Operating Manual Hand Welding Unit HG 35-3 English with Generator RL35
Disclaimer The information in this brochure corresponds to our current state of knowledge. However, it is not to be understood as a warranty for certain characteristics or for suitability of the products for certain applications. Our general contractual terms apply in this regard, and reference should also be made to these terms with regard to liability. No industrial property rights of any kind are granted to the user along with this brochure, nor are any assurances made with regard to a licence.
Note This operating manual must be read and observed before unpacking and initial operation of the unit. The unit may exclusively be operated and serviced by persons who know the operating manual and the applicable regulations with regard to industrial safety and prevention of accidents. Repairs may only be carried out through official and certified RINCO departments.
Table of contents 1 Explanation of symbols and signs 6 2 Safety information 2.1 General information 2.2 Intended use 2.3 Improper use 2.4 Important instructions 2.5 Personnel qualifications 2.6 Installation of unit 2.7 Operation 2.8 Noise emissions 2.9 Warranty statement 7 7 7 7 7 7 7 7 8 8 3 Transportation 3.1 Acceptance of delivery 3.2 Damage during transit 3.3 Positioning of the unit 9 9 9 9 7 Retooling 7.1 Changing the generator functions 7.1.1 Description of the programme selection switch 7.1.
Important! In case of enquiries concerning your unit please state the exact type designation and the unit serial number. You will find these on the type plates (A) and on the inside of the cover page of this operating manual. The construction and switching mechanism of the unit are consistently further developed and improved and conform with state-of-the-art technology. A RINCO ULTRASONICS AG Romanshorn, Switzerland A Foreword We are pleased that you have decided to purchase a RINCO product.
1 Explanation of symbols and signs Special attention must be paid to text sections with the following symbols: Set-up of the warnings Note! Information or operating instructions which are especially important for interference-free operation. Caution! Describes warnings, the non-observance of which can result in serious injuries or the risk of damage to apparatus parts. Danger! Describes warnings, the non-observance of which can result in death or very serious injuries.
2 Safety information 2.1 General information The construction of this unit corresponds with state-of-the-art technology and is safe to operate. The individual modules and the complete unit were tested by our quality control before delivery. 2.2 Intended use This unit is exclusively determined for welding suitable materials. Any other use or use beyond this is deemed as improper use. The manufacturer shall not be liable for damages caused by improper use. The risk shall be borne solely by the user.
Danger! There is high voltage in the interior of the unit – risk of injury! • • • Refrain from all methods of working which could pose a risk to safety! Only operate the system when all protective facilities and facilities due to safety e.g. detachable protective facilities, sound insulation are available and in good working order. Before switching the unit on ensure that no one can be endangered through the unit which is starting. Attention is to be paid to the sub-harmonic, i.e.
3 Transportation It is essential to observe transportation instructions on the packaging. 3.1 Acceptance of delivery The despatch container for machines and unit can withstand normal strain during transportation by road, rail and air. After receipt of the consignment you should check whether all parts correspond with the packing list and that there are no visible damages. In case damages are determined, please advise the transport company immediately and store the packaging as evidence. 3.
4 Product information 4 6 149 mm 4.1 Product overview/technical data 4.1.1 Hand welding unit HG35-3 without Booster 5 2 3 2 Converter C35-11, gain factor 1:1.5 170 mm 1 Handle 1 3 Front screw 4 Horn (customer-specific) 5 Cooling air ducts on the horn 6 Hanging clip Dimensions in mm Weight 1.1 kg HG35-3 with Booster 7 Booster body gain factor 1:1.5 /1:2 8 Converter screw connection and booster support 178 mm Converter C35-10 gain factor 1:1 Dimensions in mm Weight 1.
4.1.2 Ultrasonic generator RL35 1 Housing 1 2 Generator plug-in module 3 Type designation of the plug-in module 2 279 Dimensions in mm Weight: 7 kg 4.1.3 Available generator modules Type maximum power output UGF3 35-250 UGF3 35-400 UGF3 35-600 250 W 400 W 600 W 4.1.4 Connected loads • • • 3 396 132 230 V 50–60 Hz Option 110 V (to 600 W) Maximum current consumption 5 A 4.1.5 Cooling (accessory) During high-power applications the unit must be cooled.
5 Control and display elements 5.1 Hand welding unit 1 Trigger key Key for activating the ultrasonic. Do not touch the horn when ultrasonic is being emitted! 2 Screw connection for converter 3 Horn Never alter the tuned horn by making mechanical changes. This can cause damage to the oscillator system and the generator! 5.2 Valve box (optional) During use, the temperature on the converter and on the horn may not exceed 50° C. If this temperature is exceeded, they need to be cooled with compressed air.
5.3 Ultrasonic generator RL35 26 Generator module handle The generator module can be removed using these handles if necessary. The fixing screws for opening the generator module are located above and below the handles. 33 26 27 28 29 30 Never remove or replace the generator module when it is plugged in (high voltage)! Do not touch the conductor board, condensers charged with high voltage! 26 33 27 LED bars This display shows the power output during the welding sequence.
31 Welding time Use this key to • change the welding time. a) Increase the numeric value b) Decrease the numeric value With initialisation on the internal programme 33 31 selection switch (level 9), according to chapter 7 “Retooling”, the welding time is increased by a 32 factor of 10 (99.9s) and, with the corresponding initialisation, it can be set to switch function “ON-Off". 32 Hold time This setting is not available for manual units.
6 Initial operation 6.1 Choice of location Select an operating location for the equipment according to the following criteria: • Clean surroundings • Vibration-free resting place for the electronic equipment • Environmental temperature during operation: 10° C – 50° C when making settings: 20° C 6.2 Setting up and connecting the equipment Take the following steps to put the equipment into operating condition: 1. Connect the cables between the hand welding unit and the generator.
7 Retooling 7.1 Changing the generator functions 7.1.1 Description of the programme selection switch The programme selection switch contains 10 levels that can be set. For US operations without pneumatic tool infeed. The standard setting for manual units is “Level 0”. Level settings 0 Welding time external Welding time internal Impulse with settable welding time; maximum 99.
7.1.3 Reprogramming to “after-pulse” The after-pulse can be activated using a jumper on the mother board. The after-pulse occurs 0.3s after the hold time has elapsed. J4 Jumper "Hardware test programme" (only for use within the plant) J5 Jumper "US-after-pulse" P Motherboard The default setting for J4 and J5 is “OFF”. The time of the after-pulse cannot be changed. 7.1.4 Soft start The greatest load on the oscillator system occurs during the first oscillation.
7.2 Changing the horn 1. The horn (4) and the converter (3) can be detached from each other by using the openended spanner (G, Accessories). G G 3 Never tighten the parts in a vice or similar 4 clamping device! 2. Before mounting, clean the contact area K1 with a clean rag. Should grooves have developed on both surfaces, please contact the appropriate RINCO service location. Screw the horn on and tighten. 3 The horn must be tightened with a torque of 30 – 40 Nm.
7.3 Selecting the amplitude The amplitude cannot be changed on RL generators. 7.4 Amplitude values of the RL generators The different generator powers result in different amplitudes. The amplitude values given in the following table refer to the appropriate converter/horn configuration. The actual welding amplitude can be directly read off in this way. 3 Converter 4 Horn A Amplitude K1 Interface 3 K1 4 7.5 Amplitudes of 35 kHz RL generators 7.5.
7.5.
8 Cleaning and service 8.1 General service work 4 3 Cleaning and maintenance work may only be carried out by trained personnel. Before beginning the maintenance work, make sure that all power sources, such as electrical power, are disconnected. Attention: Never clean the keyboard or foil of the generator with acidic cleaners. 8.2 Hand welding unit 4 The hand welding unit requires no special maintenance.
8.4 Oscillator system Work on the oscillator system (S1) only if the supply voltage is switched off! High-voltage! S1 Avoid contact with the RF socket (RF1) of the hand welding unit. Do not connect any measuring device to the RF socket of the hand welding unit! The built-in transducer contains an electrical charge even after the generator has been switched off! 8.
9 Internal unit service 9.1 Fuses for generator RL35 Fuses are located in the following component groups: Power socket Print bus Generator module All fuse dimensions: 5 x 20 mm. 9.2 List of the fuses for generator RL35 9.2.1 Fuses 230 Volt Generator Power socket Busprint Generator module F1 F3 F4 F5 UGF3 35-250 3.15 A/T 400 mA/T 3.
10 Error messages and troubleshooting Troubleshooting can only be performed by specially trained personnel. If there are uncertainties, contact the service location or the producer directly. 10.1 Error messages and troubleshooting during start Error Possible cause Troubleshooting Generator does not turn on – – – – – – – – no power supply Input NOT-STOP interrupted fuse defective module not in housing insert mains plug check the “NOT-STOP” status check F1– F5 insert module and screw tight 10.
11 Service addresses The technical customer service of RINCO ULTRASONICS will be pleased to be of assistance in case of technical interferences and welding problems which may occur. Our customer service requires an exact description of the technical interference or the welding problem to be able to provide serious consultancy. Our Address: RINCO ULTRASONICS AG Industriestrasse 4 CH-8590 Romanshorn 1 Switzerland Switzerland Tel. 071 466 41 00 Fax 071 466 41 01 International Tel.
Industriestrasse 4 CH-8590 Romanshorn 1 Switzerland Tel. +41 71 466 41 00 Fax +41 71 466 41 01 26 info@rincoultrasonics.com www.rincoultrasonics.
