Hand Held Welders Model H520 T/E Model H530 T/E Model H540 T/E I N S T R U C T I O N M A N U A L
TABLE OF CONTENTS IMPORTANT SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Important Safeguards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Front Panel Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . .19 Keying in Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Operational Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Starting up the Welder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Test Feature . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT SAFETY INFORMATION IMPORTANT SAFEGUARDS – READ BEFORE INSTALLING OR USING THE EQUIPMENT Your Ultrasonic Equipment 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 safeguard, observe the following warnings at all times, read the operating instructions carefully before operating the equipment, and retain this instruction manual for future reference.
SYMBOLS Caution, risk of electric shock, hazardous voltage Caution, risk of danger. Refer to User Manual. WARNING or CAUTION Where you see the alert symbols and/or WARNING or CAUTION heading, strictly follow the warning instructions to avoid personal injury or equipment failure.
SPECIFICATIONS Power Supply Operational Input Voltage 115/230 V~ +/-10% @ 50/60 Hz Rated Voltage/Current 115/230 V~, 5 A max. Fuse Rating F6.3A 250V* Weight 13 lbs. (5.9 Kg) Dimensions 8.5"H x 13.5"W x 7.5"D 216 mm x 340 mm x 190 mm Output Voltage 1000 V rms (max.) Output Frequency 20 KHz (nom.), 30 kHz or 40 KHz Converter CV 55 & CV 53 CV 54 Weight 1.5 lbs. (0.68 Kg) 1.5 lbs. (0.68 Kg) Dimensions 7.1" (CV55) or 6.3” L (CV53) x 1.9" Dia. (180 or 160 mm x 48.3 mm) (with standard tip) 6.
IMPORTANT SERVICE LITERATURE Please read carefully before operating the equipment, then forward to your service department. 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.
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 Sonics’ hand held welders are portable 500 watt welders used for plastics assembly that consist of an ultrasonic power supply and a hand gun. These units are designed specifically for welding, staking, inserting and spot welding applications (refer to the Applications section of this manual beginning on page 26 for more information on these operations). The model H520 is a 20 kHz power supply that comes with the CV55 hand gun; the H530 is a 30 kHz power supply that comes with the CV53 hand gun.
“SONICS” ULTRASONIC ASSEMBLY SYSTEMS 50/60 Hz Electrical power Power Supply/Generator Generates ultrasonic electrical energy (20/30/40 kHz) Ultrasonic electrical energy Hand Gun Converter Transforms ultrasonic electrical energy to ultrasonic mechanical vibrations Ultrasonic Vibrations Horn/Replaceable Tip Contacts and transfers vibrational energy to plastic part Ultrasonic Vibrations • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
GLOSSARY OF ULTRASONIC TERMS POWER SUPPLY/GENERATOR – The solid state power supply converts standard 50/60 Hz electrical power to 20,000, 30,000 or 40,000 Hz (20/30/40 kHz) electrical energy. CONVERTER – The converter changes the high frequency electrical energy supplied by the power supply to high frequency mechanical vibrations. TIP/HORN – The tip/horn is a tuned component of the system which comes in contact with the parts to be assembled.
INSTALLATION AND SET UP ELECTRICAL POWER REQUIREMENTS The line cord of the controller/power supply is equipped with a 3prong, grounding plug. Do not, under any circumstances, remove the ground prong. The plug must be plugged into a mating 3-prong, grounding type outlet. The power supply requires a fused, single-phase, standard 3-terminal grounding type receptacle capable of supplying the requisite voltage and current.
CABLE CONNECTIONS: Make sure the ON/OFF switch is in the OFF position and the power supply line cord is not plugged in before making any 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.) 1. A round, 4-pin cable (with red locator dot) that connects the hand gun to the power supply. 2. A standard DB9 I/O connector that can interface with automated machines via a PLC.
KEY COMPONENTS Pictured below is the power supply with hand gun options.
TIP ASSEMBLY (CV53 & CV55) If the tip is not already assembled, follow the instructions below as applicable (CV55 unit is shown below but instructions also apply to CV53). NOTE: Never remove or install a tip by holding the hand gun case or rotating the tip with only one wrench as this may cause damage to the booster and/or converter. NOTE: Before using wrenches to assemble as shown, you should be able to seat the horn or tip without encountering resistance in the mating threads.
TIP REPLACEMENT (CVG54) 1. Clean the mating surfaces, as well as the threaded stud and hole. Check that the stud is tight. (See recommended torque requirements below.) 2. Hand assemble the tip to the horn using open-ended wrenches as shown below and tighten securely. Do not force or overtighten.
TIP SPECIFICATIONS A variety of replaceable tips – both custom and standard – are available for the hand held welding systems. Upon request, special carbide faced, wear resistant, flat, knurled, and custom faced tips are available. INSERTING STAKING FLAT SPOT WELDING KNURLED Refer to the various tables under staking, spot welding and insertion descriptions on pages 26-31 for lists of standard threaded tips. For custom tips, call our Sales Department at 203-270-4600.
OPTIONS Always turn off the power supply before installing or removing the foot switch cable. The following options and accessories are available for the hand held welding systems. 1. FOOT SWITCH for remote activation. (When foot switch actuation is used, the trigger handle is removed from the hand gun housing.) 2. MANUAL ARBOR PRESS, available with foot switch or cam actuation, is designed for assembling parts where production volume does not justify automated equipment.
3. STAPLER with special pivoting mechanism. Ideal for sealing low production rate clamshell packages (for 20 kHz Models only). STAPLER 4. PISTOL GRIP for more ergonomic handling of the hand gun in specialized applications.
OPERATING PROCEDURES FRONT PANEL CONTROLS AND INDICATORS Located at the front of the power supply are the following controls: Do not operate the power supply unless it is connected to the hand gun. 2 3 4 3 5 6 10 7 4 NOTE: The operating range of amplitude is 20-100% 11 12 8 1 9 1. ON/OFF switch which turns the power supply on and off. The switch remains in a “latched state” even if power is interrupted or disconnected.
For a complete explanation of these parameters, refer to page 22. 5. ENERGY key (active on E models only) which allows selection and display of the following energy settings and permits adjustment of the energy parameters a. through c. below in 1 joule increments (from 0 to 999,999 joules): a. Energy Setting b. Energy Limit Low c. Energy Limit High For a complete explanation of these parameters, refer to page 23. 6.
OPERATIONAL FEATURES – Adjustable tolerance limits in energy (Ws) (for E models only) and time (sec) with visual alarms. – Information displays including: number of assemblies, number of rejects, and number of cycles. – Fault displays. – Keypad security. STARTING UP THE WELDER Press the ON/OFF button to turn the welder on. The LCD screen will display the model number, wattage and frequency information. Then the LCD screen will show the following “ready” display: 00.
Frequency Display The TEST key can also be used to display the running ultrasonic frequency. Refer to page 23 for more information. READY SCREENS In addition to the start-up ready screen (shown on page 20), there are 2 other “ready” screens. The power supply must be displaying one of the 3 ready screens in order for welding to commence. Welding cannot be initiated from any other display. All 3 ready screens can be accessed by pressing the ENTER/REVIEW key.
RELATIONSHIP OF TIME AND ENERGY SETTINGS (ON E MODELS ONLY) Parameters can be set in the time and energy menus. The settings in both of these menus should be taken into account when you are setting up a job since they do not function independently of each other and a parameter in one menu can impact the effect of a parameter in another menu.
TIME SETTINGS There are 3 time parameters, or timers, that can be set. They are accessed by pressing the Time key which allows specification of the following time parameters. The first menu display will show the following: Weld Time – sets the duration of time for which ultrasonic vibrations are applied to the parts. If the time value is cleared (zero or dashes displayed on screen), then ultrasonics will be activated when the hand gun trigger switch is depressed.
ENERGY SETTINGS (ON E MODELS ONLY) There are 3 energy parameters that can be specified. These are accessed by pressing the Energy key, which allows specification of the following parameters. The first menu display will show the following: Energy Setting – sets the amount of energy in joules to be delivered to the parts being assembled. Press the Energy key again (and successively after each menu display) to advance to these next screen displays.
OVERLOAD PROTECTION When the hand gun (converter) is on, be sure to isolate it from any/all grounded surfaces (including machine frames) to avoid triggering an overload condition as the system detects an alternate ground path. There are two overload protection circuits – one for the power supply and one for the hand gun – which will terminate the welding cycle when the system is operated under adverse conditions, such as excessive wattage, voltage or current, or a loose or failed horn/tip.
KEYPAD SECURITY The keypad can be “locked,” so that no new parameters or commands can be entered via the keyboard, thereby preventing unauthorized cancellation or adjustment. To activate the security feature, press and hold the numeral 7 key on power up.
APPLICATIONS – STAKING Ultrasonic staking, also referred to as ultrasonic “heading” or “riveting”, controls the flow of the molten plastic used to capture or retain another component in place. Ultrasonic staking provides an alternative to welding when the two parts consist of dissimilar materials that cannot be welded or when simple mechanical retention of one part relative to another is inadequate (i.e. as distinct from molecular bonding). A common application is the attachment of plastic to metal.
SPHERICAL STAKE The spherical stake is preferred for bosses with an O.D. less than 1⁄16 inch (1.6 mm). It is also recommended for rigid crystalline plastics with sharp highly defined melting temperatures, for plastics with abrasive fillers, and for materials that degrade easily. HIGH PROFILE BEFORE AFTER HORN .5d 2.12d .75d METAL d PLASTIC LOW PROFILE BEFORE 2d AFTER HORN .8d .5d .375d HOLLOW STAKE Bosses with an O.D. in excess of 5⁄32 inch (4 mm) should be made hollow.
FLUSH STAKE The flush stake is used for applications requiring a flush surface. The flush stake requires that the retained piece has sufficient thickness for a chamfer or counterbore. AFTER BEFORE HORN METAL PLASTIC STANDARD THREADED TIPS FOR STAKING STAKING TIP CODE LETTER Plastic Boss Diameter Solid Boss Flare Head High Profile Conical Boss Spherical Head Low Profile Hollow Boss Stud Height* High Profile Low Profile .019 AA GG — H .0375 BB HH — .150 I .056 CC II — D .200 J .
APPLICATIONS – SPOT WELDING During spot welding, the horn tip penetrates through the top sheet and enters the bottom sheet to a depth of one half the top sheet thickness. The displaced molten plastic is shaped by a cavity in the tip to create an annular formation around the weld. Simultaneously, the molten plastic displaced from the second sheet flows into the preheated area and forms a permanent molecular bond.
APPLICATIONS – ULTRASONIC INSERTION Ultrasonic insertion involves a metal insert to be placed in a cored or drilled hole that is slightly smaller than the insert. This hole provides a certain degree of interference and also serves to guide the insert into place. The vibrating ultrasonic horn contacts the insert and the ultrasonic vibrations travel through the insert to the interface of the metal and plastic.
STANDARD THREADED TIPS FOR INSERTION INSERTING Insert Size Inside Diameter of Insert Pilot Diameter Of Tip 4-40 0.088 0.078 6-32 0.106 0.096 8-32 0.133 0.123 10-24 0.147 0.137 10-32 0.160 0.150 1/4-20 0.200 0.190 1/4-28 0.211 0.201 5/16-18 0.262 0.252 2.5 x 0.45 0.079 0.069 3 x 0.50 0.097 0.087 3.5 x 0.60 0.114 0.104 4 x 0.70 0.129 0.119 5 x 0.80 0.165 0.155 6 x 1.00 0.195 0.185 8 x 1.25 0.265 0.
MAINTENANCE CLEANING INSTRUCTIONS NOTE: If packing unit for return shipment, DO NOT use styrofoam “peanuts.” The power supply and converter may be cleaned using a solvent-free cleaning solution (i.e., glass cleaner). Horns and probes should be cleaned using isopropyl alcohol. Titanium horns can be autoclaved. REPAIRS / SERVICE If problems are encountered, contact our Service Department as follows: Phone: 1-800-745-1105 • 1-203-270-4600 Fax: 1-203-270-4610 E-Mail: service@sonics.
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.
LIMITATION OF WARRANTY This warranty does not apply to items subject to normal wear and tear or, to equipment or tooling which has been subject to unauthorized repair, misuse, abuse, negligence or accident. Misuse includes operation of equipment with tooling that is not qualified for the equipment or tooling not properly installed on the equipment.
Data supplied in Sonics instruction manuals has been verified and validated and is believed adequate for the intended use of the equipment. If the equipment or procedures are used for purposes other than those specified herein, confirmation of their validity and suitability should be obtained in writing from Sonics. Otherwise Sonics does not guarantee results and assumes no obligation or liability. This warranty is in lieu of any other warranties, either express, implied, or statutory.
APPENDIX DB9 I/O CONNECTIONS DIAGRAM • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 38 INSTRUCTION MANUAL • HAND HELD WELDERS Go To Top Of Document
