K-Sonik KWD Series Original Instructions Manual

Ultrasonic plastic welder

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ULTRASONIC PLASTIC WELDER

KWD

KWD S S S S eries

KWD

Original Instructions

Model： KWD-0930 / KWD-0935

Please read this manual carefully before use for an appropriate way

of using this product

After reading, please keep this manual properly

www.ksonic.com.my

eries

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Troubleshooting

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Summary of Contents for K-Sonik KWD Series

Page 1 ULTRASONIC PLASTIC WELDER ULTRASONIC PLASTIC WELDER ULTRASONIC PLASTIC WELDER ULTRASONIC PLASTIC WELDER KWD S S S S eries eries eries eries Original Instructions Original Instructions Original Instructions Original Instructions Model： KWD-0930 / KWD-0935 Please read this manual carefully before use for an appropriate way of using this product After reading, please keep this manual properly www.ksonic.com.my...
Page 2: Table Of Contents
Table of Contents Chapter 1 Introduction ................ 2 Chapter 2 Specifications ..............3 Chapter 3 Description of Warning Symbols ........... 4 Chapter 4 Safety Precautions ............... 5 Chapter 5 Description of Delivery and Installation ......... 6 Chapter 6 System Function and Specification 6.1 Out-look Dimensions ..............
Page 3: Chapter 1 Introduction
Chapter 1 Introduction 1.1 Operating Principle: The ultrasonic welding process of thermoplastics is accomplished by rapidly generated heat through high-frequency friction at the joint between the object. When the heat is sufficiently high so as to melt the object, the ultrasonic vibrations stop and the joint between the object is welded together after the consolidation from melting.
Page 4: Chapter 2 Specifications
Chapter 2 Specifications Model KWD0930 KWD0935 Power 900 W Rating Ultrasonic 30KHz 35KHz Frequency AC230V 10A Power supply 50/60Hz single phase 1. Frequency automatic checking with low-voltage on power 2. Full-bridge IGBT power control Control 3. Auto resonance frequency control ( PLL oscillation system ) 4.
Page 5: Chapter 3 Description Of Warning Symbols
Chapter 3 Description of Warning Symbols Symbol Description Warning Hazardous voltages cause severe injury or death. Disconnect all source of power before servicing. Caution（（（（ Lighting and Noise）））） 1. The machine should be operated under sufficient lighting. 2.
Page 6: Chapter 4 Safety Precautions
Chapter 4 Safety Precautions 4.1 Please operate the machine according to the Operation Manual. Improper operation, installation or adjustment may cause malfunction or affect the normal function of the machine. If you experience any problems in the operation, please contact the sales department of the company or a local representative. Please follow the instructions on the warning signs to avoid damage.
Page 7: Chapter 5 Description Of Delivery And Installation
Chapter 5 Description of Delivery and Installation 5.1 Condition for mechanical operation Ambient temperature： 5~40℃. Ambient humidity：20% ~ 85%RH. Operation altitude：under 2000m Maintain ventilation and airflow. Avoid operating around heavy contaminants or dusts. Avoid exposure to direct sunlight. Condition for storage and transportation Ambient temperature：...
Page 8: Chapter 6 System Function And Specification
Chapter 6 System Function and Specification 6.1 Out-look Dimensions A. Welding M/C 壓力錶壓力調整下降速度調整觸發壓力 B. Generator LOADING FREQ. COUNTER US-ON US-ON US-ON US-ON DELAY WELD HOLD AMPLITUDE POWER...
Page 9 壓力錶壓力調整下降速度調整觸發壓力...
Page 10 Item Parts Name Function Description Display the pressure exerted on the work-piece by the horn. Pressure Meter 6.3 Table 1. shows the relationship between the pressure displayed on the gauge and the actual pressure. Adjust the air-source pressure entering the air cylinder.
Page 11 Ultrasonic energy is delivered to the work-piece via the horn. Titanium or titanium-aluminum alloy with good acoustic property and tensile strength is often used as material. The acoustic property of the aluminum alloy is similar to the titanium alloy, but its tensile strength is only half as high as the titanium alloy.
Page 12 Receive instruction from Control PCBA to drive Solenoid Valve cylinder. Control PCBA Trigger signal control To drive the oscillation chamber up and down, the Cylinder Transducer set inside the oscillation chamber. Guide Rod Guide the oscillation chamber up and down Converts electrical energy into mechanical energy Transducer Set in order to oscillate horn...
Page 13 Caution: Do not apply excessive force when tightening the screw to avoid slipping of the screw thread. 【【【【 Option】】】】 Horizontal Adjustment Plate Fixing and adjusting the horizontal of nest. When the M/C doesn’t have working piece on the nest and/or base, it can be prevented to damage Blocking Screw caused by the horn and the nest and/or base...
Page 14 B. Generator LOADING FREQ. COUNTER OVERLOAD OVERLOAD OVERLOAD OVERLOAD US-ON US-ON US-ON US-ON DELAY WELD HOLD AMPLITUDE POWER COUNTER...
Page 15 Item Parts Name Function Description It means the resonance condition while the M/C works without loading working piece (Pointer shall be as low as possible, depending on the size and Loading Meter geometry of the horn, usually between scale 5 to 20) While the M/C is being loading working, it display the real working output.
Page 16 buttons simultaneously with both hands, the delay, welding, and holding timing operations will be carried out automatically. Caution: Do not push one button with a toothpick or sharp-edged object for convenience. c. Sonic Check: Check if the ultrasonic system is vibrated appropriately and used as the resonance.
Page 17 Select appropriate output amplitude percentage for the horn to meet the requirements of the Amplitude Adjuster work-piece. Upon turning on this switch, the machine will be Power Switch energized, indicators light up, and fans run. The carrying handle of the generator - When moving the generator, it can flip up the carrying handle, Handle of Generator after finished please press down to fix in the...
Page 18: Pneumatic Circuit Diagram
6.3 Pneumatic Circuit Diagram Cylinder Pressure Sensor +24 V Solenoid Valve Pressure Gauge Muffler Speed Air Filter Adjusting Controller Muffler Air Source Pressure Regulator TABLE 1 Loading KWD0928, KWD0930 Unit = Kg KWD0935, KWD0940 32 mm CYLINDER 48.0 44.3 40.6 36.9 33.0 29.4...
Page 19: Wiring Diagram
SOLENOID VALVE 橙綠綠橙白白紅黃黃黑藍藍紅白黑 TERMINAL BLOCK_5P 藍黃綠 CONTROL CONNECTER 灰灰灰 CONTROL PCBA 黑 Control Connector 藍黑 (TRIGGER CONTROL) 白棕 START1 紅 STOP 白...
Page 20 7: GND 7: NC 8: DC5V 8: AC20V+ 8: NC 9: DELAY 9: AC20V- 9: NC 10: START2 10: NC 10: NC BRIDGE 1: TRANSDUCER-(GND) 1: AC220V 2: TRANSDUCER+ 2: AC220V KWD09XX KWD2220 Module Power Transformer KWD2615 KWD Series Full-Bridge...
Page 21 CONNECTOR #1 PIN SIGNALS DESCRIPTION Solenoid Valve DC24V+ STOP Emergency Stop Button - OFF DC24V Solenoid Valve DC24V- Common for Push Button and Emergency Stop Button DC24V DC5V Fan DC24V+ Trigger Signal DELAY Fan DC24V- Trigger Signal START1 Push Button 1- ON START2 Push Button 2 - ON SOL+...
Page 22: Chapter 7 Description Of Operation
Chapter 7 Description of Operation 7.1 Cautions for Operation For safety operation, please note the following points: A. During operation, do not lift the cover of the generator or the main body to avoid high-voltage injury. B. Carry out adequate grounding to avoid electrostatic charge. C.
Page 23: Installation And Operation
7.2 Installation and Operation A. Connect the control cable to the control socket on the rear panel of the generator and screw it tightly. B. Connect the output cable to the output socket on the rear panel of the generator and screw it tightly. C.
Page 24: Sonic Check
7.3 Sonic Check: To make sure the ultrasonic system whether is in normal working, it is important to do correctly sonic checking. A. Before turning on the M/C, the horn and booster shall be tightened. The horn shall not touch the work-piece while turning on the M/C. B.
Page 25: Horn Adjustment Procedures
7.4 Horn Adjustment Procedures: To acquire the largest working capacity, the distance between the horn and the work-piece shall be as shorter as possible, but a sufficient space is required for the placement and removal of the work-piece. So the maximum stroke of the cylinder is 50 mm, please make sure the work-piece will not touch the horn before horn adjustment.
Page 26 Caution: 1. Above the horn’s adjustment procedure is only for rough adjustment. When need the precise horn adjustment , the observation and adjustment should be made carefully during the trial period. Or place carbon paper and white paper between the horn and work-piece. Generate sonic so that an indentation appears on the white paper.
Page 27: Factors Affecting Welding Results
7.5 Factors Affecting Welding Results The ultrasonic plastic processing is affected by the following factors: A. Design of the contact or joint face B. Design of the energy conducting point C. Plastic material D. Shape and size of the work-piece E.
Page 28: Ultrasonic Welding Steps
7.6 Ultrasonic Welding Steps 1. Align the horn, work-piece, and nest contact surface 2. Set the rise and down speed of the stroke Manu Mode 3. Set the welding pressure 4. Set the welding depth（adjust the blocking screw） 5. Adjust the trigger pressure 1.
Page 29: Chapter 8 Trouble Shooting
Chapter 8 Trouble Shooting 8.1 Simple trouble shooting for machine Please follow the list as below for check up. In case of a failure that is impossible to avoid, please contact your local authorized representative service center for inspection and maintenance. Symptom Causes of Failure Solution...
Page 30 Check if 10 pin control Properly insert the terminal of 10 cable disconnected pin control cable into 10P control socket When Sonic Check, Check if right side fuse, on Replace fuse HORN does not the rear of generator, oscillate broken Check if 2 pin high-voltage Properly insert the terminal of 2 output cable disconnected...
Page 31: Trouble Shooting For Welding Results
8.2 Trouble shooting for welding results A. Welding Problems Causes Solutions Too much input to the Decrease the pressure work-piece Reduce the Welding time Reduce the percentage of amplitude Over welding Reduce the down rate of the horn Use another booster with lower power Too little input to the Increase the pressure...
Page 32 Problems Causes Solutions The interior angle is too Blunt the sharp angle sharp The vibration amplitude is too Reduce vibration amplitude high The area outside the The welding time is too long Increase vibration amplitude joint face of the Increase the pressure work-piece is molten Adjust the buffer and delay time or broken...
Page 33 Problems Causes Solutions The joint face does not touch Check the work-piece size tightly Check the tolerance of the work-piece Check the thimble position of the joint face Check if the work-piece is aligned Uneven welding Check if the work-piece is flat The horn does not touch Check the bonding of the work-piece tightly...
Page 34 Problems Causes Solutions Mold release agent Clean the joint face with Freon TF If the mold release agent is required, use printable or paintable mold release agent The Tolerance of the Reduce the tolerance of the work-piece is too high work-piece Check the work-piece size Review the operation conditions...
Page 35 Problems Causes Solutions Temperature rise at the Check if the screws of the horn are welding head loose Check if the welding tools are loose Decrease the welding time Cool the horn Check the contact surface between the horn and booster Check if the horn is broken If the horn is made of steel, replace it with one made of aluminum alloy...
Page 36 Problems Causes Solutions The welding time is too long Increase the pressure or amplitude to reduce the welding time The gate position Review and change the gate of the work-piece Change the shape of the gate Review the operation conditions Improve the rib design of the work-piece The center of the...
Page 37 B. Riveting Problems Causes Solutions The rivet bore is too big or the Reduce the size of the rivet bore or The riveting point is rivet is too small increase the height of the rivet uneven and dented Residual flash appears The rivet bore is too small or Increase the size of the rivet bore or around the riveting...
Page 38 C. Embedding Problems Causes Solutions The time of the ultrasonic Reduce the delay time energy transmission is too Decrease the pressure late or the ultrasonic energy Reduce the buffer rate do not transmit Plastic parts crack Too many obstructions and Reduce the hole amount after embedding the number of hole too many...
Page 39 Problems Causes Solutions The power of the ultrasonic Use a type with higher power equipment is insufficient It takes relative long The embedded object is too Shorten the embedded object time to embed in long normal position The bore is too narrow Widen the bore diameter The down rate is too slow Increase the drop rate...
Page 40 Problems Causes Solutions The amplitude is too high Reduce the amplitude The temperature rises due to Use air-cooled equipment The welding head friction between metal pieces. If possible, use a processing method so temperature rises It is normal that the horn touches the plastic rather than the metal The threads are damaged Re-design the threads around the...
Page 41: Chapter 9 Maintenance
Chapter 9 Maintenance It is recommended to perform maintenance at least once a week. While performing maintenance and cleaning the works, please turn off the power. 1. Please wipe the machine clean when finished. 2. Purge accumulated water in the filter. 3.
Page 43 Ksonic sdn bhd. No.268,jalan 5,tmn perindustrian ehsan,kepong,kuala lumpur 52100 Malaysia . Tel : +603 62757568 Fax : +603 62747268 Website : http://www.ksonic.com.my...

This manual is also suitable for:

Kwd-0930Kwd-0935