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Sonics GXL Instruction Manual

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Model GXL

Power Supply

I N S T R U C T I O N
M A N U A L
Sonics & Materials, nc.

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  • Page 1: Power Supply

    Model GXL Power Supply I N S T R U C T I O N M A N U A L Sonics & Materials, nc.
  • 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. Rev 01, 9/10 © Sonics & Materials, Inc. 2010 Printed in U.S...

  • Page 3: 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 4 GXL Switches ........

  • 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

    I N T R O D U C T I O N The GXL power supply is an ultrasonic generator with automatic frequency tuning and a built-in Microprocessor that features time, energy and distance controls. The Microprocessor is programmed with a multi-function keypad and information is displayed on the back-lit liquid crystal display (LCD).
  • Page 8 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, Converter Booster, Horn assembly Transforms ultrasonic electrical energy to ultrasonic mechanical vibrations Ultrasonic Vibrations...

  • 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 energy to 15,000 Hz, 20,000 Hz or 40,000 Hz (15/20/40 kHz) electrical energy.

  • Page 10: Installation

    I N S T A L L A T I O N 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 POWER SPECIFICATIONS controller/power...

  • Page 11: Electrical Connections

    ELECTRICAL CONNECTIONS The standard cable supplied with a Sonics press is 10 feet. Optional extension cables are available up to 15 feet without modification. When making the initial electrical connections, make sure the power is disconnected and follow these precautions.

  • Page 12: Cable Connections - For Models With 700 To 2200 Watts Power

    CABLE CONNECTIONS – For Models with 700 to 2200 Watts Power: 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 ‚ J1, a round, 12-pin RF cable that connects the welding press or diagrams are supplied converter to the power supply.

  • Page 13: Cable Connections - For Models With 3000 To 4000 Watts Power

    CABLE CONNECTIONS – For Models with 3000 or 4000 Watts Power: 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 ‚ J1, a round, 12-pin RF cable that connects the welding press or diagrams are supplied in converter to the power supply.

  • Page 14: Available Converters

    AVAILABLE CONVERTERS Item No. Description CV00016 15 kHz with Button connector (O-ring mount) CV00161 15 kHz with Lemo connector (O-ring mount) CV00034 15 kHz with Button connector (O-ring mount) rated up to 4500 watts CV00341 15 kHz with Lemo connector (O-ring mount) rated up to 4500 watts CV00015 20 kHz with Button connector (O-ring mount)

  • Page 15: 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 on the front panel of the power supply are the following controls and indicators: 1. ON/OFF keys which turn the unit on and off. 2.
  • Page 16 5. DISTANCE key which allows selection and display of distance settings and permits adjustment of the following distance parameters in .001 inch increments (from 0.000 to 9.999 inches, or 0.000 to 253.975 millimeters): a. Distance Incremental b. Distance Absolute c. Distance Limit Low d.

  • Page 17: Keying In Parameters

    9. RECALL/SAVE key which allows up to 15 different jobs to be stored (saved) and recalled or changed upon demand. 10. ARROW keys (Up/Down) which allow scrolling through some menus and also serve as a toggle for displayed parameter options in some menus. 11.

  • Page 18: Operational Features

    OPERATIONAL FEATURES – Adjustable Afterburst Timer to separate parts from horn. – Adjustable tolerance limits in energy (Ws), time (sec) and/or distance (inches or millimeters) with visual alarms. – Information displays including: number of assemblies, number of rejects, and number of cycles. –...

  • Page 19: Initial Operation

    INITIAL OPERATION After the power supply is turned on (as described on previous page), 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.

  • Page 20: Relationship Of Time, Distance And Energy Settings

    The Alarm screen displays information about the alarm(s) that have been triggered by the system encountering parameters outside of the specified tolerance limits. The screen will indicate whether alarms occurred in Time, Distance or Energy. If there are no alarms, dashes will display. If 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, distance or energy).

  • Page 21: Time Settings

    will display “02.00 sec,” with the “sec” flashing, along with whatever energy was delivered. The peak power delivered (%Pmax) will be displayed as a percent of the supply rating. The ability to specify Time, Energy and Distance affords maximum control of the weld process.

  • Page 22: Distance Settings

    DISTANCE SETTINGS There are 7 distance parameters that can be specified. To better understand the distance parameters and corresponding terms used, please see the diagram below and note the following definitions. HEAD UP/ INITIAL TRAVEL CONTACT WELD ΠHome Position: when the converter head assembly is in the full up position, not in contact with the parts to be welded.
  • Page 23 if too many parts have been installed. If the pre-weld window is violated, the system will abort the cycle.  Post-Weld Window: If the parts are found within the pre-weld window, the weld portion of the cycle will begin. Note the “squiggle” line representing that the parts are now welded together.

  • Page 24: Energy Settings

    cycle and examined against a post-weld window (as explained in item 5 above), the lower limit of which is defined by this value. If the final travel distance is less than this entry, a distance low alarm will be indicated on the Alarm Screen display and by a flashing LED on the distance key.

  • Page 25: Amplitude/Pressure

    Press the Energy key again (and successively after each menu display) to advance to these next screen displays. Energy Limit Low – sets the low energy alarm examination point (as a process control tolerance limit). An energy alarm will be triggered if the actual weld energy is less than this value.

  • Page 26: Trigger

    TRIGGER Selection of the trigger mode is achieved by pressing the Trigger Key and then using the Up/Down arrow keys as a toggle to select one of the following modes to act as the trigger to start ultrasonics. Delay Timer – selecting this mode means that the ultrasonics will be triggered when the Delay Time specified in the Time menu is reached.

  • Page 27: Additional Features And Functions

    A D D I T I O N A L F E A T U R E S A N D F U N C T I O N S JOB STORAGE Up to 15 different jobs may be stored and recalled or changed upon demand. Typical job parameters stored include Time, Energy, Force Trigger Setting, Time and Energy Limits, Amplitude, and Cal Pulse ON/OFF.

  • Page 28: Frequency Display

    — check to see if the load meter exceeds 100% during weld process (if so, a higher powered unit is needed) If you cannot remedy the situation, contact Sonics’ Service Department at 1-800-745-1105. I N S T R U C T I O N M A N U A L • M O D E L G X L P O W E R S U P P LY...

  • Page 29: Keypad Security

    K E Y P A D S E C U R I T Y 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.

  • Page 30: Print Line Output

    P R I N T L I N E O U T P U T At the end of every weld cycle, the power supply sends an ASCII print line which includes the data for weld time, distance, energy, maximum power and alarm status.
  • Page 31 Position 2 = Actual weld time Position 3 = Distance data (applicable for Model GXL only) Position 4 = Energy data (applicable for Models GXL or GXE only) Position 5 = Maximum percent power number Position 6 = Any alarm violations for time (T), distance (D) or energy (E)

  • Page 32: Automation Interface & I/O Controls

    A U T O M A T I O N I N T E R F A C E & I / O C O N T R O L S As listed below, there are several interface signals available for operating the power supply via external digital control lines.
  • Page 33 signal to qualify these outputs, if ready is true, then the Good Part / Bad Part outputs are valid. 4. DO4 – There is one extra digital output that is reserved for future application. 5. DI1, DI2, DI3 and DI4 – Four digital input signals are used for setting an external job selection when the keyboard is “Locked.”...

  • Page 34: External Job Address Lines

    EXTERNAL JOB ADDRESS LINES 0= OFF or open line 1= ON or contact closed JOB# No job change Note that job Code 0 (0, 0, 0, 0) is not a valid job code and does not cause a job recall operation. Ex: If the last job recalled was Job 10 and the inputs are set to code 0, then Job 10 still dictates the active job settings.

  • Page 35: Maintenance

    M A I N T E N A N C E 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 1-800-745- 1105.

  • Page 36: Warranty

    Monday through Friday (excluding holidays) from 8:00 am to 5:00 pm. Any in-warranty service time requested outside of these days and hours will be billed at 150% of Sonics current rate per hour for such site service work.
  • Page 37 Under no circumstances shall Sonics be 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.

  • Page 38: Appendix

    A P P E N D I X PRINT LINE OUTPUT DATA ITEMS Item 1: Using the first line of the sample listing above, item 1 is the “Customer Resettable Counter” (CRC). It is located at position 1 through position 6 so the value of 005647 indicates that the last cycle was weld number 5647 since the last time it was reset to 0 (see page 19).
  • Page 39 Item 5: The maximum percent power number is next in line at positions 36 through 38 with a space at 39. This number is the maximum percent of power developed during the last weld cycle. The label “%Pmax” does not change case as the control items can for time, distance and energy.
  • Page 40 CkLim will only apply when the distance control is ON (system was purchased with the distance encoder option – Model GXL). Speed Consideration: If ultimate speed is more important to an application or the system is not using the print line output, it may be turned off with a switch on the internal processor board behind the front panel.

  • Page 41: Automation Interface & I/O Controls

    AUTOMATION INTERFACE & I/O CONTROLS SOURCE/SINK INPUTS AND OUTPUTS Vendor terminology and specifications can be confusing as the reference is easily misinterpreted. Does the vendor send a “Sourcing” signal or do they mean that an input is ready to receive (or sink) current from an external source? Some PLC vendors seem to contradict others and the applications engineer ends up with a bank of relays or pull up/down resistors to switch the signal type.

  • Page 42: Source/Sink Digital I/O Configuration

    SOURCE/SINK DIGITAL I/O CONFIGURATION The digital inputs and outputs are configured by moving two IC’s on the control circuit board located directly behind the front panel. Be sure that the power is OFF and then remove the top cover. The components may be moved using a small screwdriver to pry the IC’s from the socket strips.

  • Page 43: Sinking Output To Plc Input Diagram

    SINKING OUTPUT TO PLC INPUT DIAGRAM When the optical IC is placed into socket U43, the G series outputs are configured as “Sinking.” The isolated transistor emitters must be connected to the return line of the loop supply (all 4 emitters are connected together; signal name Voltage Sink Return (output);...

  • Page 44: Two Isolated Loop Supplies

    TWO ISOLATED LOOP SUPPLIES Two isolated non-regulated 24 VDC supplies (50 ma max) are available on the digital I/O connector and may be used for the I/O loop power. These are low level supplies and cannot be used to power relay inputs or outputs! They should be used for LED indicators or transistor type input cards if the PLC does not provide low level DC power for this purpose.

  • Page 45: Plc Sample Code

    PLC SAMPLE CODE The following ladder file is a simple demonstration routine to roll the external job selection from job 1 through 15 then restart at job 1 again. This routine will switch jobs as fast as possible because the next job code is generated and set during the previous weld cycle.

  • Page 46: Drawings

    When the ultrasonic supply is READY a timer is started to generate the 50 ms impulse command in rung 0. When the timer is finished it will be reset by rung 0001 so it will be ready to go as soon as the cycle is completed and ready returns true.
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  • Page 55: Gxl Switches

    GXL SWITCHES SWITCH POS. OFF POS. ON DEFAULT SW2-1 Program Flash (Production only) Enable-WD (Always on) SW2-2 Cylinder Pot (Future option) Optical Encoder SW2-3 Auto Start Wait for ‘ENTER’ SW2-4 English Metric SW2-5 Print Line-OFF Print Line-ON SW2-6 Reserved For Future Expansion...

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