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RINCO ULTRASONICS AG HW35-3 Operating Manual

Ultrasonic welding device for plastics
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Operating Manual
Ultrasonic welding device for plastics
Hand welding device HW35-3
with
Generator RL35
RL35
Version 4.0
HW35-3
................. RINCO ULTRASONICS AG
Industriestrasse 4
CH-8590 Romanshorn
............................... ++41 71 466 41 00
............................... ++41 71 466 41 01
English
Switzerland
RL35HW/N
O
7768

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  • Page 1 Operating Manual English Ultrasonic welding device for plastics Hand welding device HW35-3 with Generator RL35 RL35 HW35-3 ....RINCO ULTRASONICS AG Industriestrasse 4 CH-8590 Romanshorn Switzerland ....... ++41 71 466 41 00 ....... ++41 71 466 41 01 Version 4.0...
  • Page 2 The device may only be used, maintai- ned and repaired by persons who are familiar with the operating manual and the applicable regulations concerning working safety and accident prevention. Device specification Device Generator Representative Copyright by RINCO ULTRASONICS AG, Switzerland RL35HWV40/GB/N 7768/16279...

  • Page 3: Table Of Contents

    Hand held cutting device ....................3-1 3.1.2 Ultrasonic generator RL35 ................... 3-1 3.1.3 Cooling (optional) ......................3-2 Warranty statement ........................3-3 Technical data device HW35-3 ....................3-4 3.3.1 Concept ........................3-5 3.3.2 Compressed air ......................3-5 3.3.3 Dimensions ........................3-5 3.3.4...
  • Page 4 Table of contents Cleaning and maintenance ................... 9-1 General maintenance jobs ....................... 9-1 Hand held welding device ......................9-1 Generator ..........................9-1 Vibration system ........................9-2 Threaded coupling ........................9-2 10 Error messages and trouble shooting ............... 10-1 10.1 Error messages / corrective action: switching on ..............10-1 10.2 Generator error messages during operation ................
  • Page 5 Preface Preface Congratulations on having purchased the device. This manual is designed to provide buyers and users with all the information they will need to handle, install, operate and maintain the device. To ensure that the system is always ready for opera- tion, it is necessary to follow the notes and instructions in this manual.
  • Page 6 The design and circuitry of this device are subject to continuous further development and improvement, and represent the latest state of the art. RINCO ULTRASONICS AG Romanshorn, Switzerland RL35HWV40/GB/N 7768/16279...
  • Page 7 Notes ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...
  • Page 8 Notizen ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...

  • Page 9: Explanation Of Symbols And Signs

    Explanation of symbols and signs Explanation of symbols and signs Special attention should be paid to passages with the following symbols: Special information or operating instructions. Warnings regarding risk of personal injury or damage to parts of the equipment. The item numbers used in the illustrations and descriptions, e.g.: Generator module grips (26) correspond to the item numbering adopted in the product over- view included in the chapter "Product information", or to adjacent...
  • Page 10 Explanation of symbols and signs ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...

  • Page 11: Safety Information

    Safety information Safety information General The design of this device conforms to the current state of engineering and is safe to operate. The individual modules and the completedevice are subject to continual inspection by our quality assurance department. Intended purpose This device is intended exclusively for the ultrasonic welding of suitable plastics.

  • Page 12: Installing The Device

    Safety information Installing the device Always unplug the power cable before making any connections to peripheral devices. Be sure to fit the power supply with a grounding connector! Observe any statutory safety regulations in force in your country! Failure to observe these regulations will exempt the manufacturer from all liability for injury to persons or damage to materials! Before starting up the device, always make sure it is in a closed...
  • Page 13 Safety information ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...
  • Page 14 Safety information ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...

  • Page 15: Product Information

    Product information Product information Product overview 3.1.1 Hand held cutting device Housing Trigger switch Horn Suspension Cooling-air connections Name plate on housing 3.1.2 Ultrasonic generator RL35 Generator module handle 26.1 Model designation LED bar LED, power Function key "US-TEST" Status displays US ON (green) VALVE...

  • Page 16: Cooling (Optional)

    Product information 3.1.3 Cooling (optional) It is necessary to cool the converter for heavy duty use. Connection for hose ÿ RL35HWV40/GB/N 7768/16279...

  • Page 17: Warranty Statement

    Manual must be observed. Unauthorized conversions or modifications to parts of the device and generator are prohibited. RINCO ULTRASONICS AG shall be glad to clarify any unlcear points on the phone or to provide instruction by capable specia- lists.

  • Page 18: Technical Data Device Hw35-3

    Product information Technical data device HW35-3 Dimensions in mm RL35HWV40/GB/N 7768/16279...

  • Page 19: Concept

    Product information 3.3.1 Concept - Robust handy housing - Ergonomic trigger switch - Piezoelectric converter - Connecting screw thread for horn: ........M8 3.3.2 Compressed air - Dry compressed air, maximum: ....7 bar (105 PSI) 3.3.3 Dimensions - Dimensions:..........see fig. page 3-4 3.3.4 Weight - Weight ..............

  • Page 20: Technical Data Of The Ultrasonic Generator Rl35

    Product information Technical data of the Ultrasonic Gene- rator RL35 Dimensions in mm Weight: ........ 7 kg RL35HWV40/GB/N 7768/16279...

  • Page 21: Concept

    Product information 3.4.1 Concept - Flexible modular system with various insertable modules. - Well arranged and simple input of parameters. - Optimum efficiency and low power loss. - Detection of system malfunctions. - Interface for PLC. 3.4.2 Available generator modules max.
  • Page 22 Product information ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...

  • Page 23: Transportation

    Transportation Transportation Transportation instructions on the packaging must be observed. Unpacking/receiving inspection The shipping container used for our devices withstands the normal wear and tear of road, rail and air transportation. After receiving the consignment, check whether all the parts conform to the packing list and look for any visible signs of damage.
  • Page 24 Transportation ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...

  • Page 25: Controls And Indicators

    Controls and indicators Controls and indicators Hand held welding device Trigger switch This activates the ultrasonic vibrations. Do not touch horn ! Horn Never alter a tuned horn mechani- cally. This can result in damage to the vibration system und genera- tor.

  • Page 26: Ultrasonic Generator Rl35

    Controls and indicators Ultrasonic Generator RL35 Generator module handle If necessary, you can pull out the generator module by holding these grips. The fastening screws (33) for opening the generator modu- le are located above and below the grip bars. The generator module is never to be pulled out or plugged in while mains is connected.
  • Page 27 Controls and indicators Weld time Using this keypad you can - change the weld time. increase numeral decrease numeral With the initialisation on the inter- nal program selection switch (level 9) following section 8 „Resetting“, the welding time is increased by a factor of ten (99.9 sec.) Hold time This setting does not apply to hand...
  • Page 28 Controls and indicators ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...

  • Page 29: Initial Start-Up

    Initial start-up Initial start-up Choice of location Select the location for the device according to the following criteria: - clean surroundings - a base for the electronic de- vices which is free from vibrati- - an ambient temperature during operation: . 10 °C - 45 °C when setting: ....
  • Page 30 Initial start-up 3. Tighten the horn (9) with two spanners of correct size (G/S) Do not touch horn ! 4. The device is switched on at the main switch (34). The device is ready for operation after a built- in check. RL35HWV40/GB/N 7768/16279...
  • Page 31 Initial start-up ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...
  • Page 32 Initial start-up ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...

  • Page 33: Elements

    Elements Elements Converter The converter is a sensitive instrument. Please handle with great care! The converter (K) is the core of every ultrasonic welder. It belongs to the category of piezo-electric converters. Piezoelectric converters consist of several ceramic disks that change their size when an electric voltage is applied.

  • Page 34: Horn

    Elements Horn Any changes to the metallic body of the horn will affect its vibration characteristics and should not be performed without consulting the manufacturer! The horn (3) is the tool that transfers the ultrasonic energy produced by the converter to the welding object in the form of an intensive vibration.
  • Page 35 Elements to immense mechanical loads. It is extremely important, therefore, to design the horn in such a way as to enable the plastic part to be joined under optimal conditions. The horn surface may have a coating for abrasive plastics for longer service life.
  • Page 36 Elements ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...

  • Page 37: Retooling

    Retooling Retooling Changing horn It is important to ensure that the mains switch on the generator has been switched off before unplug- ging the HF cable! 1. Separate the horn (3) with spanners (G/S). Never put the two parts in a vice or similar tool! 2.

  • Page 38: Detailed Description Of Functions From The Program Selector Switch

    Retooling Detailed description of functions from the program selector switch Ultrasonic devices are used in a wide range of fields today, so that users have a variety of different control requirements. A welding in- stallation needs to be able to be connected to the available peripheral devices.
  • Page 39 Retooling The program selection switch has 10 set- tings. For US-operations without pneumatic tool advance. The standard setting for hand held devices is '0'. Mode Adjustment external welding time internal welding time Pulse with settable welding time; max. 99.9s With setting level ”9”: Toggle switch: Ultra sound operates automati- cally according to the pre-set...

  • Page 40: Afterpulse (Shake-Off Impulse)

    Retooling 8.2.2 Afterpulse (shake-off impulse) The afterpulse can be activated with a jumper on the main circuit board. The afterimpulse occurs 0.3 seconds after the holding time has expired. ”Hardware test program” jumper (only for use by the manu- facturer) ”US afterpulse”...
  • Page 41 Retooling ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...
  • Page 42 Retooling ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...

  • Page 43: Cleaning And Maintenance

    Cleaning and maintenance Cleaning and maintenance General maintenance jobs Cleaning and maintenance jobs may only be carried out by specially trained staff. Before beginning maintenance jobs, make sure that all energy sources such as the power and compres- sed air supply are disconnected. Attention: Never clean the keypad or plastic sheeting of the generator with caustic agents.

  • Page 44: Vibration System

    Cleaning and maintenance Vibration system Work may only be carried out on the vibration system and converter housing when the mains voltage is switched off! High voltage! Avoid contact with the RF socket of the converter. Never connect any measuring in- struments to the RF socket of the converter! The converter is electrically char-...
  • Page 45 Cleaning and maintenance ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...
  • Page 46 Cleaning and maintenance ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ RL35HWV40/GB/N 7768/16279...

  • Page 47: Error Messages And Trouble Shooting

    Error messages and corrective action Error messages and trouble shooting Troubleshooting may only be carried out by specially trained staff. In case of doubt, contact the service centre or the manufacturer directly (see appendix). 10.1 Error messages / corrective action: switching on Error Possible cause Corrective action...
  • Page 48 Error messages and corrective action ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ 10-2 RL35HWV40/GB/N 7768/16279...

  • Page 49: Electrical Diagrams

    Electrical diagrams Electrical dia- grams 11.1 Wiring diagram for housing 11.1.1 Start ST02 automatic (standard) input emergency stop input start 1 input start 2 11-1 RL35HWV40/GB/N 7768/16279...

  • Page 50: Start St02 Manual (Optional)

    Electrical diagrams 11.1.2 Start ST02 manual (optional) input emergency stop input start 1 input start 2 11.1.3 Start ST02 manual (optional) input emergency stop input start 1 input start 2 11-2 RL35HWV40/GB/N 7768/16279...

  • Page 51: Interface St03

    Electrical diagrams 11.1.4 Interface ST03 US-Stop option A US-Stop option B input US-Stop 1 input US-Stop 2 output piece counter output piece counter Error - max. 24V / 0.5A - open, if error 11-3 RL35HWV40/GB/N 7768/16279...

  • Page 52: Generator Module Ugf

    Electrical diagrams 11.1.5 Generator module UGF output converter not used not used not used mains ground mains ground mains P mains P mains N mains N not used GND24V +24V output piece counter (optional): ouput power 0-5V output magnetic valve input start 2 input start 1 input Trigger...

  • Page 53: Fuses Generator Rl35

    Electrical diagrams 11.2 Fuses Generator RL35 Fuses are to be found in the following assem- blies: Power socket Bus print Generator module All fuse dimensions: 5 x 20 mm. 11-5 RL35HWV40/GB/N 7768/16279...

  • Page 54: List Of Fuses Generator Rl35

    Electrical diagrams 11.3 List of fuses Generator RL35 11.3.1 Fuses 230 volt / 200 volt Generator Power socket Bus print Generator module UGF35-250 3.15 A/T 400 mA/T 3.15 A/T 100 mA/T UGF35-400 4 A/T 400 mA/T 4 A/T 100 mA/T UGF35-600 4 A/T 400 mA/T...

  • Page 55: Rl 35 Generator Rear Panel

    Electrical diagrams 11.4 RL 35 Generator rear panel STO1 STO2 STO3 STO4 STO5 11.5 List of device sockets and connection plugs List of device socket RINCO order-No. Appliance socket 14 pol. AMP 5445 STO1 STO2 Appliance socket 7 pol. AMP 5442 Appliance socket SUB-D 15 pol.
  • Page 56 Electrical diagrams ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ 11-8 RL35HWV40/GB/N 7768/16279...

  • Page 57: Technical Drawings And Values

    Technical drawings and values Technical drawings and values 12.1 Amplitude values of the generator RL The different generator outputs result in different amplitudes.The amplitude value described in the following table refers to the respective generator/horn configuration. The effective welding amplitude can thus be read off directly. Horn Amplitude Converter...

  • Page 58: Stud Length Of The Vibration Components; 35 Khz

    Technical drawings and values 12.3 Stud length of the vibration components; 35 kHz 35 kHz Converter The converter stud is an integral component of the converter and cannot be detached! Horn 12-2 RL35HWV40/GB/N 7768/16279...
  • Page 59 Technical drawings and values ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ 12-3 RL35HWV40/GB/N 7768/16279...
  • Page 60 Technical drawings and values ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ 12-4 RL35HWV40/GB/N 7768/16279...

  • Page 61: Service Center Addresses

    Center needs the following information: 1. The type designation and serial number of the device. 2. An exact description of the technical malfunction or welding problem. Our address: ....RINCO ULTRASONICS AG Industriestrasse 4 CH-8590 Romanshorn Switzerland Switzerland ........071 466 41 00 ........
  • Page 62 Service center addresses ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ ___________________________________________________________________ 13-2 RL35HWV40/GB/N 7768/16279...

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