Model GXC / GC Power Supply I N S T R U C T I O N M A N U A L Sonics & Materials, Inc.
WARNING SAFETY PRECAUTIONS READ BEFORE INSTALLING OR USING THE EQUIPMENT This system has been designed to assure maximum operator safety. However, no design can completely protect against improper usage. For maximum safety and equipment protection, observe the following warnings at all times and read the instruction manual carefully before you attempt to operate the equipment. – High voltage is present in the equipment. Disconnect plug before removing cover or servicing.
TABLE OF CONTENTS IMPORTANT SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Manual Change Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Visible Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Concealed Loss or Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 INTRODUCTION . . . . . . . . . . . . . . . . . . . . .
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 G-Series Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IMPORTANT SERVICE LITERATURE The system supplied with this instruction manual is constructed of the finest material and the workmanship meets the highest manufacturing standards. It has been thoroughly tested and inspected before leaving the factory and when used in accordance with the procedures outlined in this manual, will provide you with many years of safe and dependable service. NOTE: Please read carefully before operating the equipment, then forward to your service department.
UNPACKING AND INSPECTION NOTE: We recommend keeping all carton(s) and packing material in case it might be necessary to move the equipment, or to ship it for repair. Before unpacking the equipment, check the shipping carton for any visible damage. If you see any, be sure to follow the procedures described below under “Visible Loss or Damage.” Otherwise, proceed to remove the equipment from the carton. Before storing any packing material, check it carefully for small parts.
INTRODUCTION The GXC / GC power supply is an ultrasonic generator with automatic frequency tuning and a built-in Microprocessor that can be operated on a continuous duty basis, or pulsed via an outside control. The Microprocessor is programmed with a multi-function keypad and information is displayed on the back-lit liquid crystal display (LCD). This power supply can be used with a pneumatic press or actuator, or with a stand-alone converter.
SONICS ULTRASONIC ASSEMBLY SYSTEMS 50/60 Hz Electrical power Power Supply/Generator Generates ultrasonic electrical energy (15/20/40 kHz) Ultrasonic electrical energy Actuator/Press Provides compressive force and mounting for Converter, Booster, Horn assembly Converter Transforms ultrasonic electrical energy to ultrasonic mechanical vibrations Ultrasonic Vibrations Booster Increases or decreases amplitude Ultrasonic Vibrations Horn Contacts and transfers vibrational energy to plastic part Ultrasonic Vib
GLOSSARY OF ULTRASONIC TERMS POWER SUPPLY/GENERATOR – The solid state power supply converts standard 50/60 Hz electrical energy to 15,000 Hz, 20,000 Hz or 40,000 Hz (15/20/40 kHz) electrical energy. ACTUATOR/WELDING PRESS – The pneumatic actuator provides compressive force and mounting for the converter, booster and horn assembly. The tabletop press consists of a base assembly, column and actuator (head).
INSTALLATION ELECTRICAL POWER REQUIREMENTS The power supply requires a fused, single-phase, standard 3-terminal grounding type receptacle capable of supplying the requisite voltage and current. Refer to the table below for power specification. POWER SPECIFICATIONS The line cord of the controller/power supply is equipped with a 3prong, grounding plug. Do not, under any circumstances, remove the ground prong. The plug must be plugged into a mating 3-prong, grounding type outlet.
ELECTRICAL CONNECTIONS The standard cable supplied with a Sonics press is 10 feet. Optional extension cables are available up to 15 feet without modification. NOTE: Do not plug the power supply into an electrical outlet until all other connections have been made. When making the initial electrical connections, make sure the power is disconnected and follow these precautions. 1. Do not strain or kink the cables. When going around corners, allow as wide a bend as possible.
CABLE CONNECTIONS – For GXC Models with 400 to 2200 Watts Power: Located at the rear of the power supply are the cable connections as illustrated below. (The interconnecting cables will be supplied with your system.) NOTE: Detailed wiring diagrams are supplied in the Appendix at the back of this manual. ❶ J1, a round, 12-pin RF cable that connects the welding press or converter to the power supply.
CABLE CONNECTIONS – For GC Models with 400 to 2200 Watts Power: Located at the rear of the power supply are the cable connections as illustrated below. (The interconnecting cables will be supplied with your system.) NOTE: Detailed wiring diagrams are supplied in the Appendix at the back of this manual. ❶ J1, a round Lemo cable that connects the welding press or converter to the power supply. ❷ J2, a control cable that connects the power supply to a trigger source (press cable or external trigger source.
CABLE CONNECTIONS – For GC Models with 3500 or 4500 Watts Power: Located at the rear of the power supply are the cable connections as illustrated below. (The interconnecting cables will be supplied with your system.) NOTE: Detailed wiring diagrams are supplied in the Appendix at the back of this manual. ❶ J1, a round, Lemo cable that connects the welding press or converter to the power supply.
CABLE CONNECTIONS – For GXC Models with 3500 or 4500 Watts Power: Located at the rear of the power supply are the cable connections as illustrated below. (The interconnecting cables will be supplied with your system.) NOTE: Detailed wiring diagrams are supplied in the Appendix at the back of this manual. ❶ J1, a round 12 pin RF cable that connects the welding press or converter to the power supply.
AVAILABLE CONVERTERS FOR POWER SUPPLIES Item No.
OPERATING PROCEDURES FRONT PANEL CONTROLS AND INDICATORS Located on the front panel of the power supply are the following controls and indicators: 2 3 4 3 5 1 10 9 8 6 7 1. ON/OFF keys which turn the unit on and off. 2. LCD SCREEN which displays various settings, parameters and prompts as detailed in the following pages. In addition, during the weld process it displays a load meter indicator showing the power level of ultrasonics that is being delivered to the welding press (see #3 below). 3.
6. TEST key which can be used to test ultrasonic operation and displays idle losses of converter/booster/horn as a percentage of maximum power when key is depressed. Also functions as a frequency display. 7. O.L. RESET key which resets the power supply following an overload condition. Red LED in upper left corner indicates an overload condition exists. 8. ENTER/REVIEW key which Enters data into the system as keyed in with the numerical keys and displayed on the LCD screen.
STARTING UP THE POWER SUPPLY Press the ON/OFF key to turn the power supply on. The LCD screen will briefly display “Start Sequence” and show wattage and frequency information. Then the LCD screen will show the following “ready” display: NOTE: The TEST and Load Meter check should always be done for all cold start-ups, and for any start-up after the system has been idle for 20 minutes or more. Ready INITIAL OPERATION After the power supply is turned on (as described on previous page), follow these steps: 1.
READY SCREEN In addition to the start-up ready screen (shown on page 16) there is another “ready” screen as shown below. The system must be displaying one of these two ready screens in order for welding to commence. Welding cannot be initiated from any other display. Cycles: 00,004,678 CRC: 000,062 Counter Screen The Counter screen displays the number of cycles run to date and the customer resettable counter (CRC).
ADDITIONAL FEATURES AND FUNCTIONS FREQUENCY DISPLAY The TEST key can also be used to display the running frequency. When the press head is in the UP position, press and hold the TEST key for 3 seconds. The information on the display will change from the power display (watts) to a frequency counter display (Hz). After this switch, the power is captured (no longer updated) and the frequency display will update every second. This information can help diagnose problems with the horn and/or stack assembly.
KEYPAD SECURITY The keypad can be “locked,” so that no new parameters or commands can be entered via the keyboard, thereby preventing unauthorized cancellation or adjustment. To activate the security feature, press and hold the numeral 7 key on power up.
MAINTENANCE GENERAL 1. Always make sure the power supply has adequate ventilation by keeping sufficient space around the assembly. 2. Periodically check the ventilation grilles and clean as necessary. REPAIRS / SERVICE If problems are encountered, contact our Service Department at 1-800-7451105. It is suggested that a system in need of repair be sent back to the factory with a written description pertaining to the nature of the problem.
WARRANTY Sonics & Materials, Inc., hereinafter referred to as "Sonics", warrants its products for a period of one year from the date of original shipment against defects in materials and workmanship under normal installation, use and maintenance as described in the operating instructions which accompany such equipment.
For components and parts not manufactured by Sonics but included in Sonics manufactured equipment, this warranty shall be limited to the warranty as given to Sonics by said original component or part manufacturer. Ultrasonic horns supplied by Sonics are manufactured to exacting specifications and are tuned to vibrate at a specific frequency. Using an out-of-tune horn will cause damage to the equipment and may result in warranty nullification.
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APPENDIX • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 27 I N S T RU C T I O N M A N UA L • M O D E L G X C / G C P O W E R S U P P LY
G-SERIES SWITCHES SWITCH POS. OFF POS.
