Related Manuals for Sonics H520
Summary of Contents for Sonics H520
- Page 1 Models H520and H540 Hand Held Welders I N S T R U C T I O N M A N U A L Sonics & Materials, Inc.
- Page 2 (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax www.sonics.com • info@sonics.com europe@sonicsandmaterials.ch Information contained in this manual is subject to change without notice. Sonics & Materials, Inc. is not responsible for any typographic errors. © Sonics & Materials, Inc. 2007 Printed in U.S.A.
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Page 4: Table Of Contents
T A B L E O F C O N T E N T S IMPORTANT SERVICE LITERATURE ......4 Manual Change Information . -
Page 5: Important Service Literature
I M P O R T A N T S E R V I C E L I T E R A T U R E 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. -
Page 6: Unpacking And Inspection
If the system or any unit is damaged, notify “Sonics.” “Sonics” will arrange for repair or replacement of damaged equipment without waiting for the claim against the carrier to be settled, provided a new purchase order is issued to cover the repair or replacement costs. -
Page 7: Introduction
Applications section of this manual beginning on page 22 for more information on these operations). The model H520 is a 20 kHz power supply that comes with the CV52 hand gun. The CV52 hand gun is supplied with an integral 1/2" (12.7mm) diameter titanium front driver with a replaceable flat face tip. - Page 8 “SONICS” ULTRASONIC ASSEMBLY SYSTEMS 50/60 Hz Electrical power Power Supply/Generator Generates ultrasonic electrical energy (20/40 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 I N S T R U C T I O N M A N U A L •...
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Page 9: Glossary Of Ultrasonic Terms
G L O S S A R Y O F U L T R A S O N I C T E R M S POWER SUPPLY/GENERATOR – The solid state power supply converts standard 50/60 Hz electrical power to 20,000 Hz or 40,000 Hz (20/40 kHz) electrical energy. -
Page 10: Installation And Set Up
I N S T A L L A T I O N A N D S E T U P 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. -
Page 11: Cable Connections
Once these connections have been made, the power supply is ready for operation. ƒ … Always turn off the power supply before installing or removing SONICS & MATERIALS, INC. the foot switch cable. 50 CHURCH HILL RD. NEWTOWN, CT USA OUTPUT FOOTSWITCH ‚ †... -
Page 12: Key Components
KEY COMPONENTS Pictured below is the power supply with 2 hand gun options, 20 kHz (CV52) and 40 kHz (CV54). POWER SUPPLY HAND GUN CV52 TRIGGER SWITCH HAND GUN HORN CV54 I N S T R U C T I O N M A N U A L • M O D E L H 5 2 0 / H 5 4 0 Go To Top Of Document... -
Page 13: Tip Assembly (Cv52)
TIP ASSEMBLY (CV52) If the tip is not already assembled, follow the instructions below as applicable. TIP REPLACEMENT (CV52) 1. Clean the mating surfaces, as well as the threaded stud and hole. Check Never remove or install that the stud is tight (see recommended torque requirements on page 13). a tip by holding the 2. -
Page 14: Tip Replacement (Cv54)
TIP REPLACEMENT (CV54) 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. -
Page 15: Tip Specifications
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 SPOT WELDING KNURLED FLAT Refer to the various tables under staking, spot welding and insertion... -
Page 16: Options
OPTIONS The following options and accessories are available for the H520 and H540 systems. 1. FOOT SWITCH for remote activation. (When foot switch actuation is used, the trigger handle is removed from the hand gun housing.) Always turn off the 2. - Page 17 3. ST PLER with special pivoting mechanism. Ideal for sealing low production rate clamshell packages. STAPLER 4. PISTOL GRIP for more ergonomic handling of the hand gun in specialized applications. PISTOL GRIP I N S T R U C T I O N M A N U A L • M O D E L H 5 2 0 / H 5 4 0 Go To Top Of Document...
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Page 18: Operating Procedures
O P E R A T I N G P R O C E D U R E S 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. - Page 19 7. TEST key which can be used to test the actual power output (watts). When this key is pressed, the ultrasonics are activated and will remain on (cycle) for 5 seconds. The red LED in the upper left corner lights up accordingly during the cycle.
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Page 20: Initial Operation
1. When all cable connections have been made, and the hand gun is connected to the power supply, turn the ON/OFF switch to the ON position. The LCD screen will briefly display the model number (in these examples, the H520), wattage and frequency as follows: SONICS & MATERIALS MODEL H520 500W... - Page 21 5. Press the TEST key. The ultrasonics will be activated and the red LED will light up during the weld cycle. The actual wattage will be digitally displayed on the LCD screen and the bar graph line will indicate the corresponding power output percentage.
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Page 22: Overload Protection
OVERLOAD PROTECTION 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. -
Page 23: Applications - Staking
A P P L I C A T I O N S – S T A K I N G 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. -
Page 24: Spherical Stake
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. BEFORE HIGH PROFILE AFTER... -
Page 25: Flush Stake
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. BEFORE AFTER HORN METAL PLASTIC STANDARD THREADED TIPS FOR STAKING STAKING TIP CODE LETTER Plastic Boss Solid Boss... -
Page 26: Applications - Spot Welding
A P P L I C A T I O N S – S P O T W E L D I N G 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. -
Page 27: Applications - Ultrasonic Insertion
A P P L I C A T I O N S – U L T R A S O N I C I N S E R T I O N Ultrasonic insertion involves a metal insert to be placed in a cored or drilled hole that is slightly smaller than the insert. - Page 28 STANDARD THREADED TIPS FOR INSERTION INSERTING Insert Inside Diameter Pilot Diameter Size of Insert 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 METRIC 2.5 x 0.45 0.079...
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Page 29: Maintenance
M A I N T E N A N C E 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 NOTE: If packing unit E-Mail: service@sonicsandmaterials.com for return shipment, It is suggested that a system in need of repair be sent back to the factory, with DO NOT use styrofoam a written description pertaining to the nature of the problem. -
Page 30: Warranty
Ultrasonic welding horns constructed of titanium or aluminum are guaranteed against defects for a period of one year from date of shipment. “Sonics” will repair or replace a cracked or defective horn once without charge, if failure occurs within the warranty period. - Page 31 “Sonics” reserves the right not to warrant horns of unusual or experimental design which in our judgment are more likely to fail in use. This warranty does not cover equipment used for applications requiring metal- to-metal contact with weld time in excess of 1 second.
- Page 32 A P P E N D I X DB9 I/O CONNECTIONS DIAGRAM I N S T R U C T I O N M A N U A L • M O D E L H 5 2 0 / H 5 4 0 Go To Top Of Document...
- Page 33 Go To Top Of Document Sonics & Materials, Inc. Corporate Headquarters European Office 53 Church Hill Road • Newtown, CT 06470 USA 13, Rue Pre-de-la-Fontaine • CH - 1217 Meryin/Satigny, Switzerland 203.270.4600 • 800.745.1105 • 203.270.4610 fax (41) (0) 22/364 1520 • (41) (0) 22/364 2161 fax www.sonics.com •...