100.0 Ws REF = 00000.0 Ws 1 0 Enter REF Value REF = 100.0 Ws Secure keypad to prevent unauthorized adjustment of parameters.
OVERVIEW OF SET-UP PROCEDURES AND DISPLAYS CONSTANT ENERGY WITH VARIABLE FORCE TRIGGERING DISPLAY BEFORE FUNCTION START-UP Start power supply KEY OPERATION SEQUENCE — DISPLAY AFTER SONICS AND MATERIALS •••• NO PRINTER •••• READY TEST Test for idle losses in air READY TEST FORCE TRIGGER Determine whether Force Trigger function has been selected READY INFO If not: T1 EN NB IS 1 48 M Determine whether Constant Energy function has been selected READY If not: FT ZT NB IS 1 48 M Select Trig
FUNCTION UPPER LIMIT LOWER LIMIT OFF DISPLAY BEFORE Select Upper Limit function READY Set Upper Limit ex: 0.90 sec. KEY OPERATION SEQUENCE + LIM CE + LIM = 0.00 sec + LIM = 0.00 sec 9 0 + LIM = 0.90 sec Enter set-value + LIM = 0.90 sec ENTER Select Lower Limit function READY – LIM CE – LIM = 0.00 sec Set Lower Limit ex: 0.60 sec. – LIM = 0.00 sec 6 0 – LIM = 0.60 sec Enter set-value – LIM = 0.
ADDITIONAL FEATURES AND FUNCTIONS PROGRAM VERSION DESIGNATION To review the program version number, press and hold the TEST and REF keys simultaneously when “SONICS & MATERIALS” appears on the LCD DISPLAY at start-up. The display will then show the program version number i.e., V2.6 845-19 1500W. To return to system status READY, simply release the TEST and REF keys.
JOB NUMBER: __ Saved jobs will be numbered 1 through 9. Use the numerical keys to enter in the desired job number (1 - 9). Once the job number is keyed in, press the ENTER key. The following message will be displayed on the LCD screen: S AV E O. K . ! _ _ All the parameters for that job will be saved under the number keyed in. To return to system status READY, press the ENTER key. Recall To recall a job that has been saved, first access the “SAVE RECALL OTHER” display (by pressing the INFO key 6 times).
PRESSURE 0.00 Psig Use the numerical keys to enter in the new pressure value. When the desired pressure is displayed on the LCD screen, press the ENTER key. The LCD screen display will show the following: B O O S T E R G A I N = 0 . 0 0 __ To set a new Booster Gain ratio, use the CE and numerical keys in the same manner described above for recording the Pressure value.
The following is an example where four jobs are to be sequenced and one set of parameters (Job 1) is to occur twice in the sequence. The sequence is as follows: SEQUENCE 1 2 1 5 The LCD screen will show the following displays as the jobs are sequenced: Display for first cycle READY 1 STEP #1 second cycle READY 2 STEP #2 third cycle READY 1 STEP #3 fourth cycle READY 5 STEP #4 NOTE: Sequence repeats, going back to first cycle.
KEYPAD SECURITY The keypad can be “locked” so that all operating parameters that are selected and set with the keypad are locked in, preventing unauthorized cancellation or adjustment. To activate the security feature, first press the INFO key 4 times to display the current Mode Codes (i.e., T1 ZT NB IS 1 48 M, or other variation). Then, press the numerical keys 0 and 7 in sequence within one second to lock the keypad.
PRINTER INTERFACE AND OPERATION PRINTER OPERATION NOTE: Use of a printer causes the cycle to be extended by approximately 200 ms. If a printer is to be used for documentation of the dynamic process conditions, it must have an RS232 serial port interface, a buffer of 2K bytes and be capable of accepting a transmission rate of 4800 Baud. Following completion of an assembly cycle, the assembly number, percentage of maximum power used, energy level, weld cycle duration and reject status can be printed.
PRINTER DISPLAYS Time Based mode with delay timer triggering SONICS AND MATERIALS Delay Timer Timer 1 = Weld Timer Timer 2 = Hold Timer Timer 3 = Afterpulse Timer Timer 4 = Timer 5 = Pressure Assembly Number 98 Percentage of available power used 0.25 sec 0.15 sec 0.25 sec 0.00 sec 0.00 sec 30.00 Psig Program Version Power Supply Output Rating V3.0 845-73 1500W Mode Codes T1 ZT NB IS 1 48 M + LIM = 105.0 Ws Upper tolerance limit (energy) – LIM = 90.
Constant energy mode with variable force triggering Program Version SONICS AND MATERIALS V3.0 845-73 Trigger Force Trigger (F) = 2% Energy Set-Value REF = 91.0 Ws + LIM = Hold Timer Timer 3 = 0.25 sec – LIM = Afterpulse Timer Timer 4 = 0.00 sec Timer 5 = 0.25 sec Pressure 30.00 Psig Assembly Number 100 Percentage of available power used Power Supply Output Rating 1500W Mode Codes FT EN NB IS 1 48 M 0.20 sec Upper Limit (Time) 0.10 sec Lower Limit (Time) CAL PULSE = ON BOOSTER GAIN = 1.
The keypad is not functional during the time a printout is being made until a short audible tone is heard and the LCD returns to system status “READY.” Printing can be stopped at any time by pressing any key. The printer will continue printing, however, until the data stored in the buffer has been printed. Time axis plot lengths of 250 ms, 500 ms, 1 second, 5 seconds and 10 seconds are available for printout. The time axis desired must be specified prior to the assembly cycle, as follows.
REJECT PRINTOUTS The reason for a reject, such as ± LIM or T5, will be printed out for each weld. If the Timer 5 limit is exceeded, then the printout will read as follows: 25 76/o 176.6 ws 0.40 sec. **** Reject T5 For the example above, the printout indicates that this cycle was rejected because the Timer 5 setting (0.40 sec.) was exceeded. In this case, the red LED’s in the corners of both the +LIM and -Lim keys will be illuminated.
SYSTEM STATUS TESTS AND FUNCTIONS POWER SUPPLY TEST AND DISPLAY The ultrasonic power supply can be actuated briefly and tested by pressing and holding the TEST key. The value displayed on the LCD screen should not exceed 10% or 20% on the LED bar graph. OPERATION SEQUENCE DISPLAY The operation sequence, which includes the trigger, time and energy functions in use during a process cycle, can be displayed on the LCD screen during subsequent cycles.
Input No. Alphabetical Status Codes Function 1. Emergency stop/converter door interlock A = ON a = OFF 2. Not used at present time B = ON b = OFF 3. Stop timer 2 C = OFF c = ON 4. Not used at present time D = OFF d = ON 5. Stop timer 3 E = OFF e = ON 6. Stop timer 4 F = OFF f = ON 7. Rotary table valve monitoring G = Missing g = OK 8. Press valve monitoring H = Missing h = OK 9. Head advance control I = OFF i = ON 10. External Start J = OFF j 11.
COUPLING FORCE MEASUREMENT (Model 1098 only) To measure the actual horn coupling force, turn the head down key switch clockwise. Then, as the head is descending, press the F TRIGGER key and keep it depressed until the horn contacts the parts. The F TRIGGER key must be depressed before the horn makes contact or an invalid force measurement, or the value “0%,” will be displayed. The coupling force will be displayed on the LCD screen as a percentage of the maximum available force. (100% = 50 Psig = 245 Ibs.
SYSTEM STATUS TESTS SYSTEM STATUS TESTS AND MISCELLANEOUS FUNCTIONS FUNCTION Input Test DISPLAY BEFORE SONICS AND MATERIALS KEY OPERATION SEQUENCE TEST + AUTO DISPLAY AFTER INPUT TEST ABCDEFGhIJKLMNoP CRT Monitor/Printer Test SONICS AND MATERIALS INFO + Cancel Parameters SONICS AND MATERIALS INFO + Program Version Designation SONICS AND MATERIALS TEST + PRT F TRIGGER REF * * PRINTER TEST * * * * * * OFF * * * * V2.
OVERLOAD PROTECTION The overload protection circuit will terminate sonics 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 button is pressed (regardless of whether the condition is corrected or not).
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. REPAIRS / SERVICE If problems are encountered, contact our Service Department at 1-800-7451105. 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.
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 DIP SWITCH DEFAULT SETTINGS SWITCH POS. OFF POS. ON DIP-1 Force Trigger Mode (FT) T1 (ZT) Model OFF DIP-2 Weld by Timer 2 (T2) Weld by Energy (EN) OFF DIP-3 Normal mode without Rotary table Rotary table mode to DIP-4 OFF DIP-4 Rotary table mode with pulse control Rotary table mode with continuous control and ackn.
APPENDIX EQUIPMENT WIRING DIAGRAMS AND ASSOCIATED I/O Model Wiring Diagram Actuation J2 I/O J3 I/O J6 I/O J7 I/O J8 I/O J9 FM E-2952 E-2703 E-2480 E-2483 E-3014 E-3013 E-2902 Drawing Description E-2480 Printer Cable E-2483 Rotary Table Cable E-2703 Impulse Actuation Cable E-2902 Good Part/Bad Part and Abort Cable.
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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.
