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Sonics H520E Instruction Manual

Hand held welders
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Sonics & Materials, Inc.
Models
H520E / H540E
Hand Held
Welders
I N S T R U C T I O N
M A N U A L
Hong Kong Office:15B Granville House, 41C Granville Road,T.S.T., Kowloon,Hong Kong
Tel:+86(00852)61717217 & 81463719 Fax:+86(00852)81479859
Dongguan Office: 6 Hang, No 17, Heng Xin Road Heng Gang Tou, Xin An Qu Chang An,
Dongguan Guangdong, China 523882
Tel:+86(0769)8532-0321 Fex:+86(0769)8532-0145
info@qoovia-hk.com
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www.qoovia-hk.com

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  • Page 1 Sonics & Materials, Inc. Models H520E / H540E Hand Held Welders I N S T R U C T I O N M A N U A L Hong Kong Office:15B Granville House, 41C Granville Road,T.S.T., Kowloon,Hong Kong Tel:+86(00852)61717217 & 81463719 Fax:+86(00852)81479859...

  • Page 2: Table Of Contents

    Dongguan Office: 6 Hang, No 17, Heng Xin Road Heng Gang Tou, Xin An Qu Chang An, Dongguan Guangdong, China 523882 Tel:+86(0769)8532-0321 Fex:+86(0769)8532-0145 Information contained in this manual is subject to change without notice. Sonics & Materials, Inc. is not responsible for any typographic errors. © Sonics & Materials, Inc. 2009 Printed in U.S.A.
  • Page 3 OPERATING PROCEDURES ........19 Front Panel Controls and Indicators ..... . .19 Keying in Parameters .

  • Page 4: Important Service Information

    I M P O R T A N T S A F E T Y I N F O R M A T I O N 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.

  • Page 5: Symbols

    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. •...

  • Page 6: Specifications

    S P E C I F I C A T I O N S 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 3 lbs. (5.9 Kg) Dimensions 8.5"H x 13.5"W x 7.5"D 216 mm x 340 mm x 190 mm...

  • Page 7: 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 8: 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 9: Introduction

    Applications section of this manual beginning on page 26 for more information on these operations). The model H520E is a 20 kHz power supply that comes with the CV55 hand gun. The CV55 hand gun is supplied with an integral 1/2" (12.7mm) diameter titanium front driver with a replaceable flat face tip.
  • Page 10 “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 •...

  • Page 11: 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 12: 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 13: 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 the foot switch cable. SONICS & MATERIALS, INC. 50 CHURCH HILL RD. NEWTOWN, CT USA OUTPUT FOOTSWITCH ‚ † „ Do not use a damaged...

  • Page 14: Key Components

    KEY COMPONENTS Pictured below is the power supply with 2 hand gun options, 20 kHz (CV55) and 40 kHz (CVG54). POWER SUPPLY HAND GUN CV55 TRIGGER SWITCH HAND GUN HORN CVG54 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • I N S T R U C T I O N M A N U A L •...

  • Page 15: Tip Assembly (Cv55)

    TIP ASSEMBLY (CV55) If the tip is not already assembled, follow the instructions below as applicable. NOTE: Never remove TIP REPLACEMENT (CV55) or install a tip by 1. Clean the mating surfaces, as well as the threaded stud and hole. Check holding the hand gun that the stud is tight (see recommended torque requirements on page 13).

  • Page 16: Tip Replacement (Cvg54)

    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.

  • Page 17: 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 18: Options

    OPTIONS The following options and accessories are available for the H520E and H540E systems. 1. FOOT SWITCH for remote activation. (When foot switch actuation is Always turn off the used, the trigger handle is removed from the hand gun housing.)
  • Page 19 3. STAPLER 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 E / H 5 4 0 E info@qoovia-hk.com ¸...

  • Page 20: 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 21: Keying In Parameters

    For a complete explanation of these parameters, refer to page 22. 5. ENERGY key 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.

  • Page 22: Operational Features

    OPERATIONAL FEATURES – Adjustable tolerance limits in energy (Ws) 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.

  • Page 23: Ready Screens

    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.

  • Page 24: Relationship Of Time And Energy Settings

    RELATIONSHIP OF TIME AND ENERGY SETTINGS 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.

  • Page 25: Time Settings

    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.

  • Page 26: Energy Settings

    ENERGY SETTINGS 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.

  • Page 27: 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, When the hand gun is voltage or current, or a loose or failed horn/tip.

  • Page 28: Keypad Security

    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.

  • Page 29: 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 30: 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 31: 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 32: 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 33: 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 34 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...

  • Page 35: Maintenance

    M A I N T E N A N C E CLEANING INSTRUCTIONS 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. NOTE: If packing unit REPAIRS / SERVICE for return shipment,...

  • 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: Limitation Of Warranty

    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.
  • Page 38 No person or company is authorized to change, modify, or amend the terms of this warranty in any manner or fashion whatsoever. 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 39: Appendix

    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 info@qoovia-hk.com ¸...

This manual is also suitable for:

H540e

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