Sonics FM, Instruction Manual

Page 1: ...I N S T R U C T I O N M A N U A L Sonics Materials Inc ModelFMPowerSupply ...

Page 2: ...ke sure equipment is properly grounded with a 3 prong plug Before plugging in equipment test outlet for proper earth grounding Ultrasonic welders operate above normal audibility for most people Ear protection is recommended Sonics Materials Inc Corporate Headquarters European Office 53 Church Hill Road Newtown CT 06470 USA 22 ch du Vernay CH 1196 Gland Switzerland 203 270 4600 800 745 1105 203 270...

Page 3: ...s 11 Available Converters 12 OPERATING PROCEDURES 13 Front Panel Controls and Indicators 13 OPERATIONAL SIGNALS 15 Operational Features 15 Starting up the Power Supply 15 Initial Operation 16 BASIC MODES OF OPERATION 17 Time Based Modes 17 Energy Based Modes 17 Mode Codes Display 18 TIME BASED MODES 19 Selecting and Setting Timers in a Time Based Cycle 19 Selecting and Setting the Afterpulse Timer...

Page 4: ... 29 Cancel Number of Rejects 29 Job Storage 29 Job Sequence 31 Cal Pulse 32 KEYPAD SECURITY 33 PRINTER INTERFACE AND OPERATION 34 Printer Operation 34 Printout of the Weld Energy Curve 34 Printer Displays 35 Graph Header 37 Reject Printouts 38 SYSTEM STATUS TESTS AND FUNCTIONS 39 Power Supply Test and Display 39 Operation Sequence Display 39 System Status Tests and Miscellaneous Functions 39 Print...

Page 5: ...nt as soon as they are developed and tested Sometimes due to printing and shipping requirements we cannot incorporate these changes immediately into printed manuals Hence your manual may contain new change information Change information if any is located in the Appendix We reserve the right to make any changes in the design or construction of our equipment at any time without incurring any obligat...

Page 6: ...the freight bill or express receipt and signed by the carrier s agent Failure to adequately describe such external evidence of loss or damage may result in the carrier s refusal to honor a damage claim The form required to file such a claim will be supplied by the carrier CONCEALED LOSS OR DAMAGE Concealed loss or damage means loss or damage which does not become apparent until the merchandise has...

Page 7: ...c assembly involves conversion of high frequency electrical energy to high frequency mechanical energy in the form of reciprocating vertical motion which when applied to a thermoplastic generates frictional heat at the plastic plastic or plastic metal interface In ultrasonic welding this frictional heat melts the plastic allowing the two surfaces to fuse together in ultrasonic staking or insertion...

Page 8: ...gy Ultrasonic Vibrations Provides compressive force and mounting for Converter Booster Horn assembly Aligns and supports part Transforms ultrasonic electrical energy to ultrasonic mechanical vibrations Increases or decreases amplitude Contacts and transfers vibrational energy to plastic part Converter Booster Horn Ultrasonic Vibrations Ultrasonic Vibrations Power Supply Generator Actuator Press Ho...

Page 9: ...lding often depends on having the right amplitude at the horn face Often it is not possible to design a horn which has both the necessary shape and required gain ratios of input amplitude to output amplitude In such cases a booster is placed between the converter and the horn to either increase or decrease the amplitude of the horn In addition to changing maintaining the amplitude the booster prov...

Page 10: ...cable connections b Position the power supply so that the front panel controls are visible and readily accessible c The power supply is air cooled allow sufficient space around the assembly to ensure adequate ventilation If the power supply must be housed in a confined space forced air cooling may be necessary to keep surrounding air within acceptable ambient temperature limits Periodically check ...

Page 11: ...ng 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 305mm 2 To prevent the possibility of an electrical shock ensure that the power supply line cord is properly grounded Also make sure that the voltage rating of the electrical power source matches the power supply requirement refer to the Power Specifications tab...

Page 12: ... press side are correct and that the press is ready for operation Also located at the rear of the power supply are the following 4 J3 Printer Output 5 fuse based on requirements listed in Power Specifications table p 9 6 J6 Rotary Table Output see wiring diagrams in Appendix 7 J7 I O see wiring diagrams in Appendix 8 J8 I O see wiring diagrams in Appendix 9 J9 Reject Output 10 fuse based on requir...

Page 13: ...V00157 20 kHz with Button connector and fitting for air cooling CV00158 20 kHz Hand Gun with handles and cables CV00331 20 kHz with Fischer connector CV00334 20 kHz with Fischer connector and fitting for air cooling CV00023 40 kHz with Button connector CV00231 40 kHz with Lemo connector CV00232 40 kHz with SHV connector side mounted CV00234 40 kHz with Lemo connector and fitting for air cooling CV...

Page 14: ...ts adjustment of timer duration in 01 second increments from 0 00 to 9 99 seconds for five timers as follows T1 Delay Timer for normal delay triggering or pre triggering T2 Weld Timer in time based operation T3 Hold Timer in both time and energy based operation T4 Afterpulse Timer to release assemblies adhering to horn T5 Abort Cycle Timer limits maximum weld time permitted for an assembly 6 F TRI...

Page 15: ...power of system Mode Codes functions selected Length of Graph Time Axis when printed out on optional printer SAVE RECALL OTHER options Job Sequencing Calibration Pulse activation or deactivation 11 PRT key which permits display of parameters and dynamic process conditions when optional CRT monitor or printer is used Green LED in upper left corner indicates when data is being transmitted to a perip...

Page 16: ...ult displays CHECK PRESS CHECK PRESSURE OR b8 FORCE MISSING PRESS VALVE FAILURE Keypad security to prevent unauthorized adjustment of parameters Self diagnostic input test Display of coupling force measurement Model 1098 only Storage capabilities of up to 9 programs Job sequence of up to 9 programs Deactivation of calibration pulse i e when utilizing vacuum horns Variable weld time in constant ene...

Page 17: ...e the reading on the LCD display see example below does not exceed 10 a If the display is above 10 contact Sonics immediately for further instructions before proceeding b If the display is below 10 you can proceed with operation 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 ter...

Page 18: ...iable Force Triggering the Weld and Hold Timers are actuated after a pre determined coupling force is exerted on the components For both of these time based modes of operation upper and lower tolerance limits in energy Ws can be adjusted ENERGY BASED MODES In a Constant Energy Based Cycle with Time Delay Triggering the weld cycle follows the termination of a pre determined delay period The weld cy...

Page 19: ...rmination of delay time or pre trigger or FT Ultrasonics actuated when trigger force has been reached 2nd Position ZT Time based welding or EN Constant energy welding 3rd Position NB Normal operation no rotary table or RT Rotary table control and operation provided by microprocessor 4th Position IS Rotary table pulse control or DS Rotary table continuous signal control with acknowledgement 5th Pos...

Page 20: ...l key to select a timer value to be displayed or set i e press key 1 to display the set value of the Delay Timer T1 key 2 to display the set value of the Weld Timer T2 and so on Once a timer number has been selected the red LED in the upper corner of the CE key will light up indicating that the CE key is functional and must be depressed to enter a new time value regardless of whether or not a prev...

Page 21: ...an be used to actuate the ultrasonics briefly to release the assembly as the press retracts to rest position To use the Afterpulse Timer T4 press the INFO key four times to display the current Mode Codes for example T1 ZT NB IS 1 48 M Press the numerical key 5 and the letter U will appear in the fifth position of the LCD display between IS and 1 indicating that the Afterpulse Timer T4 is operation...

Page 22: ...w value with the numeric keys and set it by pressing the ENTER key If the ENTER key is not depressed the value is accepted automatically after 30 seconds Selection and adjustment of the upper tolerance limit is accomplished in the same manner once the LIM key is pressed If entry of an improper limit value is attempted i e a lower limit value that exceeds the upper limit value the following display...

Page 23: ... access FT by depressing the F Trigger Key when the Time Delay Triggering T1 function is in effect will result in this display If the required coupling force is not reached because air pressure is not sufficient the head will retract after five seconds and the following message will be displayed An assembly cycle can be completed only when the fault has been corrected either by increasing gauge pr...

Page 24: ... indicate that the CE key is functional and must be pressed in order to enter a new energy value Press the CE key to clear the current display values and use the numerical keys to set the new energy value Press the ENTER key or wait 30 seconds for automatic acceptance The REF value in Ws can only be set or changed when Constant Energy EN is in effect It is not operational when the Time Based funct...

Page 25: ...T and the quality control tolerance limits LIM LIM are also active in this mode and can be set in the usual manner TIMER 5 Timer 5 is an abort cycle timer that can override the hard coded value of 9 99 seconds as an absolute time out when in the Energy mode Timer 5 is set in the same manner as the other timers l through 4 If the abort cycle feature is not to be used Timer 5 should be set to 9 99 s...

Page 26: ...Select either Delay Timer Triggering or Force Triggering Functions If Delay Triggering T1 If Force Triggering FT ENERGY Select either Time Based function or Constant Energy Function If Time Based ZT If Constant Energy EN READY READY READY READY READY READY READY TIMER NR 1 5 TIMER 1 0 00 sec TIMER 1 0 25 sec LIM 14985 0 Ws LIM 00000 0 Ws LIM 115 0 Ws T1 ZT NB IS 1 48 M FT ZT NB IS 1 48 M T1 ZT NB ...

Page 27: ...RITY Secure keypad to prevent unauthorized adjustment of parameters Release keypad security PRINT Continuous sequential display or printout of dynamic operating conditions on optional CRT or printer Printout of weld curve by optional printer READY READY READY TRIGGER F 1 READY T1 ZT NB IS 1 48 M TRIGGER F 25 REF 100 0 Ws REF 00000 0 Ws READY READY FT ZT NB IS 1 48 M F TRIGGER CE ENTER 2 5 0 1 7 5 ...

Page 28: ... Afterpulse Timer T4 READY READY REF 00000 0 WS REF 1000 WS READY READY READY T1 EN NB IS 1 48 M FT ZT NB IS 1 48 M READY READY SONICS AND MATERIALS NO PRINTER US TEST 5 FT EN NB IS 1 48 M FT EN NB IS 1 48 M TIMER 3 0 25 sec TIMER NR 1 5 TRIGGER F 00 3 TEST TIMER 1 CE ENTER 0 0 CE 2 1 5 0 ENTER INFO INFO INFO INFO 2 INFO INFO INFO INFO FT EN NB IS 1 48 M FT EN NB IS 1 48 M TRIGGER F 25 F TRIGGER T...

Page 29: ...Limit ex 0 90 sec Enter set value LOWER LIMIT Select Lower Limit function Set Lower Limit ex 0 60 sec Enter set value OFF Turn off power supply and Microsonic Processor READY READY 0 CE ENTER 9 LIM 0 00 sec LIM 0 90 sec READY LIM 0 90 sec READY LIM 0 00 sec LIM 0 60 sec 0 CE ENTER 6 LIM 0 00 sec READY LIM 0 60 sec LIM 0 00 sec LIM LIM Or any other display when power supply is ON OFF ...

Page 30: ...lier the number of rejects can be displayed by pressing the INFO key twice when the system status READY is displayed or by using the procedure described directly above to Clear the Weld Counter To clear the displayed value of rejects when required press the CE key twice The LCD screen display will change to DELETE CE Press the CE key once to cancel the number of rejects display and return to the s...

Page 31: ...se the numerical keys to enter in the number 1 through 9 of the job to be recalled Once the number is keyed in press the ENTER key The LCD screen will display The system will not respond if there is no job saved under a number corresponding to the numerical key pressed Other The OTHER option in the SAVE RECALL OTHER display allows the storage of Pressure Booster Gain and Horn Number parameters To ...

Page 32: ...d one step with a maximum of 9 steps in a sequence before the sequence is repeated The weld line report to the printer CRT will include the step number in the sequence The LCD screen display will indicate the step in the sequence that will be performed in the next weld operation To use the job sequence feature press the INFO key 7 times from the READY 1 mode The LCD display will show the following...

Page 33: ...d begins its descent to the part The system adds the energy necessary to vibrate the horn in air to the total energy programmed to weld a part The cal pulse is utilized only in the Constant Energy mode although it is activated during all modes of operation Occasionally it is necessary to turn the cal pulse off For example in order to place a part into the horn prior to welding i e vacuum horns the...

Page 34: ...anner all parameter values can still be displayed but the CE key is not functional the red LED will not light up and parameters cannot be cancelled or changed Any attempt to change or enter parameters with the CE key will result in the following message being displayed on the LCD screen To return to normal operation and unlock the keypad repeat the lock procedure press the numerical keys 0 and 7 w...

Page 35: ...T OF THE WELD ENERGY CURVE A graphic display of the actual weld curve can also be printed out if a printer with a serial port interface and a buffer of 2K bytes such as an Epson Model LX 810 or comparable unit is used The printout of the weld curve plots the actual pattern of instantaneous loading as a function of time The vertical line at the beginning of the printout indicates the idle losses of...

Page 36: ...ZT NB IS 1 48 M Delay Timer Timer 1 0 25 sec Weld Timer Timer 2 0 15 sec LIM 105 0 Ws Upper tolerance limit energy Hold Timer Timer 3 0 25 sec LIM 90 0 Ws Lower tolerance limit energy Afterpulse Timer Timer 4 0 00 sec CAL PULSE ON Timer 5 0 00 sec BOOSTER GAIN 1 50 HORN NUMBER 123 Pressure 30 00 Psig 0 15 sec Predetermined Weld Cycle Assembly Number 98 90 8 Ws Actual energy delivered Percentage of...

Page 37: ...er F 2 Energy Set Value REF 91 0 Ws LIM 0 20 sec Upper Limit Time Hold Timer Timer 3 0 25 sec LIM 0 10 sec Lower Limit Time Afterpulse Timer Timer 4 0 00 sec CAL PULSE ON Timer 5 0 25 sec BOOSTER GAIN 1 50 HORN NUMBER 123 Pressure 30 00 Psig 0 17 sec Actual Weld Cycle Duration Assembly Number 100 91 2 Ws Actual energy delivered Percentage of available 65 P max power used P 100 50 0 0 0 05 0 10 0 1...

Page 38: ...en The red LED in the corner or the CE key indicates that it is functional and therefore the displayed value can be cancelled and changed Press the CE key and then key in the appropriate numerical code see below for the Time Axis Plot Length desired Acknowledge the entry by pressing the ENTER key or wait 30 seconds for automatic acceptance GRAPH HEADER In addition to cycle parameters the printout ...

Page 39: ... will read as follows 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 38 I N S T R U C T I O N M A N U A L M O D E L F M P O W E R S U P P LY 25 76 o 176 6 ws 0 40 sec Reject T5 ...

Page 40: ... T2 T3 T4 T1 T2 T3 T4 US FT T2 T3 FT EN T3 and other variations The power supply can be returned to the system status READY display during the process cycle by repeating the procedure used above to select the operation sequence display press the numerical key 4 when the Mode Codes are displayed SYSTEM STATUS TESTS AND MISCELLANEOUS FUNCTIONS In addition to the basic modes and functions described i...

Page 41: ...table acknowledgement 1 M OFF m ON 14 Rotary table acknowledgement 2 N OFF n ON 15 Press upper limit switch O OPEN o CLOSED 16 Horn contact acknowledgement P OFF p ON To terminate the test and clear the display press the ON OFF key PRINTER TEST only with Optional Peripherals To access the Printer Test feature first ensure that the optional printer is ON Then press the TEST and PRINT keys simultane...

Page 42: ... and the period of measurement does not exceed 30 seconds If a 30 second duration is exceeded release the head advance control and repeat the procedure above CLEAR PARAMETERS To cancel all variable parameters and release keypad security press the INFO and F TRIGGER keys simultaneously when SONICS MATERIALS appears on the LCD screen at start up The power supply will return to normal Force Trigger O...

Page 43: ...ot Length Advance Head For Set Up Force Measurement READY READY GRAPH TIME AXIS 02 READY PRINTER TEST SONICS AND MATERIALS ABCDEFGhIJKLMNoP OFF ADJUST TRIGGER TEST 15 TEST ENTER 5 CE INFO INFO INFO INFO INFO WELD CYCLES 100 DELETE CE F TRIGGER REJECTS 5 READY READY AUTO SONICS AND MATERIALS INFO PRT SONICS AND MATERIALS SONICS AND MATERIALS V2 6 845 19 1500W TEST REF Typical Display CE WELD CYCLES...

Page 44: ...ed or not If a repeated overload condition exists resolve the problem before a failure of the power supply occurs If an overload condition exists try the following decrease horn force decrease amplitude change booster or decrease output control decrease downspeed check for loose or broken studs check the coupling surfaces between horn booster and booster converter check for cracked horn or booster...

Page 45: ... 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 Include date of purchase model number and serial number For units not covered by the warranty a purchase order should be forwarded to avoid unnecessary delay Care should be exercised to provide adequate packing to insure ...

Page 46: ...e liable to the purchaser or to any other person for any incidental or consequential damages or loss of profit or product resulting from any malfunction or failure of this Sonics product This warranty does not apply to equipment which has been subject to unauthorized repair misuse abuse negligence or accident Equipment which in our judgment shows evidence of having been used in violation of operat...

Page 47: ... table Rotary table mode to DIP 4 OFF DIP 4 Rotary table mode with pulse control Rotary table mode with continuous OFF control and ackn DIP 5 Timer 4 adds to hold time Timer 4 as shake off pulse OFF during press return DIP 6 N A N A OFF DIP 7 Printer output 1 200 Baud Printer output 4 800 Baud ON DIP 8 Alternate start method Two hand start only ON APPENDIX DIP SWITCH DEFAULT SETTINGS Refer to p 18...

Page 48: ...on E 2480 Printer Cable E 2483 Rotary Table Cable E 2703 Impulse Actuation Cable E 2902 Good Part Bad Part and Abort Cable Special E 2952 FM Wiring Diagram E 3013 F Series General I O E 3014 F Series General I O APPENDIX EQUIPMENT WIRING DIAGRAMS AND ASSOCIATED I O Pin 3 has 24 vdc for the reject output and pin 2 has a switched return on standard machines Good part Bad part and Abort is a special ...

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Page 55: ...Office 53 Church Hill Road Newtown CT 06470 USA 22 ch du Vernay CH 1196 Gland Switzerland 203 270 4600 800 745 1105 203 270 4610 fax 41 0 22 364 1520 41 0 22 364 2161 fax www sonicsandmaterials com info sonicsandmaterials com europe sonicsandmaterials ch ...