Ultrasonic Welding Generator-15KHZ 2600W

一． Safety requirements and warnings

The following precautions should be taken before contact with the ultrasonic generator:

1. Make sure the power supply is OFF (OFF) before making any electrical connection.Use a power outlet with a ground terminal to prevent electrical shock.

2, ultrasonic generator will produce high pressure.Before operation:

(1) turn off the power switch;

(2) unplug the main power plug;

(3) wait 2 minutes for full discharge of capacitor.

3, ultrasonic generator will produce high pressure, non-professional personnel do not open the shell.

4, do not put your hand under the welding head, downward pressure and ultrasonic vibration may cause injury accident.

5. Do not perform welding and test operation when the high-frequency cables or transducers are disconnected.

6. Do not put your finger between the welding head and the mould when using the big welding head.

7. This model must be operated by one person, and multiple people are forbidden to operate and debug at the same time.

二. Introduction to intelligent ultrasonic generator

Our r & d production of intelligent ultrasonic generator compact structure, simple and generous appearance, operation

It is simple, flexible and easy to maintain.The complete circuit for our company independent original, with

Have chase frequency range wide, chase frequency accuracy high, ultrasonic energy instantaneous output big, hair force fierce, reaction

Fast, safe and reliable, high control accuracy.

The intelligent ultrasonic generator converts the input 220V 50/60hz ac rectifier and filter

The direct current of 310V is chopped into a specific high frequency alternating current and passed through a high frequency transformer

The signal is amplified to a few kilovolt ac signal and drives the transducer to its resonance point

Produce resonance.The control module can cut off ultrasonic output when ultrasonic welding fails.

Thus provides extremely high security guarantee for the ultrasonic generator as well as the integer and the welding equipment.

The whole machine core main control system adopts imported high speed and large capacity MCU, equipped with the latest and efficient

Mu cos Ⅲ operating system, modular management current, signal sampling, the output port, the input port

Functions such as acquisition, high-speed communication, security protection and fault warning enable the equipment to operate efficiently and stably.

三、 Main technical parameters

1. External dimensions: length 340mm x width 210mm x height 94mm

2. Net weight of main machine: 4Kg

3. Output power: 0-2600w

4. Output voltage: 0-3000vac

5, working environment temperature: - 20 ℃ to + 65 ℃

6. Sinusoidal harmonic parameters: less than or equal to 0.2%

7. Input power factor: 75%

8, working frequency: 15 KHZ / 20 KHZ / 28 KHZ / 30 KHZ / 35 KHZ / 40 KHZ

9. Working power supply: AC220V 50Hz/60Hz

10. Mold frequency range: 400Hz (according to 15KHz ultrasonic wave as an example, mold frequency 14.40-15.20khz can be automatically used for frequency tracking.)

11. Automatic frequency chasing accuracy: 0.1hz

12. Power repetition consistency: 97%

13. Dynamic response time of remote terminal: 30ms

14. 485 communication, supporting standard MODBUS RTU protocotl

四、Installation requirements

Environmental requirements

The use/storage/transportation of the equipment must meet the following environmental requirements:

Table 4.1 plastic welding machine environmental requirements list

Environmental factors	Comfortable with van
Operating/operating temperature	-20℃to+65℃
Storage/transportation temperature	-20℃to+75℃
Relative humidity	30%to95%，no condensation

Power input range

The power plug must be inserted into the single-phase three-eye socket with grounding terminal. The applicable power range of the plastic welding machine is 220VAC + 10% @ 50/60hz.

The input voltage of the generator is 220VAC. To use 110VAC, please contact relevant service personnel for guidance and support.

Do not use 110VAC as the input power without consulting, or it may cause serious damage to the equipment!

System of attachment

The system requires the user to provide a single-phase input power supply with a grounding terminal, a voltage of 220vac@50/60hz, and a load current of not less than 10A. Make sure that the socket of the power supply matches the random power plug, and then insert the power plug of the machine into the socket.Be sure to check and confirm that the voltage is 220VAC before inserting the power plug, and the power switch on the left side of the power box is closed!

五、 Operation instructions

Function description of main display window:

1. Frequency range PLL: display the resonant frequency point of the transducer and the mold tracked by the generator. It is better to adjust the mold and the transducer to the middle of the frequency point of the generator center.If the center frequency point is left or right, the frequency of ultrasonic mold is low or high.

2. Frequency F: shows the actual resonant frequency to the current time in KHz.

3. Output: display the production times of ultrasonic welding equipment.(line 2 to the right)

4. Power P: display the maximum output power immediately after welding.

5. Amplitude % : shows the percentage of ultrasonic output amplitude and power.

6. Working mode M: this model has three working modes to choose from.

A. time: when the start button is pressed, the welding head of the machine will drop. The working process is as follows: delay -- welding -- pressure maintaining -- welding head reset.

B. external control: when the external switch is connected, the ultrasonic wave will be output immediately, and the ultrasonic wave will be stopped immediately after the switch is disconnected.

C. Spot welding: this mode is suitable for hand-held welding tools, and the welding time and pressure holding (blowing) time can be set.

7. Mode adjustment: this model can be set to automatic working mode or mode adjustment mode. When pressing the "mode adjustment" button, the LCD display can take turns to switch between automatic mode adjustment.

Toolbar description:

1. Acoustic wave: this model is used for automatic frequency tracking by the computer. Press the acoustic wave after replacing the mold, and the system will automatically execute the frequency scanning program.If the scan is abnormal, the system will give an alarm and prompt the corresponding fault information.

2. Next page: the display screen enters the next screen.

3. Previous page: the display screen returns to the previous screen.

4. Mold adjustment: switch between automatic working mode and mold adjustment mode.

5. Reset: press this button for 5 seconds to reset the output quantity.

6. : the cursor moves left or down

7. Setting: the cursor moves to the right or up

8.- : the value decreases or changes the mode

9.+ : the value increases or changes the mode

10. Confirm: press the confirm key to save the data and return to the initial screen.

Time mode parameter setting:

Under the time mode, press the next page to enter the above interface to set each technical parameter. Press the setting setting to move the technical parameter to be modified up and down, and then press the "+" and "-" button to adjust, and then press the "confirm" button to save and exit the setting interface.

L delay time: displays the time when the delay triggers the ultrasonic wave.

L welding time: display the time of triggering ultrasonic wave.

Pressure holding time: the time when the cylinder stops to cool the welding parts after ultrasonic welding.

Vibro-falling time: shows the time when the vibro-falling sticks to the ultrasonic wave to weld the mold parts (this function is not normally used).

Setting of system parameters:

1.Press "next page" in the initial screen to enter the password.

2.Enter the access password: 8888 and press "confirm" to enter the system parameter setting page.

3. LF (lower limit frequency setting) : 15KHz and 20KHz are generally 0.4-0.6khz lower than the actual frequency of the mold.28K, 30K, 35K and 40KHz are 1KHz lower than the actual frequency of the mold.

4. The value to the right of the lower limit frequency is the correction voltage, which is the read-only value of the system parameters. Normally, it should be 1.5v-4v, and generally we will adjust it around 3V.

5. No-load amplitude: range of 2%-100% can be set.If the setting value is too high, it will affect the service life of ultrasonic vibrator and ultrasonic mold. Please set the appropriate value carefully.

6. Address of slave: set the corresponding address of slave. The setting range is 2~254.

7. Mode selection: three modes can be set: time, external control and spot welding.Toggle the selection by pressing the + and - keys.

8. Press "next page" to set the remaining parameters.

Instructions for wiring on the back of the case:

9. Rated power: display the rated power value of the machine.

10. Language selection: Chinese and English display languages can be set.Toggle the selection by pressing the + and - keys.

11. Alarm mode: it can be set as standard or automatic control.Standard mode: in case of alarm, press "ok" or external alarm reset key to cancel the alarm;Automatic control mode: when there is an alarm, the alarm state will only maintain 200ms, and then the system will automatically reset. After five consecutive alarms, the alarm state will not be automatically reset, which can only be reset by pressing the "ok" button or external alarm reset button.If there is more than one case of normal welding in the process of 5 alarms, the alarm times shall be reset to 0 and the counting shall be started again.

12.After setting, long press "ok" for 3 seconds to return to the initial screen.

Instructions for wiring on the back of the case:

1. Startup interface: it is directly connected to the "emergency stop" button and the "start" button on the rack, and the common and the normally closed end of the emergency stop button;Common and the start of the start button.

2.4 core aviation socket: 24V solenoid valve and 220V power supply, the left (3, 4) two core connected to the 24V solenoid valve on the rack, the right (1, 2) two core for the rack to provide 220V power supply, can be connected to the frame 220V fan or 220V lifting motor, attention: can not connect the wrong four core, otherwise it may cause serious damage to the equipment!

3.2 core aviation socket: 2pin of high-frequency output outlet is connected with positive pole of ultrasonic vibrator;The foot is connected with the negative pole of ultrasonic vibrator.

4. Cooling fan: please ensure that the cooling fan mouth is well ventilated during work, and please timely clean foreign matters and dust in the cooling mouth.

5. Input voltage: the system requires the user to provide a single-phase power supply with grounding terminal and a voltage of 220vac@50/60hz and a load current of not less than 10A.

6. Fuse: this model USES PCB board to install the fuse. If the fuse burns out, it shall be returned to the factory for repair.

Ultrasonic plastic welding equipment generator has four types of alarm:

No	Alarm content	Reference processing method
1	Frequency lockout VZH TIMES UP alarm	(1)Mold level adjustment;
		(2)Check whether the mold is tight;
		(3)Check whether there are cracks or damage to the mold;
		(4)Check whether the correction voltage is greater than 1.5v, less than 5V;
		(5)If the automatic matching value is A0, the matching circuit needs to be adjusted. Please contact the dealer
2	Frequency lockout VZL TIMES UP alarm	(1)Mold level adjustment;
		(2)Check whether the transducer has been connected with the generator;
		(3)Check whether the mold is tight;
		(4)Check whether there are cracks or damage to the mold;
		(5)Check whether the correction voltage is greater than 1.5v, less than 5V;
		(6)To observe whether in automatic frequency, if the automatic match value is B0, then need to adjust the matching circuit, please contact the dealer
3	Frequency lockout PHES TIMES UP alarm	(1)Mold level adjustment;
		(2)Adjust the lower limit frequency;
		(3)Check whether the mold is tight;
		(4)Check whether there are cracks or damage to the mold;
		(5)Check whether the mold is tightly pressed on the product,  causing mold vibration difficulties;
		(6)Check whether the air pressure is too high;
4	SON ultrasonic signal failure alarm	220V ac input voltage low