Sonics H520 T/E Instruction Manual Download Page 33

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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 • [email protected]

[email protected]

Summary of Contents for H520 T/E

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: ...or gases hazardous to an operator s health Where such materials are processed proper ventilation of the work station should be provided If in doubt about the toxicity of your plastic material contact...

Page 3: ...2 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...

Page 4: ...Electrical Power Requirements 9 Setting Up 9 Electrical Connections 9 Cable Connections 10 Key Components 11 Tip Assembly CV52 12 Tip Replacement CV52 12 Horn Assembly CV54 Only 12 Tip Replacement CV5...

Page 5: ...soon as they are developed and tested Sometimes due to printing and shipping requirements we cannot incorporate these changes immediately into printed manuals Hence your manual may contain new change...

Page 6: ...freight bill or express receipt and signed by the carrier s agent Failure to adequately describe such external evidence of loss or damage may result in the carrier s refusal to honor a damage claim T...

Page 7: ...power supplies of both models feature autotune circuitry OVERVIEW OF ULTRASONIC PLASTICS ASSEMBLY WHAT IS ULTRASONICS Ultrasonics refers to vibrational waves with a frequency above the human audible r...

Page 8: ...ectrical energy 20 40 kHz 50 60 Hz Electrical power Ultrasonic electrical energy Ultrasonic Vibrations Transforms ultrasonic electrical energy to ultrasonic mechanical vibrations Contacts and transfer...

Page 9: ...ges the high frequency electrical energy supplied by the power supply to high frequency mechanical vibrations TIP HORN The tip horn is a tuned component of the system which comes in contact with the p...

Page 10: ...If the power supply must be housed in a confined space forced air cooling may be necessary to keep surrounding air within acceptable ambient temperature limits Periodically check the ventilation gril...

Page 11: ...ake this connection until the hand gun is connected to the power supply Once these connections have been made the power supply is ready for operation Also located at the rear of the power supply are t...

Page 12: ...ctured below is the power supply with 2 hand gun options 20 kHz CV52 and 40 kHz 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 11 POWER SUPPLY HAND GUN TRIGGER SWITCH CV52 CV54 HORN...

Page 13: ...converter and horn as well as the threaded stud and hole Check that the stud is tight see recommended torque requirements on page 13 2 Hand assemble the converter and horn together using open ended w...

Page 14: ...onverter Horn 8 mm 25 35 34 47 40 kHz Horn Tip 1 4 28 25 35 34 47 RECOMMENDED TORQUE REQUIREMENTS TIP REPLACEMENT CV54 1 Clean the mating surfaces as well as the threaded stud and hole Check that the...

Page 15: ...hand held welding systems Upon request special carbide faced wear resistant flat knurled and custom faced tips are available Refer to the various tables under staking spot welding and insertion descri...

Page 16: ...le is removed from the hand gun housing 2 MANUAL ARBOR PRESS available with foot switch or cam actuation is designed for assembling parts where production volume does not justify automated equipment T...

Page 17: ...A L M O D E L H 5 2 0 H 5 4 0 3 STAPLER with special pivoting mechanism Ideal for sealing low production rate clamshell packages 4 PISTOL GRIP for more ergonomic handling of the hand gun in specialize...

Page 18: ...llows input of numeric data by pressing the keys 4 CLEAR key which clears the preceding entry when pressed 5 ENTER REVIEW key which serves to enter data into the system and or to display data or param...

Page 19: ...l remain on cycle for 5 seconds The red LED in the upper left corner lights up accordingly during the cycle The number of watts will be displayed on the LCD screen and a line will display along the ba...

Page 20: ...the welding time value press the TIMER key The current time setting such as the example below will be displayed Use the numeric keypad to enter the number of seconds desired a value between 0 1 and 9...

Page 21: ...hen the switch on the hand gun is depressed the LCD screen will display the amplitude percentage like the example below 7 If test readings do not exceed the maximum allowable values proceed to actual...

Page 22: ...contacts a grounded surface while the power is on the power supply will overload because it detects an alternate ground path The overload protection circuits will prevent damage to internal system com...

Page 23: ...the light pressure from the horn forms a head to a shape determined by the horn tip configuration When the vibrations stop the plastic material solidifies and the dissimilar materials are fastened to...

Page 24: ...llow stake avoids sink marks on the opposite side of the component and enables the parts to be reassembled with self taping screws should repair and disassembly be necessary KNURLED STAKE The knurled...

Page 25: ...L M O D E L H 5 2 0 H 5 4 0 TIP CODE LETTER Plastic Boss Solid Boss Conical Boss Diameter Flare Head Spherical Head Hollow inches mm High Profile Low Profile High Low Boss Tip Size Stud Height Tip Si...

Page 26: ...nd Large thermoplastic parts and applications with hard to reach joining surfaces can easily be welded together using an ultrasonic spot welder and standard replaceable tips STANDARD THREADED TIPS FOR...

Page 27: ...plastic flows into the serrations flutes or undercuts of the inserts and when the vibrations terminate the plastic resolidifies and the insert is securely encapsulated in place Inserts can be ultraso...

Page 28: ...Size of Insert Of Tip SAE 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 0 069...

Page 29: ...pertaining to the nature of the problem Always contact the factory for return authorization before shipping any instrument Include date of purchase model number and serial number For units not covere...

Page 30: ...F WARRANTY This warranty is in lieu of any other warranties either express implied or statutory Sonics neither assumes nor authorizes any person to assume for it any other obligation or liability in c...

Page 31: ...cover equipment used for applications requiring metal to metal contact with weld time in excess of 1 second Data supplied in the instruction manual has been verified and validated and is believed ade...

Page 32: ...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 31 APPENDIX DB9 I O CONNECTIONS DIAGRAM...

Page 33: ...n 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 soni...

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