Integrated Welder 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Manual Change Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Visible Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Concealed Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 INTRODUCTION . . . . . . . . . . . . . . . . . . . . .
FINE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Booster Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Re-Establishing Proper Booster/Horn Interfaces . . . . . . . . . . . . .28 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Repairs / Service . . . . . . . . . . . .
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 X-Press integrated welders, models XPT and XPE, are 20 kHz ultrasonic benchtop presses with built-in microprocessor-controlled power supplies. 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 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 built-in solid state power supply converts standard 50/60 Hz electrical power to 20,000 Hz electrical energy (20 kHz). 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 REQUIREMENTS The press 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 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.
KEY COMPONENTS SPEED CONTROL KNOBS PRESSURE GAUGE REGULATOR HEAD DOWN SWITCH MICROPROCESSOR CONTROLS CONVERTER HOUSING DOOR CONNECTION PLATE CONVERTER HOUSING with converter, booster & horn (stack) assembly PALM BUTTONS AIR CONNECTION EMERGENCY STOP BUTTON CONNECTIONS When making initial air supply or impulse cable connections, make sure all electrical power is disconnected. Located on the connection plate at the base of the press head are the following: NOTE: Do not strain or kink cables.
2. If you are using an impulse cable, connect it as noted above (disconnect the base cable if necessary). Refer to the Impulse Cable drawing in the Appendix, page 36. 3. When the above connections are secure, the power line cord can be plugged into an appropriate electrical outlet. 4. To prevent the possibility of an electrical shock, ensure that the power supply line cord is properly grounded.
OPERATING PROCEDURES CONTROL PANEL Located above the converter housing on the X-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. Pull the red ring out to release and push in to lock setting. Excessive velocity may be unnecessary and harmful to the system.
OPERATING PROCEDURES MICROPROCESSOR CONTROLS AND INDICATORS Located at the front of the press are the following controls and indicators: 2 3 4 3 5 6 10 7 4 11 12 8 1 9 1. ON/OFF keys which turn the unit on and off. 2. LCD SCREEN which displays various settings, parameters and prompts as detailed in the following pages. In addition, during the weld process it displays a load meter indicator showing the power level of ultrasonics that is being delivered to the welding press (see #3 below). 3.
5. ENERGY key (active on XPE 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 19. 6. AMPLITUDE key which controls adjustment of the amplitude setting, relating to the system’s high-frequency vibrations over the full operating range.
KEYING IN PARAMETERS To make numeric entries into a cursor location that is displayed on a screen menu, use the numeric keypad. When the desired entry is displayed on the LCD screen, use the ENTER key to register the new value. Entries are made left to right. The CLEAR key will clear an existing value to 0, displayed as a series of dashes, and relocate the cursor to the extreme left-hand entry position ready to accept entries again.
TEST FEATURE After the press is turned on, press and hold the TEST button. While depressing the TEST button, check the display. Make sure the bar graph indicator on the display (a series of vertical lines that register to the 0 to 100% load meter scale – see example below) does not exceed 20%. 0045 Watts During the testing process, keep in mind that the ultrasonics are only activated as long as the TEST button is depressed – once you release the TEST button, ultrasonics is terminated.
there are alarms, an L (for Low limit, indicating that the low limit was violated) and/or an H (for High limit, indicating that the high limit was violated) will display by the applicable mode (time or energy). Once another new cycle is begun, the system will automatically clear the current alarm.
described below, keep in mind that the settings from previous use remain in effect until you make a change and use the Enter key to register a new value. This means that if you want to achieve a weld time of 2 seconds, for example, you will need to ensure that other entries in the Energy menu will allow a 2-second weld before an Energy setting is reached (and ultrasonics are terminated). TIME SETTINGS There are six time parameters, or timers, that can be set.
ENERGY SETTINGS (ON XPE MODELS ONLY) There are 4 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 The overload protection circuit will terminate ultrasonics 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, a repetitive beep will sound and the O. L. RESET button will illuminate and remain lit until the button is pressed (regardless of whether the condition is corrected or not).
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.
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 23). 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 24-25, DO NOT turn on the press. 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).
4. Loosen the cap screws on the converter housing door and gently rotate the head and horn as required to ensure proper horn-to-part alignment. 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.
OPERATION ACTUATION The press is equipped with two maintained anti-repeat (non-tie-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: 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. 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.com 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.
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 X-PRESS LAYOUT FRONT VIEW Dimensions are shown in inches and millimeters, i.e., 11/2 (38.1) signifies 11/2" (38.
APPENDIX X-PRESS LAYOUT SIDE VIEW Dimensions are shown in inches and millimeters, i.e., 11/2 (38.1) signifies 11/2" (38.
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.
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Go To Top Of Document INSTRUCTION MANUAL • MODEL X-PRESS 36 TIE BLACK AND WHITE TOGETHER W/N.C CONTACT. BREAK CONNECTION FOR E-STOP PROTECTION.
APPENDIX EXPLODED ASSEMBLY DRAWING • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • I N S T RU C T I O N M A N UA L • M O D E L X - P R E S S 37
