Generator SDG20/30/35/ 40/70 - RINCO ULTRASONICS · 5 A Introduction Thank you for purchasing a RINCO product. We are sure that you will achieve the highest possible econo-mic benefits

Operating manual

Generator

SDG20/30/35/ 40/70

Engl

ish

Copyright by RINCO ULTRASONICS AG, Switzerland

Version 1, gb, article no. 40595

Date of compilation: 28.02.2011

Release date: 29.11.2010

DisclaimerThe information contained in this manual corresponds to our current level of knowledge. It cannot, however, be regarded as a guarantee for specific pro-perties or suitability of the respective products for specific applications. Our general contract conditions apply in this case, also with regard to liability. The information contained in this manual does not grant the user any intellectual property rights nor any licence assurances. Suitable agreements must be made to this purpose. Suitability of the products for specific applications must be examined in collaboration with our specialists. The German version of the manual and the information it contains is binding.

Notes

This operating manual must be read and carefully followed before unpacking and starting operation of the device.The device must only be used, serviced and repaired by persons who are familiar with the operating manual and the applicable health and safety regulations for the prevention of accidents in the workplace.

Unit specifications

Representative

Table of Contents1 Explanation of symbols and marks 62 Transport 7

2.1 Receipt of the shipment 72.2 Damage during transit 7

3 Technical data 83.1 Standards and conditions of use 83.2 Limit values, connected loads 8

4 Safety information 94.1 General information 94.2 Intended use 94.3 Requirements for use 94.4 Installation 94.5 Electrical connections 104.6 Operation 10

5 Installation 115.1 Mechanical installation 11

5.1.1 Dimensions and assembly 115.2 Ambient conditions 125.3 Electrical installation 13

5.3.1 Power supply connections and other electrical connections 14

5.3.2 Connection of the protective earth con-ductor 14

5.3.3 Equipotential bonding 155.4 EMC compliant installation 14

5.4.1 Installation of a CE-typical ultrasonic system 14

6 Operation 156.1 High voltage 156.2 Noise emissions 156.3 Vapours and dust emissions 156.4 Temperature 156.5 Guarantee 16

7 Product information 177.1 Brief overview of the key features 17

8 Available generators and their variants 198.1 Power classes 19

9 Operating controls and indicators 209.1 Characters on the LCD display 21

10 Connection of the generator 2210.1 Signals 2210.2 Description of the signals 23

10.2.1 STO_0 2310.2.2 STO_1 2310.2.3 STO_2 2310.2.4 STO_3 2510.2.5 STO_3.1 2510.2.6 STO_5 2510.2.7 STO_6 25

11 Description of the process 2711.1 Welding mode 28

11.1.1 Time Mode 2811.1.2 Energy Mode 2811.1.3 Time and Energy Mode 2811.1.4 Time or Energy Mode 2811.1.5 Continuous Mode 2811.1.6 Contact Cut-off 28

11.2 Start mode 2911.2.1 Manual 2911.2.2 Automatic 3011.2.3 Pulse 30

11.3 Trigger mode 3011.3.1 Trigger «OFF» 3011.3.2 Trigger «ON» 3011.3.3 Trigger «Start» 30

11.3.4 Trigger «Time» 3011.3.5 Trigger «Pre-trigger» 31

11.4 Power and energy measurement 3111.4.1 Power measurement and

power curve 3111.5 Power overload 32

11.5.1 Energy measurement 3211.6 Soft start and start amplitude 3211.7 Ultrasonic test, power loss

measurement and amplitude measurement 3211.8 Frequency lock-in range 3311.9 Amplitude selection 33

12 Parameter overview 3412.1 Operator, User PIN 3412.2 Analysis PIN 4012.3 Reset function PIN 40

13 Settings 4113.1 DipSwitches for CAN terminating resistors 4113.2 Jumper J6 4113.3 Jumper J9 / J10 42

14 Amplitude values 4314.1 Amplitude values for 20 kHz generators 43 14.1.1 Amplitude diagram for 20 kHz generators 4314.2 Amplitude values for 30 kHz generators 44 14.2.1 Amplitude diagram for 30 kHz generators 4414.3 Amplitude values for 35 kHz generators 45 14.3.1 Amplitude diagram for 35 kHz generators 4514.4 Amplitude values for 40 kHz generators 46 14.4.1 Amplitude diagram for 40 kHz generators 4614.5 Amplitude values for 70 kHz generators 47 14.5.1 Amplitude diagram for 70 kHz generators 47

15 Example applications 4815.1 Starting and stopping ultrasonic operation 48

15.1.1 STO_2 4815.1.2 STO_3 / STO_5 4915.1.3 Time diagram 50

15.2 Amplitude selection 5115.2.1 Time diagram 52

15.3 Power measurement 5315.3.1 Time diagram 54

16 Technical data 5516.1 Voltage supply 5516.2 Generator fuses 5516.3 Analogue and digital inputs and outputs 55

16.3.1 Overview of inputs and outputs 5616.3.2 Analogue input and output 5716.3.3 Digital time response Inputs and outputs 58

17 Cleaning and maintenance 5917.1 Periodic checks 59

18 Disposal 6019 Error messages and error analysis 6120 Menu tree 6321 Operating parameters 6422 Troubleshooting 65 22.1 General errors 65

22.2 Generator error LED1 6622.3 Converter and application error LED2 6722.4 Limit error LED3 68

23 Service centre addresses 69

5

A

IntroductionThank you for purchasing a RINCO product. We are sure that you will achieve the highest possible econo-mic benefits and product quality with the use of this device.The aim of this manual is to provide the purchaser and user with all necessary information on handling, assembly, operation and care of the device.To ensure the constant operational availability of the device it is necessary to observe and follow the notes and instructions in this manual.

Important!If you have any questions regarding your unit, please state the exact type designation and the unit series number.This can be found on the type plate(A) on the rear of the generator as well as on page two of this operating manual .The design and circuitry of these devices are subject to constant further development and improvement and are always in keeping with the state of the art.

RINCO ULTRASONICS AGRomanshorn, Switzerland.

6

1 Explanation of symbols and marks

Pay special attention to text sections marked with the following symbols:

Note!

Indicates important information or operational notes

for trouble-free operation.

Caution!

Indicates hazard warnings which can result in seri-

ous injury or damage to equipment if ignored.

Danger!

Indicates hazard warnings which can result in death

or very serious injury if ignored.

Danger -

High voltage!

This warns about dangerous voltages. Take great

care if you see this warning. Keeping a safe distance

is the best way to stay safe.

Instruction

Wear ear defenders. This indicates which protection

measures need to be followed at the corresponding

workstation.

7

2 Transport

Always follow the transport information provided on

the packaging.

2.1 Receipt of the shipment

The shipping container for machines and equipment withstands normal stress and strain during transport by road, rail and air.After receipt of the consignment check that all parts correspond with the packing list and that no damage is visible. If damage is detected, inform the transport com-pany immediately and keep the packaging as evidence.

2.2 Damage during transit

The transport company is responsible for damage occurring during transport. A complete report descri-bing the exact damage must be submitted to the trans-port company; this will subsequently serve as the basis for the claim for damages.We must be notified immediately of any damage to or loss of the goods we have supplied - this must be con-firmed by a copy of the above-mentioned report.If the consignment is sent free of charge by RINCO ULTRASONICS or by CIF, the damaged shipment will be replaced (if applicable) and claims will be submitted to the relevant transport insurance company.

Type HF power HF power HF power Mains supply Standby

Peak Pulsed Continuous Voltage Input (max)

operation operation frequency power

(1); (4) (2); (4) (3); (4) (max.)

SDG20-2000P-230 2400 W 1600 W 1000 W 3800 VA

SDG20-1500P-230 1800 W 1200 W 700 W 2600 VA

SDG20-1000P-230 1200 W 1000 W 700 W 2200 VA

SDG30-1000P-230 1200W 1000 W 700 W 2000 VA

SDG30-500P-230 600 W 500 W 400 W 1100 VA

SDG35-4-900P-230 1080 W 700 W 500 W 2000 VA

SDG35-750P-230 900 W 650 W 500 W 1700 VA 60 VA

SDG35-4-750P-230

SDG35-400P-230 480 W 400 W 400 W 1100 VA

SDG35-4-400P-230

SDG35-4-200P-230 240 W 200 W 200 W 510 VA

SDG40-800P-230 960 W 700 W 500 W 1900 VA

SDG40-400P-230 480 W 400 W 400 W 1100 VA

SDG70-100P-230 120 W 100 W 100 W 320 VA

8

L1/N PE 230V

+/- 10%

50 / 60 Hz

3 Technical data

3.1 Standards and conditions of use

3.2 Limit values, connected loads

Conformity: CE

Ambient conditions: - non-condensing, average relative humidity 20 - 90% - 0 to 1000 over NN.Temperature range: Transport / storage -20 to +70 degrees Celsius(ambient temperature) Operation +10 to +50 degrees Celsius

Leakage current: > 10 mA to PEProtective measures against: Short-circuit, overload, overtemperature in the output stage

(1) Max. peak power (in the range of milliseconds)(2) Pulsed mode 1 to 9 (e.g. 1 s ON 9 s OFF)(3) At 100% amplitude(4) These values should be treated as non-guaranteed guide values for the SDG generator. The actual values for an overall system may differ significantly from this.

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4 Safety information

4.1 General information

Some of the components in the ultrasonic system (HF cables, converter, horns) may move or rotate as a result of the way in which they are operated.

Unauthorised removal of the necessary covers,

improper use and incorrect installation or operation

can potentially cause serious personal injuries or

material damage.

All activities associated with transportation, installa-tion, commissioning and servicing must only be per-formed by qualified and trained experts (IEC 364 and CENELEC HD 384, or DIN VDE 0100 and IEC Report 664, or DIN VDE 0110, as well as any pertinent nati-onal health and safety legislation regarding accident prevention must be complied with at all times).In the context of this basic safety information, a "qua-lified and trained expert" is a person who is familiar with the installation, assembly, commissioning and operation of the product. A qualified and trained per-son also has the necessary qualifications required to carry out the relevant activities.

4.2 Intended use

SDG generators and accessories are intended only for the welding and cutting of suitable materials.Depending on the material and application,people working on the machine may in some cases be exposed to harmful vapours, abraded material, high temperatures on materials or tools and high levels of noise. In these cases, make sure that adequate protec-tive measures are in place (e.g. covers, soundproofing cabins, fire extinguishing system) so that nobody who is working on the machine can come to harm.Please consult your material supplier for information about potential hazards which can arise due to ultra-sonic welding or cutting.

For more information about suitable materials please contact RINCO ULTRASONICS AG.

4.3 Requirements for use

SDG generators are components (incompletemachines) which are designed for installation in electrical systems or machinery. They must not be used as a standalone device. They are designed exclu-sively for professional and commercial purposes in accordance with EN 61000-3-2. This documentation contains information on compliance with the standard EN 61000-3-2.When SDG generators are being installed in a larger system, they must not be taken into operation (i.e. started up in accordance with the specified operatio-nal start-up procedure) until it has been demonstrated that the machine complies with the requirements ofEC directive 98/37/EC (machinery directive) and that the requirements of harmonised standard EN 60204 have been met.Commissioning (i.e. start-up in accordance with the specified start-up procedure) is only permitted if the requirements of the EMC directive 89/336/EEC are satisfied.SDG generators satisfy the requirements of the low voltage directive 73/23/EEC. The harmonised stan-dards in the series EN 50178/DIN VDE 0160 are appli-cable to the generator.

4.4 Installation

Ensure that everything is handled properly and avoid any excessive mechanical stresses or strains. Avoid bending components and changing insulation distan-ces during transportation or when handling the unit. Do not touch any electronic components or contacts.SDG generators contain components which are sensi-tive to electrostatic discharge. These components can easily be damaged if the unit is not handled correctly. Do not damage or destroy any electrical components - this could be harmful to your health!

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4.5 Electrical connections

If work needs to be carried out on SDG generators

while they carry a live voltage then the applicable

national health and safety legislation concerning the

prevention of accidents in the workplace (e.g. VBG

4) must be satisfied.

The electrical installation must be performed in accordance with the applicable regulations (e.g. in terms of the required conductor cross-sections, fuses, PE connections). Additional information can be found in the documentation.The documentation contains information about instal-lation in accordance with the EMC guidelines.(Shielding, earthing, filters and cables/wires).

4.6 Operation

Systems with SDG generators must be equipped with additional monitoring and protection devices which meet the applicable standards (e.g. standards for technical installations, accident prevention regulations etc.).Independently of this, the following must be provided: an EMERGENCY OFF circuit, a mains supply discon-nection device and all-phase fuses for the input circuit.

11

285

mm

430 mm

150 mm

5 Installation

5.1 Mechanical installation

5.1.1 Dimensions and assembly

The SDG generator weight approx. 9.5 kg and has the installation dimensions shown in the diagram below.

For more information please contact RINCO ULTRASONICS AG.

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5.2 Ambient conditions

The SDG generators must not be installed in locations in which they would be subjected to adverse ambient conditions. This includes:combustible, oily or harmful vapours or dust, excessi-vely high humidity, extreme vibrations or temperatu-res. For additional information please contact RINCO ULTRASONICS AG directly.

Operation of the SDG generator is affected by the ambient temperature. The permissible ambient tem-perature range is 10° C to 50° C. The SDG generator must be installed in such a way that its maximum per-missible temperature is never exceeded. The ambient temperature must be monitored.In the event that the stated temperature limits are exceeded, corresponding temperature control mea-sures must be put in place (cooling etc.). Cooling should generally be provided for applications involving operation under high loads or for continuous or semi-continuous operation.

RINCO ULTRASONICS AG will be happy to advise you on selection of a suitable version.

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5.3 Electrical installation5.3.1 Power supply connections and other electrical

connections

Carry out the following steps to ready the unit for operation:

• Connect the plug of the device to the outlet on the generator. - STO_0 Mains connection - STO_1 RS485 - STO_2 Interface (optional) - STO_3 Actuator (optional) - STO_3_1 Easy 745 / Easy 3000 (optional) - STO_4 Converter connection - STO_5 Start - STO_6 CANopen• Screw the equipotential bonding wire to the PE con-ductor connection.

Please refer to sections 5.3.2 and 5.3.3.

Only use an earthed mains connection.

For more information about pin assignment refer to section 10.1.

Attachment for the equipotential bonding

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5.3.2 Connection of the protective earth conductor

The SDG generator must never be operated without

a PE conductor connected. In addition, a PE con-

ductor with a minimum cross-section of 2.5 mm²

must be connected from the SDG generator to every

ultrasonic converter.

5.3.3 Equipotential bonding

All components of an ultrasonic system must be con-nected to one main potential. This connection can be established e.g. via a mounting plate or a cable with a minimum cross-section of 6 mm².

5.4 EMC compliant installation

RINCO ULTRASONICS AG has performed conformity tests with the SDG-type generators on specific, defined vibration units. Ultrasonic systems which have been assessed in this way are referred to as "CE-typical ult-rasonic systems" in the following.

5.4.1 Installation of a CE-typical ultrasonic system

The following points must be observed in order to ensure that the connections are compliant with EMC requirements:

• Apply ferrite on both sides to HF cables • Data cables must not be routed parallel to the HF cable or to the mains cable • Use cables which are shielded on both sides

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6 Operation

During installation of the SDG generator in machines, it must not be taken into operation (i.e. started up in accordance with the specified operational start-up procedure) until it has been demonstrated that the machine complies with the requirements of EC directive 2006/42 EC (machinery directive) and that the requirements of harmonised standard EN 60204-1 have been met.

6.1 High voltage

Caution!

While the unit is in operation, never pull out the

generator insert module.

Danger!

High voltage inside the devices – risk of injury!

Please observe the following points:

• Never do anything which might be dangerous or could jeopardise your safety. • Only run the system if all safety devices and safety-related equipment, for example removable protection devices and soundproofing, are fitted and fully functional. • Before switching on the unit, ensure that no-one can be endangered as a result of the unit starting up.

6.2 Noise emissions

Caution!

Limit values: according to the latest findings, ultra-sound does not cause any damage if the maximum level is below 140 dB and the average level is below a linear value of 110 dB (based on 8 hours per day).In the case of a 20 kHz application, the system integra-tor must either instruct the operator to use ear defen-ders by attaching a corresponding warning sticker to the machine, or he must ensure that the operator is

protected against arising noise emissions through the use of a sound enclosure.Sound components in the audible range are deemed to be potentially harmful to hearing if the energy-equi-valent continuous sound pressure level Leq reaches a level of 88 dB(A) or more (in relation to a representati-ve working period of 8 h/day, max. 2000 h/year).Energy-equivalent continuous sound pressure levels Leq of 85 to 87 dB(A) per day or week and pulsed sound events with a peak value LPeak in excess of 140 dB(C) are deemed to be on the threshold of potentially causing harm to hearing.

When certain materials are welded, noise levels can

exceed 70 dB (A).

Countermeasures:

• Wear ear defenders • Install a sound protection hood (option) (information taken from SUVA (Swiss Accident Insurance Fund) publication no. 86048 d 4.94)Additional measured values can be found in the document "Noise Measurement Report for RINCO Systems" (no. 920-3903/1.95).

6.3 Vapours and dust emissions

Depending on the material, harmful vapours or dust

can be generated during welding or cutting.

Countermeasures:

• Provide an extraction system • Wear a dust mask

6.4 Temperature

Depending on the material, high temperatures may

be generated on the material and/or tool during

welding or cutting.

In these cases we recommend considering the instal-lation of a fire extinguishing system.

16

The user should obtain the specifications (safety data sheet) for every material which is processed and check for potential hazards associated with ultrasonic treatment.The user is also responsible for ensuring proper dispo-sal of any leftover material.

6.5 Guarantee statement

In supplying the device RINCO ULTRASONICS enters into a guarantee obligation in compliance with the regulations of the VSM (Swiss Association of Machinery Manufacturers).

The requirements for fulfilment of the guarantee condi-tions by RINCO ULTRASONICS include the following:• The user must be familiar with the content of this

operating manual.• The instructions and warnings contained in this

operating manual must be observed.• Unauthorised modifications or conversions to parts

of the device, the oscillator system and the genera-tor are not permitted.

If anything is unclear, RINCO ULTRASONICS would be happy to help clarify any questions by phone. Alternatively, we can also arrange instruction sessions with our qualified experts.

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7 Product information

7.1 Brief overview of the key features

Clear control concept for special purpose machines

• Flexible modular system with various plug-in modules • All control tasks and parameter inputs are made possible via integral PLC • User-friendly thanks to a new keyboard and a large 5x20 character LCD display • Menu guidance is currently offered in 7 languages • Error coding (generator errors, oscillator system errors, limit errors) • Digital inputs and outputs for control • Analogue amplitude selection • Analogue power output (0 - 120%) • 0 - 4 V • 0 - 10 V

Increased process reliability thanks to active pro-

cess monitoring

• Digital open and closed-loop control technology designed according to the latest findings in the field of ultrasonic welding technology • Welding controlled via a digital signal processor (DSP) • Digital PLL for frequency control • Welding modes: - Time Mode (accuracy 1ms) with energy limits - Energy Mode (accuracy 0.1Ws) with time limits - Time and Energy Mode with energy and time limits - Time or Energy Mode with energy and time limits - Continuous Mode with power limits (accuracy 1W) - Contact Cut-off with time limits • Amplitude control • Power measurement with an accuracy of ± 1% of the rated generator power output • In-depth understanding of the electrical signals of the generator for system analysis and, as a result, identification of limit load states for the generator and converter

18

Comprehensive protection for the generator

• Shutdown in the event of a fault or if the limits are reached • Adjustable soft start and soft stop time for protection of the oscillator system

Data transfer via bus-capable interfaces

• Serial interface RS485 • CANopen interface • Operating parameters can be adjusted via interfaces

19

8 Available generators and theirvariants

8.1 Power classes

The flexible and modular system allows users to choo-se a perfectly well suited generators for any specific application.

The following power classes are available:

20 kHz: 2000 W 1500 W 1000 W

30 kHz: 1000 W 500 W

35 kHz: 750 W 400 W

35(-4)* kHz: 900 W 750 W 400 W 200 W

40 kHz: 800 W 400 W

70kHz: 100 W

*for 4PZT converter

The vibration units and generators should only be

procured from RINCO ULTRASONICS AG.

For applications involving high loads the internal

cooling should be adapted to the ambient condi-

tions.

For more information, please contact your nearest RINCO ULTRASONICS AG service centre.

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9 Operating controls and indicators

26 Handles The generator insert module can be pulled out by

these handles if necessary.

The generator insert module must never be pul-

led out or inserted while the unit is connected to

the mains.

27 Power bar Indicates the power delivered during the welding

process.

The maximum power value for the last welding process is indicated by an LED and then deleted during the next welding process or if a fault occurs.

29 TEST button With the aid of the TEST button, ultrasonics can be

activated for a maximum of 15 seconds.

30 PIN button For entering the relevant access code.

31 Navigation keys For navigation in menus and changing pre-defined

values. • Enter: for confirmation of parameter inputs.

32 LEDs • READY This lights up when the generator is ready for

operation.

• US ACTIVE This lights up when ultrasonic operation is

activated.

• ERROR This lights up if a fault has occurred.

In order make troubleshooting easier, the error type is indicated through flashing of LED 1 to LED 3 on the power bar (see section 19)

33 The fixing screws of the generator insert module are located above and beneath the handles (26) and must be locked before the unit is taken into operation.

27

26

26

33

33

32

29

31

30

21

9.1 Characters on the LCD displayThe program dialogue or the measured values of the last ultrasonic welding are represented numerically.

The background illumination of the display is automatically deactivated 15 minutes after a button was last pressed. It is immediately reactivated as soon as a button is pressed again.

22

10 Connection of the generator

The power supply connection, connections for control via digital inputs/outputs and the connection for the oscillator system are made via the connectors on the rear panel of the generator.

Only original RINCO ULTRASONICS AG components

must be used for this. Otherwise the overall system

may fail to work properly.

10.1 Signals

All digital and analogue inputs and outputs can be tapped via the connectors. In the process, the prescri-bed wiring for the generator which is used must always be adhered to.

Plug connection back board

START_EXTERN_2_IN

This input can be used to start the welding process. The input is low-active.

TRIGGER_IN

External trigger input

RESET_INBy applying a 24VDC signal to this input the present fault can be acknowledged. If the input is connected to 24VDC while welding is active then the welding process is stopped and an error message is generated.

AMPL_AIN

The amplitude can be changed in real-time during welding in the range from the start amplitude to 100%.

The generator must be parameterised for external amplitudes. More detailed information can be found in section 12.

Example: AMPL_AIN

Voltage at AMPL_AIN in V Amplitude in %

4.0 4010.0 100

US_STOP_1_IN / US_STOP_2_IN

The input US_STOP_1_IN can be used to stop the welding process. If, during active welding, the input is set to 24VDC and US_STOP_2_IN is connected to GND then ultrasonic operation will stop immediately.

MV_OUT_PLC

This NPN output can be used to actuate the magnetic valve, e.g. for a special actuator. In the process, the load is switched to 24VDC. A maximum of 24 V / 0.25 A can be applied to this output.

MV_OUT_ACTUATOR

This NPN output can be used to actuate the solenoid valve, e.g. for a special actuator. In the process, the load is switched to 24VDC. A maximum of 24 V / 0.25 A can be applied to this output.

23

10.2 Description of the signalsThe available signals are briefly described below. The time behaviour of the signals is described in section 16.3.3.

10.2.1 STO_0Voltage supply of the SDG generator. Fuses F3, F4, mains switch.

Please refer to sections 16.1 and 16.2

10.2.2 STO_1

RS485_A

RS485_B

RS485_Y

RS485_ZSignals of the serial RS485 interface

The protocol of the RS485 interface is specific to RINCO.A detailed description of actuation via the RS485 inter-face can be requested from RINCO ULTRASONICS AG.

10.2.3 STO_2

24VDC_OUTA 24V power supply unit is integrated in the SDG generator. It can be used e.g. to actuate the digital inputs/outputs. The output voltage of the 24V power supply is fused via the fuse F2. It is located on the rear panel of the SDG generator.

Please refer to section 16.2

START_EXTERN_1_INThis input can be used to start the welding process. The input is ‹high active›.

This input needs to be activated by setting jumper J10.

Please refer to sections 11.2 and 13.3

24

PART_COUNT_OUT

Fault-free welding is signalled via a 100 ms pulse at the NPN output. In the process, the load is switched to 24VDC. A maximum of 24 V / 40 mA can be applied to this output. Alternatively, this output can be used to measure the current power (0 - 4VDC). The maximum output voltage of 4VDC corresponds to 120% of the generator power.


US_ACTIVE_OUT

If ultrasonic operation is activated, this is signalled with 24VDC at this output.

SSW1_PRESS_IN.1

If the security switch is activated, this is signalled with 24VDC at this output. (only with a Easy 745 or Easy 3000 welding machine)

POWER_AOUT

This analogue output outputs a linear voltage from 0 to 10VDC which is proportional to the current power. The maximum output voltage of 10VDC is used for 120% of the rated generator output power.

Example: POWER_AOUT (0 - 10 V)

ERROR_24_VDC_IN / ERROR_OUT

Normally, ERROR_24VDC_IN and ERROR_OUT are short-circuited via relay contacts. If a fault is present this connection is interrupted.A maximum of 24V / 0.5A can be applied to this output.

Generator Current power output in W Current power output in % Voltage at

POWER_AOUT in V

SDG20-2000 1600 80 6.67SDG30-1000 1000 100 8.33SDG35-900 360 40 3.33SDG40-800 400 50 4.17SDG70-100 30 30 2.50

25

HOMEPOS_24VDC_IN / HOMEPOS_OUT

If the input HOMEPOSITION_IN is connected to 24VDCthen HOMEPOS_24VDC_IN and HOMEPOSITION_OUT are short-circuited via relay contacts.

READY_OUT

If the SDG generator is ready for the next weld, then this is signalled with 24VDC at this output. If the output is connected to 0VDC then the generator is switched off, in the process of welding or blocked by a fault.

READY_1_OUT

If the SDG generator is ready for the next weld and the input HOMEPOSITION_IN is connected to 24VDC then this is signalled with a 24VDC signal at this output.

GND

Reference ground for 24VDC_OUT.

10.2.4 STO_3

Connection of the MP welding press.

24VDC_EMERGENCY_IN

Emergency stop input.

TRIGGER_IN

External trigger input.

MV_OUT_ACTUATOR

This NPN output can be used to actuate the solenoid valve, e.g. for a special actuator. In the process, the load is switched to 24VDC. A maximum of 24 V / 0.25 A can be applied to this output.

GND


HOMEPOSITION_IN

This can be used to detect the end position when an actuator is used. If the 24VDC signal is present at this input then HOMPOSITION_IN and HOMEPOSITION_OUT or READY_OUT and READY_1_OUT are short-circuited via relay contacts.

24VDC_EMERGENCY_OUT

24VDC voltage supply for the emergency stop device.

START_1_AMP_IN

This input can be used to start the welding process. The input is high active.

START_2_AMP_IN


10.2.5 STO_3.1

Connection of the Easy welding press.

10.2.6 STO_5

24VDC_EMERGENCY_OUT

24VDC voltage supply for the emergency stop device.

24VDC_EMERGENCY_IN

Emergency stop input.

The emergency stop device can be connected to both STO_5 and to STO_3. Jumper J9 must be set to posi-tion 1 - 2.


START_1_AMP_IN

This input can be used to start the welding process. The input is high active.


Please refer to section 11.2 and 13.3

START_2_AMP_IN



Please refer to section 11.2 and 13.3

GND


26

10.2.7 STO_6

Signals of the CANopen bus system

A detailed description of actuation via the CANopen inter-face can be requested from RINCO ULTRASONICS AG.

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11 Description of the process

A welding cycle can be divided into eight sequences:

• 1 The time from the start condition to the trigger signal < 10s• 2 Ultrasonics active (stop condition depending on the welding mode)• 3 Hold time• 4 Delay time of the afterpulse• 5 Afterpulse• 6 Delay time of the PV test (50 ms)• 7 PV test (250 ms)• 8 Part counter pulse (100 ms)

Depending on the selected start mode or welding mode, the start and stop conditions may differ.Please refer to section 11.2

US-Cycle Start Stop ConditionsUS-Cycle End

STARTCONDITIONS

28

11.1.4 Time or Energy Mode

In Time or Energy Mode, the user defines the target welding time and the target welding energy.The ultrasonic process is terminated if one of the two criteria (time or energy) is satisfied.If after the end of the ultrasonic process the minimum welding time or the minimum welding energy have not been attained then an error message is generated.

11.1.5 Continuous Mode

In Continuous Mode, a lower and upper power limit can be adjusted in 1W increments. If the power exceeds these limits for longer than an adjustable time, then the ultrasonic process is aborted with an error message. No time or energy monitoring is per-formed.

11.1.6 Contact Cut-off

For the stamping of fabrics or non-woven materials, the ultrasonics can be stopped with a voltage poten-tial of 24 VDC if metallic contact is made between the horn and the counter-tool.

US_STOP_1_IN is connected to 24VDC.

US_STOP_2_IN is connected to the metal mounting which is insulated against the machine table.

11.1 Welding mode

The SDG generator can be operated in six welding modes.

11.1.1 Time Mode

In Time Mode, the user defines the target welding time. When the ultrasonic process is started, the wel-ding time is reset and counted up in millisecond steps. When the target welding time has elapsed the ultraso-nic process is stopped.In time mode, the energy which is converted during the ultrasonic process is measured. If an adjustable maximum energy limit is exceeded, the ultrasonic process is aborted with an error message. If an adjus-table minimum energy level is not attained during the ultrasonic process, then an error message is displayed after the end of the ultrasonic process.

11.1.2 Energy Mode

In Energy Mode, the user defines the target welding energy. The ultrasonic process is terminated after the target welding energy is reached. If an adjustable maximum welding time is exceeded before the target welding energy is attained, then the ultrasonic process is aborted with an error message.After the end of the ultrasonic process the welding time is compared to an adjustable minimum welding time. If the minimum welding time was not attained an error message is generated.

11.1.3 Time and Energy Mode

In Time and Energy Mode, the user defines the target welding time and the target welding energy.The ultrasonic process is terminated when both crite-ria (time and energy) are satisfied.If an adjustable maximum welding time or maximum welding energy is exceeded the ultrasonic process is aborted with an error message.

29

11.2.3 Pulse

The cycle start is performed by briefly pressing the 2-handed release. For the start condition to be valid, the change at the normally open contact (START_EXT_1_IN) from low to high and at the normally closed contact (START_EXT_2_IN) from high to low must happen within 300 ms.

Zeit

Start AK

Start RKkein Einfluss

US-Zyklus Start

11.2 Start mode11.2.1 Manual

The cycle is started with a 2-handed release. For the start condition to be valid, the change at the normally open contact (START_EXT_1_IN) from low to high and at the normally closed contact (START_EXT_2_IN) from high to low must happen within 300 ms.

The start condition must remain satisfied until the trig-ger signal becomes active. (Trigger_IN)

The trigger signal must occur within 10 seconds of the cycle start.

11.2.2 Automatic

The cycle start is performed via a signal at the normally open contact. (START_EXT_1_IN). In order for the start condition to be valid, the signal must be present for at least 5 ms.

The signal at the normally closed contact (START_EXT_2_IN) is not analysed.

Zeit

Trigger IN

Start AK

Start RK

US-Zyklus Start

Manuell

Zeit

Start AK

Start RK

US-Zyklus StartUS-Cycle Start

Time

US-Cycle Start

Time

US-Cycle Start

Time

30

11.3.3 Trigger "Start"

To start ultrasonics, the start condition must remain satisfied until the trigger signal becomes active (Trigger_IN).

11.3.4 Trigger "Time"

Ultrasonics are started after the time set in the welding parameters (trigger time) has elapsed after the cycle start.

11.3.5 Trigger "Pre-trigger"

Ultrasonics are started after the time set in the welding parameters (trigger time) has elapsed after the cycle start. From the trigger signal onwards (Trigger_IN), the system welds until the programmed time (in Time Mode) or energy (in Energy Mode) is reached.

The trigger signal must occur within 10 seconds of the start of ultrasonics.

11.3 Trigger mode

The ultrasonic release moment (trigger) can be adjus-ted under the system parameters (OFF, ON, Start, Time and PreTrigger).

11.3.1 Trigger "OFF"

Ultrasonics are started immediately after the cycle start via a valid start condition. The trigger signal (TRIGGER_IN) is not analysed.

11.3.2 Trigger "ON"

Ultrasonics are started after the cycle start via a valid start condition via the trigger signal (TRIGGER_IN). The trigger signal must be present for at least 5 ms.

The trigger signal must occur within 10 seconds of the cycle start.

Zeit

Trigger

US_ON

StartBedingung

US-Zyklus Start Stopp Bedingung

Zeit

Trigger

US_ON

StartBedingung


Zeit

Trigger IN

US_ON

StartBedingung


Triggerzeit Zeit/ Energie

US-Cycle Start Stop Condition

Trigger "OFF"

StartCondition


Time

StartCondition


Time

StartCondition


Time

StartCondition

Trigger Time


Time

StartCondition

Trigger Time Time Energy

31

11.4 Power and energy measurement

11.4.1 Power measurement and power curve

The converter power is measured during the ultrasonicprocess, and the power curve (as a percentage of the generator power) is stored in the SDG generator.The SDG generator automatically determines the time intervals (power measurement interval) at which a measured value is stored. The power measurement interval depends on the welding time.

Welding time Power meas. int. in milliseconds

5 – 512 ms 1 513 – 1024 ms 2 1025 – 2048 ms 4 2049 – 4096 ms 84097 – 8192 ms 168193 – 16384 ms 32

The data memory of the SDG generator can store 16384 milliseconds. The power curve is only saved for a normal ultrasonic process; the power curve is not saved for the shake-off pulse or for the power loss measurement.

32

Power overload

Soft start and start amplitude

11.5 Power overload

If the generator is operated for longer than 50 ms at a power above the maximum of 120 % of the generator power, then the welding process is aborted with an error message in order to protect the oscillator system and the generator.

The upper limit for the maximum power can be adjus-ted in 1 Watt increments as required.

11.5.1 Energy measurement

The energy value is updated every millisecond.

11.6 Soft start and start amplitude

A soft start time is implemented in order to protect the oscillator system. The soft start starts the ultrasonic process with a start amplitude and increases the amp-litude linearly every millisecond until the target ampli-tude is reached. The time from the start amplitude to the target amplitude is referred to as the soft start time and can be adjusted from 5 ms to 200 ms. At the same time, the frequency control is slowed down during the soft start. As a result, the process of building up the oscillations on horns which are difficult to do this with is made easier. During the soft stop the ultrasonic pro-cess is not switched off immediately. The amplitude is reduced linearly from the current amplitude value to 0. This time is referred to as the soft stop time and can be adjusted from 0 ms to 50 ms.During the soft stop the frequency control is switched off. The illustration shows the ramp start value, soft start time, soft stop time, target welding time and target energy.It must be prevented that these times are incorrectly adjusted.

For example, if the welding time is less than the soft start time it will not be possible to reach the target amplitude.

33

Signal flow diagram for the amplitude selection

The amplitude selection via CANopen and the ana-logue amplitude selection are real-time capable, i.e. the amplitude can be adjusted while the ultrasonic process is running.

This is possible with restrictions via the RS485 inter-face; due to the transfer speed of the interface the command has a delay of 5 ms.

11.7 Ultrasonic test, power loss measure-ment and amplitude measurement

The ultrasonic test can be used for fault diagnosis or when replacing the oscillator system in order to find the optimum starting frequency for an ultrasonic pro-cess. The ultrasonic test can be activated via the TEST button for a maximum of 10 seconds.

The display of the measured values for the power loss and the frequency is continuously updated. In order to protect the system and to ensure that the measu-rements are reproducible, the power loss is always measured at 60% of the target amplitude.The power loss measurement can be started via the CANopen interface or the RS485 interface. The power loss measurement starts at the current frequency and lasts for 250 ms. The soft start and the soft stop are used during the measurement of the power loss. The power curve is not recorded.In order to measure the amplitude, the corresponding PIN code should be entered so that you can access the "Amplitude measurement" menu. Here, the target amplitude corresponds to the value set in the welding parameters. Ultrasonic operation can be activated for a maximum of 15 seconds via the TEST button during the amplitude measurement.

11.8 Frequency lock-in range

The maximum frequency lock-in range (permitted range of the ultrasonic oscillator) is at +500 Hz and –500 Hz of the nominal frequency for 20, 30, 35 and 40 kHz generator and at +3000 Hz and -3000 Hz for 70 kHz generators. The ultrasonic process is aborted with an error message if the lock-in range is exited.

Lower and upper frequency limits can be adjusted in 1 Hz increments as required.

11.9 Amplitude selection

The target amplitude can be adjusted via the keyboard input, the CANopen interface, the RS485 interface or the analogue amplitude input. The amplitude is indi-cated in percent. The valid range goes from the value of the start amplitude to 100 %.Whether the internal variable or the analogue input is to be used is adjusted via a parameter which can be changed via the interface.

Selection Amplitude

Internal AmplitudeSettings

AmplitudeAnalog Output

34

Block Description

Set-up/adjustment After the start of the cycle the magnetic valve is activated. The status of the trigger is signalled by 0/1 in the display.

Access is only possible with the aid of the "User PIN". The start mode is automatically switched to "Manual". The set-up/adjustment mode is only available via the two-handed control. After the set-up/adjustment, the start mode needs to be checked.Welding parameters Welding mode Defines the conditions for the stop of ultrasonics. • Time Mode • Energy Mode • Continuous Mode • Time and Energy Mode • Time or Energy Mode • Contact Cut-off Mode

The individual modes are described in detail in section 11.1.

Welding time / welding energy / afterwelding time Target welding time in [ms] in Time Mode, target energy in [Ws] in Energy Mode or afterwelding time in [ms] in Contact Cut-off Mode.

Depending on the selected mode, other parameters are hidden.

Hold time In order to harden the weld, the horn can be held on the workpiece for this predefined time in [ms].

This setting is only available if the magnetic valve has been activated in the system parameters.

12 Parameter overview

By entering the corresponding PIN, users can gain wider access to options via the main menu. The main menu will then allow access to the following additional options:

• Set-up/adjustment• Welding parameters• System parameters• Amplitude measurement• Measured values

12.1 Operator, User PIN

35

Block Description

Welding parameters Amplitude

Target welding amplitude in [%].

Maximum limit

Maximum welding time in [ms] ] in Energy Mode or maximum Energy in [Ws] in Time Mode.

Please refer to sections 11.1.3 and 11.1.4.

Minimum limit

Minimum welding time in [ms] in Energy Mode or minimum energy in [Ws] in Time Mode.

Please refer to sections 11.1.3 and 11.1.4

Maximum power loss

Maximum limit value for the power loss measurement in [%].

P overload

Maximum limit value for the welding power in [W].

Power limit

If the output power exceeds the adjusted value then the welding amplitude is reduced by the generator.

This setting is only available if the power limit has been activated in the system parameters.

Afterpulse delay

The afterpulse is delayed by this time in [ms].

This setting is only available if the afterpulse has been activated in the system parameters.

Afterpulse

The afterpulse time in [ms].

36

Block Description

Welding parameters Start frequency

Welding starts at the set frequency.

This setting is only available if the start frequency has been activated in the system parameters.

Shut-off delay

Delay time in [ms] until the ultrasonic process is aborted after P overload is reached.System parameters

The system parameters cannot be changed with the "Operator PIN".

Power loss measurement

Adjustment of the power loss measurement before or after the welding cycle. • Before • After

Interval for the Pv measurement Measuring interval • 0 - 99; 0 = no measurement

Soft start time

The time in [ms] to build up the oscillations on complicated horns. (see section 11.6) • 0 – 200 ms

Afterpulse

Ultrasonic pulse length [ms] during the return stroke of the press. Prevents adhesion of the plastic part to the horn.

Soft stop time

The time in [ms] taken for the oscillations to build up on compl. horns. (see section 11.6) • 0 – 50 ms

Start amplitude

This is the start value in [%] for the soft start formation. (see section 11.6) • 15 - 40%

Max. frequency limit

Upper frequency limit • +50 - +500 Hz • +50 - +3000 Hz (70 kHz generator)

37

Block Description

System parameters Min. frequency limit

Lower frequency limit • -50 - -500 Hz • -50 - -3000 Hz (70 kHz generator)

Slow Control Rate

Factor for reduction of the control rate of the frequency control. This parameter can be activated in the event of problems with the build-up of oscillations on larger or more complex horns. • 1 - 20; 1 = deactivated (recommended)

Start frequency

Activates the setting for the start frequency. • On • Off

Power limit

Activates the setting for the power limit. • On • Off

Frequency reset

Welding starts with the last used frequency. If the frequency reset is switched on then the welding always starts at the nominal frequency. • On • Off

If the start frequency is switched on then the welding always starts at the frequency set under "Welding parameters".

Amplitude

• Internal Internally set amplitude • External External control of the amplitude for special machine configurations

Start mode

• Manual (compliant with EC requirements) • Automatic (EC conformity is no longer assured. The plant operator must adapt the machine concept so that it is compliant with the EC Machinery Directive.) • Pulse (EC conformity is no longer assured. The plant operator must adapt the machine concept so that it is compliant with the EC Machinery Directive.)

38

Block Description

System parameters Trigger

Selection of the ultrasonic trigger moment. • On Digital trigger input • Off No trigger present • Time After a certain length of time after the cycle start • Start Same as "On". The start condition is monitored up to the signal Trigger_IN. • PreTrigger Ultrasonic operation is started after a certain amount of time after the cycle start. The stop condition Time/ Energy is counted from the signal Trigger_IN.

Magnetic valve

• On activated • Off deactivated

Afterpulse

• On activated • Off deactivated

Error positions

Press position (magnetic valve state) in the event of blocking after an error. • Up • Down

The setting “Down” is only available if the parameter “Reset” is switched on. In the event of a fault before the start of ultrasonic operation the magnetic valve is always deactivated.

Cable length

The length of the RF cable in metres between the generator and the ultrasonic converter. • 1 - 20 m

Reset

• On The error message must be acknowledged with the TEST button or with a Reset_IN (pin N) signal. • Off The error message can be deleted with the next cycle start.

Start PV test

• On Activated • Off Deactivated

39

Block Description

Language

• de German • en English • fr French • it Italian • tr Turkish • sv Swedish • cs Czech • zh Chinese

Contrast

Display contrast • -3 to +3Change PIN Operator PIN

• 0-6999

User PIN

• 0-6999

Analysis PIN

• 0-6999

PIN code

• Internal • External

If the PIN code is set to internal then the standard PIN codes 1000, 3000 and 5000 are active. If the option is set to external, then the set-up engineer can define the PIN codes.Amplitude measurement The amplitude measurement can be activated with the TEST button for a maximum of 15 seconds.

Amplitude

Target welding amplitude in [%] • 10-100%

The target amplitude can be adjusted under "Welding parameters".

Power loss

The current power loss measurement in [%]

Frequency

The current frequency in [Hz]

40

Block Description

Measured values The measured values of the last welding are displayed.

No adjustments can be made here.

12.2 Analysis PIN

For analysis in the event of faulty machine functions. However, no adjustments are possible.

Block Description

Input analysis Analysis of the signal inputs.

Output analysis Analysis of the signal outputs

Cycle analysis Display of the switching variables and measured values

Cycle phases Time dependant display of the cycle phases

Block Description

PIN reset Sets the PIN to "Internal" and activates the standard PIN codes

Generator reset Initialises the generator with the standard settings

Factory settings Directly performs all the resets mentioned above

12.3 Reset functions PIN

41

13 SettingsThe dip switches and the jumper J6 are located on the UGH generator insert module, and the jumpers J9 and J10 are located on the BUS PCB in the housing.

The generator insert module must never be pulled

out or inserted while the unit is connected to the

mains.

13.1 DIP switch for CAN terminating resistors

ON - terminating resistors are switched on.

Both CAN wires are connected to terminating resis-tors. These are connected if both of the DIP switches are set to "On".

13.2 Jumper J6

With the aid of the jumper J6, the output signal can be set as follows on the pin PART_COUNT_OUT (15):

J6 position 1-2: counter pulse (100ms)J6 position 3-4: analogue current power (0-4V)

The counter pulse is only output if the welding cycle has been completed without errors.

Example: PART_COUNT_OUT (0-4V)Generator Current power output in W Current power output in % Voltage at

PART_COUNT_OUT in V

SDG20-2000 1600 80 2.67SDG30-1000 1000 100 3.33SDG35-900 360 40 1.33SDG40-800 400 50 1.67SDG70-100 30 30 1.00

2

2

1

1

42

13.3 Jumper J9 / J10

The jumpers J9 and J10 are located on the BUS PCB in the housing of the generator. To change the jumper settings, it is necessary to remove the left-hand side panel of the generator. To do this, undo the 6 screws.

J10

J9

J9 (Emergency OFF): When using MP, ABW, SPA, SV, MA, G or HC this must be set to position 1 - 2. When using Easy press this must be set to position 3 - 4.

J10 (Start) Position 1 - 3: Start signal at STO_2 Position 4 - 3: Start signal at STO_3 or STO_5 Position 3 - 5: Easy welding machine

43

14 Amplitude values

The different generator output power levels result indifferent amplitudes. The amplitude value described in the table below refers to the configuration of the corresponding horn/generator/booster combination.The effective welding amplitude can therefore be read off directly.

14.1 Amplitude values for 20 kHz generators

9 Horn24 Converter25 BoosterA AmplitudeK1 Interface (converter/booster)K2 Interface (booster/horn)

14.1.1 Amplitude diagram for 20 kHz generators

A

24

K1

25

K2

9

44


9 Horn24 Converter with integrated boosterA AmplitudeK2 Interface (converter/horn)


24

K2

9

A

500 W (converter C30-1)1000 W (converter C30-2)

100%

40%

90%

80%

70%

60%

50%

1:1 1:1

Am

plitu

de [

m]

1:1 V1:1.51:21:31:4

HornIntegrated

boosterGain

100%

40%

90%

80%

70%

60%

50%

45


9 Horn24 Converter25 BoosterA AmplitudeK1 Interface (converter/booster)K2 Interface (booster/horn)


A

24

K1

25

K2

9

46


9 Horn24 Converter with integrated boosterA AmplitudeK2 Interface (converter/horn)


24

K2

9

A

800 W (converter C40-2)400 W (converter C40-2)

100%

90%80%

70%

60%

40%

50%

1:1 1:1Horns

Am

plitu

de [

m]

Integrated booster

V1:1.51:21:31:4

Gain

100%

90%

80%

70%

60%

40%50%

47

14.5 Amplitude diagram for 70 kHz genera-tors

9 Horn24 ConverterA AmplitudeK2 Interface (converter/horn)


24

K29

2

4

6

8

3

6

9

12

4

8

12

16

5

10

15

20

V1:11:21:31:41:5

Sonotroden

Ampl

itude

[µm

]

Verstärkung

1

2

3

4

9

18

27

36

8

16

24

32

7

14

21

28

6

12

18

24

10

20

30

40

1:101:91:81:71:6

SonotrodenVerstärkung

1

9 100%7 90%

5 80%3 70%

86

42

A

48

15 Example applications

A number of example applications are presented below. Please contact RINCO ULTRASONICS AG if you require any additional information.

The example applications show that the SDG gene-

rator must be fused upstream of the line filter and

that there must be a PE conductor connection to the

ultrasonic converter.

Detailed information about the electrical installation can be found in section 5.3.

In the example applications, the digital inputs and outputs are operated via an external 24VDC supply voltage.

15.1 Starting and stopping ultrasonic opera-tion

15.1.1 STO_2

The diagram shows the basic circuit for starting ultrasonic operation via the digital input START_EXTERN_1_IN. To start, the signal is set to 24VDC, and the signal needs to be set back to 0VDC to stop ultra-sonic operation. The input US_STOP_1_IN serves as a further option for switching off the ultrasonic process.The input US_STOP_2_IN must be connected to GND.

Alternatively, the input US_STOP_1_IN can be con-nected to 24VDC_IO_IN, and the input US_STOP_2_IN can be connected to GND to switch off the ultrasound.Ultrasonic operation is immediately switched off in the event of a fault.

In addition, the readiness signal (READY_OUT signal), the monitoring of ultrasonic operation (US_ACTIVE_OUT signal) and the error message (ERROR_OUT signal) are explained.

The input START_EXTERN_1_IN of STO_2 must be activated by setting the jumper J10.Please refer to section 11.2 and 13.3

Terminal connection diagram for starting and stopping ultra-

sonic operation

49

15.1.2 STO_3 / STO_5

The diagram shows the basic circuit for starting ultrasonic operation via the digital input START_1_AMP_IN. To start, the signal is set to 24VDC, and the signal needs to be set back to 0VDC to stop ultrasonic operation.

The input START_EXTERN_1_IN of STO_3 / STO_5 must be activated by setting the jumper J10.Please refer to section 11.2 and 13.3

50

15.1.3 Time diagram

1 The end of welding was triggered by the input START_EXT_1 being set to 0VDC (continuous mode).

2 The welding process was aborted due to an error:– Oscillator, generator or limit error

3 Welding stopped by applying 24VDC to US_STOP_1_IN.

A US_STOP_1_IN must be present for 5 ms before the stop is executed.

B The signal level of START_EXT_1 is not relevant.

C The solenoid valve output is activated immediately after the start of ultrasonic operation and deactiva-ted immediately after the stop of ultrasonic operati-on.

51

15.2 Amplitude selectionVia the analogue input AMPL_AIN, the amplitude can be externally varied from the start amplitude to 100%. If the analogue signal is below the value for the start amplitude, the generator will report a fault. The ampli-tude can be changed at any time.


Terminal connection diagram - amplitude selection

Error

Ready

52

15.2.1 Time diagram

1 The end of the welding cycle was triggered by set-ting the input START_EXT_1 to 0VDC.

2 The end of welding was triggered by setting the input START_EXT_1 to 0VDC.

3 Welding was aborted because of an error.– Oscillator, generator or limit error

A Welding is performed at 80% of the target amplitu-de (80% corresponds to 8VDC).

B Welding is started at 100% of the target amplitude (10VDC) and then reduced to 40% of the amplitude (4VDC) after the required period of time.

C Welding is started at 40% of the target amplitude (4VDC) and then consistently and linearly incre-ased.

53

15.3 Power measurement

The analogue signal of the output POWER_AOUT(0 to 10VDC) can be tapped and used for arbitrary interpretation or control tasks. Here, the maximum value of 10VDC corresponds to a power output of 120% of the nominal power. As a result, 100% of the nominal power is represented by a voltage value of 8.33VDC.Alternatively, the analogue signal of the output PART_COUNT_OUT (0 to 4VDC) can also be used. Here, the maximum value of 4VDC corresponds to a power output of 120% of the nominal power.As a result, 100% of the nominal power is represented by a voltage value of 3.33 V.

To do this, the jumper J6 must be set to the position 3-4.

Please refer to section 13.2.

The time diagram for POWER_AOUT was set up using a theoretical model for welding, since all applications differ greatly in practice. It is assumed that the pro-perties of the workpiece which is to be processed and the pressure conditions at the tool remain unchanged. The power output will display different behaviour to this in practice.

Connection diagram - power measurement

Error

Ready

54

15.3.1 Time diagram

1,2

The end of the welding cycle is triggered by setting the input START_EXT_1 to 0VDC.

A The welding is started at 80% of the target ampli-tude (8VDC) - this remains unchanged throughout the entire welding time.

In the theoretical model, the power depends on the amplitude and remains constant in the process.

B The welding is started at 70% of the target amplitu-de (7VDC) - this is then increased to 100% amplitu-de (10VDC) in the required time. In the theoretical model, the power depends on the amplitude and therefore also jumps up. The power value (0 to 10VDC) varies according to the application.

55

16 Technical data

16.1 Voltage supply

The SDG generator requires a voltage supply of 230VAC 50 / 60 Hz.

The tolerance of the 230VAC voltage must not exceed +/- 10%.

16.2 Generator fuses

16.3 Analogue and digital inputs and outputs

The voltage levels of the voltage supply and the digital inputs/outputs are shown in the table below.

Parameter Condition Min. Nominal Max. Unit

24VDC_EXT_IN 20 24 28 VDigital Input High Signal 20 VDigital Input Low Signal 1 VDigital Output High Signal Vsupply = 24V 24 VDigital >Output Low Signal Vsupply = 24V 0 0.5 V

GENERATOR

Sicherung F15x20mm

Sicherung F25x20mm

Sicherung F35x20mm

Sicherung F45x20mm

Generatortyp Sicherung F16.3x32mm

Sicherung F25x20mm

SDG20-2000P-230 12,5A 12,5A UGH20-2000P-230 12,5ASDG20-1500P-230 10A 10A UGH20-1500P-230 10ASDG20-1000P-230 10A 10A UGH20-1000P-230 10ASDG30-1000P-230 10A 10A UGH30-1000P-230 10ASDG30-500P-230 4A 4A UGH30-500P-230 4ASDG35-750P-230 6,3A 6,3A UGH35-750P-230 6,3ASDG35-750P-230 K3 6,3A 6,3A UGH35-750P-230 K3 6,3ASDG35-400P-230 4A 4A UGH35-400P-230 4ASDG40-800P-230 6,3A 6,3A UGH40-800P-230 6,3ASDG40-400P-230 4A 4A UGH40-400P-230 4ASDG70-100P-230 2A 2A UGH70-100P-230 2ASDG35-4-900P-230 6,3A 6,3A UGH35-4-900P-230 6,3ASDG35-4-750P-230 6,3A 6,3A UGH35-4-750P-230 6,3ASDG35-4-400P-230 4A 4A UGH35-4-400P-230 4ASDG35-4-200P-230 4A 4A UGH35-4-200P-230 4A

Generator Rückwand Netzdose Generatoreinschub

800mA 160mA 400mA

Fuse Fuse Fuse Fuse Fuse FuseGenerator rear panel Power plug

Generator typeGenerator module

56

16.3.1 Overview of inputs and outputs

The following table shows an overview of inputs/outputs.

Name Type Description Voltage level

RESET_IN Input Error acknowledgement, 24VDC Input current stop = 5 mA typ. Weld cycle Input resistance = 8.2 kΩUS_ACTIVE_OUT Output Ultrasonic process active 24VDC = ultrasonic process active Output current = 100 mA max.POWER_AOUT Output Analogue power output 0–10 V corresponds to 0W to generator output * 1.2 (e.g. 0 to 2400 W at 2000 W generator) Accuracy = ± 3% Output current = 10 mA max.READY_OUT Output Generator is ready for the 24VDC = ready next ultrasonic process Output current = 100 mA max.AMPL_AIN Input Analogue amplitude selection 15–10 V corresponds to an amplitude of 15% to 100% Accuracy = ± 3% Input current = 0.3 mA typ. Input resistance = 33 kΩMV_OUT NPN Output Magnetic valve Output current = 0.25 A max.PART_COUTNT_OUT NPN Output Counter output Output current = 40 mA max. Option: analogue Option: 0 - 4 V corresponds to line output 0 W to generator power * 1.2START_EXT_IN Input Starts the ultrasonic process 24VDC = activates ultrasonic process Input current = 5 mA typ. Input resistance = 8.2 kΩUS_STOP_1_IN Input Stops the ultrasonic process 24VDC = stop Input current = 5 mA typ. Input resistance = 3.5 kΩERROR_OUT Output Generator error 0VDC = error, 24VDC no error Output current = 0.5 A max.

57

AMPL_AIN input

POWER_AOUT output

SDG

SDG

10

3

16.3.2 Analogue input and output

Due to the circuit layout, the analogue input AMPL_AIN has a delay of a maximum of 0.7 ms. The analogue power output also has a delay of 0.7 ms. To ensure that no errors occur at the analogue input, the internal resistance of the supply source must not exceed 330 Ω.

In order to prevent the generation of errors at the ana-logue power output POWER_AOUT or PART_COUNT_OUT, the internal resistance of the connected drain must be greater than 10 kΩ.

In order to be able to use the analogue power output at the pin PART_COUNT_OUT, jumper J6 must be set to the position 3-4.

Please refer to section 13.2.

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16.3.3 Time behaviour of digital inputs and outputs

The diagrams below show the time behaviour of the different inputs and outputs.

START_EXT_1, US_STOP_1_IN, US_ACTIVE_OUT

and US_READY_OUT

Star

t

End

cycl

e

Star

t

Stop

START_EXT_1_IN

US_STOP_1_IN

Parameter Condition Symbol Min. Nominal Max. Unit

START_EXT_1_IN Pulse Width High tUS_ON_HI 100 msSTART_EXT_1_IN Pulse Width Low tUS_ON_LO 200 msUS_STOP_1_IN Pulse Width High tUS_STOP_HI 5 msUS_ACTIVE_OUT High tUS_ACTIVE_HI tUS_ON_HI -5 msSTART_EXT_1_IN High to tOn1 105.2 105.8 msUS_ACTIVE_OUT High DelaySTART_EXT_1_IN Low to tOff2 0.5 1 msUS_ACTIVE_OUT Low DelayUS_STOP_1_IN High to tOff3 5.2 5.8 msUS_ACTIVE_OUT Low DelayUS_READY_OUT Low tUS_READY_LO tUS_ON_HI -5 msSTART_EXT_1_IN High to tOff1 105.2 105.8 msUS_READY_OUT Low DelaySTART_EXT_1_IN Low to tOn2 1 1.3 msUS_READY_OUT High DelayUS_STOP_1_IN High to tOn3 5.2 5.8 msUS_READY_OUT High Delay

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17 Cleaning and maintenance

The generator requires no maintenance. However, the converter, booster and horn should be checked perio-dically and kept clean on the outside.

17.1 Periodic checks

If a cooling fan is provided then it should be checked periodically (according to the operating environment) for dust and cleaned as required. If filters are provided upstream of the fan then they should be replaced.

All connecting cables must be checked periodically.

If any damage to insulation is noted then the affec-ted components must be replaced immediately. All fastening screws must be properly tightened.

Before the start of any maintenance or cleaning

work, make sure that all energy sources, such as the

electrical power supply, are disconnected.

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18 DisposalThe generator must be disposed of properly in accord-ance with the applicable legislation and requirements.Please contact RINCO ULTRASONICS AG for more information.

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19 Error messages and error analysis

If an error is present, this is signalled by the ERROR LED coming on and by the error code being dis-played. The connection between ERROR_24VDC_IN and ERROR_OUT is interrupted.In order make it easier to analyse the error, errors are classed in three groups which are indicated by flas-hing of the LEDs (LED1 to LED3) on the power bar.

The table below shows the possible errors which can occur on the SDG generator:

• Generator error LED1 of the generator bar flashes

• Converter or LED2 of theapplication error generator bar flashes

• Limit error LED3 of the generator bar flashes

Converter and application errors and limit errors can be deleted with a new start signal. This means that, with these types of error, the generator can start a new cycle without the error message needing to be acknowledged first.

However, an acknowledgement is only possible if the fault is no longer active, e.g. if an upper temperature limit is no longer being violated.

All generator errors must always be acknowledged with the TEST button or with the Reset_IN signal.The new cycle start is not possible until the error has been acknowledged with the TEST button or with the Reset_IN signal.

Please refer to the adjustment of the"System parameters / reset" in section 12

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Error code of the SDG ultrasonic generator

1 Main supply voltage too low2 Fault in the internal 12 V supply3 Minimum PWM level reached4 Temperature too high5 Reserved6 Reserved7 Reserved8 Reserved9 Frequency too low10 Frequency too high11 Maximum converter voltage reached12 Overload13 Maximum PWM level reached14 No converter connected15 Missing cable or converter short-circuit16 Reserved17 Error - lower energy limit value18 Error - upper energy limit value19 Error - lower time limit20 Error - upper time limit21 Error - lower power limit value22 Error - upper power limit value23 External analogue amplitude too low24 No trigger signal25 Reserved26 Reserved27 Ultrasonics stopped irregularly28 Reserved29 Reserved30 Reserved31 Reserved

A detailed description of the possible errors and their remedies can be found in section 22.

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20 Menu tree

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21 Operating parameters

The SDG oscillator contains various parameters which are required for correct processing of the ultrasonic process. These can be entered directly via keyboard or modified via the CANopen or RS485 interface.

Value tluafedValue xaM Value NIM

Welding time[ms] 000199995 rewoPlanimoN01 * rewoPlanimoN0001 / rewoPlanimoN]sW[ Welding energy

HOLDING TIME [ms] 099990wELDING amplitude [%] 00100151

rewoPlanimoN01 * rewoPlanimoN0001 / rewoPlanimoN]sW[ ygrenE000199995]sm[ Time

P Overcharge [W] 5 NominalPower * 1.2 NominalPower * 1.2Power limit [W] 5 NominalPower * 1.2 NominalPower * 1.2Power loss max.[%] 01525Delay afterpulse [ms] 00100015

0599905]sm[ AfterpulseAfterwelding [ms] 000010Start frequency [Hz] xaM timil+0Turn-off delay [ms] 0019990

0990Measuring power loss Soft start time [ms] 050025Start amplitude [%] 030401

005 +005 + 05 + Nominal frequency]zH[Frequency limit max.005 - 005 - 05 - ]zH[Frequency limit min.

Soft stop time [ms] 0050Slow control rate 1021Contrast 033-Cable length[m] 3021

Value tluafedPossible settings

Welding mode

Time/ Energy/Time and Energy/ Time or Energy/

itnoKContact switch off /itnoKbeforebefore/afterPower loss measuring

offon/offFrequency ResetStart frequencyPower limit

nalretniinternal/externaledutilpmAlaunamslupmI/kitamotuA/leunaMedomtratS

reggirTerP / reggirTVM

After impulsenebobelow/topError position

teseRontseT VP tratS

ne* hz /sc /vcs /rt /ti /rf /ne /edLanguagenalretniedoC

SYSTEM PARAMETER

*german, english, french, italien, turk, swedish, tschech, chinese

WELDING PARAMETER

Limite

SYSTEM PARAMETER

SCHWEISS PARAMETER

on/offon/off

on/ off/ Timeon/offon/off

on/offon/off

internal/external

offoff

offoffoff

off

Nominal frequency

Nominal frequency Nominal frequency

Nominal frequencyNominal frequency

Nominal frequencyNominal frequency

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22 Troubleshooting

In the case of errors which do not originate in the application, always contact your nearest RINCO ULTRASONICS AG service centre.

22.1 General errors

Error Error remedy

Ready (green) LED - Check the mains voltage supplynot lighting up - Check the fuse

Actuation via digital - Check the voltage supply 24VDC_IO_IN I/Os not possible

Noise - Check the mounting/fixtures - Check the tightening torques of the oscillator system (between converter, booster and horn) - Check the power losses of the oscillator system when not clamped and when clamped - if necessary replace the converter, booster and/or horn

Heat - Cooling of the converter and horn is recommended depending on the application - An unusual build-up of heat can be caused by loose components or cracks in the oscillator system

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22.2 Generator error LED1

Error Cause Response Error remedy

Mains voltage too - The mains voltage applied- - Error message - Check the mains voltagelow at the generator is generated. is below 85% of the - Ultrasonic process nominal voltage. is aborted. - A new ultrasonic process is prevented. - The error message must be acknowledged via the TEST button or via the Reset_IN signal.

Internal power supply -Internal power supply failure -Error message is generated - Contact the service centredefective due to short circuit, - Ultrasonic process is overtemperature aborted or defective components - A new ultrasonic process is prevented - The error message must be acknowledged via the TEST button or via the Reset_IN signal.

Minimum signal - Minimum signal operation - Error message is generated - Increase amplitudeoperation of of the output stage due to - Ultrasonic process isthe output stage defective components in the aborted generator - Very low amplitude selection - A new ultrasonic process is prevented - The error message must be acknowledged via the TEST button or via the Reset_IN signal.

Temperature of - Internal temperature - Error message is generated - Cooling insert shouldthe generator is monitoring of the generator - Ultrasonic process is be providedtoo high reports value is too high aborted - Reduce ambient - A new ultrasonic process temperature is prevented - Reduce duty cycle - The error message must be acknowledged via the TEST button or via the Reset_IN signal.

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22.3 Converter and application errors LED2


Minimum frequency - Oscillator system not - Error message is - Check cable connectionlimit violation connected generated - Check cable(s) - Oscillator system defective - Ultrasonic process is - Check/replace converter - Excessive damping of aborted - Check installation of the oscillator system due to - A new ultrasonic process oscillator system high pressure is started at the nominal - Check the temperature of the - Defect on the oscillator frequency oscillator system system - Check/replace the horn - Reduce the welding pressure

Maximum frequency - Oscillator system not - Error message is - Horn wearlimit violation connected generated - Check cable connection - Oscillator system defective - Ultrasonic process is - Check cable(s) - Excessive damping of aborted - Check/replace converter the oscillator system due to - A new ultrasonic process - Check installation of high pressure is started at the nominal oscillator system - Defect on the oscillator frequency - Check the temperature of the system oscillator system - Check/replace the horn - Reduce the welding pressure

Maximum - Oscillator system defective - Error message is generated - Check/replace the converter,converter voltage - Excessive damping of - Ultrasonic process is - Horn, boosterexceeded the oscillator system due to aborted high pressure - A new ultrasonic process is started at the nominal frequency

Power - Oscillator system defective - Error message is generated - Reduce pressureoverload level - Excessive damping of - Ultrasonic process is - Use more powerfulexceeded the oscillator system due to aborted generator high pressure - A new ultrasonic process is started at the last welding frequency

Converter not - No converter - Error message is generated - Check converter connectionconnected connected - Ultrasonic process is aborted to generator - Converter defective after 100 ms - Check/replace converter - HF cable(s) not - A new ultrasonic process - Check/replace cable(s) connected or defective is started at the nominal frequency

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22.4 Limit error LED3


Maximum power - Power too high - Error message is generated - With this type of error,exceeded - Ultrasonic process is it is also vital to aborted reconsider the choice of - A new ultrasonic process is delay time started at the last - Check the workpiece welding frequency - Check the process sequence - Check/replace the oscillator system

Analogue amplitude - The voltage at the external - Error message is generated - Correct the voltage at thetoo low analogue amplitude- - Ultrasonic process is external analogue input is below the aborted amplitude input value for the start - A new ultrasonic process is amplitude (less than started at the last 3V) before or during welding frequency the ultrasonic process. - Start of the ultrasonic process is refused

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23 Service centre addresses

In the event of any technical faults or welding pro-blems please contact the RINCO ULTRASONICS AG technical customer service team, who will be pleased to help.To enable our service team to provide the best possib-le assistance we will need the following:

– Detailed description of the technical fault or wel-ding problem

- Designation/name of the device- Article no. and series no. of the device refer

to the type plate

Our address:

RINCO ULTRASONICS AGIndustriestrasse 4CH-8590 Romanshorn 1Switzerland

Tel. ++41 71 466 41 00Fax ++41 71 466 41 [email protected]

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RINCO ULTRASONICS AG

Industriestrasse 4CH-8590 Romanshorn 1Switzerland

Tel. +41 71 466 41 00Fax +41 71 466 41 01

[email protected] A

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Documents

Generator SDG20/30/35/ 40/70 - RINCO ULTRASONICS · 5 A Introduction Thank you for purchasing a RINCO product. We are sure that you will achieve the highest possible econo-mic benefits