Ultrasonic Manual

Ultrasonic Generator
Boa
Typ 35-600 / 35-900 / 20-1000 / 20-1500
Instruction Manual
Version 1.2
Distribution and Service :
SWISS-SONIC - Ultraschalltechnik
Seemoosholzstrasse 14 - CH-9320 Arbon
Tel. +41 71 680 08 05 - Fax +41 71 680 08 06
info@swiss-sonic.ch - www.swiss-sonic.ch
Generator Boa V1.2 2
Table of Contents
1 Safety Instructions ......................................................................................................................................... 4
2 Technical Data ................................................................................................................................................ 5
3 Power on Message ......................................................................................................................................... 6
4 Key Functions ................................................................................................................................................. 6
5 Indicator .......................................................................................................................................................... 6
6 US - Test .......................................................................................................................................................... 7
6.1 Tuning frequency .............................................................................................................................................. 7
6.2 Frequency range during operation ................................................................................................................... 7
7 Amplitude Table .............................................................................................................................................. 7
8 Welding Cycle ................................................................................................................................................. 8
9 Welding Parameter External Mode ............................................................................................................... 9
10 Welding Parameter External Mode 2 .......................................................................................................... 10
11 Welding Parameter Time Mode ................................................................................................................... 11
12 Welding Parameter US-STOP Mode ........................................................................................................... 12
13 Error Message ............................................................................................................................................... 13
14 Inputs & Outputs .......................................................................................................................................... 14

14.1 Inputs 14
14.2 Outputs ........................................................................................................................................................... 14
15 Connections .................................................................................................................................................. 15
15.1 Interface X1 25 pin Sub D ............................................................................................................................ 15
15.2 Line X2 C13 / C15 ....................................................................................................................................... 17
15.3 RF Connector X3 Lemo 1 & 2 ..................................................................................................................... 17
16 Fuses 18
17 Standard Init .................................................................................................................................................. 18
18 System Init Menu .......................................................................................................................................... 19
19 Jumper on the Main Board .......................................................................................................................... 20

19.1 Buzzer J2 ........................................................................................................................................................ 20
19.2 Emergency Stop J3 ....................................................................................................................................... 20
20 Jumper on the Front Board ......................................................................................................................... 21

20.1 Jumper J1 External 2..................................................................................................................................... 21
20.2 Jumper J2 on/off ............................................................................................................................................ 21
20.3 Jumper J3 ..................................................................................................................................................... 21
21 Encyclopedia ................................................................................................................................................ 22
21.1 After Pulse Time ............................................................................................................................................. 22
21.2 After Pulse Delay Time ................................................................................................................................... 22
21.3 Amplitude ........................................................................................................................................................ 22
21.4 Amplitude Values Guideline ........................................................................................................................... 22
21.5 Booster ........................................................................................................................................................... 22
21.6 Control Time ................................................................................................................................................... 22
21.7 Converter ........................................................................................................................................................ 23
21.8 Cutting of Synthetic Textiles ........................................................................................................................... 23
Version V1.2 / 22. February 2010 / SHJ

21.9 Cutting of food ................................................................................................................................................ 23

21.10 Design of the welding line .............................................................................................................................. 23
21.11 Emergency Stop ............................................................................................................................................. 23
21.12 Hold Time ....................................................................................................................................................... 23
21.13 Horn ( Sonotrode ) .......................................................................................................................................... 23
21.14 Overload ......................................................................................................................................................... 23
21.15 Parts Counter ................................................................................................................................................. 24
21.16 Problems with the welding .............................................................................................................................. 24
21.17 Power 24
21.18 Power Maximum ............................................................................................................................................. 24
21.19 Service Program ............................................................................................................................................. 24
21.20 Speed Reduction Valve .................................................................................................................................. 24
21.21 Speed Throttle ................................................................................................................................................ 24
21.22 Ultrasonic Trigger ........................................................................................................................................... 24
21.23 Welding ........................................................................................................................................................... 25
21.24 Welding Modes ............................................................................................................................................... 25
21.25 Welding continuous ........................................................................................................................................ 25
21.26 Welding of rigid Parts ..................................................................................................................................... 25
21.27 Welding Staking .............................................................................................................................................. 25

1 Safety Instructions
The design of the generator conforms to the current state of engineering and is safe to use.
The parts and the complete unit are subject to continual inspection by our quality assurance department.
The generator is intended exclusively for the ultrasonic welding of thermoplastic materials. Any other use is
regarded as inconsistent with the intended purpose, and is undertaken at the user’s own risk.
The manufacturer is not liable for any resultant damage.
Before you are using this generator the first time you must read this instruction manual carefully.
In case of lack of knowledge of the user, malfunction on the unit can result in damage.
Always keep this instruction manual next to the unit.
Do not make any modifications witch might endanger safety without permission of the manufacturer.
Work on the unit may only performed by reliable staff.
ATTENTION !!!
Before you open the cover of the generator you must remove all
connections.
Do not touch any part inside of the generator before all LED on the main
board are dark. The capacitors are still loaded for some time after power off.
See chapter POSITION FUSES AND LED
ATTENTION !!!
Be sure to fit the power connection with a grounded connector.

2 Technical Data
Pos Function Specs
1 Input Voltage 190 - 265 V AC / 50-60 Hz
2 Size H250 x B130 x L 415
3 Line Filter Integrated
4 Weight 5,5 kg
5 Colour RAL 3020 red other colours on request
6 Display 2 x 16 Characters with backlight
7 LED Bar 10 LED with Peak Memory for Output power
8 Keyboard 24 Keys plus on/off
9 Microcontroller Generator 16 bit / 20 MHz
10 Microcontroller Controller 16 bit / 16 MHz
11 AD / DA Converter 12 bit
12 Power Measuring Real Time
13 Frequency Range 19700 - 20150 Hz, 34700 - 35150 Hz
14 Auto tuning Real time
15 Nominal Output power 600, 900 W at 35 kHz
16 Nominal Output power 1000, 1500 at 20 kHz
17 Maximum Output power 10 % above nominal Power
18 Constant Amplitude 205 -265 V AC
19 Internal Amplitude 60 to 100% at 5 % steps
20 External Amplitude 60 to 100% at 5 % steps
21 Time Mode 0.005 - 9.999s
22 US Stop Mode Integrated
23 Time Trigger 0 - 9.999s
24 Parts and Reject Counter 999999
25 Inputs Opto coupler 20 - 28 V DC / max. 7 mA
26 Integrated Power Supply 24V DC / 400 mA stabilized & short circuit protected
27 Outputs Opto coupler 22 - 26 V DC / 250 mA short circuit protected
28 Emergency Stop Message in Display
29 Error Message Display / Hardware Output
30 Interface for PLC Various digital Input and Output
31 Buzzer Error Message
32 Connectors All Standard D SUB
33 Main Power Switch On the back Panel
34 Languages E,D,SP,F,I,P,S,DK,N,SF;NL
35 Service Program Hardware Test for all Input & Output
36 Temperature -5°C ~ 45°C / Stock -20°C ~ 60°C
37 Design & Production Switzerland

3 Power on Message
Swiss made
www.apsonic.com
Boa 35-900
Version V 1.2
123456 80% Parts Counter Power

1.000s 100% Weld Time Power Maximum
The power on procedure will take about 7s.
The Boa is ready as soon as the parts counter will be displayed. The output READY will be activated.
4 Key Functions
E select parameter menu / quit & save parameter menu
 decrease values / reset errors


 increase values / US Test

 Scrolling up

 Scrolling down
on / off Power on / off
The power on/off button can be set inactive with a jumper on the front board. The jumper on the front board must
be set to ON if the power on/off switch must be inactive.
5 Indicator
LED Bar red Power Output power in 10 % steps. Peak value will be
Displayed after each welding
Display After each welding you can see the welding result
in the display

6 US - Test
Press the key + for manual US Test. The minimum test time will be 300 ms.
ATTENTION !!!
Do not touch the horn when the US Test is executed.
6.1 Tuning frequency
20.000 Hz – 20.050 Hz & 35.000 – 35.050 Hz
Newly made horn must meet this specification.
6.2 Frequency range during operation
19700 Hz – 20150 Hz & 34.700 – 35.150 Hz*
* The frequency range is depending on the connected vibration system. The above values are valid for the
following vibration system.
20 kHz Booster 1: 2 with Horn 1:1 diameter 100mm

35 kHz Booster 1: 2 with Horn 1:1 diameter 30mm
Frequency
35.00 kHz 10% Frequency & Loss power
7 Amplitude Table
Depending on the output power each generator has different output amplitude. The output amplitude has a
tolerance of + / - 2 %. The output amplitude of the horn is also depending on the output amplitude of the converter.
The output amplitude of the converter has a tolerance of + / - 10 % .
Type Basic Output Amplitude with Booster V1:1 & Horn V1:1
35 – 600 3 75 um
35 – 900 5.00 um
20 – 1000 6.50 um
20 – 1500 8.50 um

8 Welding Cycle
External Mode
The cycle will start over Input START. The output VALVE will be activated. The WELD TIME will start after the
TRIGGER TIME is elapsed. The WELD TIME is active as long Input START is active. After the WELD TIME the
HOLD TIME will be activated. The VALVE will be switched off after the HOLD TIME is elapsed. The DELAY US
PULSE TIME will be activated. The US PULSE TIME will be activated after the DELAY US PULSE TIME is
elapsed. The cycle is finished.
Press the - key to reset an ERROR. The next START will reset the ERROR as well.
The Boa will be blocked after 8 consecutive ERROR. Press the - key to reset the blocking.
The effective WELD TIME will be displayed. If the WELD TIME is longer then 9.999s, the display will always show
9.999s.
Time Mode
The cycle will start over an impulse of 100m at the Input START. The output VALVE will be activated. The WELD
TIME will start after the TRIGGER TIME is elapsed. The WELD TIME is active as long Input START is active. After
the WELD TIME the HOLD TIME will be activated. The VALVE will be switched off after the HOLD TIME is
elapsed. The DELAY US PULSE TIME will be activated. The US PULSE TIME will be activated after the DELAY
US PULSE TIME is elapsed. The cycle is finished.
Press the - key to reset an ERROR. The next START will reset the ERROR as well. The Boa will be blocked after
8 consecutive ERROR. Press the - key to reset the blocking.
US Stop Mode
The cycle will start over an impulse of 100m at the Input START. The output VALVE will be activated. The WELD
TIME will start after the TRIGGER TIME is elapsed. The WELD TIME is active as until the input US-STOP will be
activated. As the input US-STOP is activated then the Output US-STOP will be activated for 100ms. If the input
US-STOP is activated after the CONTROL TIIME is elapsed then the ERROR TIMEOVERFLOW will be displayed.
After the WELD TIME the AFTER WELD TIME will be activated. After the AFTER WELD TIME the HOLD TIME will
be activated. The VALVE will be switched off after the HOLD TIME is elapsed. The DELAY US PULSE TIME will
be activated. The US PULSE TIME will be activated after the DELAY US PULSE TIME is elapsed. The cycle is
finished.
Press the - key to reset an ERROR. The next START will reset the ERROR as well. The Boa will be blocked after
8 consecutive ERROR. Press the - key to reset the blocking.

9 Welding Parameter External Mode

Press the key E to activate Parameter Setup menu.
Press the key  to scroll up and down in the menu.
Press the key  to change the parameter.
Weld Time
EXTERNAL WELD TIME over Input +/- START
Amplitude
100 % ( external ) * Change with key +/- 50 % - 100 %
Hold Time
0.000 s Change with key +/- 0.000 s – 9.999 s
Trigger Time
After Weld Time

Not active
Delay US Pulse
0.000 s Change with key +/- 0.000s – 9.999 s
US Pulse
Parts
1234546 Reset with key - 0 – 999999
* If the System is set to AMPITUDE=EXTERNAL then the AMPLITUDE is depending on the settings of the inputs
AMPLITUDE 1-4.
The display will show the word EXTRENAL behind the % value.

10 Welding Parameter External Mode 2

Jumper J1 must be set to 1 to activate this menu. For details see page 24.
Weld Time
EXTERNAL WELD TIME over Input START
Amplitude
100 % ( external ) * Change with key +/- 50 % - 100 %
Parts
1234546 Reset with key - 0 – 999999
AMPLITUDE 1-4.

11 Welding Parameter Time Mode

Weld Time
Amplitude
100 % ( external ) Change with key +/- 50 % - 100 %
Hold Time
Trigger Time
After Weld Time

Not active
Delay US Pulse
0.000 s Change with key +/- 0.000s – 9.999 s
US Pulse
Parts
1234546 Reset with key - 0 – 999999
AMPLITUDE 1-4.

12 Welding Parameter US-STOP Mode

Press the key  to scroll up and down in the menu.
Control Time
0.500 s Change with key + / - 0.005 s – 9.999 s
Amplitude
100 % ( external ) Change with key + / - 50 % - 100 %
Hold Time
Trigger Time
After Weld Time

Delay US Pulse
0.000 s Change with key + / - 0.000s – 9.999 s
US Pulse
Parts
1234546 Reset with key - 0 – 999999
AMPLITUDE 1-4.

13 Error Message
Press the - key to reset an ERROR.
The next START will reset the ERROR as well.
The Boa will be blocked after 8 consecutive ERROR. Press the - key to reset the blocking.
Error message 1 Power to small, amplitude too high, welding pressure too high
Overload
Error message 2 Horn, Converter, Booster or RF cable defect, pressure too high
Converter voltage
Error message 3 Bad horn tuning or horn defect

Frequency min.
Error message 4 Bad horn tuning or horn defect

Frequency max.
Error message 5 US – Stop signal not activated

Time Overflow
Error message 6 One of the 24V output is overloaded or output driver defect
Output 24V
EMERGENCY STOP Emergency stop not closed

14 Inputs & Outputs
14.1 Inputs
Connection : Opt coupler
Voltage : 20 – 28 V DC
Currant : maximum 7 mA
14.2 Outputs
Connection : Opt coupler
Voltage : 22 – 26 V DC
Currant : maximum 250 mA for each output
The maximum load to the internal power supply is 400 mA. The power supply is overload protected.
Each output is overload protected. In case on an overload the message OUTPUT 24V will appear in the display.
Press key - to reset the overload.
All connections come as female.

15 Connections
15.1 Interface X1 25 pin Sub D

Pin Signal
1 Emergency
2 Emergency
3 24V DC after Emergency
4 24V DC after Emergency
5 GND
6 Input AMPLITUDE 1
7 Input AMPLITUDE 2
8 Input AMPLITUDE 3
9 Input AMPLITUDE 4
10 NC
11 Input START
12 Input US STOP -
13 GND
14 NC
15 NC
16 NC
17 Output US-STOP
18 NC
19 Output FREQUENCY ERROR
20 Output OVERLAOD ERROR
21 Output ULTRASONICS ACTIVE
22 Output READY
23 Output VALVE
24 Output GLOBAL ERROR
25 Input US STOP +
Pin 1 or 2
Pin 1 or 2 must be connected with Pin 3 or 4 though an EMERGENCY STOP BUTTON. The function can be
disabled with jumper on the main board. The jumper must be set to INTERNAL to bypass the ERMERGENCY
STOP feature.
Pin 3 & 4
24VDC as soon as the EMERGENY STOP BUTTON is closed.
Pin 5 & 13
GND

Pin 6 – 9
The function AMPLITUDE=EXTERNAL is only active if set in the SYSTEM INIT Menu. You can set the
AMPLITUDE according to the table below. The maximum time to change the AMPLITUDE is 50ms. If the setting is
wrong it will be set to 50%
INPUT AMPLITUDE 1 (6) AMPLITUDE 2 ( 7) AMPLITUDE 3 (8) AMPLITUDE 4 ( 9)

100% 0 0 0 0
95 % 0 0 0 1
90 % 0 0 1 0
85 % 0 0 1 1
80 % 0 1 0 0
75 % 0 1 0 1
70 % 0 1 1 0
65 % 0 1 1 1
60 % 1 0 0 0
55 % 1 0 0 1
50 % 1 0 1 0
Pin 11
The input START will activate the cycle if activated with 24VDC.
Pin 12
The input US-STOP - will activate the US-STOP is activated with GND. The input US-STOP+ must be connected
with 24VDC.
Pin 17
The output US-STOP has 24VDC if active. If Input US-Stop is activated the is an impulse of 100ms.
Pin 19
The output FREQUENCY ERROR has 24VDC if active.
Pin 20
The output OVERLAOD ERROR has 24VDC if active.
Pin 21
The output ULTRASONICS ACTIVE has 24VDC if active.
The output is active as long as the ULTRASONICS is active.
Pin 22
The output READY has 24VDC if active. The output is activated after the power on procedure. During the welding
cycle the output is inactive.
Pin 23
Output VALVE has 24V DC if active.
Pin 24
The Output ERROR GLOBAL has 24V DC if active. The error will be activated if on of the welding gun produces an
error. On the main board there is a buzzer with the same function. The buzzer can be activated with a jumper on
the main bard.
Pin 25
The input US-STOP + will activate the US-STOP is activated with 24VDC. The input US-STOP- must be connected
with GND.

15.2 Line X2 C13 / C15
Pin Signal
1 Phase
2 Neutral
3 Ground
230 V AC Specs see TECHNICAL DATA

Values see FUSES
ATTENTION !!!
Be sure to fit the power connection with a grounded connector.
15.3 RF Connector X3 Lemo 1 & 2

Pin Signal
1 RF Output
2 Ground
ATTENTION !!!
Do not disconnect the RF Plug during operation.

16 Fuses
Fuse Type Value
F1 & F3 all 1.25AT
F2 35-600 4.0 AT
F2 35-900 6.3 AT
F2 20-1000 6.3 AT
F2 20-1500 8 AT
All fuses 5x20 slow.
Check F1 if the power switch on the rear panel is on, but it is not possible to switch on the unit with the power
switch on the front panel.
Check F2 if the 3 mm LED next to the 390u capacitor on the main board is not alight.
Check F3 if there is no 24VDC output.
ATTENTION !!!
Before you open the cover of the generator you must remove all
connections.
Do not touch any part inside of the generator before all LED on the main
board are dark. The capacitors are still loaded for some time after power off.
17 Standard Init
Press the key  during power on. You can release the button when the message INIT is shown in the display.
Init
The Generator will be reset to factory settings.
ATTENTION !!!
All Parameters will be lost.

18 System Init Menu

Press the key E during power on. You can release the button when the message MODE is shown in the
display.
Swiss made
www.apsonic.com
Boa 35-900
Version V 1.2 Press E Key during Power on
Mode
External Time / US-STOP / External Change with key + / -
Amplitude
Internal External Change with key + / -
English
German,… Change with key + / -
Soft start
20 2-30 Change with key + / -

19 Jumper on the Main Board

There are two jumpers on the main board. Depending on the settings you can select different features.
19.1 Buzzer J2
The buzzer is active if jumper is in position BUZZER .
19.2 Emergency Stop J3

The Emergency Stop is not active if jumper is set to INTERNAL.

20 Jumper on the Front Board

There are three jumpers on the front board. Depending on the settings you can select different features.
20.1 Jumper J1 External 2

If the jumper is set to position 1, then the welding parameter menu EXTERNAL 2 is activated.
Position marked on the PCB.
20.2 Jumper J2 on/off

If the jumper is set to position ON, then the ON/OFF switch on the front is no longer active.
20.3 Jumper J3
This Jumper is for Factory settings only. For regular use the Jumper in not place.

21 Encyclopedia
21.1 After Pulse Time

The AFTER PULSE TIME is used to shake of a part that is sticking on the horn after welding.
21.2 After Pulse Delay Time

The AFTER PULSE DELAY TIME is starting after the hold time. The after pulse time is to make sure that the horn
is no longer on the part before the after pulse is activated.
21.3 Amplitude
The amplitude is the movement on the horn surface. The amplitude is depending on the output power of the
power supply, Generator setting ( 60 – 100% ) Gain Booster und Gain of the horn. The amplitude is chosen
depending on the material to weld. The best amplitude to weld you can get from the supplier of the raw material.
The amplitude is measured in micro meter. The value is peak. Typical amplitude values are 10 – 60 micro meter.
21.4 Amplitude Values Guideline

Material Typ3 Guideline in [ um ]
ABS amorphous 15 - 30
CA Semi crystalline 20 - 35
PA Semi crystalline 35 - 55
PBTP Semi crystalline 40 - 50
PC amorphous 25 - 40
PE Semi crystalline 25 - 60
PETP Semi crystalline 45 - 55
PMMA amorphous 20 - 35
POM Semi crystalline 40 - 50
PP Semi crystalline 30 - 60
PPO amorphous 25 - 40
PS amorphous 15 - 30
PVC hard amorphous 20 - 40
PVC soft amorphous 25 - 40
SAN amorphous 15 - 30
SB amorphous 20 - 35
21.5 Booster
The booster is amplifying the amplitude produced by the converter. The gain on the booster is fix. Standard
Booster : 1:1 = green, 1:1.5 = yellow; 1:2 = white, 1:2.5 = black, 1:3= brown. The booster is tuned to the resonant
frequency. Do not modify anything on the booster. Boosters are made of titanium or aircraft grade aluminum.
Make sure that the horn stud can not touch the bottom of the thread in the booster. Thread Converter = M16.
Thread Horn = M12.
21.6 Control Time

The control time is used in US- STOP and TRAVEL. If the sensor in US-Stop Mode ort he set travel in the travel
mode is not reached in the set time you will get an error. The welding will stop automatically after the control time is
reached.

21.7 Converter
The converter is transferring an electrical voltage to a mechanical vibration. The converter is tuned to resonant
frequency. Do not modify anything on the converter. The stud M16 is part of the converter an can not be taken off.
If the temperature on the converter body is reaching 50 degree Celsius you must use a cooling.
Too high temperature can destroy the converter.
21.8 Cutting of Synthetic Textiles

Cutting with Ultrasonic has the big advantage that you get a sealed edge after cutting. Compared to a cut with a hot
knife the cutting edge will stay soft. In most cases a flat horn is used against a cutting knife. In some case the horn
shape is built as a knife.
To reduce the wear of horn and knife the cutting is done in the US – STOP Mode. The knife is mounted insulated
from the press. A cable from the knife is connected with X3. The Ultrasonic’s will stop as the horn will touch the
knife.
21.9 Cutting of food

The cutting of food with ultrasonic has the advantage that you can get a clear cut. The build up of food on the knife
is reduced to a minimum.
The horn is designed to a knife.
Typical application : Cheese, Cake, Pizza, Pasta, Chocolate
21.10 Design of the welding line

It is very important that you have a good design of the welding area. Mostly there is an energy director design or
butt joint design. It is very important that you have sharp edges on the energy director and on butt joint. The sharp
edges will help to bring the energy into the part..
If you welding films or non woven then you do not need a joint design. In this case the horn has some lines or a
knurled surface. This surface will help to bring the energy into the part.
21.11 Emergency Stop

If you press the emergency stop button then the welding will stop and the power off the press will be shout down.
The 24V supply in the generator will switched off as well. In the display you will get the message EMERGENCY
STOP.
21.12 Hold Time

The horn will stay under pressure on the part during the hold time. The hold time is used to cool off the welded part.
If the hold time is to short you might get a bad welding result.
21.13 Horn ( Sonotrode )

The horn or Sonotrode is the welding tool. The horn is tuned to the resonant frequency. Modification should only be
done by trained stuff. Wrong modification can end in destroying the horn or the generator. Horns are made of
titanium, aircraft grade aluminum or harden steel. The stud on the horn is M12. The stud is part of the horn and can
not be removed. The shape of the horn is influencing the welding result.
21.14 Overload
In case of an overload then the generator does not have enough output power.

To reduce the power consumption you can reduce the pressure or the amplitude. If this does not help you need to
use a generator with more output power.
.
21.15 Parts Counter

The parts counter is counting the good welds. In case of an error the Reject counter will count it.
21.16 Problems with the welding

Bad welding can have many reasons.
 Wrong design of the welding area

 Wrong raw material
 Recycled material
 Too much water in the part
 Too much glass in the part
 Too much other additive in the part
 Wrong amplitude
 Bad amplitude on the horn surface, not even
 Jig does not support the part well
 Wrong welding parameter
 Pressure to high
21.17 Power
The output power is displayed on the LED bar on the front panel. After the welding the maximum power is shown
with one LED. In the LCD display you see maximum power and the power at the end of the welding.
21.18 Power Maximum

In the force profile menu you can set a maximum power value. If this value is reached the welding pressure will be
reduced to the set pressure automatically. This will help to reduce the risk to get an overload of the generator.
Mostly you with semi crystalline material that need a high trigger force.
21.19 Service Program

In the service program you test all inputs and outputs of the generator. This must be done by trained stuff only.
21.20 Speed Reduction Valve

In a press with a linear encoder you can activate the speed reduction valve over a set travel. The value can be set
in the SPECIAL FUNCTION MENU. The valve must be connected at Output 2 PIN 8 of ST 5 on the trigger board
TIP 002..
In a press without linear encoder you have to add an extra switch to the press. The switch must be connected to
ST8 on the trigger board TIP002. The valve must be connected to the ST9 on the trigger board TIP002. The trigger
board TIP002 is inside of the press.
21.21 Speed Throttle

The setting of the Speed throttle is influencing the horn down speed. The down speed has influence to the welding
result.
21.22 Ultrasonic Trigger

The Trigger will start the ultrasonic. The trigger can be a timer or a pressure sensor. This can be set in the
SYSTEM INIT Menu. In case of the timer, the delay time will start after reaching the safety switch. In case of a
pressure sensor the welding will start after the safety switch and the set pressure is reached. The trigger is
influencing the welding result.

21.23 Welding
The welding will be influenced by the following parameters.
 Amplitude
 Pressure
 Down Speed
 Trigger
 Weld Time
The weld time is depending on the set welding mode.
21.24 Welding Modes

The generator is supporting different welding modes. The welding parameters are depending on the set mode.
 Time Mode set Weld Time

 US Stop Mode by external sensor
 US Stop Mode Cutting of synthetic fabrics
 Hand continuous
21.25 Welding continuous

Welding of Films, Textiles, Non Woven and coated Carton. In the continuous welding you can have a fix horn or a
rotating horn. The anvil is either fix or rotating too.
With continuous welding you can be waterproof and airtight seals.
Typical application : Filter, outdoor cloths, awnings
21.26 Welding of rigid Parts

Welding of two rigid part. The pars must be designed for Ultrasonic Welding. The parts will have an energy director
or a shear joint. Both parts should be made with the same material. In some case similar materials can be welded.
Typical applications : Welding of Display window on Mobile Phone, Welding of cigarette
21.27 Welding Staking

In staking the lower part must have a pin coming out of the part. The upper part has a hole. The pin is overlooking
the hole of the upper part. The pin will be welded down by the horn to a rivet. The upper part can be any material.
Typical applications : Door panel of car, Bumper of car, IP of car

Ultrasonic Manual

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Ultrasonic Manual

Загружено:

Авторское право:

Доступные форматы

Ultrasonic Generator

Distribution and Service :

1 Safety Instructions ......................................................................................................................................... 4

2 Technical Data ................................................................................................................................................ 5

3 Power on Message ......................................................................................................................................... 6

4 Key Functions ................................................................................................................................................. 6

7 Amplitude Table .............................................................................................................................................. 7

8 Welding Cycle ................................................................................................................................................. 8

9 Welding Parameter External Mode ............................................................................................................... 9

10 Welding Parameter External Mode 2 .......................................................................................................... 10

11 Welding Parameter Time Mode ................................................................................................................... 11

12 Welding Parameter US-STOP Mode ........................................................................................................... 12

13 Error Message ............................................................................................................................................... 13

14 Inputs & Outputs .......................................................................................................................................... 14

17 Standard Init .................................................................................................................................................. 18

18 System Init Menu .......................................................................................................................................... 19

19 Jumper on the Main Board .......................................................................................................................... 20

20 Jumper on the Front Board ......................................................................................................................... 21

Version V1.2 / 22. February 2010 / SHJ

21.9 Cutting of food ................................................................................................................................................ 23

Version V1.2 / 22. February 2010 / SHJ

Work on the unit may only performed by reliable staff.

Be sure to fit the power connection with a grounded connector.

Version V1.2 / 22. February 2010 / SHJ

Version V1.2 / 22. February 2010 / SHJ

123456 80% Parts Counter Power

The power on procedure will take about 7s.

 decrease values / reset errors

on / off Power on / off

Version V1.2 / 22. February 2010 / SHJ

6.1 Tuning frequency

20.000 Hz – 20.050 Hz & 35.000 – 35.050 Hz

Newly made horn must meet this specification.

6.2 Frequency range during operation

19700 Hz – 20150 Hz & 34.700 – 35.150 Hz*

20 kHz Booster 1: 2 with Horn 1:1 diameter 100mm

Version V1.2 / 22. February 2010 / SHJ

Version V1.2 / 22. February 2010 / SHJ

9 Welding Parameter External Mode

Press the key  to scroll up and down in the menu.

Press the key  to change the parameter.

After Weld Time

Version V1.2 / 22. February 2010 / SHJ

10 Welding Parameter External Mode 2

Press the key E to activate Parameter Setup menu.

Press the key  to scroll up and down in the menu.

Press the key  to change the parameter.

Version V1.2 / 22. February 2010 / SHJ

11 Welding Parameter Time Mode

Press the key  to scroll up and down in the menu.

Press the key  to change the parameter.

After Weld Time

Version V1.2 / 22. February 2010 / SHJ

12 Welding Parameter US-STOP Mode

Press the key  to scroll up and down in the menu.

Press the key  to change the parameter.

After Weld Time

Version V1.2 / 22. February 2010 / SHJ

The next START will reset the ERROR as well.

Error message 3 Bad horn tuning or horn defect

Error message 4 Bad horn tuning or horn defect

Error message 5 US – Stop signal not activated

EMERGENCY STOP Emergency stop not closed