Ultrasonic Welding Generator-20KHZ 2000W(20k intermittent)

I.Introduction and Overview

1.1. Safety requirements and warnings

This section explains the meaning of the various "safety caution" symbols and signs on the manual, and provides general safety precautions for ultrasonic generator systems.

The following two signs will appear frequently in the manual, please pay special attention:

Attention:"Attention" is used to indicate possible dangers, and give special tips on some key information for correct use and parts that are easily overlooked. Users should have a certain understanding of it.

Warning:The "Warning" logo is used to warn of possible dangers and possible damage to the equipment. Failure to comply will result in personal injury or equipment damage to varying degrees.

Attention:Ultrasonic generators must be used strictly in the prescribed manner.

The following precautions should be taken when using an ultrasonic generator:

The user manual introduces you to the correct use of the ultrasonic generator, please strictly follow it.

It is important to use a power socket with a ground terminal to prevent electric shock.

Before carrying out maintenance and inspection of the ultrasonic generator, the power supply should be cut off. Without the prior permission of the company, it is not allowed to disassemble and adjust by itself. Otherwise, all guarantees will automatically lapse.

Ultrasonic generators can generate high voltages of tens of thousands of volts in certain positions under certain special circumstances.

The emergency stop switch of the welding machine should be checked regularly to ensure that the emergency stop switch is always effective

Relevant technical data of ultrasonic equipment must be strictly observed. In particular, the rated parameters of the power supply and the operating environment of the system should be configured in full accordance with the relevant regulations.

This equipment can only be adjusted by personnel who have read and understood this operating manual, and only by personnel with appropriate training!

Before installing or commissioning the product, you should read this manual carefully in order to better use our products. Failure to follow these instructions may result in damage to the transducer / horn or mold.

Ultrasonic generators must be used strictly in the prescribed manner.

II. Introduction of basic information

JYD-2700G is a new universal ultrasonic generator newly developed by our company. Universal means that it can directly replace almost all existing generators on the market (including domestic and foreign) with only a small amount of adjustment. / Food cutting / long wave application / screening / cleaning / atomization and almost all applications. Through the customization of the laboratory, it can output a frequency of 15k to 100k and a power of several hundred watts to tens of thousands of watts.

With an available bandwidth of 3KHz (such as 20K range 18.5KHz ~ 21.5KHz), it can directly drive all the transducers on the market that meet the frequency of this model without modifying the matching capacitor.

Intelligent fan control: When the temperature is low, the fan starts following the sound wave output. If there is no sound wave output within 30 seconds, the fan stops, preventing excessive dust inhalation and improving the reliability of the device.

When the high temperature exceeds 45 ° C, the fan will continue to work to cool down.

When the temperature exceeds 80 ° C, the device will provide over-temperature protection and prompt on the screen.

Power limitation: In order to be able to work continuously around 2000W, the actual power protection threshold of the generator is 2400W,

Our universal ultrasonic generator is particularly suitable for long wave applications such as cutting and non-woven welding. The built-in circuit provides a purer sine wave driven transducer than most generators on the market, making the heat generation smaller and more efficient higher. Reduce heat dissipation requirements and extend life.

Working mode: automatic mode: long wave mode, suitable for cleaning / cutting / non-woven welding, etc.

Welding machine mode: Delay time (Delay time);

Welding time (Welding time);

Holding time (curing time) (Holding time);

Voltage: 198-242VAC (50 / 60Hz), the output will be much weaker when AC110V is input, it needs some adjustment, direct use is almost only used for cutting applications

Volume: 384mm * 240mm * 110mm

Weight: 7KG

Color: light gray

Features:

Automatic frequency tracking: The system automatically tracks the resonance frequency of the welding head. Compensation for detuning caused by heat and other reasons.

Digital frequency control: The operating frequency is digitally controlled by the microcontroller.

Digital amplitude setting: This feature allows users to set accurate amplitudes according to application requirements, which provides a larger range and repeatability of settings than analog systems.

The amplitude can be adjusted in a large range: 20% ~ 100% continuously adjustable, which is different from the shortcomings of traditional generators that are difficult to work with low amplitude.

High-speed microcontroller: The operating frequency of the internal microcontroller is up to 168MHz, which can accurately and timely control the working conditions.

0.5 millisecond control and sampling interval: 2000 times of sampling and control for the welding process per second.

LED and key operation interface are stable and reliable.

Slant start: Ultrasonic energy supply and welding head start at the most suitable ascent speed to reduce the electromechanical pressure of the system.

Vibration after welding: The user can start the ultrasonic wave after the welding and pressure holding process is finished, and the workpiece sticking to the welding head will be shaken off.

Welding quality monitoring: user-definable process alarm, when it is outside the range of user-defined defective products, the system will generate an alarm to remind the user.

Diagnosis at startup: During the startup process, the main components of the system are tested.

Timing frequency search: When starting the system, the system performs frequency search every one minute to update the resonance frequency of the welding head. This is especially effective for a welding process that can affect the temperature of the welding head. A change in the temperature of the welding head will cause resonance frequency drift.

All kinds of protection are complete: including over power consumption of the whole machine,

Inverter tube overcurrent,

Inverter drive undervoltage,

Load overvoltage,

Load overcurrent,

Load overpower,

The load impedance is abnormal,

The load frequency is out of range,

Over temperature,

Overcurrent of external devices (such as solenoid valve),

The control circuit voltage is out of range

Most of the functions can be used only by updating the program. We provide an offline burner with a limit on the number of flashes

Warning:

III. Environment requirements

Try to use this equipment in an environment that meets the following conditions, which will help the working life of the generator:

Environmental factors	Range of application
Operate/Working temperature	0℃ to 55℃
Save/Shipping temperature	–25°C to +70°C
Relative temperature	30%  to  90%,without condensation

Warning:To ensure that the ultrasonic generator has good ventilation, care must be taken not to cover the generator's ventilation openings. It is strictly forbidden to use this equipment in adverse environment such as corrosive gas. The inhaled air will flow through the internal circuit module. Use in the environment with corrosive gas may greatly reduce the service life of the equipment.

IV. Packing list

Name	QTY	Name	QTY
Ultrasonic generator	1	User manual	1
1.5meter power cable	1	DB9 connector	1
2pin navigation plug	1

· When receiving the equipment unpacking

· Check the packing list for missing items;

· Check the appearance to confirm whether it has obvious damage

· Whether the power-on test equipment works normally

· The user manual may be given by sending a PDF file.

Warning:Ultrasonic generators have sophisticated components and structures and are sensitive to static electricity. If they are dropped or bumped during transportation or transportation, the circuit of the generator may be damaged.

V. Interface definition

We will include a DB9 connection kit with the generator, which is very easy to use.

Error code table:

1,6	input	24V voltage, connect is start, typical application is to connect a normally open micro switch or self-locking switch
2,7	input	24V voltage, emergency stop when connected, typical application is to connect a normally open micro switch or self-locking switch
4,8	output	24V output voltage, connected to a solenoid valve for controlling the lifting of the welding head of the cylinder.
Besides, pins 6, 7, and 8 are the same ground, so 6/7/8 can share a line

Attention:The power plug must be inserted into a socket with a ground terminal. The adaptable power supply range of the ultrasonic signal generator is 220VAC ± 10% @ 50 / 60Hz. By adjusting the internal settings of the generator, it can also adapt to a power supply range of 110VAC ± 10% @ 50 / 60Hz.

Using 110V without adjustment can almost only be used for cutting and atomizing. The minimum diameter of the power connection cable is 1.5mm².

Internal adjustable options

Power selection, the transformer provides three output gears, and the L gear is generally used for cutting knives and other applications. The amplitude is relatively weak and the loading capacity is poor.

M block, used for most applications.

H file is used for occasions requiring high power output, such as metal welding.

You should not adjust the position without permission from our company.

When designing and manufacturing generators, we have fully considered various safety aspects. Modifications or certain changes to the system may affect the safety of the device during operation. Therefore, when modifying or modifying the equipment, keep the following in mind:

Before modifying the ultrasonic welding system using components provided by other manufacturers, you must contact our company to determine whether these components are suitable for modifying the machine.

If the customer makes such modifications or changes to the ultrasonic generator without the permission of the company, all the manufacturer's guarantees will automatically become invalid.

VI. Display interface and parameter introduction

6.1、Setting interface

Button function:

+: Value / setting +

-: Value / setting-

Test / Enter: A combination of sonic test and input confirmation. When the Test / Enter button is pressed for more than 0.8 seconds, it is a sonic test function and is used for no-load test mode.

When the Test / Enter button is short-pressed, it is used to confirm entering the setting state or the confirmation after the data is set.

Mode: The Mode button is used to select the display mode of the digital display. In the normal display mode, if it is originally in the Amp display state, press once to enter the KHz display state; press again to enter the Time / Plc display state; press again, Enter the Power display state; press it again to return to the Amp display state, and so on, in a loop display.

AFT: One-key frequency chase function, short press, the ultrasonic generator will automatically track the resonance frequency of the mold or transducer (vibrator)

Indicator function:

Amp: When the Amp light is on, the data displayed on the digital display is the current, which is X.X ampere. If the mold is too small, press the sonic test key, and the current displayed may be 0.0A, which is normal.

KHz: When the KHz light is on, the data displayed on the digital display is the frequency, which is XX.XX KHz, which is the working frequency of the mold.

Time / Plc: When the Time / Plc light is on, the digital display shows the current working mode of the ultrasonic generator. If PLC is displayed, the working mode of the ultrasonic generator is the automatic mode, and the ultrasonic generator's wave transmission time is only controlled by the external PLC.

If the display is X.XX and the Delay light is on at the same time, the working mode of the ultrasonic generator is the plastic welding machine mode, and the ultrasonic generator

The transmission time is the time set internally.

Power: When the Power light is on, the digital display shows the amplitude percentage value, which can be set from 20% -100%.

AFT: When the AFT button is pressed, the ultrasonic generator will enter the one-key frequency tracking mode, the AFT light will turn on, and after the frequency tracking is completed, the AFT light will turn off.

Delay: When the Delay and Time / Plc lights are on at the same time, the digital display shows the delayed transmission time in the welder mode.

Welding: When the Welding and Time / Plc lights are on at the same time, the digital display shows the wave time in the plastic welding machine mode.

Holding: When the Holding and Time / Plc lights are on at the same time, the digital display shows the holding time in the plastic welding machine mode.

Warning: When the Warning light is on, the digital display shows the alarm code, such as E-01, E-02, etc.

Working: When the Working light is on, the original state of the digital display will not change, only that the current ultrasonic generator is transmitting.

Light bar: represents the set amplitude of the ultrasonic generator from 20% to 80%, and lights 1-8 lights respectively.

6.2、automatic mode (long wave mode, continuous working mode)

Long press the Test / Enter button on the ultrasonic generator panel, turn on the power switch, enter the automatic mode (PLC), plastic welding machine mode switching interface; you can switch the control mode of the ultrasonic generator by pressing the +/- button.

When the digital display shows PLC, the ultrasonic generator can work in automatic mode.

When the digital display shows X.XX and the Delay light is on, the ultrasonic generator can work in the plastic welding machine mode.

After selecting the working mode, wait for more than 2 seconds, turn off the power switch, wait for the machine to discharge power, and then restart it to use it normally. (You can also press and hold the Test / Enter button after turning off the power switch to speed up the machine discharge.)

Warning:When the automatic mode is selected: the interface provides a reminder of the current working status, the Working light will be on, and the display is running, indicating that the sound wave is being output. At this time, you should be careful. If you are carrying a cutter mold, you should avoid touching the blade tip.

Warning:In the case of continuous work (welding time exceeds 5S), it should be ensured to work at a lower power. It is recommended to be below 1/3 of the model power (such as 2000W model, continuous work should not exceed 666W). In order to prevent excessively rapid heating, extend the life of the mold, continuous output power can be appropriately increased under enhanced heat dissipation conditions.

6.3、Ultrasonic welding machine mode (various parameter settings)

1. Press the Mode button to adjust the display mode of the digital display to Time / Plc mode, and the Delay and Time / Plc indicator lights.

2. Press the Test / Enter button to enter the Delay time setting mode, the digital display and the Delay indicator will flash, then you can press the +/- button to adjust the delay time parameter.

3. Press the Mode button again to enter the Welding time setting mode. The digital display and Welding indicator will flash, then you can press the +/- button to adjust the welding parameters.

4. Press the Mode button again to enter the holding time setting mode. The digital display and the holding indicator light will flash, then you can press the +/- button to adjust the welding parameters.

5. After adjusting all parameters, press the Test / Enter button to confirm, it will exit the parameter setting mode, and at the same time, the digital display will not flash.

Ultrasonic welding machine mode (various parameter settings)

1. Press the Mode button to adjust the display mode of the digital display to Time / Plc mode, and the Delay and Time / Plc indicator lights.

2. Press the Test / Enter button to enter the Delay time setting mode, the digital display and the Delay indicator will flash, then you can press the +/- button to adjust the delay time parameter.

3. Press the Mode button again to enter the Welding time setting mode. The digital display and Welding indicator will flash, then you can press the +/- button to adjust the welding parameters.

4. Press the Mode button again to enter the holding time setting mode. The digital display and the holding indicator light will flash, then you can press the +/- button to adjust the welding parameters.

5. After adjusting all parameters, press the Test / Enter button to confirm, it will exit the parameter setting mode, and at the same time, the digital display will not flash.

6.4 Ultrasound amplitude adjustment

1. If you want to adjust the output amplitude of the ultrasonic wave, in the normal mode, press the Mode button, select the display mode of the digital display as POWER, the Power light is on.

2. Press the Test / Enter button to enter the amplitude percentage setting mode, and the digital display will flash.

3. Short press +/- button to set the amplitude output, 20% -100%.

4. After setting the parameters, press the Test / Enter button to confirm, the system will exit the setting mode.

Sonic test: The maximum limit of the sonic test amplitude is 40% of the total amplitude, even if your setting exceeds 40%, if you want to output more than 40%, you must use the external start. The purpose of this is to protect the mold to a certain extent, to prevent irreversible damage caused by direct drive with large amplitude in the case of abnormal mold (such as not locked).

Attention:Any time you press the emergency stop switch, you can immediately raise the welding head, stop the ultrasonic wave and end a welding process, and return to the standby state.

6.5、The role of each parameter in the setting items:

Delay time: the time from pressing the welding button to trigger the action until the welding head is about to press the welding workpiece. That is, the time from the first stage to the second stage in the figure, which will be related to the cylinder stroke and the lowering speed. If you don't know how much to set, set a relatively large value, and then reduce it according to the situation, such as 0.8s. 0 ~ 9.99s can be set

Holding time (also known as curing time / cooling time): After the ultrasonic wave is stopped in the fourth stage, in order to make the welding workpiece tightly adhere to wait for cooling, sometimes the welding head needs to press the product for a period of time to make the welding workpiece tightly adhere and cool , This time is the curing time. Corresponds to the fourth stage in the figure. The curing time is not necessary. In order to minimize the welding time and improve the efficiency, in most cases this parameter can be set to a minimum of 0.5s. The specific value depends on the actual welding effect. 0 ~ 9.99s can be set

6.5.1. For different welding modes, you need to set

Welding time in time mode: After the delay time has elapsed, the welding head will press the welding surface and start to send ultrasonic waves to the welding time until the welding is completed. That is, the time used in the third stage of the figure, this value is more or less directly related to power, air pressure, welding area size, welding depth, etc. 0 ~ 9.99s can be set

VII.The most common setting process for welding applications

Select the welding machine mode to start

1. Turn on and wait for the system to detect the working frequency to be completed and obtain the operating frequency

2. Set the amplitude to 60%, press the sound wave test, and observe whether the current is within 1A, the power is within 500W, and whether the sound is based on the crisp model frequency. If it is not within the scope, you should check whether the mold or transducer is abnormal, whether the mold is not tightened, cracked, etc.

3. Click "Parameter Setting" ----> "Time Mode" ----> "Setting". Time mode is the most common mode. All generators provide this mode, which is simple and easy to use. Of course, our other models are also very useful.

4. Set the delay time: 0.5s, this time depends on the time from the movement of the welding head to the contact with the weldment, adjust as appropriate.

5. Set the welding time: 0.5s, this depends on the welding material / welding area and amplitude, etc. First set a more reasonable value, and then adjust as appropriate according to the results.

6. Set the holding time: 0.5s, this depends on the solidification time of the welding material and the melting degree of the welding. It is recommended to use a large value first, reduce it to a satisfactory value as appropriate, and speed up the process.

7. The energy upper limit / lower limit, power upper limit / lower limit and the second wave time are kept at 0, that is, this function is not used, and when the welding can be performed correctly, the power and energy displayed on the interface after the welding is completed are filled in to increase quality monitoring Features.

8. Press the "Exit" button to return to the main interface.

9. Test welding, continuously adjust the above amplitude / delay time / welding time / curing time and air pressure value of the rack, mold position, etc. according to the welding situation until a satisfactory result is obtained.

10. Steps can be omitted: according to the results displayed after several welding is completed, the energy values obtained multiple times are averaged, and the energy welding mode is used instead. Energy welding can make up for the difference in welding consistency caused by voltage / air pressure fluctuations or unsatisfactory plastic parts.

11. If the fusion of welded parts is required to be more thorough, the peak power welding mode can be used. The power that the welded parts can absorb after melting and softening will become larger. Set a peak power value according to this principle to achieve better welding consistency.

VIII.Warning information and possible causes

8.1. Error: The lock frequency exceeds the DAC coarse adjustment range

Trigger the protection, indicating that the frequency has lost lock, the microcontroller frequency is adjusted to its own capacity limit or the correct operating frequency has not been found.

When this error occurs, you can try:

Whether the load is connected to the mold during the frequency search, because the device searches for the resonance frequency with a very low amplitude. If the load is connected (such as searching the frequency in water), the driving capacity is not enough to drive the load to obtain correct feedback Load search frequency.

Reset a higher frequency and search for the frequency manually.

Check whether the welding head is cracked, not locked, slip wire and sticky dirt.

Check whether the direct connection line between the generator and the load is disconnected, disconnected or disconnected.

Check whether the contact surface between the welding head and the horn is smooth and flat.

Replace a normal welding head test to confirm that the equipment is working properly, and check whether the resonance frequency of the welding head is within the allowable frequency range of the equipment, such as 20k models between 18.5k ~ 21.5k.

8.2 Error: phase lock exceeds the DAC fine adjustment range

Trigger the protection, indicating that the resonance frequency cannot be found or the frequency has been locked when the frequency is adjusted in real time during system operation.

When this error occurs, you can try:

Reduce the load, such as reducing the size of the mold, the air pressure value in the plastic welding machine mode, etc.

Increase the amplitude and use a higher voltage to push.

Replace the horn with a ratio of 1: 2 and below. This is what we recommend. The traditional 1: 3 horn is more suitable for traditional self-excited ultrasound.

Search the resonance frequency again, and set the frequency to work at the resonance frequency + 0.06khZ.

Check for other possible causes, such as connection wires, molds, transducers, voltage, etc., for any abnormalities.

8.3 Error: Over power consumption

During the working process, the system will detect the real-time power in real time and protect it immediately when the power exceeds the rated power of the device to avoid damage to the device.

When this error occurs, you can try:

Re-search the frequency and check whether the search frequency is under the sonic test, whether the current and power are out of range, the specific value can be found in this article.

Excessive load, such as large mold plus heavy load (such as water load), exceeds its own safe power output range and provides protection.

Abnormal mold or generator, such as cracked mold but not completely damaged, the resonance characteristics at this time become worse, the power consumption becomes larger but the actual amplitude is small.

The amplitude is too large. Large amplitude means a large driving voltage, and the power required to output by some loads increases sharply, beyond the range, and the amplitude is appropriately reduced.

If it is confirmed that the load is too large or the amplitude is too large and you must use this parameter, please consider using other models of our company with higher power.

8.4 Error: Over temperature

During the working process, the system will continuously monitor the temperature of the power inverter part of the generator to ensure that over temperature can prevent further temperature rise and damage the equipment in time. The design has fully considered the temperature generation and heat dissipation, and the protection will not occur under normal circumstances.

When this prompt occurs, you can try:

Improve the use environment, increase the heat dissipation space or provide external heat dissipation.

Check whether the vents are blocked and the fans are damaged.

Wait a few minutes for the temperature to drop, restart the computer and continue working.

8.5 Error: IGBT overcurrent protection

The protection shows that some reasons have caused a very large power consumption of the whole machine, which has exceeded more than twice the rated power in a short time, and should be handled with great care.

When this prompt occurs, you can try:

Check whether the frequency is correct. Under no-load conditions, set the frequency of the chase frequency to a relatively high value, such as the 20k model to 20.4k, and perform a frequency search.

Check whether the mold has been damaged, remove the mold or replace it with a mold that is confirmed to be good, and check again.

Whether the load is short-circuited, check whether there is a short circuit or insufficient voltage resistance on the load connection line and the plug, which leads to short-circuit overcurrent protection.

Other problems that cause severe overpower consumption ...

8.6 Error: Over load

The system detects that the load current exceeds the internally set protection current value.

When this prompt occurs, you can try in turn:

Check whether the load is too large and reduce the load.

If the overcurrent is caused by an excessive load, you can increase the amplitude appropriately and output the same power by increasing the driving voltage to reduce the driving current. Big.

If there is no sound wave output, check the load line for short circuit.

Increase the intermediate frequency by 0.1khz and try again.

8.7 Error: Over-load

The system detects that the load voltage exceeds the internally set protection voltage value.

When this prompt occurs, you can try in turn:

Reduce the amplitude to reduce the driving voltage.

Check if the load is not connected.

Check if the mains power is seriously exceeded.

Contact us

No.	Error code	Error message
1	E-01	The display board and the MCU main control board cannot communicate
2	E-02	Overcurrent alarm
3	E-03	Load overvoltage alarm
4	E-04	Power tube overheating alarm
5	E-05	Load error alarm
6	E-06	Frequency error alarm

If you still can't find the reason after testing, please contact us to solve.

VIIII. After sales service

The device provides one-year warranty service. If there is any quality problem within one year, the device will not work properly (the appearance is not covered by the warranty), please contact us. We will solve it for you as soon as possible and resume production.

9.1 The warranty clause does not apply to:

Any product that has been misused, not used according to the instructions, ignored (including insufficient maintenance), accidental, or user's incorrect installation, adjustment, or adjustment;

Any product that is exposed to harsh environments, incorrectly repaired, or repaired without the use of our methods or materials;

Use accessories not from our company (horn, transducer, or problematic welding head, etc.);

The equipment is damaged due to irresistible factors (natural disasters, etc.).

9.2 The warranty terms include:

Any quality problems that lead to abnormal production during the warranty period will not be charged for the warranty.

For parts that are replaced during the warranty period, the warranty period for new parts is the remaining period for replacing old parts.

Parts replaced after the warranty period will have a warranty period of 3 months.

Users can call our company for any warranty questions. Press the contact information on the cover or contact the sales person who sold the device.

(Working hours: Monday to Saturday, 8:00 am to 12:00 am, 13:30 pm to 17:30 pm)

Please understand the information of the product to be sold in advance (including your company name, address, product model, purchase time, your company contact person and contact information, etc.)

Please read this product manual carefully before contacting the company to confirm that the problem manual does not provide a solution or the solution is not feasible.