AMTECH 2032 Manual soldadora ultrasónica cable

Instruction Set for Special Information Page 1 of 9

Product Manual:

Sales Order Customer Create Date 10/25/2004 3:31:38 PM By DAS Last Rev Date 8/5/2005 By DAS Manual Include Instruction Sets Description DCM01112 Special Information |------------> DCM00003 General Information |------------> DCM00025 Ultrasplice 2032 |------------> DCM00001 Touchscreen

Special Actuator Controller

American Technology Inc.

41 Eagle Rd. Danbury, Connecticut 06810, U.S.A.

(203) 926-2677 (800) 888-6089

(203) 796-0380 FAX http://www.amtechultrasonic.com [email protected]

AmTech Product Manual- Special Information Table of contents Product Manual:.............................................................................................................................. 1 Table of contents............................................................................................................................. 2 Introduction:.................................................................................................................................... 3 Using this manual: .......................................................................................................................... 4

Classification of Hazards:............................................................................................................ 4 System Specification Sheet:............................................................................................................ 5 Tooling Table:................................................................................................................................. 6 Parameter Preset Information ......................................................................................................... 7 File Attachments: ............................................................................................................................ 8 Special Instructions:........................................................................................................................ 9


AmTech Product Manual- Special Information Introduction: This is the product manual for your AmTech ultrasonic welding system. Several combined Instruction Sets form the contents of this manual. This section contains information which relates most uniquely to you as the customer, your particular system and application. It also documents other Instruction Sets used in the manual. The figure below illustrates how the manual is organized.

AmTech Product Manual

Special Information Instruction Set

Instruction

General Information Instruction Set

Actuator Instruction Set

Controller Instruction Set

(Other) Instruction Set (s)

Set for Special Information Page 3 of 9

AmTech Product Manual- Special Information Using this manual: It is highly recommended that you read and understand the contents of this manual prior to operating your AmTech system. Each Instruction Set has a table of contents and is intended to logically group information in a manner which the user will find convenient. Classification of Hazards: The safety indications in this manual are divided into different classes. The figure below shows the assignment of symbols (pictograms) and signal words to the specific hazards and its potential consequence.

PICTOGRAM SIGNAL

WORD DEFINITION

DANGER !

A potentially dangerous situation that could cause injury to persons and serious damage to equipment.

ATTENTION !

A situation that may cause damage to the equipment

NOTE

Useful information, an application hint or other important or useful information.


AmTech Product Manual- Special Information System Specification Sheet: Sales Order Customer Create Date 10/25/2004 3:31:38 PM Actuator Type Ultrasplice 2032 Shuttle Type N/A Serial Number Program No N/A Controller Type TOUCHSCREEN Serial No Firmware Type Splicer Firmware Version Firmware Lang Multi Lingual Power Supply Type N/A Serial Number N/A PLC Type N/A Program Number N/A Part Number Description See Table 1 Booster 101-135-032 Converter See Table 1 Horn See Table 1 Tip 11008-03-118 Tip Nut See Table 1 Tip Guide See Table 1 Gather See Table 1 Anvil See Table 1 Anvil Holder See Table 1 Anvil Wear plate To serve you better, please be aware of the following: All tools have a 5 to 6 week lead time. Prices are subject to change without notice. An additional fee may be charged for expedited service.


AmTech Product Manual- Special Information Tooling Table: The (computer) file name of this manual contains a two digit suffix number. Example: DCM01112- ##. PDF

Use the suffix number and Table 1 to determine the tooling used on your welder.

Description DCM01112-01 ½” Replacable Tip

DCM01112-02 3/8” Replacable Tip

Booster 11008-03-133-01 Y5A90012 Horn Y5A90003 Y5A90000 Tip Y4A90021 Y4A90020 Tip Guide Y5A50034 Y5A50056 Gather Y5A50010 Y5A50055 Anvil Y5A90002 Y5A90004 Anvil Holder Y5A50032 Y5A50053 Anvil Wear plate Y5A50033 Y5A50054

Table 1


AmTech Product Manual- Special Information Parameter Preset Information Sales Order Customer Name or preset Number

Energy (joules) Force (psi/bar) Pressure (psi/bar) Amplitude (microns) Squeeze Time (ms) Pre-Burst (ms) Hold Time (ms)

Wel

ding

Par

amet

ers

After Burst Delay (ms) After Burst Duration (ms) Weld Time Min. (ms) Weld Time Max. (ms) Weld Power Min. (watts) Weld Power Max. (watts) Pre-Height Min. (mm) Pre-Height Max.(mm) Post Height Min.(mm)

Qua

lity

Mon

itori

ng

Post Height Max. (mm) Name or preset Number

Energy (joules) Force (psi/bar) Pressure (psi/bar) Amplitude (microns) Squeeze Time (ms) Pre-Burst (ms) Hold Time (ms)

Wel

ding

Par

amet

ers

After Burst Delay (ms) After Burst Duration (ms) Weld Time Min. (ms) Weld Time Max. (ms) Weld Power Min. (watts) Weld Power Max. (watts) Pre-Height Min. (mm) Pre-Height Max.(mm) Post Height Min.(mm)

Qua

lity

Mon

itori

ng

Post Height Max. (mm)


AmTech Product Manual- Special Information File Attachments:

Sales Order Customer Description File Hookup Diagram J1A00111-14

File Attachments are included at the end of this instruction set.


AmTech Product Manual- Special Information Special Instructions:


AmTech Product Manual- General Information

Instruction Set for General Information Page 1 of 30

General Information and InstructionsDocument Number DCM00003 Last revised 6/4/02

Use of this document is intended for use on all AmTech products.

American Technology Inc.41 Eagle RdDanbury, Connecticut 06810 U.S.A.(203) 926-2677(800) 888-6089(203) 796-0380 FAXhttp://[email protected]

This document is intended for use in conjunction with others to form a complete manualfor your AmTech system.

Introduction:This Instruction Set includes common information which relates to AmTech products. It willhelp you in setting up your system and to understand the fundamentals of the ultrasonic metalwelding process.

Portions of this section may be superseded by more specific and detailed informationprovided in other Instruction Sets.



Table of ContentsIntroduction:.................................................................................................................................... 1Table of Contents............................................................................................................................ 2Thank You: ..................................................................................................................................... 3Warranty: ........................................................................................................................................ 4Intended Use: .................................................................................................................................. 5Safety, Personal: ............................................................................................................................. 5

Safety Devices ............................................................................................................................. 5Emergency Stops: ........................................................................................................................ 5Safety Guidelines:........................................................................................................................ 5Maintenance Safety: .................................................................................................................... 6

Safety, System: ............................................................................................................................... 6System Protection Monitoring (SPM) ......................................................................................... 6Thermal Switch............................................................................................................................ 6Daily Functional Safety Checks: ................................................................................................. 6

Unpacking, Handling & Installation: .............................................................................................. 7If damage has occurred:............................................................................................................... 7System Location: ......................................................................................................................... 7System Assembly: ....................................................................................................................... 7

Operating the System:..................................................................................................................... 8Troubleshooting: ............................................................................................................................. 9

Weld Overload............................................................................................................................. 9Low Air Pressure ......................................................................................................................... 9Ready Check................................................................................................................................ 9Troubleshooting Guide .............................................................................................................. 10

Periodic Maintenance.................................................................................................................... 13Contacting AmTech:..................................................................................................................... 14

Spare Parts & Replacement Tooling: ........................................................................................ 14Questions or Problems:.............................................................................................................. 14Returning Equipment:................................................................................................................ 15

Return Authorization Form .................................................................................................... 16New Applications: ..................................................................................................................... 17

Evaluation Request Form....................................................................................................... 18Terminology:................................................................................................................................. 19Ultrasonic Theory: ........................................................................................................................ 24

What Is An Ultrasonic Weld?.................................................................................................... 24How Does It Work?................................................................................................................... 24



Thank You:

Thank you, and congratulations on selecting AmTech ULTRAWELD/ ULTRASPLICE Systemsfor your welding production. This system has been developed to produce the highest qualitywelds at the lowest cost per weld.

If you should experience difficulty or have any recommendations for improvement, please do nothesitate to contact us.

Please be advised that the ULTRAWELD/ ULTRASPLICE machine is protected under theUnited States and International patents listed below. This operators manual is also protected bycopyright and may not be copied without prior written permission by AmTech.

PatentsUS 4,730,764 US 4,749,437 US 4,757,933US 4,782,990 US 4,799,614 US 4,817,814US 4,852,788 US 4,867,370 DE 0286975EP 0286975 GB 0286975 JP 1,658,406

TrademarksULTRAWELD� andULTRASPLICE�

are registered trademarks ofAmerican Technology, Inc.

CopyrightULTRAWELD� Computer Softwareand the ULTRAWELD� Manual

are copyrighted 1994,1995,1996,1997 byAmerican Technology, Inc.



Warranty:

American Technology, Inc. warrants this equipment to be free from defects in material andworkmanship for one (1) year from date of original delivery by AmTech or by an authorizedrepresentative when used in accordance with written instructions. Any unit which provesdefective during this period will be repaired or replaced free of charge at the sole discretion ofAmTech, F.O.B. Shelton, Connecticut or an authorized repair station as advised by AmTech.This is the buyer’s sole and exclusive remedy. The defective unit must be returned properlypacked with all transportation charges prepaid.

Expendable tooling produced by AmTech such as the horn, tip and anvil will wear at varyingrates depending upon the application and duty cycle. For this reason, AmTech warrants that alltooling complies with specifications on design and materials but cannot guarantee its useful lifefor a fixed period of time.

The warranty provisions contained herein are expressly in lieu of all other warranties, express orimplied. THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY ORFITNESS FOR A PARTICULAR PURPOSE MADE IN CONNECTION WITH THEEQUIPMENT TO BE DELIVERED THEREUNDER.

This warranty is limited to the original purchaser and is not transferable.

American Technology, Inc. will not be liable for any consequential damages claimed in relationto the purchase or warranty of the equipment to be delivered thereunder. AmTech will not beliable for any injury to persons or property caused directly or indirectly by the use of theequipment delivered thereunder.

Horns fabricated by AmTech for use in AmTech equipment are manufactured to exactingparameters and tuned to vibrate at the equipment’s ultrasonic operating frequency. Animproperly tuned horn can cause undue stress or damage to the converter and power supply.Contact your AmTech representative or AmTech’s world headquarters in Shelton, Connecticut,should you have any questions concerning horn qualifications.

Authorization to return equipment for repair is required. A Return Authorization Number mustbe obtained from AmTech’s Service Department. Equipment being returned for repair must bepackaged in the original carton(s) to protect it from damage and returned freight prepaid. Anydamage that is sustained as a result of improper packaging may void the warranty and is thesole responsibility of the customer.

For questions relating to warranty or repair please contact our Repair Department.



.Intended Use:This equipment is for the joining of metal parts using ultrasonic energy. A complete systemincludes an actuator, controller and tooling (which delivers mechanical energy to the workpieces). Some systems also include special fixturing and machine automation. AmTech systemsmay only be utilized to weld soft, ductile, metal parts together with AmTech-supplied weldtooling (such as horns, tips, anvils, and converters) unless an explicit, written, contraryagreement between the ordering party and AmTech has been consummated.

Safety, Personal:

Safety Devices The removal, bridging or disabling of safety devices is not condoned for production operation.Individual safety devices mentioned below may only be disabled if super-ordinate safety devicesare employed in their place.

Emergency Stops:In case of danger, hit the red, emergency stop Which is found on the red, top portion of the footpedal. The actuator, power supply and related fixturing are returned to the “Home” position. Ifdual anti-tie start buttons are used, there must be a red emergency stop associated in line. Freeaccess to the emergency stop button must be maintained.

Controller CoverThe power supply is equipped with a top cover which should only be removed for maintenanceand installation purposes.

Safety Guidelines: For operating safety, please observe the following precautions:� Plug the power supply into a grounded electrical supply to avoid electrical shock.� Ensure that no one is in contact with system moving parts when operating.� Keep hands away from the horn tip as high force and ultrasonic vibration can cause injury to

hands and fingers.� Do not test ultrasonics when the converter is removed from the actuator. Without the

converter there is the danger of damage or shock.� Before adjusting or repairing the ultrasonic stack or power supply, disconnect the line power.� Any unauthorized modification of the units control circuitry or wiring may cause a

malfunction, which could result in injury to operating personnel.� Do not operate the equipment until repairs and adjustments have been made and the

equipment is in good working order.



Maintenance Safety:Safety devices, especially covers, guards and ground cables should only be removed when it isabsolutely essential for the completion of maintenance work. If safety devices were removedprior to starting maintenance work, be sure to re-install those devices after finishing themaintenance work. The following installation and maintenance operations must be performedprior to any disassembly of equipment:

� All system components must be disconnected from the main electrical supply� Remove the plug from the main electrical supply and secure it from being re-inserted

accidentally.� All system components must be disconnected from the main air supply� Disconnect the air hose from the main air supply and release system air pressure via the

pressure regulator.

Safety, System:

System Protection Monitoring (SPM)The SPM (System Protection Monitoring) stops ultrasonics when the power supply has beenoverloaded or when inappropriate or defective horns are used.

Thermal SwitchA thermal switch is contained within the power supply to automatically disconnect power to themachine if the unit gets too hot. This will occur if the exhaust fans from the generator areinadvertently blocked or clogged.

Daily Functional Safety Checks:� Check the machine tip and anvil for any signs of grinding, cracking, or galling that could be

the result of misalignment or tooling contact. Replace tooling that has excessive wear.� Check for any loose material or debris in the welding cavity, cleaning it out.� Check all parameter settings on the controller to ensure they are properly set for the weld to

be made.� Drain water and contaminants from the airline filters as necessary



Unpacking, Handling & Installation:Unpack the Actuator and Touchscreen Controller. Remove the top cover of the power supplyand check if any components became loose during shipment.

If damage has occurred:Notify the shipping company immediately. Retain packaging materials for inspection andpossible re-use.

System Location:Locate the Touchscreen Controller in an area away from radiators or heating vents. Allowsufficient clearance in back of the controller to access the connectors. Observe the following:

� Do not block the exhaust or air intake areas. Proper air circulation is necessary to maintain asafe operating temperature.

� Only operate the controller within an ambient temperature range of 41�F to 122�F (5�C to50�C).

� Verify that neither dust nor dirt are allowed to restrict the flow of air exhaust or air intake.Clean the air ports as necessary.

If the temperature of the power supply exceeds the recommended operating range, a thermalswitch will stop ultrasonics and the power supply will display an Overload alarm. Ultrasonicswill remain off until the power supply cools to a safe operating temperature and the RESETbutton is pressed.

If the environment is excessively dirty or oily, contact AmTech for assistance. SpecialTouchscreen Controller enclosures, filters (i.e. filter/separator/regulator), and other equipmentare available.

System Assembly:Connect the actuator system per the Hookup diagram contained in the Special InformationInstruction Set. Verify that connections are complete and correct before proceeding. Plug theController into a proper power source. See the Touchscreen Controller Instruction Set for powerspecifications, plugs and receptacles used.

Connect the system to a clean (5 micron air filter with 0.5 micron mist separator), dry, 80 psig(5.5 bar) minimum air supply.

See the Actuator Instruction Set for information on the set up of application tooling and the useof this equipment for ultrasonic welding.



Crash Gap Adjustment:In most applications, adjustment of the gap between the ultrasonic Horn Tip and the Anvil isfactory set to prevent these surfaces from contacting each other when no parts to be welded arepresent and the foot pedal is depressed. A poorly adjusted crash gap can cause serious damage tothe tooling. See the Actuator Instruction Set for proper setup instructions.

Operating the System:With all proper connections made and with tooling properly set up, welding may be performed.In most instances it is likely that AmTech has developed weld settings for your application andstored them as presets in the controller prior to shipping. See the Touchscreen ControllerInstruction Set for information on retrieving presets. For other weld parameter informationpertaining to your system, see the parameter preset page included in the Special InformationInstruction Set.



Troubleshooting:This section shows how to fix some of the possible errors and problems which may occur innormal use of the Ultraweld/ Ultrasplice system.

Weld OverloadWeld overloads are premature shut downs of the power supply. Overloads signify excessiveloads and must be corrected if continued reliability of the equipment is to be maintained.Hardware internal to the supply are controlling this function and it can not be defeated.

The control system analyzes the end of weld characteristics to check for overloads. If the systemdetermines an overload an alarm occurs. The control halts action until the system is reset.

Some of the possible causes for overloads are:� The tool clearances are too small, horn and anvil touch during welding� Excessive air pressure with low amplitude� Defective Stack assembly� Defective Power Transistors in power supply

Low Air Pressure

The control system and its components were designed to run with a clean air supply of from 90to 120 psi. The control system monitors the air pressure from the low air pressure switch(optional). The low pressure threshold is set from the controller. An alarm occurs whenincoming line pressure the drops below the set pressure.

Ready CheckThe system undergoes a Ready Check operation at every startup, the end of every weld, and atthe exit of Setup mode. This procedure checks the height encoder position. If an incorrect heightvalue is returned, an alarm occurs.

Some of the possible causes of a Ready Check alarm are:� The horn is stuck in the closed position� Maintenance has moved the height encoder to an out of limit condition� Defective encoder or electronics� Encoder not plugged in to its connector



Troubleshooting Guide

PROBLEM SOLUTIONSystem will not turn on. Power cable plugged in.

Power turned on at the outlet.Check internal fuses on the Controller LineBoard.

Plant fuse fails or circuit breaker tripswhen plugging the unit into an electricaloutlet.

Inspect power cord, replace if shorted.Check line filter, replace if failed.

Plant fuse fails or circuit breaker tripsduring weld cycle

Check current rating of the plant fuse or thecircuit breaker, replace if failed.

Line fuse fails. Check fuse current rating, replace ifincompatible.Check fan motor, replace if failed.

Horn will not move down or up. System not connected to air supply.Air not turned on.

Get Emergency Stop when system isturned on.

Check Emergency Stop Switch.All cables properly connected.Press red switch on foot pedal. (if system isequipped with one)

No Sonics when test button is pressed. RF Cable connected.Check RF cable for broken wire.Ribbon cable in power supply between SPM andprogrammer unplugged.

No sonics during weld cycle Check all cable connections.Check start cable for broken wires.Check inside power supply for loose start cablefrom rear of unit to programmer board.Check thermo switch in power supply.

Overloads when welding Stack not tuned properly.Tooling not set up properly.Crash gap not set properly.Tip nut cracked, replace if needed.Check weld parameters.Check stack interfaces for fretting.Check for loose or failed horn or booster, tightenor replace as necessary.

When touching the system you get aslight electrical shock.

Inspect power cord, replace if needed.Inspect system ground, repair if needed.



Tooling heats up after machine runs awhile.

Cooling air is not turned on or is not on longenough.Cooling air is not directed at tooling.

Low weld strength. Check weld parameters.Check tooling gaps.Check knurl on tooling. If worn replacetooling.Increase Energy.Check the Down stop adjustment.Check for part contamination.Ensure all hardware is tight.

Excessive welding. Reset parameters.Reset amplitude.Reset pressure.Measure and re-calibrate amplitude display.

Time limit error or peak power errordisplayed after weld cycle.

Reset limits.Check tip, rotate or replace if worn.Check anvil for wear, rotate or replace if worn.Check air pressure setting.Check up stop for proper adjustment.Process settings have to be opened up due topart variance or limits should be adjustedaccording to the part/wire being run.Check anvil clamp for proper torque.

Squealing sound during welding or whentest key is depressed

Check plate screws and tighten or replace.Check cover plate screws and tighten.Reset gaps.Re-square horn/tip and reset gaps.Reset horn tip and gap.

Weld heights are inconsistent Re-calibrate encoders with 1mm gauge.Ensure the connector for the encoder is tightlyplugged into the actuator card.

Horn is stuck in down position Check air pressure.Ensure air lines are installed properly.Check for kinks in air lines.

Air leaking from machine. Ensure all air line connections are tight.Check for cracked or broken air lines.

Unusual sound during weld cycle. Check tooling gap.Check converter.Check stack assembly.



Squealing sound from power supply whenunit is turned on.

Check cooling fans in rear of unit

Maintenance counter alarm. Reset maintenance counter.Actuator arm moves sluggish Check air lines for contamination.

NOTE: Air must be filtered to 5 microns and beoil and water free.Check solenoid valve, replace if needed.Check air regulator.

System has READY CHECK message The horn is stuck in the closed position.Maintenance has moved the height encoder toan out of limit condition.Defective encoder or electronics.Encoder not plugged into the actuator card.

Time, height and energy inconsistent. Switch to energy mode & open height window.Make some sample welds. Check the time andthe height of the welds for consistency. If thetime or weld thickness varies greatly, check theair regulator.



Periodic MaintenanceIn order to maintain optimum operating conditions, it is important to perform variousmaintenance and equipment inspections at periodic intervals. Please observe the followingrecommendations.

Daily:� Drain water and contaminants from the airline filters, if required.

Every Tool Rotation:� Inspect the clamping surfaces of the Tip, the Tip Nut

and the Horn for fretting.� Vacuum and clean out any copper residue or dirt in the actuator.

After one million cycles:� Vacuum and clean inside of power supply� Calibrate pressure regulator. � Clean and torque the stack interface.� Calibrate amplitude.

FSR AssemblyAir Filter/Separator/Regulator (Optional AmTech Part #207-020) should be serviced after 1 yearor when a pressure drop of 15 psi is reached.

� Disconnect the air supply.� Remove and clean out filter bowl with a clean rag.� Replace the white filter element and re-assemble. � Remove and clean out separator bowl with a clean rag. � Replace brass-colored filter element and reassemble.� Reconnect air supply.

Do not use solvent to clean filter bowlsClean the air filter bowl with a mild household soap only. The bowl is made from apolycarbonate material, which can rupture if exposed to synthetic lubricating oils solvents orharsh chemicals. The bowl is rated for a maximum line pressure of 140 psig (1043 kPa) and amaximum temperature of 120�F (49�C).



Contacting AmTech:

Spare Parts & Replacement Tooling:Spare parts or replacement tooling for the ultrasonic welding system may be ordered directlyfrom AmTech. A spare tooling specification sheet is included in the Special InformationInstruction Set. Additional part listings are contained in the Actuator and TouchscreenController Instruction Set sections of this manual.

AmTech will work with you and recommend components you need and should carry ininventory based upon your manufacturing philosophy and or production needs. We will quoteprice, delivery and can coordinate special arrangements such as expedited service or blanketorders.

When Ordering Spare or Replacement Parts have the purchasing agent Fax the order to us withthe following information provided:

� Purchase Order Number,� AmTech Part Number, Quantity, and Date Required,� Ship To Information, (including “Ship to the Attention of”)� Bill To Information� Shipping Instructions, (such as air freight, truck, etc.)� Special Instructions, (such as “Hold at Pick-Up Counter and Call” -- Be sure to provide a

name and a phone number)

Questions or Problems:If you have any questions or are experiencing a problem, call the local AmTech field sales and/orservice representative. He or she will be familiar with your equipment and application and, inmost cases, will be able to help you. He or she may have the replacement part you need, instock, that will return your system to operation in the shortest possible time.

If necessary, the representative will contact AmTech for additional service and, in some cases,will put you into contact with the appropriate personnel. If the local representative is unavailable,please call us directly.

Before you call, take the following steps:� Have this manual with you.� Know how your system has been set up and equipped, including your MBOS version.� Be able to describe the situation or problem.� Have a list of steps that you have already taken.� Have a list of spare parts in your inventory� Have the name and phone number of the Local AmTech Representative



Returning Equipment:In order to properly and efficiently handle an equipment return to AmTech, the followingprocedure must be followed. Contact your Local Sales Manager or AmTech Customer Servicefor assistance. Proper handling and identification of your equipment will expedite servicingand/or return.

Using the Return Authorization Form, (next page), complete the following:� Customer Information Section� Description of Problem� Equipment Information

Call AmTech and Receive a Return Authorization Number (RA#) from AmTech CustomerService. � Properly package the equipment to prevent damage� Clearly mark the RA# on the outside of the package� Include a copy of the completed Return Authorization Form inside the package� Return general repairs by any convenient method. Send priority repairs via Air Freight� Prepay the transportation charges, (FOB Shelton, CT)



Return Authorization Form

Customer Information Authorization InformationCustomer name: Return Authorization No:

Assigned By:Address:

Contact:Phone:Fax:

Special Instructions:

Description of Problem:

Equipment Information:Machine Type:Machine Serial Number:Date of Original Purchase:

Part Number of Component:PO Number for Repair:

For AmTech Use OnlyUnder WarrantyBillable RepairCharge Repair to Sales

Do not ship to AmTech without an RAnumber. Mark the RA number on the shippinglabel. Please fax a copy of this completedform to AmTech Customer Service prior toShipping. Sold Replacement Part



New Applications:AmTech is always eager to work with you on a new ultrasonic application. Whether it be amanual workstation, a semi or fully automated system, AmTech has the personnel and technicalcompetence to support your requirements. AmTech’s application laboratory, product andautomation engineering, customer service and manufacturing capabilities are second to none.AmTech is the world leader in ultrasonic metal welding and our business philosophy is practicedto assure customer success.

Application assistance is always available. For initial application review, contact your LocalSales Manager who can indicate initial feasibility and assist you in completing the UltrasonicWeld Evaluation Request Form, (next page). Please complete one (1) request form for eachapplication.

Please copy the attached Ultrasonic Evaluation Request Form (next page), complete thecustomer and application information section and forward it to AmTech along with enoughcomponent material to produce 24 assemblies, (if this is not practical please advise). Afeasibility evaluation will be performed and samples returned, for review, along with a systemquotation/ proposal. Be sure to include drawings of the completed assembly and include theelectrical, mechanical, and production requirements. Complete the form as completely aspossible. The AmTech Sales Representative can assist you.



Evaluation Request Form

Lab Application No: Date:Please fill out this form with at least 24 samples parts for an ultrasonic weld analysisName:Company:Address:City:Telephone:

Component Description:Part 1 Part 2

Material:Hardness:Plating:Insulation:Application Requirements:Production Rate: (parts/hr)Location tolerance: (in)Is weld appearance important:Pull Strength (lbs)Drawing Notes:

This information to be completed by AmTechRepresentative:Telephone:Return samples to: Representative CustomerSales Engineer:Applications Engineer:



Terminology:

Actuator: A mechanical device which houses the converter/booster/horn (stack) assembly in arigid mounting and is utilized to move the stack up or down. This allows for precise control ofwelding pressure for efficient while delivering mechanical vibrations from the ultrasonic stack tothe work piece(s).

After Burst: A short duration (burst) of ultrasonic energy that begins after completion of theAFTER BURST DELAY. (Also See: AFTER BURST DELAY & AFTER BURSTDURATION)

After Burst Delay: The amount of time, in seconds, between the completion of the ultrasonicwelding cycle and the start of the AFTER BURST. (Also See: AFTER BURST & AFTERBURST DURATION)

After Burst Duration: The amount of time, in seconds, that AFTER BURST energy isdelivered. (Also See: AFTER BURST & AFTER BURST DELAY)

Amplitude: Amplitude is the peak-to-peak displacement of mechanical motion as measured atthe face of the horn tip. Amplitude is measured in thousandths of an inch or in microns. (i.e. Astandard 40 kHz converter produces approximately .0004” or 10 microns of amplitude), Inches x25.4 = microns. -- With ‘Advanced Power Supply’ this is adjustable depending on systemfrequency and application tooling.

Anti-Node: The anti-node is the area of the horn and booster that exhibits maximumlongitudinal displacement and where the internal dynamic forces are equal to zero. This area isat the face and back surface on half-wave technology.

Anvil: A device specially designed to grip the lower component and hold it stationary againstthe energy of vibration(s) which allows a weld to be created.

Baud Rate: A communications measure describing the speed at which signals are transmittedserially (the number of signal events per second).

BBRAM: Nonvolatile random access memory (battery back-up random access memory).Equipped with long life built in batteries, this memory area preserves weld parameters and menusettings when the system is powered off. (also known as BBR)

Booster: The central component of an ultrasonic stack assembly. A device which transfersmechanical energy from the converter to the ultrasonic horn. The booster will, depending ondesign, increase, decrease, or maintain the specific energy (amplitude) as received from theconverter.

Calibration: The process of adjusting a device to a known position for purposes of inspectionand/or monitoring position, direction, speed, and/or velocity.



Clock: An electronic circuit that generates timing pulses to synchronize the operations ofvarious other circuits in a device(s).

Communications: Transmission of information between points of origin and reception withoutalteration of the sequence and or structure of that information content.

Consumable Spare Tooling: The tooling portion of the ultrasonic system that wears andrequires replacement due to production use. This includes but is not limited to ultrasonic horns,replaceable tips, anvil, and positioning mask. A Spare Tooling Specification Sheet is includedwithin the Operation Manual to document the spare tooling for a specific metal weldingapplication.

Continuous Sonics Mode: A system setting in which the power supply will deliver ultrasonicelectrical energy until the start signal is terminated.

Controller: The portion of the welding system that provides specific settings & instruction(s) tothe overall welding system.

Converter: A device which utilizes a lead-zirconate-titanate electrorestrictive element tochange high frequency electrical energy into high frequency mechanical energy.

Counter: A programmable device used to monitor system cycles and alert personnel whenspecific conditions are met.

Data: Any representation(s) of instructions, characters, information, or analog quantities towhich meaning may be assigned

Default: A chosen system setting or parameter in which the system does not require externaldata input. In some cases the default value will be changed based upon equipment use.

Dynamic Spring: An, adjustable, energy storage mechanism (shock absorber) which allows forstack follow through upon engagement of application tooling with the work pieces to be welded.

Energy: Energy is the area beneath the ultrasonic power curve and is calculated in joules,(Watts X Seconds = Joules). When the ultrasonic welding system is setup in the “Weld InEnergy” mode the system will deliver the amount of energy as programmed. NOTE: Themaximum (default) time allowed for delivering ultrasonic energy is five (5) seconds.

Energy Mode: A welding method in which the ultrasonic power supply is active until therequired amount of energy is delivered (See ENERGY)

Fixture: A device for positioning and or holding a component for assembly.

Force: The amount of mechanical pressure that is used to deliver, (bring down) the mechanicalactuator. This programmed force is also called TRIGGER FORCE and is used to engage theknurl pattern into the component part(s) prior to the initiation of ultrasonic energy.



Frequency: The number of complete oscillations per second expressed in Hertz (Hz) orkilohertz (1 kilohertz = 1000 Hz). Typically 20 kHz or 40 kHz.

Gain: The ratio of the amplitude of motion produced by the converter and delivered by the hornis called the gain. It is determined by the difference in mass on either side of the nodal point.

Hand Shaking: The procedure (signal exchange) when a connection is established between twoelectronic devices. A common example is the signal exchange between a terminal and aMODEM. These signals (hardware and software) are used to control the flow of data (start/stop)between devices.

Height: A display value, in millimeters (mm), as registered by a linear encoder upon completionof an ultrasonic welding cycle. -- Programmable, in millimeters, with Upper Control Limit &Lower Control Limit

Height Encoder: A device utilized to monitor position, direction, speed, and/or velocity.

Horn: An acoustically designed metal tool that delivers mechanical energy from the converter/booster into the work piece. Most applications utilize half wave technology, (40 kHz = 2.2” �,20 kHz = 5.5” �).

Hold Time: The amount of time after delivery of ultrasonic energy until the stack tooling beginsto retract from the component material(s).

Joint: The welded surfaces

Linear Height Encoder: (See: Height Encoder)

Loading Meter: A meter which indicates the power drawn from the ultrasonic power supply.

Maintenance Counter: A programmable device used to alert production personnel of the needto review/ inspect application tooling and/or the ultrasonic system for preventive maintenancepurposes. The device increments one (1) count for each system cycle. (See: Counters)

Mode: The method of operating the system (also see WELDING MODE)

Node: The node is the area of the horn, (and booster), that exhibits no longitudinal displacementand where the internal dynamic forces are at the maximum. This area is in the center location onhalf-wave technology.

Parameter(s): Programmable units used to control and or monitor the ultrasonic process. --Include but not limited to ENERGY, FORCE, PRESSURE, AMPLITUDE

Parts Counter: A programmable device used to monitor system cycles and alert personnelwhen specific conditions are met. (See: Counters)



Peak Power: Peak power is the maximum amount of power in watts that was required to keepthe ultrasonic stack in motion during the weld cycle.

Power: Power, measured in watts, is a function of pressure and amplitude. The amount ofpower, (watts) required to keep the ultrasonic stack in motion is monitored and used to develop apower curve. This power curve is used to calculate the amount of energy delivered/ dissipated,(Watts = Joules / Time). The power as displayed on the control box is peak power.

Power Supply (Ultrasonic): An electronic device that converts 50/60 cycle electrical currentinto 40 kHz, (40,000) or 20 kHz, (20,000) cycles per second high frequency electrical energy.

Power Supply Overload (Ultrasonic): The point or limit at which the amount of power inwatts, required to keep the ultrasonic stack in motion, exceeds the available power from thepower supply. The system will go into an overload condition in order to prevent system damage.

Preheight: A pre-sonic inspection display, in millimeters (mm), as registered by a linearencoder prior to initiation of the ultrasonic welding cycle. -- Programmable, in millimeters, withUpper Control Limit & Lower Control Limit

Presets: System memory available for storage and retrieval of welding parameters.

Pressure: The amount of mechanical pressure supplied to the ultrasonic stack assembly whiledelivering ultrasonic energy to the components.

Quality Widows & Limits: Programmable values used by the system to compare actualprocess data. Actual process data must be within limits or an alarm condition will exist.

Setup Mode: The condition the control box must be in prior to adjusting parameters, qualitywindows, and/or any others settings except those contained within the Command Mode.

Squeeze Time : The amount of time after the ultrasonic tooling engages the component(s) andbefore delivery of ultrasonic energy. -- Adjustable from 0 - 0.5 seconds

Stress: Stress is the amount of dynamic force per cross sectional area.

Time : Time is the duration of the ultrasonic, mechanical, activity. Time is a component used tocalculate the amount of ultrasonic energy delivered during a weld cycle, (Time = Joules / Watts).

Tip: Device specially designed to grip the upper component, to be welded, and to direct theultrasonic energy into the work piece, (Also: Horn Tip & Replaceable Horn Tip).

Tip Nut: Device specially designed to securely clamp a replaceable tip onto the horn.

Trigger Force: (See: Force)



Tuning: Adjusting to optimize power supply performance according to resonance frequency,especially with regard to the horn and converter.

Velocity: The rate of motion at a specific time [velocity = distance � time] (also referred to asspeed)

Weld Mode:

� Weld In Energy: System delivers ultrasonic energy until a predetermined amount of energy,in joules is dissipated. The system determines energy by calculating the area beneath thepower curve -- Watts x Time = Joules (1 watt per second = 1 joule).

� Weld In Height: System delivers ultrasonic energy until the ultrasonic tooling reaches apredetermined position.

� Weld In Time: System delivers ultrasonic energy for a predetermined amount of time.

� Welding Parameters: (See: Parameters)



Ultrasonic Theory:

What Is An Ultrasonic Weld?Ultrasonic welding joins metal parts by applying the energy of high frequency vibrations onto theinterface area between the parts to be welded.

How Does It Work?Electrical Energy is transformed into high frequency mechanical vibration. This mechanicalvibration is transferred to a welding tip through an acoustically tuned horn (Figure 1). The partsare “scrubbed” together under pressure at 20,000 or 40,000 cycles per second. This highfrequency vibration, applied under force, disperses surface films and oxides, creating a clean,controlled, diffusion weld (Figure 2). As the atoms are combined between the parts to bewelded, a true, metallurgical bond is produced.

Figure 1 Figure 2

Benefits of Ultrasonic Welding

Ultrasonic metal welding exhibits unique welding properties that include:

� Excellent electrical, mechanical, and thermal connections between similar and dissimilarmetals.

� Low heat build up during the ultrasonic process (no annealing of materials).

� Compensation for normal surface variations of the material.

� Ability to clean surface oxides and contaminants prior to welding.

� Ability to weld large areas using minimal energy.

� Ability to weld thin materials to thick materials.

� Low cost per weld.



How Is An Ultrasonic Weld Made?

Although the theoretical process of producing an ultrasonic weld is uncomplicated, theinteractions of the various weld parameters are important and should be understood. Whenproducing an ultrasonic weld, there are three primary variables that interact; they are:

Time: The duration of applied ultrasonic vibration

Amplitude: The longitudinal displacement of the vibration

Force: The compressive force applied perpendicular (normal) to the direction of vibration

Power required to initiate and maintain vibration (motion) during the weld cycle can be definedas:

P = F x A

Where:� P = Power (watts)� F = Force * (psi)� A = Amplitude (microns)

*Note: Force is determined by multiplying:Force = (Surface Area of the Cylinder) X ( Air Pressure) X ( Mechanical Advantage)

Energy is calculated as:E = P x T

Where:� E = Energy (joules)� P = Power (watts)� T = Time (seconds)

Thus the complete ‘Weld To Energy’ process would be defined as:

E = ( F x A ) x T

A well designed ultrasonic metal welding system will compensate for normal variations in thesurface conditions of the metals by delivering the specified energy value. This is achieved byallowing Time (T) to adjust to suit the condition of the materials and deliver the desired energy.



Welding To Energy - Why?

Most metal welding applications are produced by ‘Welding To Energy’ in order to compensatefor the various surface oxides and contaminants associated with the metals being joined. In afew applications ‘Welding To Time’ or ‘Welding To Height’ will yield better results. Since themajority of all metal welds are produced using energy as the controlling factor we will confineour discussion to that condition.

Welding to energy is necessary because of the non-metallic oxides that form on the metal’ssurface as well as other contaminates such as grease and dirt. To producing quality weldsreliably it is necessary that the surfaces to be joined are clean. The high frequency scrubbingaction, combined with pressure, cleans the weld interface at the beginning of the weld process.

The following graph (Figure 3) illustrates a weld produced. The weld ‘power graph’ issometimes to referred to a weld ‘footprint’. It can be used to visualize the weld cycle and assistsin parameter optimization. Graphs from consecutive welds will vary slightly as the systemdynamically adjusts time to accommodate varying surface conditions. The weld power data isgathered by sampling the power used in 5 millisecond intervals.



PowerThe converter/ booster/ horn, (stack assembly), requires minimal electrical power to initiate andmaintain motion (vibration) at a ‘no-load’ condition. As the mechanical load increases, thepower required to maintain the mechanical vibration also increases. The maximum powerrequired during a weld cycle is ‘Peak Power’.

Figure 3

By increasing Pressure and maintaining all other parameters, the mechanical load or force on theweld joint increases, therefore, the amount of Power required to maintain the vibration of thestack increases. Subsequently, because of the increased Power Level, less time is required deliverthe same amount of Energy. This relationship is illustrated in the following diagram (Figure 4):

Figure 4

The difference in the appearance of each of the above weld graphs is the result of increasedPower loading. Based upon an increase in Pressure, additional Power is required to maintain themotion of vibration. Thus, the same amount of energy is delivered in less time. This approach istypically used to raise the loading of the power supply during a weld cycle to the desired level asdetermined by the application.



Time: The time required to deliver the necessary energy is defined as the Weld Time. For most welds,the time required will be less than one second. If more energy is required and all other weldparameters are maintained, the weld time will increase (Figure 5).

Figure 5

Amplitude: An ultrasonic tool is a resonant acoustical device. The term Amplitude is used to describe theamount of longitudinal expansion and contraction that the tooling endures as it vibrates (Figure6). The amplitude correlates to the scrubbing action at the weld interface. This scrubbing actioncombined with pressure is what advances the weld by a diffusing or mixing of the base materials.

Figure 6



As previously mentioned, the converter/ booster/ horn, (stack assembly), requires minimalelectrical power to initiate and maintain vibration in a ‘no-load’ condition. As the amplitudeincreases, the power required to maintain the increased velocity of vibration also increases.Subsequently, because of the increased Power less time is required deliver the same amount ofEnergy. This relationship is illustrated in the power diagram (Figure 7):

Figure 7

Resonant Frequency:The ultrasonic tooling acts as a spring having node points and anti-node points. The mechanicalenergy used to vibrate the tool is created by the converter. As the vibrations are propagatedthrough the acoustical tool, a harmonic resonance is established consisting of nodes and anti-nodes. This action results in a resonant wave being transferred through the tooling (Figure 8).The efficiency of the resonant wave transfer depends on the natural resonant frequency of thehorn and is determined by two factors:

� The speed of sound through the material� The geometric shape of the object

Figure 8



Avoiding An Overload Condition: It is possible to increase the Amplitude and or the Pressureto a point where the power available is not adequate to initiate or maintain vibration under thegiven mechanical load. At this point, the power supply will stall resulting in an Overloadcondition. Electronic circuits in the system will protect the power supply if this condition exists.

Welding To Time: In specific applications, ‘Welding To Time’ may be desired. As previouslymentioned, there are three primary variables that interact; they are:

� TIME: The duration of applied ultrasonic vibration.� AMPLITUDE: The longitudinal displacement of the vibration.� FORCE: The compressive force applied perpendicular (normal) to the direction of vibration.

Generally, welding for a specific time will produce acceptable results when:

� The equipment is installed on an automated production line and each station must completeits process within a certain time limit.

� Very small low energy welds on clean components are being made.

Welding Temperature: Ultrasonic welding produces a localized temperature rise from thecombined effects of elastic hysteresis, interfacial slip and plastic deformation. The weldinterfaces reach approximately 1/3 the temperatures needed to melt the metals. Since thetemperature does not reach the melting point of the material, the physical properties of thewelded material are preserved. As the ultrasonic welding process is an exothermic reaction, aswelding time increases so does weld temperature.

AmTech Product Manual- Actuator Information Ultrasplice 2032 Actuator Information and Instructions Document Number: DCM00025 Last revised: 8/5/05 DAS This document is intended for use with the AmTech Ultrasplice 2032 actuator American Technology Inc. 41 Eagle Rd Danbury, Connecticut 06810 U.S.A. (203) 926-2677 (800) 888-6089 (203) 796-0380 FAX http://www.amtechultrasonic.com [email protected]

This document is intended for use in conjunction with others to form a complete manual for your AmTech system. Introduction This Instruction Set includes information on how to maintain and operate the Ultrasplice 2032Actuator. This actuator, when combined with an AmTech controller forms a system used to join and solidify wires with ultrasonic energy.

Instruction Set for Actuator Information Page 1 of 36

AmTech Product Manual- Actuator Information Ultrasplice 2032 Table of Contents Introduction..................................................................................................................................... 1 Table of Contents............................................................................................................................ 2 Mechanical Actuator Specifications ............................................................................................... 3 Ultrasonic Stack Assembly ............................................................................................................. 4

Converter ..................................................................................................................................... 4 Horn ............................................................................................................................................. 4 Welding Tip (Replaceable Tip Tooling) ..................................................................................... 5 Tip Nut (Replaceable Tip Tooling) ............................................................................................. 5 Ultrasonic Stack Mounting.......................................................................................................... 5

Anvil and Gather Operation............................................................................................................ 6 Application Tooling ........................................................................................................................ 7 Weld Parameters ............................................................................................................................. 8 Establishing Splice Parameters ....................................................................................................... 8

Proper Wire Insertion .................................................................................................................. 9 Evaluation of Splice...................................................................................................................... 10

Destructive Testing.................................................................................................................... 10 Quality Monitoring.................................................................................................................... 11 Compaction vs. Tensile Strength............................................................................................... 12

Wire Splice Comparison ............................................................................................................... 13 Periodic Maintenance.................................................................................................................... 15

Checking Splicer Sonics............................................................................................................ 15 Calibrate Amplitude .................................................................................................................. 15 Ultrasplice 2032 Tooling Set-up................................................................................................ 16 Tool Cleaning ........................................................................................................................... 18 Adjustment of Down Stop: ........................................................................................................ 18 Anvil Eccentric Set-up............................................................................................................... 20 Ultrasonic Stack Disassembly ................................................................................................... 22 Ultrasonic Stack Reassembly .................................................................................................... 24 Lubrication: ............................................................................................................................... 29 Lubrication Schedule:................................................................................................................ 31

Encoder Board Calibration ........................................................................................................... 32 Calibrate Height......................................................................................................................... 32 Height Span Adjustment............................................................................................................ 33 Calibrate Width.......................................................................................................................... 34 Width Span Adjustment............................................................................................................. 35

File Attachments: .......................................................................................................................... 36


AmTech Product Manual- Actuator Information Ultrasplice 2032 Mechanical Actuator Specifications The ULTRASPLICE system is comprised of a controller and mechanical actuator. The mechanical actuator (Figure 1) is the subject of this Instruction Set. It rigidly holds the converter, booster and horn assembly known as the ultrasonic stack (Figure 2). A pneumatic cylinder and cam mechanism drives the anvil to apply precise pressure to the parts being welded. The application tooling (i.e. anvil, tip, tip guide & gather block) is designed for easy replacement.

Figure 1

Specifications ULTRASLPLICE 2032 Actuator Y5A00001 Length 20.39” (518mm) Height 9.19” (233mm) Width 7.14” (181mm) Weight 44 lbs. (20Kg)


AmTech Product Manual- Actuator Information Ultrasplice 2032 Ultrasonic Stack Assembly

Figure 2

Converter The 20 kHz electrical energy from the power supply is applied to the transducer element or converter, which transforms the high frequency electric current into high frequency mechanical vibrations at the same frequency. The heart of the converter is a lead-zirconate-titanate electrostrictive element that, when subjected to an alternating voltage expands and contracts. The converter’s efficiency of changing electrical energy to mechanical vibrations exceeds ninety-five percent. Horn The horn is a half-wave length resonant metal device that transfers the ultrasonic vibrations from the converter to the weld tip. The horn is made of titanium and is designed to resonate at 20 kHz. The acoustical efficiency of titanium helps to maintain constant amplitude throughout the operating temperature of the welder. Since the horn is a vital part of the ultrasonic assembly system, it should not be altered without proper training and advice from AmTech.


AmTech Product Manual- Actuator Information Ultrasplice 2032 Welding Tip (Replaceable Tip Tooling) The welding tip is designed to grip the lower component of the parts being welded, and to couple the ultrasonic vibrations through that element into the bonding area. Welding tips are fabricated from high-speed tool steel and heat-treated to precise specifications to provide maximum life. The tip is coated to further enhance tool life and to provide corrosion resistance. Tip Nut (Replaceable Tip Tooling) The tip nut is made of titanium and is designed to securely clamp the tip onto the horn. The horn-welding tip-tip nut assembly is a very efficient system for transmitting ultrasonic vibration to the parts to be welded and offers an interchangeable tool at a very low cost. Ultrasonic Stack Mounting The ultrasonic stack is mounted into a pair of stack supports and securely clamped in place. The anvil arm is attached to the polar block using a re-circulating roller bearing slide. This slide provides the necessary precise travel required for the entire anvil assembly. The slide also provides excellent rigidity to resist any loss of ultrasonic energy in the horizontal direction of sonic vibrations.


AmTech Product Manual- Actuator Information Ultrasplice 2032 Anvil and Gather Operation The anvil is made of high-grade carbide for maximum wear and corrosion resistance. The patented tool design allows it to be rotated to present multiple weld surfaces. A Gathering Block sweeps across the face of the Tip to collect the wire strands and forms the width of the compression chamber.

Gather Block

Anvil

Figure 3


AmTech Product Manual- Actuator Information Ultrasplice 2032

Figure 4 Application Tooling Application tooling is designed and manufactured to position and weld component materials to meet customer specifications. Application tooling typically consists of a horn, tip, tip nut, tip guide, anvil, anvil holder and gather block. (Figure 4) Application tooling is as per the System Specification Sheet located in the Special Information Instruction Set.


AmTech Product Manual- Actuator Information Ultrasplice 2032 Weld Parameters To obtain quality welds each and every time; the correct combination of weld parameter settings must be developed. These parameters include: • Energy (Joules) • Weld Pressure, Pressure During Sonics (psi/bar) • Amplitude (Microns) • Splice Height to Width Ratio

stablishing Splice Parameters E After you have properly installed the system and have a comprehensive understanding of the nformation in this manual, you may safely operate the Ultrasplice 2032. i

Splice parameters for your application may have already been developed at AmTech and stored in the controller’s non-volatile memory. Refer to Parameter Preset Information located in the

pecial Information Instruction Set. S In the event parameters must be developed, the following is a step by step process for doing so. Included are suggestions and photographs of actual wire splices. The photographs illustrate the progression of poor splices from under welded to over welded ending with a representation of the perfect splice that will give excellent Cpk values when destructively tested. Guidance is also provided for the proper procedure for destructive testing. To develop a splice, proceed as

llofo ws: • From the controller, enter the quantity, size and configuration of wires that will make up the

desired splice. Refer to the Splice Drawing Screen section of the Touchscreen Controller

• It is

e s

to ensure good welding from wire to wire and to avoid the possibility of a “side splice”.

Instruction set. Place the wires into the target area of the splicer using the tip guide block as a locator. recommended that larger wires be closest to the welding tip (Figure 5) when there is a significant difference in wire sizes being spliced. The reason for this is that the larger wire takes more energy to weld each of its strands to its neighbor. With the orientation reversed, there is a possibility the smaller wire could be damaged or over welded before the larger wirwas welded. It is also recommended that wires be placed on top of one another as much apossible


AmTech Product Manual- Actuator Information Ultrasplice 2032 Proper Wire Insertion

TH STRIP LENG

o

epth.

Wires should be stripped ta dimension 2 mm longer than the Tip/Anvil d

PLACEMENT IN WELDING ZONE

Care should be taken to stack the wires vertically wherever possible to ensure an optimum splice.

Figure 5

9.5mm & 12.7m m



• Activate the splicer and make a splice. • Examine the splice and refer to the Wire Splice Comparisons in Table 1. Based upon

observation make adjustments as follows:

If you see loose strands (Ref. C) increase the welding pressure in 10% increments as you make additional splices. If after increasing the welding pressure by 20% there are still loose strands then increase the amplitude by 10%. Continue to follow this sequence until the splice looks good with no loose or broken strands (Ref. H). If you see broken strands or flash (Ref. D) reduce the amplitude by 10% and make a splice. If the splice is still over welded, reduce the welding energy by 10% and make another splice. If the splice is still over welded, reduce the welding pressure by 10%. Continue to follow this sequence until the splice looks good with no broken strands or flash.

Evaluation of Splice A splice must withstand vibration, moisture, high current loads, heat, and cold. Extensive studies have shown that the ability to meet these requirements is directly related to the pull strength of the wire splice. Peel strength is also important. A minimum level of resistance to peel must be associated with each splice to allow handling of wire harnesses during manufacturing and installation without an adverse effect on the splice. Peel strength does not however relate directly to the ability to meet the aforementioned requirements. For instance, over welding or extruding a wire splice will increase peel strength while decreasing the pull strength and therefore the ability of the splice to perform satisfactorily. Destructive Testing When the splice appears good as result of following the above instructions, evaluate samples using destructive testing. Pull test the splice according to recommended pull test technique. Fixturing of the splice for tensile testing is very important. Care must be taken to ensure no twisting of the nugget occurs. Testing should be on the smallest diameter wire and/or the wire closest to the anvil. The reason for this is that the anvil side of the nugget has received the least amount of ultrasonic energy and should be the weakest part. If this wire meets the tensile strength specification then it is safe to assume the splice is good. Wherever possible, it is a good idea to use multiple wires to anchor the test specimen and ensure an even pull on the wire being tested. If the splice meets specifications for strength make a minimum of 10 splices, pull test them and calculate the Cpk. If the Cpk is not satisfactory, examine the splice carefully to determine how it is failing. An under welded splice will fail by separating at the weld. An over welded splice will fail at the transition point of welded to unwelded wire. Based upon your observation return to the prior instructions and repeat the optimization process. Note that the best splices will fail at the transition but will do so at a consistent and predictable force. It is therefore necessary to pick weld parameters that meet this condition without excessive deformation of the wire strands.



Failed torsion (twist) test

Controller Instruction Set for information on Quality Settings.

Pull test values must meet the required value established by your customer for the smallest gage wire in the splice. In addition, the following conditions have always been cause for rejection: • Broken strands • One or more loose strands • Excessively burnt insulation • Excessively frayed ends •

uality Monitoring Q

The system, through its controller is capable of monitoring four welding variables during each cycle. The weld time (secs), peak weld power (watts), component(s) preheight (mm), and component(s) post-weld height (mm). Each variable can be set with upper and lower limits. When a limit or limits are violated, an audible alarm sounds. The type of alarm and associated value are displayed on the controller. Quality limits are the responsibility of the end user. It is recommended that these limits be calculated using statistical methods. Refer to the Touchscreen


AmTech Product Manual- Actuator Information Ultrasplice 2032 Compaction vs. Tensile Strength Knowing that pull (tensile) strength directly relates to the ability of the splice to meet performance criteria the question becomes, “How is tensile strength maximized?” Studies at AmTech on a range of wires in a 2 X 2 splice configuration clearly show that maximum tensile strength is achieved when the wires are welded and compacted to a dimension, which is 20% greater than their solid copper cross section, (Figure 6).

Figure 6


AmTech Product Manual- Actuator Information Ultrasplice 2032 Wire Splice Comparison

Table 1 Ref. Photo of Condition Schematic Description A

WIRE OVERLAP – Damaged or burnt insulation

B

OVER WELDED - Wire not fully inserted into weld pocket

C

UNDER WELDED – Pressure too low

D

OVER WELDED – Pressure and amplitude too high (flash & burning)

E

FLASH - Tip guide gap too big



Ref. Photo of Condition Schematic Description F

FLASH - Gather gap too big

G

SIDE SPLICE – Incorrect wire stacking in weld pocket

H

GOOD SPLICE


AmTech Product Manual- Actuator Information Ultrasplice 2032 Periodic Maintenance In order to maintain optimum operating conditions, it is important to perform various maintenance and equipment inspections at periodic intervals. In addition to recommendations found in the General Information Instruction set under Periodic Maintenance, please observe the following. Tooling should be inspected to confirm a gap of approximately .001”(.02mm) between adjacent tools. If the tooling is in contact during the application of ultrasonic energy, severe damage may result to the tooling and power supply. If the gap between tooling is too large, the wire strands may extrude out of the weld nugget resulting in excess flash or loose wires. With the tooling closed, place a .001”(.02mm) shim between the tools to check the gap. The .001”(.02mm) shim should pass through snugly, but a .0015”(.02mm) shim should not fit between the tools.

The tooling gap should be checked whenever the tooling is changed or when tool contact is suspected. All tooling that contacts the splice nugget has several wear surfaces. When one surface is worn and no longer useful, an alternate surface can be used thereby extending tool life. These surfaces can be changed quickly by following the Ultrasplice 2032 Tooling Setup Procedure (Figure 7) Checking Splicer Sonics Ensure that nothing is touching the tip on all four sides. The tooling must be disengaged and unloaded. From the controller, momentarily test the sonics (step reference- Menu >Maintain >Sonic> Test). If there is a loud squealing noise, the problem may be in the following areas: • The Tip may not be secured properly. • The Horn may not be secured properly. • Tooling may be in contact with each other. Calibrate Amplitude • From the controller proceed to the sonic generator screen. (step reference- Menu> Maintain>

Sonic) • Position a dial gage indicator on a fixed stand to contact the face of the horn in line with the

direction of sonic movement. Preload the indicator .02 mm min. (0.0008”) against the horn travel remaining. with .01 mm min.

• Set Bezel to zero • From the controller operate sonics (step ref- 100% Sonics) and read the gage value.

of screen). • From the controller exit the sonic generator screen (step reference- Exit)

• Multiply the gage reading by 2. • From the controller enter the value (step ref- “-“ or “+” on right hand side



Figure 7

Ultrasplice 2032 Tooling Set-up 11 • Set the gather width to 1 mm (system must be in Anti-side splice mode) • Turn off main disconnect and lock out. • Remove the front cover by removing the (4) screws using 3 mm hex wrench. • Remove safety cover by removing the rear (2) screws using 2.5 mm hex wrench. • Remove the gather block by removing the (2) screws using 4 mm hex wrench. • Remove the anvil cap by removing the (2) screws using 3 mm hex wrench. • Remove the anvil holder by removing the (2) screws using 6 mm hex wrench.

p if required).

h.

• Remove the tip-retaining nut using the torque wrench and 5/8” socket. • Remove the tip and rotate to new welding surface (Or replace ti• Replace the tip-retaining nut and torque to 70 ft-lbs. (95 N/M) • Loosen the gather support by loosening the (4) screws using 4 mm hex wrenc



e tip. 01” shim.

.001” gap between the gather and tip.

nd tight. en the tip and the tip guide, using

n screw using 2.5 mm hex wrench. er screws using 6 mm hex wrench.

• Back off the anvil hold down screw against the top stop. • Re-• Re-• From the controller:

Turn on power. Calibrate gather width (step reference- Menu >Maintain >Width >Zero). Calibrate height (step reference- Menu >Maintain >Height > follow screen instructions) Return to run mode (step reference- Exit)

• Replace the gather block and tighten the (2) screws using 4 mm hex wrench.• Snug the (4) screws that retain the gather support hand tight. • Place a 0.001” shim between the bottom of the gather and the top of th

slight drag is felt on the 0.0• Tighten the gather adjustment screw until aews. • Tighten the (4) retaining scr

• Check to ensure that there is a 0• Slide the tip guide out of the anvil holder. • Replace or rotate the anvil. • Replace or rotate the tip guide. • Slide the tip guide back into the anvil holder under the anvil. • Inspect or replace the anvil wear plate. • Reinstall anvil holder assembly and snug the (2) screws ha• Use the tip guide jacking screws to set a 0.001” gap betwe

2.5 mm hex wrench. • Tighten the anvil hold dow• Tighten the anvil hold

install the safety cover. install the front cover.



Figure 8

Tool Cleaning After prolonged use, burrs may form on the clamping surfaces of the tooling (Figure 8). These burrs may be removed from the tip by polishing with 600-grit emery paper placed on a flat surface. With light pressure, polish the clamp faces as shown. The burrs on the horn clamping surface must be removed by machining back the horn clamp surface. Minimal material should be removed, and in no case exceed more than .020”/0.5mm. The undercut at this clamping surface must also be recut.

Figure 9

Adjustment of Down Stop: The Down Stop is used as a safety to prevent contact between the Tip and Anvil if the welder is cycled without wires. A .010”(.25mm) gap between the Tip and Anvil is recommended. See Figure 9 for adjustment location.



Figure 10

Figure 11

Figure 12



• k away from the tip so that it extends out the back of the anvil holder

• •

e ed ¼ turn clockwise to remove the backlash. After the

nt) should allow the gap between the tip and the tip

e more to verify the indicator reading.

• down the anvil holder screws. t a 0.001” gap between the tip and the tip guide. Note:

ould be between 0 to 0.002” wider at the bottom than at the

• Tighten the anvil holder screws.

Anvil Eccentric Set-up An eccentric pin is provided to allow for precise adjustment of the anvil holder. The eccentric is adjusted to assure that the face of the tip guide is set exactly parallel to motion of the anvil arm. This adjustment is factory preset and should only need adjustment when the anvil holder is replaced. The adjustment procedure is as follows: • Turn off the main power and disconnect the air supply. • Remove the top and front covers. • Remove the screws from the anvil air manifold and place the anvil air manifold to the side. • Remove the anvil holder screws and anvil holder/wear plate assembly

avel. (Figure 10) .

• Set the eccentric pin until it is at the bottom of it’s tr• Replace the anvil holder/wear plate assembly.

Slide the tip guide bacapproximately 1mm.

• Tighten the anvil hold down screw. • Snug down the anvil holder screws. • Loosen the eccentric pin lock screw. (Figure 11) • Attach the magnetic base mounting plate using (2) M6 screws. (Figure 12) • Place a magnetic base dial indicator as shown in to rest against the tip guide

Use a screwdriver to adjust the eccentric cam Bring the anvil arm up and down by hand and use the eccentric pin to adjust the reading on the dial indicator to less the 12 microns (0.0005”). Only turn the eccentric pin in the counter clockwise direction until the proper indicator reading is reached. If the adjustment has gontoo far, the eccentric pin must be turnbacklash has been removed, re-adjust the pin in the counter clockwise direction until the proper indicator reading is reached.

• Note: the 12 micron tolerance (if preseguide to decrease as the anvil arm is lowered.

• Tighten the eccentric cam lock screw. • Bring the anvil arm up and down onc• Loosen the anvil hold down screw and anvil holder screws. • Reinstall the anvil air manifold.

Snug• Use the tip guide jacking screw to se

the tip guide and tip alignment shtop.

• Tighten the anvil hold down screw.


AmTech Product Manual- Actuator Information Ultrasplice 2032 Back off the anvil hold down screw against the top stop.

vers. •• Reinstall the top and front co


AmTech Product Manual- Actuator Information Ultrasplice 2032 Ultrasonic Stack Disassembly T ong tthe Converter, Booster and Horn. cycles o blem is suspected. The procedure is as follows:

2032 – Ultrasonic Stack Disassembly

he transmission of ultrasonic energy al

r whenever a pro

he stack requires a tight and clean interface between Remove the stack and check the interfaces after one million

ULTRASPLICE

Turn off the main power. Disconnect the air supply and remove the quick

disconnect. Remove the top cover. Remove the front cover.

Loosen the (2) M4 SHCS and slide the R.F. connector cap off of the converter.

Remove the safety slide cover and the gather block.



Uconverter and booster. Use a wrench as shown to hold the actuator steady.

sing a spanner wrench, remove the

Remove the (2) front nodal clamps and lift the horn out of the stack mounts. Remove the phenolic nodal ring. NBn

ote: e careful not to damage the phenolic odal ring.

Clamp the horn across the flats in a vise with protected jaws. Use a torque wrench with a 5/8” socket t o remove the tip and tip nut.


AmTech Product Manual- Actuator Information Ultrasplice 2032 Ul

nic St

trasonic Stack Reassembly

ULTRASPLICE 2032 – Ultraso ack Re-Assembly

Clean the horn, converter, booster and diaphragm spring surfaces with solventto remove all contam

inants and

sly used paste. previou

Check tip and tip nut to be sure clampsurfaces are clean and smooth. Replace tip and tip nut onto horn and torque to 70 FT-LBS. Be sure to orient the knurls on the tip parallel to the

flats on the orn.

h

Inspect the phenolic nodal ring and place onto the horn with the gap facing up as shown.



Apply an even coat of Molykote G-n paste (about equal to half a paper match head) to the horn face. Do not apply paste to the threaded opening. Replace the horn into the stack mounts.

n of the tip is facing up. Re-install front hold down clamps and tighten hand tight. Note: Be careful not to damage the phenolic stack ring.

Be sure that the knurled portio

Apply an even coat of Molykote G-paste (about equal to half a paper m

n atch

head) to the Booster face. Do not apply paste to the threaded opening. Reinstall the booster hand tight.

Apply an even coat of Molykote G-paste (about equal to half a paper mhead) to the Con

n atch

verter face. Do not apply paste to the threaded opening. Reinstall the converter hand tight.



Remove the gather assembly.

Tighten a clamp over the tip and tip guide as shown. Tighten front nodal clamp screws.

Torque the booster to 100 Ft-Lbs. Torque the converter to 55 Ft-Lbs. Use a wrench as shown to hold the actuator steady.



rallel to the tip guide. Remove the clamp and verify that the tip is pa

If the parallelism is not correct, loosen the (2) m6 screws on the front nodal clamps and the (6) M5 screws on the rear nodal mount. This will allow the stack to rotate slightly.

Tighten a clamp over the tip and tip guide as shown.



Tighnodthe rear nodal mclam

ten the (2) m6 screws on the front al mount and the (6) M5 screws on

ount and remove the p.

Reinstall the gather assembly

Replace the R.F. connector cap. Ensure that the cap is pushed all the way up against the converter before tightening. Reinstall the top cover. Reattach the actuator to the quick disconnect housing and air supply. Follow the tool setup procedure outlined in this section of the manual. (Figure 7)


AmTech Product Manual- Actuator Information Ultrasplice 2032 Lubrication

ed.

: The purpose of lubrication for the linear motion rolling guides and cam support guides is to prevent direct metal-to-metal contact components, thereby reducing friction, wear, and heat generation. When an adequate grease film is formed between the components, the contact stresses due to weld loading can be moderated. A quality lithium-soap base grease containing extreme pressure additives (Alvania EP Grease 2 (SHELL)) is pre-packed in the recirculation crossed roller slide and cam support guides. However, the quality of any grease will gradually deteriorate over time Periodic re-lubrication is essential. The re-lubrication interval varies depending on the operating conditions of the rolling guides. A three-month interval is generally recommended. Grease nipples have been provided at three points for re-lubrication. (Figure 13) To access to the grease fittings’ remove the Rear Cover and the anvil arm slide cover and insert the grease nozzle to apply the grease. New grease must be supplied through the grease fitting until the old grease is dischargAfter the grease is replenished, cycling the actuator will cause the excess grease to be discharged from the inside of the rolling guide. Discharged grease must then be removed before starting regular operation. Generally, immediately after grease is replenished, frictional resistance tends to increase. If cycling the actuator is performed for 10 to 20 cycles after excess grease is discharged, frictional



r esisnce becomes small and stable.

ta

Figure 13



Lubrication Schedule:

Actual lubrication interval is under the influence of each application and environment.

When re-mounting the slide block to the rail for any reason, care must be taken to avoid dislodging rollers from the tracks within the slide block. AmTech recommends the following schedule as an initial plan to follow: 1. After 1 month of normal operation:

a. Inspect interior of actuator for possible grease discharge. b. Re-lubricate slide and guides with specified grease. c. Allow full travel of the slide unit inside the actuator. d. Cycle the slide 10-20 to re-circulate the grease.

2. After 3 months of normal operation: a. Inspect interior of actuator for possible grease discharge. b. Re-lubricate slide with specified grease. c. Allow full travel of the slide the actuator.

10-20 to re-circulate the grease.

ation,

g on slide IKO #B-M4 (AmTech #209-336)

unit inside d. Cycle the slide

If, after the 1st and 2nd inspections, the slide grease is abnormally low, has discoloror there is dust/dirt in the slide and guides, more frequent inspections will be required. Lubrication used: Alvania EP Grease 2 (Shell) – Extreme Pressure Grease Grease fittinand lower cam guide: Grease upper cam guide IKO #A-M4 (AmTech #209-343) Supply Nozzle: IKO #A-8120V (AmTech #209-337)



Figure 14

Encoder Board Calibration Encoder board calibration is factory set and generally does not need to be changed. Any calibration required due to tool wear or adjustment is built into the controller software and may be accomplished using touchscreen commands (refer to the Touchscreen Controller Instruction Set). If a new encoder board is installed it will be necessary to calibrate Height and Width as follows. If a new width encoder belt is installed, follow the procedures for Width only. Calibrate Height • From the controller, lower the horn (step reference- Menu >Maintain >Height > Horn) • Remove the top cover from the actuator and locate the actuator board. • With digital voltmeter measure dc voltage at test point R14 (Figure 14) to ground. The 9 pin

connector should be used as the ground point. • Voltage should read + 0.150 vdc. If not turn voltage the HGT ZERO potentiometer (Figure

14) until the voltmeter reads + 0.150 vdc. (The voltage must be positive) • From the controller raise the horn (step reference- Horn).



• • •

• • •

•

Height Span Adjustment Position a 1mm shim on the tip. From the controller lower the horn (step reference- Menu >Maintain >Height > Horn) From the controller calibrate the height (step reference- Calibrate). The controller will reset the zero point and the anvil arm will move up. Position a 6mm shim on the tip. From the controller lower the horn (step reference- Horn) Verify that the height reads 6mm. Adjust the HGT CAL (Figure 14) potentiometer until a reading of 6mm is obtained. Repeat above steps until the height reads 6mm without adjustment at the previous step.

• From the controller exit the calibration screen (step reference- Exit)



Figure 15

Calibrate Width • Remove the top actuator cover. • From the controller ensure that the gather is in the retracted (open) position (step reference-

Menu> Maintain> Width>Gather) • Use the << (fast adjust) button to close the gather stop to the end of the motor travel. • Press the Gather button to extend the gather. • Use the >> (fast adjust) button to open the gather hard stop to the end of the motor travel.

(with the gather still extended to zero) • With a digital voltmeter set to dc, measure voltage between R16 (Figure 14) and ground.

The 9-pin connector should be used as the ground point. • If voltage does not read + 0.150 vdc proceed as follows: • Loosen the encoder bracket screws and release tension on the belt.(Figure 15)



er pulley until a voltage of +0.150 vdc is obtained. 211-633) and

rews. etract)

Width• • zero width point. The controller he zero point and

• controller open or close the achieve a slight

• CAL potentiometer (Figure 14) until the h reading on the

• om the controller “zero” the gather. • adjustment procedure until the 6mm readin• r exit the width adjustment screen (step re

• Rotate the encod• Re-tension the belt to 2 lbs tension using the tension gauge (Amtech p/n:

tighten the encoder bracket sc Press Gather. (the Gather Block will r•

• From the controller exit the width adjustment screen (step reference- Exit)

Span Adjustment troller “zero” the gather (step ref- Menu> Maintain> Width > Zero ) From the con

The gather will move to the then resets topens the gather to 6 mm wide. Insert a 6mm pin and from the

ref- “<< -“ or “+ >>”). gather until you

drag on the pin (stepAdjust the WIDTH Relative Widtcontroller screen is 6 mm. Remove the pin and frRepeat this span g is correct. From the controlle f- Exit).




File Attachments: The (computer) file name of this manual contains a two digit suffix number. Example: DCM01112- U##U. PDF Use the suffix number to determine the file attachments for your welder.

DCM01112-01 ½” Replaceable Tip Ultrasplice 2032 Description File Bill of Materials, Tool Kit Y5A50101 Actuator Assembly ½” Replaceable tip Y5A00001 Actuator Overall Dimensions Y5A00001-1 Housing Assembly Y5A00005-1,-2A,-3 Gather Assembly Y5A00006-A Stack Assembly ½” Replaceable tip Y5A00008 Pneumatic Schematic Y5A00018 Internal Harness Y5A50058 Regulator Cable J1A00150 Harness Assembly Y5A00010 Cable Assembly J1A00132 R.F. Cable J1A00096 Motor Cable J1A00098 Data Cable J1A00130 Control Cable J1A00131

DCM01112-02 3/8” Replaceable Tip Ultrasplice 2032 Description File Bill of Materials, Tool Kit Y5A50101 Actuator Assembly ½” Replaceable tip Y5A00003 Actuator Overall Dimensions Y5A00003-1 Housing Assembly Y5A00005-1,-2B,-3 Gather Assembly Y5A00006-B Stack Assembly 3/8” Replaceable tip Y5A00015 Pneumatic Schematic Y5A00018 Internal Harness Y5A50058 Regulator Cable J1A00150 Harness Assembly Y5A00010 Cable Assembly J1A00132 R.F. Cable J1A00096 Motor Cable J1A00098 Data Cable J1A00130 Control Cable J1A00131

AmTech Product Manual- Actuator Information Ultrasplice 2032 Tool Kit –Y5A50101

Item # Description Qty Per Tool Kit

AmTech P/N Comments

1 20 kHz Torque Wrench N/A 211-050 (Optional Item) Purchase Separately

2 Dial Indicator with Modified Magnetic Base

N/A X3A50252 (Optional Item) Purchase Separately

3 Extension Handle 1 11008-09-001 4 Spanner Wrench 1 201-118-019 5 Molykote GN Paste 1 211-099 6 Tension Gauge 1 211-633 7 Canvas Bag 1 211-636 8 Metric Allen Wrenches 1 211-658 9 Spanner Wrench 1 48000-03-011 10 0.0015” Shim 3 M1A50A18 11 0.001” shim 3 M1A50A42 12 5/8"Socket 1 X3A50075 13 6 mm Spacer 1 X3A50325 14 1 mm Spacer 1 Y4A50239 15 Indicator Mount 1 Y5A50094

1

3

4

5

3

7

8

6

7 851

WITHOUT THE EXPRESSED WRITTEN CONSENT OF AMTECH

PART NAME:

USED ON ASSEMBLY DRAWING NUMBER REV

The World Leader in Ultrasonic Metal Joining

DO NOT SCALE DRAWINGS

3RD ANGLE PROJECTION

APPR BY:

DRAWN BY:

DRAWN ON:

SCALE:

SHT QTY:WORK ORDER: DATE:

DIMENSIONS ARE IN INCHES [MM]

MATERIAL:

HARDNESS:

FINISH:

OF AMTECH, AND IT MAY NOT BE USED OR DISCLOSED IN ANY WAYAND REPRESENTS CONFIDENTIAL AND PROPRIETARY INFORMATIONTHIS PRINT IS THE PROPERTY OF AMERICAN TECHNOLOGY, INC.

4

FOR MFG. FORM#ESFM-001

DIMENSIONAL TOLERANCES

ENGINEERING SPECIFICATION

AND TOLERANCES, REFER TO:FOR ALL SPECIFICATIONSUNLESS OTHERWISE STATED

2 3 6

87

1/2

ACTUATOR ASSEMBLY, 3/8" REPLACEABLE TIP

Y5A00003 1

-

-

1:3

ANGULAR DIM: 1/64

1

-

-

-

-

OF

Y5A00003

A

B

C

D

E

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B

E

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A

1 2 3 4 5 6

4 PLACE DECIMAL: .00053 PLACE DECIMAL: .0052 PLACE DECIMAL: .010FRACTIONAL DIM:

1

I:\_ENGINEERING APPROVED DRAWINGS\Y___XL\

SF 031114

REVISIONS

ZONE ECN REV. DESCRIPTION DATE BY APP

- - 1 INITIAL RELEASE

ITEM NO. PART NUMBER DESCRIPTION Y5A00001/QTY.

1 Y5A50047 REAR COVER 1

2 Y5A50048 FRONT COVER 1

3 Y5A00010 HARNESS ASSEMBLY 1

4 Y5A00005 HOUSING ASSEMBLY 1

5 Y5A00006 GATHER ASSEMBLY 1

6 Y5A00015 STACK ASSEMBLY, 3/8" REPLACABLE TIP 1

7 M6 x 65 SOCKET HEAD CAP SCREW 2

8 M5 x 12 BUTTON HEAD CAP SCREW 8

851 4

FOR ALL SPECIFICATIONS


PART NAME:





APPR BY:

DRAWN BY:

DRAWN ON:

SCALE:



MATERIAL:

HARDNESS:

1:3

DAS

72

UNLESS OTHERWISE STATED


THIS PRINT IS THE PROPERTY OF AMERICAN TECHNOLOGY, INC.AND REPRESENTS CONFIDENTIAL AND PROPRIETARY INFORMATIONOF AMTECH, AND IT MAY NOT BE USED OR DISCLOSED IN ANY WAY

FINISH:

3 6

876


1/2

ULTRASPLICE 2032 ACTUATOR

Y5A00001-1 1

3/7/05

-


AND TOLERANCES, REFER TO:

1/64

1

-

-

-

ANGULAR DIM:

OF

Y5A00001 OVERALL

A

B

C

D

E

C

B

E

D

A

1 2 3 4 5


1


SF 031114

REVISIONS



21.73552

51820.39

8.81224

9.19233

2278.92

7.14181

7 851


PART NAME:





APPR BY:

DRAWN BY:

DRAWN ON:

SCALE:



MATERIAL:

HARDNESS:

FINISH:

OF AMTECH, AND IT MAY NOT BE USED OR DISCLOSED IN ANY WAYAND REPRESENTS CONFIDENTIAL AND PROPRIETARY INFORMATION

THIS PRINT IS THE PROPERTY OF AMERICAN TECHNOLOGY, INC.

4





2 3 6

87

1/2

LOWER PAN ASSEMBLY

Y5A00005-1 1

11/9/04

DAS

1:3

ANGULAR DIM: 1/64

1

-

-

-

DAS

OF

Y5A00005-1

A

B

C

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1


SF 031114

7

6

1

2423

10

5

9

17

17

4

13 12

22

11 16 15

15

2

8

21

A

2.0

3.5

.5

REVISIONS



ITEM NO. PART NUMBER DESCRIPTIONHOUSINGASSEMBLY

STEP 1/QTY.

1 J1A00150 REGULATOR CABLE 1

2 U1A00002 ENCODER BOARD 1

3 Y5A50041 LOWER PAN ASSEMBLY 1

4 Y5A50058 ACTUATOR HARNESS ASSEMBLY 1

5 206-155 VALVE STACK 1

6 207-048 PRESSURE REGULATOR 1

7 209-066 ELBOW, KQ2L07-35S 1

8 209-082 BULKHEAD FITTING, KQ2E07-35 1

9 209-273 BRANCH, KQ2Z07-35S 1

10 209-342 PLUG IN "Y", KQ2U04-99 1

11 211-009 RUBBER BUMPER 4

12 #4-40 x 1_4 BUTTON HEAD CAP SCREW 2


14 M3 LOCKNUT NYLOC NUT 2




18 #10-32 x 3_4 BRASS SCREW 1

19 #10 STAR WASHER BRASS STAR WASHER 2

20 #10-32 NUT BRASS NUT 2

DETAIL A

182019

7 851


PART NAME:





APPR BY:

DRAWN BY:

DRAWN ON:

SCALE:



MATERIAL:

HARDNESS:

FINISH:

OF AMTECH, AND IT MAY NOT BE USED OR DISCLOSED IN ANY WAYAND REPRESENTS CONFIDENTIAL AND PROPRIETARY INFORMATION

THIS PRINT IS THE PROPERTY OF AMERICAN TECHNOLOGY, INC.

4





2 3 6

87

1/2

MAIN HOUSING ASSEMBLY, 1/2"

Y5A00005-2A 1

11/9/04

DAS

1:4

ANGULAR DIM: 1/64

1

-

-

-

DAS

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Y5A00005-2A

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1


SF 031114

15

30

6

1

39

28

57

31

55

2242

21

754

48

49

5

39

2520

46

12

28

29

27

13

38

34

514350

50

59

1

103347

45

1439

11

9

56

441

53

44

24

5247

19

60

58

6261

64

23

36

35

31

REVISIONS



ITEM

NO.PART NUMBER DESCRIPTION

HOUSING

ASSEMBLY STEP

2/QTY.

1 Y4A50099 ECCENTIRC PIN 2

2 Y5A50000 MAIN HOUSING 1

3 Y5A50001 ANVIL ARM 1

4 Y5A50002 CAM COVER 1

5 Y5A50009 DOWNSTOP 1

6 Y5A50027 WELD CAM 1

7 Y5A50028 WELD CAM GUIDE 1

8 Y5A50030 CLYINDER ROD END 1

9 Y5A50032 ANVIL HOLDER, 1/2" 1

10 Y5A50033 ANVIL WEAR PLATE 1/2" 1

11 Y5A50034 TIP GUIDE, 1/2" 1

12 Y5A50035 ANVIL PISTON 1

13 Y5A50036 ANVIL PISTION MANIFOLD 1

14 Y5A50037 ANVIL CAP 1

15 Y5A50052 CAM FOLLOWER PIN 1

19 Y5A50082 GUIDE KEY 1

20 Y5A50081 GUIDE KEY SLOT 1

21 Y5A50085 KEY SLIDE DUST COVER 1

22 Y5A50086 SLIDE DUST COVER 1

23 Y5A50095 WELD CAM GUIDE 2

24 Y5A90002 ANVIL, 1/2" 1

26 105-359 LINEAR ROLLER WAY/RAIL 1

27 203-416 O'RING, AS-006, 1/8 I.D.x 1/4 O.D 1

28 203-449 O'RING, AS-016, 5/8 I.D.x 3/4 O.D 2

29 203-450 O'RING, AS-018, 3/4 I.D.x 7/8 O.D 1

30 204-049 CAM FOLLOWER 1

31 205-251 Cylinder, GNN-SB050-050D 1

32 207-057 FLOW CONTROL 2

33 209-131 ELBOW, BARB, M-5ALU-4 1

34 209-231 ELBOW, M-3-ALU-4 2

35 209-336 ANGLE GREASE FITTING 1

36 209-343 GREASE FITTING 1

37 GASKET 1/16 DIA O-RING CORD 1


39 M4 X 4 BRASS TIP S.S.S. 3

40 M4 x 4 SOCKET HEAD SET SCREW 1







47 M5 x 12 FLAT HEAD CAP SCREW 6



50 M6 X 6 BRASS TIP S.S.S. 2







57 1_2-20 X 1 S.S.S. 1

58 1_8 DIA x 3_8 LG DOWEL PIN 2

59 1_8 x 5_8 DOWEL PIN 1





64 1_4 DIA x 1 1_2 LG DOWEL PIN 1

REVISIONS



ITEM NO. PART NUMBER DESCRIPTIONHOUSING ASSEMBLY STEP

3/QTY.

1 Y5A00005-2 MAIN HOUSING ASSEMBLY 1

2 Y5A00005-1 LOWER PAN ASSEMBLY 1

3 Y5A50091 HEIGHT ENCODER 1

4 A0A06A25 ENCODER CLAMP 2

5 211-009 RUBBER BUMPER 2




1

5

76

48

3 2

7 851


PART NAME:





APPR BY:

DRAWN BY:

DRAWN ON:

SCALE:



MATERIAL:

HARDNESS:

FINISH:


4





2 3 6

87

1/2

FINAL HOUSING ASSEMBLY

Y5A00005-3 1

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ANGULAR DIM: 1/64

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1


SF 031114

48

9

48

50

12

4510

27

47

46

183830

31

29

16

11

8

240

3 42

521

33

35

43

4

42

38

20

3823

39

28

36

14

13

2817 49

6 41

25 41

6 41

37

1

49

55

15

53 44

24

2251

32

34

19

52

5758

56

26

54

7 851


PART NAME:





APPR BY:

DRAWN BY:

DRAWN ON:

SCALE:



MATERIAL:

HARDNESS:

FINISH:


4





2 3 6

87

1/2

GATHER ASSEMBLY

Y5A00006-A 1

11/10/04

DAS

1:2.5

ANGULAR DIM: 1/64

1

-

-

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DAS

OF

Y5A00006-A

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B

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1 2 3 4 5 6


1


SF 031114

REVISIONS



ITEM NO. PART NUMBER DESCRIPTIONGATHER

ASSEMBLY/QTY.

1 Y4A50232 STEPPER MOTOR 1

2 Y4A50236 PROX SWITCH 1

3 Y5A50023 SAFETY COVER 1

4 Y5A50024 CYLINDER BRACKET 1

5 Y5A50025 SENSOR TRIGGER 1

6 Y5A50026 PULLEY MOD 2

8 Y5A50003 GATHER HOUSING 1

9 Y5A50006 GATHER SUPPORT 1

10 Y5A50007 GATHER SLIDE 1

11 Y5A50008 GATHER CAM BUSHING 1

12 Y5A50010 GATHER BLOCK 1/2" 1

13 Y5A50011 GATHER STOP SCREW 1

14 Y5A50012 GATHER STOP BLOCK 1

15 Y5A50013 GATHER MOTOR PLATE 1

16 Y5A50014 GATHER CAM 1

17 Y5A50015 GATHER BEARING PLATE 1

18 Y5A50016 GATHER DUST COVER, LEFT 1

19 Y5A50017 CYLINDER ROD END 1

20 Y5A50018 GATHER DUST COVER, RIGHT 1

21 Y5A50022 SAFETY COVER ACTUATOR 1

22 Y5A50061 WIDTH ENCODER 1

23 Y5A50080 GATHER END STOP 1

24 Y5A50087 WIDTH ENCODER BRACKET 1

25 Y5A50089 ENCODER PULLEY MOD 1

26 Y5A50096 BEARING STOP 1

27 202-098 COMPRESSION SPRING 1

28 204-054 BEARING, B-44 2

29 204-109 INNER BEARING RAIL 2

30 204-110 OUTER BEARING RAIL 2

31 204-111 ROLLER BEARING CAGE ASS'Y 2

32 205-266 Global Series Air Cylinder 1

33 205-283 SAFETY CYLINDER 1

34 209-070 ELBOW, KQ2L07-34S 2

35 209-231 ELBOW, M-3-ALU-4 2

36 210-043 THRUST WASHER 1

37 211-742 GATHER BELT 1
















53 M10x.75 HEX NUT ENCODER LOCK NUT 1

54 #10 lock washer WASHER 4

55 #4-40 HEX NUT NUT 2



58 1_4 DIA x 1 1_4 LG DOWEL PIN 1

851 4

FOR ALL SPECIFICATIONS


PART NAME:





APPR BY:

DRAWN BY:

DRAWN ON:

SCALE:



MATERIAL:

HARDNESS:

1:3

DAS

72

UNLESS OTHERWISE STATED


THIS PRINT IS THE PROPERTY OF AMERICAN TECHNOLOGY, INC.AND REPRESENTS CONFIDENTIAL AND PROPRIETARY INFORMATIONOF AMTECH, AND IT MAY NOT BE USED OR DISCLOSED IN ANY WAY

FINISH:

3 6

876


1/2

STACK ASSEMBLY 3/8" REPLACABLE TIP

Y5A00015 2

11/11/04

DAS


AND TOLERANCES, REFER TO:

1/64

1

-

-

-

ANGULAR DIM:

OF

Y5A00015

A

B

C

D

E

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B

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1 2 3 4 5


1


SF 031114

REVISIONS



2248 2 REVISED REAR STACK MOUNT 8/1/2005 DAS DAS

ITEM NO. PART NUMBER DESCRIPTION STACK ASSEMBLY, 3_8 REPLACABLETIP/QTY.

1 X3A50019 DIAPRAGHM SPRING 1

2 Y4A50042 LOWER CONTACT SHELL 1

3 Y4A50044 CONTACT, RF 1

4 Y4A50045 CONTACT, GROUND 1

5 Y4A50132 CLAMP RING 2

6 Y4A90020 TIP, NON ROTATING, 3/8 1

7 Y5A50039 FRONT NODAL MOUNT 1

8 Y5A50042 FRONT NODAL HOLD DOWN 2

9 Y5A50051 FRONT NODAL RING 1

10 Y5A50059 UPPER CONTACT SHELL 1

11 Y5A50114 SPRING MOUNT 1

12 Y5A50115 REAR STACK MOUNT 1

13 Y5A90000 HORN, 3/8" KEYED 1

14 Y5A90012 BOOSTER, 2032 1

16 101-135-032 CONVERTER, 502 1

17 11008-03-118 TIP NUT 1

18 209-131 ELBOW, BARB, M-5ALU-4 1







25 #8 STAR WASHER 2

26 #8 FLAT WASHER 3

28 R.F. LEAD REFERENCE ONLY 1

29 GROUND LEAD REFERENCE ONLY 1

17 6

7

23

9

13

8

23

20

18

19 26 25 29

19

26

25

28

3

4

16

10

2

215

1

11

12

5

22

24

14

RETRACTGATHER

REVISIONS



7 851


PART NAME:





APPR BY:

DRAWN BY:

DRAWN ON:

SCALE:



MATERIAL:

HARDNESS:

FINISH:


4





2 3 6

87

1/2

PNEUMATIC SCHEMATIC

Y5A00018 1

11/10/04

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1:2

ANGULAR DIM: 1/64

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Y5A00018

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SF 031114

ANVIL

HORN (ANVIL ARM)

ANVIL

SAFETY

COOLING

GATHER

RETRACT

COOLING

LINE PRESSURE

CONVERTER

DOWNANVIL ARM

UPANVIL ARM

PRESSURELINE

PRESSURELINE

DOWNANVIL ARM

RETRACTSAFETY

EXTENDSAFETY

EXTENDGATHER

COOLINGANVIL

ANVILEXTEND

$URL

REVISIONS


1 INITIAL RELEASE - - -

ITEM NO. PART NUMBER Description QTY. Comments

1 J1A00132 HARNESS ASSEMBLY 1

2 J1A00096 R.F. CABLE 1 REF. ONLY - INCLUDED IN J1A00132

3 J1A00098 MOTOR CABLE 1 REF. ONLY - INCLUDED IN J1A00132

4 J1A00130 DATA CABLE 1 REF. ONLY - INCLUDED IN J1A00132

5 J1A00131 CONTROL CABLE 1 REF. ONLY - INCLUDED IN J1A00132

6 Y5A50045 CONNECTOR HOUSING 1

7 Y5A50046 CONNECTOR PLATE 1

8 101-444 CONNECTR,D-SUB DCM025W3S 1 REF. ONLY - INCLUDED IN J1A00132

9 101-203 CONNECTOR, DB 9 PIN FEMALE 1 REF. ONLY - INCLUDED IN J1A00132

10 101-385 SOCKET #50F5758 1 REF. ONLY - INCLUDED IN J1A00132

11 101-446 SOCKET,D-SUB DM51155-7 1 REF. ONLY - INCLUDED IN J1A00132

12 #10 RING TERMINAL CRIMP TERMINAL 3 REF. ONLY - INCLUDED IN J1A00132

13 LOCK NUT 1 REF. ONLY - INCLUDED IN J1A00132



16 #10-32 x 1 BRASS SCREW 1

17 #10-32 NUT BRASS NUT 4

18 #10 STAR WASHER BRASS STAR WASHER 4



7 851


PART NAME:





APPR BY:

DRAWN BY:

DRAWN ON:

SCALE:



MATERIAL:

HARDNESS:

FINISH:


4





2 3 6

87 1/2

XL II HARNESS ASSEMBLY

Y5A00010 1

10/22/04

DAS

1:1

ANGULAR DIM: 1/64

1

-

-

-

DAS

OF

Y5A00010

A

B

C

D

E

C

B

E

D

A

1 2 3 4 5 6


1


SF 031114

1

20

5

3

4

2

6

17

18

12

15

1011

8

9

719

14

16

AmTech Product Manual- Touchscreen Controller Touchscreen Controller Instructions Part Number DCM00001 Last Revised 02/22/05 MGD This document is intended for use with the following AmTech products: Touchscreen Controller with the following actuators: 2020, XL, Advanced Terminator, Mod 9, Mod 10, Mod10 HD American Technology Inc. 41 Eagle Rd. Danbury, Connecticut 06810, U.S.A. (203) 926-2677 (800) 888-6089 (203) 926-2678 FAX http://www.amtechultrasonic.com [email protected]

This document is intended for use in conjunction with others to form a complete manual for your AmTech system. Introduction: This Instruction Set includes information for the Touchscreen Controller. This controller is intended for use with the Amtech family of actuator products. Please refer to the Table of Contents and Index of this Instruction Set to find specific information.

Instruction Set for Touchscreen Controller - Page 1 of 61

AmTech Product Manual- Touchscreen Controller Table of Contents: Introduction:.................................................................................................................................... 1 Table of Contents:........................................................................................................................... 2 Description and Specifications: ...................................................................................................... 5 Operation: ....................................................................................................................................... 6 Controller User Screen Hierarchy:.................................................................................................. 6

Run Screen:.................................................................................................................................. 7 GRAPH/WIRES/DATA TOGGLE.......................................................................................... 7 TEACH TOGGLE.................................................................................................................... 7 PRESETS ................................................................................................................................. 8 CYCLES................................................................................................................................... 8

Menu Options Screen: ................................................................................................................. 9 Weld Settings Screen:................................................................................................................ 11

ENERGY................................................................................................................................ 11 WELD PRESSURE................................................................................................................ 11 BATCH .................................................................................................................................. 11 WIDTH................................................................................................................................... 11 TRIGGER PRESSURE.......................................................................................................... 11 TIME ...................................................................................................................................... 11 AMPLITUDE......................................................................................................................... 11 WELDMODE......................................................................................................................... 12 COUNTER............................................................................................................................. 12

Weld Mode Screen: ................................................................................................................... 13 ENERGY................................................................................................................................ 13 TIME ...................................................................................................................................... 13 HEIGHT ................................................................................................................................ 13 ENERGY W/ HEIGHT COMPENSATION ......................................................................... 13

Advanced Weld Settings Screen: .............................................................................................. 14 AFTERBURST TIME............................................................................................................ 14 SQUEEZE TIME ................................................................................................................... 14 HOLD..................................................................................................................................... 14

Preset Menu Screen: .................................................................................................................. 15 MAKE NEW.......................................................................................................................... 15

Preset Name Screen:.................................................................................................................. 16 Splice Drawing Screen: ............................................................................................................. 17 Preset Library Screen: ............................................................................................................... 18 Maintenance Menu Screen: ....................................................................................................... 19

ANVIL / GATHER ................................................................................................................ 19 HORN..................................................................................................................................... 19 SAFETY / ANVIL ................................................................................................................. 19 COOLING.............................................................................................................................. 20

Width Adjustment Screen: ........................................................................................................ 21 Height Calibration Screen: ....................................................................................................... 22 Sonic Generator Screen: ............................................................................................................ 23 Printing Screen: ......................................................................................................................... 24 Maintenance Counters and Limits Screen:................................................................................ 25


AmTech Product Manual- Touchscreen Controller

Weld Limits Screen: .................................................................................................................. 26 Sequence Menu Screen: ............................................................................................................ 27 Sequence Name & Edit Screen: ................................................................................................ 28 Sequence Steps Screen: ............................................................................................................ 29 Sequence Library Screen: ......................................................................................................... 30 Width and Height Adjustment Screen: ..................................................................................... 31 System Configuration Screen: ................................................................................................... 32

ADVANCED (Default).......................................................................................................... 32 WIRESIZE ............................................................................................................................. 32 PRESSURE ............................................................................................................................ 32

Cooling Screen: ......................................................................................................................... 33 Teach Mode Setup Screen: ........................................................................................................ 34 System Configuration Screen (Next):........................................................................................ 36

REWELD ............................................................................................................................... 36 ON ALARM........................................................................................................................... 36

Select Actuator Screen: ............................................................................................................. 37 Password Changing Screen: ...................................................................................................... 38

LEVEL 1 ................................................................................................................................ 38 LEVEL 2 ................................................................................................................................ 38

Formula Adjustment Screen: ..................................................................................................... 39 Low Air Alarm Screen: ............................................................................................................. 40 System Configuration Screen (Next, Next):.............................................................................. 41 Transducer Configuration Screen:............................................................................................. 42

WIDTH ENCODER............................................................................................................... 42 HEIGHT ENCODER ............................................................................................................. 42 PRESSURE READING ......................................................................................................... 42 SEEK...................................................................................................................................... 42

Sequence Error Screen: ............................................................................................................. 43 DOUBLE CLICK (ALLOW)................................................................................................. 43 DOUBLE CLICK (OPTION) ................................................................................................ 43 SEQUENCE ERROR............................................................................................................. 43

Diagnostic Screen:..................................................................................................................... 44 INITIALIZE........................................................................................................................... 44 TOUCH PANEL .................................................................................................................... 44

Serial Port Diagnostics Screen: ................................................................................................. 45 SEND PO ............................................................................................................................... 45 RECEIVE PO......................................................................................................................... 45 COM DATA........................................................................................................................... 45 SEND P1 ................................................................................................................................ 45 RECEIVE P1.......................................................................................................................... 45 BARCODE............................................................................................................................. 45 BAUD..................................................................................................................................... 45

Cycles Screen: ........................................................................................................................... 46 Typical Keypad Entry Screen:................................................................................................... 47

Maintenance:................................................................................................................................. 48 Components: ................................................................................................................................. 50


AmTech Product Manual- Touchscreen Controller Saving / Transferring Preset and Sequence Information: ............................................................. 55 Encoder Board Calibration ........................................................................................................... 57

Calibrate Height......................................................................................................................... 57 Height Span Adjustment............................................................................................................ 58

File Attachments: .......................................................................................................................... 59 Alphabetical Index:....................................................................................................................... 60 Endnotes:....................................................................................................................................... 61


AmTech Product Manual- Touchscreen Controller Description and Specifications: The Touchscreen Controller controls all welding functions and parameters through the touch screen on the front panel. This unit contains a microprocessor controller and the power supply module which generates high frequency (20,000Hz or 40,000Hz ) electrical energy.

SPECIFICATION POWER SUPPLY TYPE Touchscreen Controller Watts 3300w (20 kHz)

4400w (20 kHz) 800w (40 kHz)

Length 22.2”(564mm) Height 5.6”(142mm) Width 17.5”(444mm)

Weight 36 lbs (16 kg)

Frequency Power Rating and Nominal Input Voltage

Maximum Current

Plug Receptacle

20 kHz 3300w, 200v-230v 17 Amp max NEMA L6-20P NEMA L6-20R 20 kHz 4400w, 200v-230v 22 Amp max NEMA L6-20P NEMA L6-20R 40 kHz 800w, 200v-230v 6 Amp max NEMA L6-20P NEMA L6-20R


AmTech Product Manual- Touchscreen Controller Operation: Before attempting to operate the controller, make sure you have reviewed the entire manual and have an understanding of safety procedures. Check that connections between the controller and actuator are as shown in the Hookup Diagram provided in Special Information Instruction Set. The power button on the front of the system may then be used to turn the system on.

Danger-When operating the controller keep clear of the actuator moving parts

If power is removed from the system while the controller is on, it will be necessary to press the power button to its off position and then once again to its on position in order to restore power to the system. Interactive user screens supply a means of function selection and data entry for setting up the controller. The following pages provide illustrations, function descriptions and screen navigation instructions. In the event of a system fault or an improper keyed entry, the controller will provide an instructional prompt screen in order to remedy the condition. Controller User Screen Hierarchy: A drawing included in the back of this Instruction Set provides an overview of the controller user screens and functions shown in tree structure. It serves as a useful tool for navigating the command structure of the controller. See page 59 to identify the drawing number for Controller User Screen Hierarchy.



AMTECH SPLICE (NAME) SCREEN STEPS

CYCLES

MENU GRAPH TEACH PRESETS

(INFORMATION WINDOW)

A page header similar to the above will accompany the controller instructions in this section. The image on the right side resembles the controller touchscreen display. The left sidebar shows the screen steps required to arrive at the current display. If you are viewing the manual on a computer you may click on the blue links which will emulate many of the touchscreen operations. Run Screen: This is the Run Screen. When you turn on your Controller it will start at this screen. Navigating from this menu will allow setup and configuration of the unit for your application. Press one of the following options for this screen: MENU To go to the Menu Options which allows access to the settings and features of the controller. See Page 9 GRAPH/WIRES/DATA TOGGLE To alternately display: Power/ time graph of previous weld. Drawing arrangement for the current splice. Current weld settings and feedback from previous weld. TEACH TOGGLE To accept teach samples when TEACH is shown highlighted. Used in standard mode the PRESET button will be replaced by an ACCEPT button which is pressed to add the previous weld data to the sample set. For more on teach mode see page 34



AMTECH SPLICE (NAME) SCREEN STEPS

CYCLES

MENU GRAPH TEACH PRESETS

(INFORMATION WINDOW)

PRESETS To retrieve a preset or save over an existing one stored in the controller preset library. For more on presets see page 15. CYCLES To reset the continuous cycle counter provided for user reference.



AMTECH MENU OPTIONS SCREEN STEPS

SETTINGS

PRESETS

MAINTAIN

*SEQUENC

*ADJUST

RUN MODE CONFIG DIAGNOST

QUALITY MENU

Menu Options Screen: This screen allows access to the features of the controller. Features are divided in to related groups. Access to Configuration and Diagnostics are protected by a user changeable password. The password is initially set to 2677, the last four digits of AmTech’s phone number. Press one of the following options for this screen: SETTINGS To change individual weld parameters which are the basic elements required to make a weld. See Page 11 PRESETS To name, save and recall specific weld parameter settings which may be stored in the controller’s non volatile memory. See page 15 MAINTAIN To allow adjustment and on demand control of the various motion devices in the weld actuator. Also allows access to maintenance counters which monitor tool life and printer functions. See page 19 QUALITY To allow setting min and max parameters for weld time, power, preheight and height. See page 26 SEQUENCE 1 To name, save and recall sequences which may be stored in the controller’s non volatile memory. A sequence is a series of grouped presets which are to be executed in a particular quantity and order. See page 27.



AMTECH MENU OPTIONS SCREEN STEPS

SETTINGS

PRESETS

MAINTAIN

*SEQUENC

*ADJUST

RUN MODE CONFIG DIAGNOST

QUALITY MENU

ADJUST 2 To set weld width and height adjustment based on the measurements taken from the previous weld. See page 31 CONFIGURATION To access configuration features of the controller. These include actuator, units and language selection as well as various other operational settings. See page 32 DIAGNOSTIC To make changes at the operating system level. These include initialization, serial port configuration and touchpanel calibration. See page 44 RUN MODE To return to Run Mode. See page 7



AMTECH WELD SETTINGS SCREEN STEPS

ENERGY

W. PRESS

BATCH

EXIT ADVANCED

MENU SETTINGS

WIDTH

T. PRESS

AMPLIT

WELDMOD

COUNTER TIME

Weld Settings Screen: From this screen you may change individual weld parameters which are the basic elements required to make a weld. Press one of the following options for this screen: ENERGY To change the amount of energy (joules) delivered for each weld. See page 47 WELD PRESSURE To change the clamping pressure delivered by the actuator while the weld is taking place. See page 47 BATCH To set a batch count quantity which will display from the Run Screen in data mode. See page 47 WIDTH To change width settings for the gather mechanism. See page 47 TRIGGER PRESSURE To change the pressure used to engage the knurl pattern into the component parts prior to initiation of ultrasonic energy. See page 47 TIME To change the time duration of ultrasonic energy applied for each weld cycle. See page 47. Available only when Weld Mode is set to Time. See page 13 AMPLITUDE To change amplitude which is measured in microns. Amplitude is the displacement of mechanical motion of the horn. See page 47



AMTECH WELD SETTINGS SCREEN STEPS

ENERGY

W. PRESS

BATCH

EXIT ADVANCED

MENU SETTINGS

WIDTH

T. PRESS

AMPLIT

WELDMOD

COUNTER TIME

WELDMODE To select the determining criteria for cut off of the ultrasonic energy. See page 13 COUNTER To reset the batch counter. ADVANCED To enter selections pertaining to afterburst, squeeze and hold time. See page 14 EXIT To return to Menu Options. See page 9



AMTECH WELD MODE SCREEN STEPS

ENERGY

EXIT

MENU SETTINGS WELDMODE

TIME *HEIGHT *ENER/HG

Weld Mode Screen: From this screen the weld mode may be selected. The weld mode dictates which weld setting variable will serve as the cutoff limit for the delivery of ultrasonic energy during each weld cycle. Press one of the following options for this screen: ENERGY To weld in energy mode. The system delivers ultrasonic energy until a predetermined amount of energy (joules) is dissipated. TIME To weld in time mode. The system delivers ultrasonic energy for a predetermined amount of time (sec). HEIGHT 2 To weld in height mode. The system delivers ultrasonic energy until the tooling reaches a predetermined height (mm). ENERGY W/ HEIGHT COMPENSATION 2 To weld in energy with height compensation mode. The system first delivers the predetermined amount of energy. If after the energy is delivered the welded part size does not fall within the height (mm) window, the system will deliver as required up to 300% more energy in order to achieve a mid window weld height. EXIT To return to Weld Settings. See page 11



AMTECH ADVANCED WELD SETTINGS SCREEN STEPS

AB TIME

------

SQZ TIME

EXIT

MENU SETTINGS ADVANCED

------

HOLD

(VAL)

(VAL)

(VAL)

Advanced Weld Settings Screen: This screen allows access to the advanced options features defined below. These values will normally reflect the default settings made in Configuration mode. Values set from this screen will only effect the preset currently in use. Press one of the following options for this screen: AFTERBURST TIME To change the amount of time (sec) of a short burst of ultrasonic energy that begins after the ultrasonic welding cycle. See page 47 SQUEEZE TIME To change the amount of time (sec) between when the horn engages the components(s) and when the delivery of ultrasonic energy occurs. See page 47 HOLD To change the amount of time (sec) the components remain held under weld pressure after the delivery of ultrasonic energy. See page 47 EXIT To return to Weld Settings. See page 11



AMTECH SPLICE MENU SCREEN STEPS

NAME

MAKE NEW

EXIT

MENU PRESETS

DRAWING LIBRARY

CURRENT SPLICE: (NAME)

Preset Menu Screen: The controller allows for the storage of weld settings and splice configurations (drawings). The stored information is known as a preset. When a name is created and saved in the library, presets may then be saved under that name. Press one of the following options for this screen: MAKE NEW To clear the current preset name in use. Advanced settings will default to those set under Configuration. NAME To create or edit a preset name. See page 16 DRAWING To build a splice configuration. See page 17 LIBRARY To save a preset by name for later recall. See page 18 EXIT To return to Menu Options. See page 9



AMTECH PART NAME (SPLICE NAME) SCREEN STEPS

<

ENTER

MENU PRESETS NAME

(NAME WINDOW)

KEY SPACE <

>

^

V

A B C D . . . . . .

CLEAR

Preset Name Screen: Names are created from this screen. The reason for creating a name is to associate it with particular group of weld settings and then store it in the controller library. A preset name may contain up to 20 characters. Press one of the following options for this screen: UP, DOWN, LEFT or RIGHT ARROWS To navigate cursor over the desired character in the selection box. KEY To add the character in the name window. SPACE To add spaces in name window. ARROW (lower right hand of screen) To backspace one character. CLEAR To erase all characters in the name window. ENTER To return to Splice Menu when you are satisfied with the name you have created. See page 15.

Note: the name will not be saved until it is stored in the library. See page 18



AMTECH DRAWING (SPLICE NAME) SCREEN STEPS

EXIT NAME PREVIOUS NEXT

CLEAR SMALLER LARGER

MENU PRESETS DRAWING

(NAME) (NAME)

(NAME)

Splice Drawing Screen: Splice configurations are built from this screen. The name associated with the splice configuration is shown at the top of the screen. The center of the screen graphically illustrates the splice as it is built. Splices may be built with wires shown extending from the right or left side. Press one of the following options for this screen: LARGER To step through larger wire sizes. SMALLER To step through smaller wire sizes. NAME To associate a name or color with a particular wire. The procedure for naming a wire is identical to creating a preset name covered earlier. See page 16 for reference. NEXT To add a wire to the splice, or press NEXT twice to add a wire to the splice from the opposite side. PREVIOUS To move the cursor to the previous wire position. CLEAR To remove the wire located at the cursor position. EXIT To return to the Splice Menu. See Page 15. If the drawing is new or edited the controller will calculate and suggest weld parameters you may choose to start with.

Note: the drawing will not be saved until it is stored in the library. See page 18



PRESET OPTIONS RUNNING: (NAME)

SCREEN STEPS

EXIT

MENU PRESETS LIBRARY

GET SAVE CLEAR

REVIEW

V

^ 0001 EMPTY < 0002 EM……

Preset Library Screen: When presets have been named and configured they must be stored in the library memory in order to retrieve them at a later date. Previously stored presets are also retrieved from this screen. The storage registers are shown mid screen starting with the number 0001 EMPTY. The preset that has been created or is in use is shown at the top of the screen. The library may store up to 1000 presets. Press one of the following options for this screen: UP or DOWN ARROWS (inside the storage register display window) To scan the library a page at a time. UP or DOWN ARROWS (outside the storage register display window) To position the selection cursor next to the storage register you wish to fill, edit or retrieve from. REVIEW To view the weld settings associated with the register you have selected. GET To retrieve the preset into current memory. SAVE To retain the preset information in a selected register. CLEAR To erase information stored in a register. EXIT To return to the Splice Menu. See page 15



AMTECH MAINTENANCE MENU SCREEN STEPS

EXIT PRINTING COUNTER LIMITS

MENU MAINTAIN

*WIDTH

*HEIGHT

SONICS

ANVIL

HORN

COOLING

SAFETY

CLAMP

Maintenance Menu Screen: The maintenance screen allows adjustment and on demand control of motion devices that are used in the weld actuator. This screen also allows access to printer functions, maintenance counters and limit settings. Press one of the following options for this screen: WIDTH 2 To allow on demand control of and calibrate the gather motion. See page 21 HEIGHT 2 To calibrate the horn to anvil clearance. See page 22 SONICS To allow on demand control of ultrasonic weld energy and calibrate amplitude. See page 23 ANVIL / GATHER To toggle the anvil between open and closed positions (XL, Advanced Term, Mod 9, Mod 10, Mod 10 HD). To toggle the gather between open and closed positions (2020). HORN To toggle the horn between up and down positions. SAFETY / ANVIL To toggle the safety cover slide between open and closed positions. (2020, XL, Mod 9, Mod 10, Mod 10 HD). To toggle the anvil between open and closed positions. (Advanced Term).



AMTECH MAINTENANCE MENU SCREEN STEPS

EXIT PRINTING COUNTER LIMITS

MENU MAINTAIN

*WIDTH

*HEIGHT

SONICS

ANVIL

HORN

COOLING

SAFETY

CLAMP

COOLING To toggle the cooling air control solenoid on and off. PRINTING To initialize and set printer variables. See page 24 COUNTERS To set individual maintenance counters for critical parts on the actuator. See page 25 LIMITS To set individual maintenance limits for critical parts on the actuator. See page 25 EXIT To return to Menu Options. See page 9



AMTECH WIDTH ADJUSTMENTS SCREEN STEPS

EXIT ZERO

MENU MAINTAIN *WIDTH

<< - + >>

RELATIVE WIDTH (VALUE) ABSOLUTE WIDTH (VALUE)

Width Adjustment Screen: 2 This screen provides access to on demand control of the gather motion and calibration. The Relative Width display value is the actual measured width reading. The Absolute Width display value is for reference only. absolute width - the relative width = unused encoder travel. When absolute width is greater than the relative width it assures that the gather is mechanically closing all the way prior to reaching the end of the encoder range. Press one of the following options for this screen: << or >> To quickly open or close the gather. MINUS or PLUS To incrementally open or close the gather. ZERO To calibrate the width. Gather will close completely and then open. EXIT To return to Maintenance Menu. See page 19



AMTECH HEIGHT CALIBRATION SCREEN STEPS

EXIT HORN CALIBRATE

MENU MAINTAIN *HEIGHT

TO CALIBRATE THE HEIGHT: POSITION A 1.00 MM GAUGE PUSH HORN TO BRING DOWN THE HORN AND ACTIVATE THE GATHER PUSH CALIBRATE CALIBRATED HEIGHT = (VALUE).

Height Calibration Screen: 2 This screen is for height (horn to anvil) calibration. The instructions on the screen explain the procedure for calibrating. Also see page 57 for written instructions for setting potentiometer voltages. Press one of the following options for this screen: HORN To open and close horn against anvil. CALIBRATE To calibrate height EXIT To return to Maintenance Menu. See page 19



AMTECH SONIC GENERATOR SCREEN STEPS

TEST

RESET

EXIT

MENU MAINTAIN SONIC

- + - +

100% TEST

READY (AMPLITUDE VAL)

(W VAL)

POWER

Sonic Generator Screen: This screen allows on demand control of ultrasonic weld energy and calibration of amplitude. Amplitude calibration requires a dial indicator to be temporarily mounted in line with and in front of the horn usually on a magnetic base. The 100% test button is held and gage reading is viewed. The gage reading x 2 = total amplitude, this is the value to be entered for the amplitude value when calibrating. Press one of the following options for this screen: TEST To fire ultrasonic energy at the current amplitude setting. RESET To reset the controller if a weld overload should occur. PLUS or MINUS (W) Is set by AmTech for a given actuator and is not changed. Generally the setting for 20 kHz actuators is 3300 W and the setting for a 40 kHz actuators is 800W. 100% TEST To fire ultrasonic energy at 100% amplitude. This is used when calibrating amplitude. PLUS OR MINUS (MICRONS ) To set the amplitude value based on the indicator reading. See above. EXIT To return to Maintenance Menu. See page 19



AMTECH PRINTING SCREEN STEPS

EXIT INIT PAGE SIZE

MENU MAINTAIN PRINTING PRINTING

TEST PAGE

INTERVAL

HISTORY

PAGE SIZE (VALUE) (PRINTING OPTION)

ADVANCED

Printing Screen: This screen is for setup and test of an optional printer used for recording weld information. Most inkjet and laser printers are currently supported. Turn on the Touchscreen Controller before the printer or the printer may not function properly. Press one of the following options for this screen: PRINTING

To select the printing options which include: Printing off Print each weld (used also with interval feature below) Graph each weld Print on alarm

TEST PAGE To print a test page INTERVAL To set an interval value (1 to 99) for printing weld data. See page 47 HISTORY To print weld history information for previous welds. Prints up to 128 welds. INITIALIZE To initialize a newly installed printer. PAGE SIZE To select page size option of 8.5 x11 or A4 ADVANCED To set printer compatibility with AmTech CPU boards. A toggle button will appear. Select version 3 or version 5 (current). EXIT To return to Maintenance Menu. See page 19



AMTECH MAINTENANCE (COUNTERS / LIMITS) SCREEN STEPS

EXIT

MENU MAINTAIN COUNTERS OR LIMITS

TIP ANVIL GATHER GUIDE

HORN CONVER GENERA ACTUAT

(VALUE kj) (VALUE kj) (VALUE kj) (VALUE kj)

(VALUE) (VALUE) (VALUE) (VALUE)

Maintenance Counters and Limits Screen: Maintenance counters and limits are related. Both are set using the above screen. A maintenance counter will increment after each weld cycle up to the limit values set by the user. When a limit is exceeded the controller will issue a warning the next time it is turned on. Maintenance counters and limits may be reset at will. Any maintenance counter value which is less than its corresponding set limit value does not produce a warning on startup. The top four values on the screen for tip, anvil, gather and guide are set in kilo joule units. Example: if the energy weld setting in use is 1500 joules, a limit setting of 7500 kilo joules will produce about 5000 cycles before reaching its limit. The bottom four values on the screen for horn, converter, generator (ultrasonic power supply), and actuator are set in number of cycles. If a limit is set to 0 it will not yield a warning regardless of the maintenance count. Press one of the following options for this screen: ANY BUTTON That you wish to set counter or limit values for. See page 47 EXIT To return to Maintenance Menu. See page 19



AMTECH WELD LIMITS SCREEN STEPS

MENU QUALITY

TIME

POWER

PREHEIGHT

HEIGHT

(VALUE)

(VALUE)

*(VALUE)

*(VALUE)

(VALUE)

(VALUE)

*(VALUE)

*(VALUE)

MIN MAX

EXIT

Weld Limits Screen: Weld limits assure that certain weld settings fall within a min/max range. This operating window assures the user of consistency between welds. If values fall outside these limits an alarm is given. Press one of the following options for this screen: TIME MIN or MAX To set the min/max time (sec) that ultrasonic energy may be applied to a weld. See page 47 POWER MIN or MAX To set the min/max power (watts) which may be applied to a weld. See page 47 PREHEIGHT MIN or MAX 2 To set the min/max preheight (mm). This is a pre sonic inspection reading from the height encoder prior to weld. See page 47 HEIGHT MIN or MAX 2 To set the min/max height (mm). This is a post sonic inspection reading from the height encoder after welding. See page 47 EXIT To return to Menu Options. See page 9



AMTECH SEQUENCE MENU SCREEN STEPS

MENU *SEQUENCE

NEW

EXIT

EDIT LIBRARY

CURRENT SEQUENCE: (NAME) SEQUENCE MODE IS (VALUE)

ON/OFF

Sequence Menu Screen: 1 A sequence is a series of grouped presets which are to be executed in a particular quantity and order. Sequences are constructed using existing presets which have been previously stored in the preset library. When the combination of presets and their desired cycle quantities have been constructed they may be saved into the sequence library for future recall. Press one of the following options for this screen: NEW To create a new sequence name. See page 28 EDIT To edit an existing sequence name. See page 28 LIBRARY To access the sequence library. See page 30 ON/OFF To toggle sequence mode on and off. EXIT To return to Menu Options. See page 9



AMTECH SEQUENCE (VALUE) SCREEN STEPS

MENU *SEQUENCE *NEW OR EDIT

<

ENTER

(SEQUENCE NAME BEING ENTERED)

KEY SPACE <

>

^

V

A B C D . . . . . .

CLEAR

Sequence Name & Edit Screen: 1 Sequence names are created and edited from this screen. Once the name is created the user may choose the presets which make up the sequence. Up to 50 sequences may be stored. Press one of the following options for this screen: UP, DOWN, LEFT or RIGHT ARROWS To navigate cursor over the desired character in the selection box. KEY To add the character in the name window. SPACE To add spaces in name window. ARROW (lower right hand of screen) To backspace one character. CLEAR To erase all characters in the name window. ENTER When satisfied with the sequence name. The Sequence Steps screen will appear and presets used in the sequence may be selected. See page 29



SCREEN STEPS

MENU *SEQUENCE *NEW OR EDIT *ENTER

SEQUENCE NAME: (VALUE) STEP PART NAME QUANTITY

EXIT ADD DELETE QUANTITY

V

^ 0001 EMPTY < 0002 EM……

000 000 …

Sequence Steps Screen: 1 A sequence consists of a series of presets, each of which is executed a designated number of times. This screen allows selection of presets and assignment of quantities. Press one of the following options for this screen: UP or DOWN ARROWS (inside the storage register display window) To scan sequence steps a page at a time. UP or DOWN ARROWS (outside the storage register display window) To position the selection cursor next to the storage register you wish to fill, edit or retrieve from. ADD To add a preset to the sequence. A screen will appear which allows you to select a preset from the preset library. DELETE To delete the selected preset from the sequence. QUANTITY To specify the number of times to execute the selected preset in the sequence (250 times maximum). EXIT When satisfied with the sequence steps. If the sequence is new or has been changed, an option to try the sequence (return to the Run Screen, see page 7 ) or exit (return to Sequence Menu, see page 27) is given.



SEQUENCES SEQUENCE: (NAME)

SCREEN STEPS

EXIT

MENU *SEQUENCE *LIBRARY

GET SAVE CLEAR

REVIEW

V

^ 0001 EMPTY < 0002 EM……

Sequence Library Screen: 1 When a sequence has been named and configured it must be stored in the library memory in order to retrieve it at a later date. The sequence that has been created or is in use is shown at the top of the screen. Press one of the following options for this screen: UP or DOWN ARROWS (inside the storage register display window) To scan the sequence library a page at a time. UP or DOWN ARROWS (outside the storage register display window) To position the selection cursor next to the sequence storage register you wish to fill, edit or retrieve from. REVIEW To view the presets associated with the selected sequence. GET To retrieve the sequence into current memory. SAVE To retain the sequence information in a selected register. CLEAR To clear a stored sequence from its storage register. EXIT To return to the Sequence Menu. See page 27



SCREEN STEPS

MENU *ADJUST

AMTECH WIDTH AND HEIGHT ADJUSTMENT

EXIT

ADJUST

ADJUST

RESULT MEASURED WIDTH (VAL) (VAL) HEIGHT (VAL) (VAL)

ADJUST WIDTH AND HEIGHT TO THE ACTUAL MEASUREMENTS OF THE LAST SPLICE. PART NAME: (VAL)

Width and Height Adjustment Screen: 2 The actual measured value of a splice may vary from the width and height settings in the controller. The height setting does not include added height of component material which extrudes into the knurl patterns of the tooling. The width dimension does not include variation caused by possible gather deflection. This screen allows an offset compensation to be entered so that the resultant splice matches the set values for width and height. The result values are set in the controller and represent the desired actual dimension of the splice. The measured values are taken from an actual sample and input using the adjust buttons. The controller will then create a compensation factor to produce the desired splice size. Press one of the following options for this screen: ADJUST (top) To enter a measured width (mm) value . See page 47 ADJUST (bottom) To enter a measured height (mm) value . See page 47 EXIT To return to Menu Options. See page 9



AMTECH SYSTEM CONFIGURATION SCREEN STEPS

MENU CONFIGURE (PASSWORD)

EXIT NEXT

COOLING

TEACH

ADVANCED

WIRESIZE

PRESSURE

LANGUAGE

SET UP

(VAL)

(VAL)

System Configuration Screen: Features in this screen are global and remain unchanged regardless of other weld setting or presets that are currently in use. The exception is Advanced settings which serve as defaults and may be overridden on an individual preset basis. See page 14 for reference. Press one of the following options for this screen: COOLING To set timers that control post weld cooling air. See page 33 TEACH To set mode and criteria for the teach function. The teach feature is a method for establishing weld limits. See page 34 ADVANCED (Default) To set default values for advanced features. The screen and features are identical to those in Advanced Weld settings. See page 14 for reference. WIRESIZE To toggle wire size units between AWG and mm2 PRESSURE To toggle pressure units between PSI and bar LANGUAGE To select a controller display language in English, Spanish, Portuguese, French or German. NEXT To view more configuration features. See page 36 EXIT To return to Menu Options. See page 9



AMTECH WIDTH AND HEIGHT ADJUSTMENT SCREEN STEPS

MENU CONFIGURE (PASSWORD) COOLING

EXIT

DURATION

DELAY

(VAL)

(VAL)

Cooling Screen: This screen allows access to timer settings which control post weld cooling air for tooling. Press one of the following options for this screen: DURATION To change the length of time the cooling air is on after each weld cycle. See page 47 DELAY To change the delay period after weld and before cooling air is turned on. See page 47 EXIT To return to System Configuration. See page 32



AMTECH TEACH MODE SETUP SCREEN STEPS

MENU CONFIGURE (PASSWORD) TEACH

EXIT TEACH ^ v

(VAL)% (VAL)% *(VAL)% *(VAL)%


(QTY) (MODE)

MAX

MIN

TIME POWER PREHEIGHT HEIGHT

Teach Mode Setup Screen: The teach feature may be used to establish weld limits (see page 26 for reference) from a series of sample welds made by the user. Upon successful completion of the sample set the controller does the following: Calculates average values for Time, Power, Preheight and Height variables. Factors the allowable min/max deviation percentages as entered in this screen. Uses the resultant values to create the weld limits. There are two teach modes available as means to do sampling. The mode in use will be displayed at the top of this screen. These modes area as follows: In the Standard Teach Mode the user may accept or reject each weld as part of the sample set. The button to accept the samples will appear to the right of the TEACH button on the Run Screen. Sample sets of 1 to 50 may be used. In the Auto Teach Mode the user may not reject samples. Instead, the first five welds form a basis using the averaged values for Time, Power, Preheight and Height. A plus or minus ten percent tolerance is added to these averages which are used to evaluate the acceptability of the remaining samples. If a remaining sample falls outside of this range it is rejected and an alarm occurs. A teach session may encounter up to three errors in the first 15 welds made after which the sampling must be started over. Once the teach mode sample size and variation criteria has been established, a sample run may be initiated by pressing the TEACH button on this screen or on the Run Screen. Press one of the following options for this screen: ANY MIN/MAX % VALUE To select an allowable deviation to be applied to the sample average. Availability of Preheight & Height settings is actuator dependant. See endnote 2.



AMTECH TEACH MODE SETUP SCREEN STEPS

MENU CONFIGURE (PASSWORD) TEACH

EXIT TEACH ^ v



(QTY) (MODE)

MAX

MIN

TIME POWER PREHEIGHT HEIGHT

(MODE) To toggle between Standard and Auto teach modes (QTY) To enter a quantity for the sample set. The sample set may include up to fifty welds. In Auto mode the sample set has a fifteen weld minimum. TEACH To put the controller in teach mode. EXIT To return to System Configuration. See page 32




MENU CONFIGURE (PASSWORD) NEXT

EXIT NEXT

ACTUATOR

PASSWOR

REWELD

ON ALARM

FORMULA

LOW AIR

(VAL) (VAL)

(VAL)

System Configuration Screen (Next): This screen allows access to other configuration settings. Press one of the following options for this screen: ACTUATOR To select an actuator. See page 37 PASSWORD To create passwords that control operator access to the touchscreen commands. See page 38 REWELD To toggle the reweld mode on/off. This provides an option when a weld limit alarm (see page 26 for reference) occurs. If the reweld setting is on the user may choose to reweld the same part again. Weld limits are turned off for one cycle while the reweld takes place. ON ALARM To toggle between lock or allow a weld to continue when an alarm condition exists. When set to lock the actuator will not release the part until a level 1 password is entered. FORMULA To set formula offsets when weld settings are calculated in drawing mode. See page 39 LOW AIR To set options and threshold for low line air pressure. See page 40 NEXT To view more configuration features. See page 41 EXIT to return to System Configuration. See page 32



AMTECH SELECT ACTUATOR SCREEN STEPS

MENU CONFIGURE (PASSWORD) NEXT ACTUATOR

EXIT

2020

MOD 9

XL

MOD 10

CURRENT ACTUATOR: (VALUE) CURRENT OPTION: (VALUE) UNLOAD TIME: (VALUE)

ADV TERM

OPTIONS TIME

MOD10HD

Select Actuator Screen: This screen is used to match the controller firmware to its attached actuator type. The user may also select home position options for the gather mechanism on XL and Advanced Terminator actuators. Press one of the following options for this screen: 2020, XL, ADV TERM, MOD 9, MOD 10 OR MOD 10 HD To match the controller software to its attached actuator type. OPTIONS TOGGLE (XL and Advanced Terminator only) To set home position option for the gather mechanism. For width setting reference see page 11.

Width + 2mm = width setting + 2mm Width + 25% = width setting + (.25 * width setting) Anti side splice = width setting with no clearance. Gather opens after weld for a specified time for splice removal.

TIME (Anti side splice option only) To set gather open time for spliced wire removal. EXIT to return to System Configuration. See page 36



AMTECH CHANGING PASSWORDS SCREEN STEPS

MENU CONFIGURE (PASSWORD) NEXT PASSWORD

LEVEL 1

RESET

LEVEL 2

Password Changing Screen: This screen is used to create passwords that control operator access to the touchscreen commands. Level 1 passwords restrict access to the following screens: Maintain Settings Quality Sequence Splices Adjust Teach Level 2 passwords restrict access to the Configuration and Diagnostic screens. In order to use a Level 1 password a Level 2 password must be set. A Level 1 or Level 2 password which is set to “0” turns password protection off. The factory settings for the controller are “0” for Level 1 and “2677” for Level 2 To change a password the user must first enter the current password. If password protection is off, enter ”0” as the current password. A new password may then be entered. A password may be up to 4 numbers. Press one of the following options for this screen: LEVEL 1 To change the Level 1 password setting. LEVEL 2 To change the Level 2 password setting. RESET To return to System Configuration. See page 36



AMTECH DEFAULT FORMULA ADJUSTMENT SCREEN STEPS

MENU CONFIGURE (PASSWORD) NEXT FORMULA

EXIT

*WIDTH ENERGY

(VAL)% (VAL)% (VAL)% (VAL)%

AMPLIT PRESSU

<< - >> +

Formula Adjustment Screen: When a splice Drawing is created (see page 17 for reference), the controller recommends weld settings based on a formula which considers the number and size of the wires used in the splice. This screen is used to increase or decrease the formula resultant values by a percentage amount to affect width, energy, amplitude and pressure. Press one of the following options for this screen: WIDTH 1, ENERGY, AMPLITUDE OR PRESSURE To increase or decrease the formula value for the selected variable. MINUS or PLUS To adjust percentage of selected variable incrementally. << or >> To adjust percentage of selected variable by a factor of 10% EXIT to return to System Configuration. See page 36



AMTECH LOW AIR PRESSURE ALARM SCREEN STEPS

MENU CONFIGURE (PASSWORD) NEXT LOW AIR

EXIT

DISABLED CONTINUE

PRESSURE (VAL)%

LOCK

PRESSURE

Low Air Alarm Screen: This screen is for setting low air line pressure alarm options. Press one of the following options for this screen: DISABLED To disable low pressure alarm. Select this setting if the system is not equipped with a pressure switch. CONTINUE To finish weld after sensing low pressure. LOCK To not allow weld after sensing low air pressure. PRESSURE To set the alarm threshold for low line pressure. See page 47 EXIT To return to System Configuration. See page 36




MENU CONFIGURE (PASSWORD) NEXT NEXT

EXIT

HARDWAR

SEQ ERR

System Configuration Screen (Next, Next): This screen allows access to other configuration settings. Press one of the following options for this screen: HARDWARE To set information feedback devices. See Page 42 SEQUENCE ERROR To set error handling options when running in Sequence mode. See page 43 EXIT To return to System Configuration. See page 36



AMTECH TRANSDUCER CONFIGURATION SCREEN STEPS

MENU CONFIGURE (PASSWORD) NEXT NEXT HARDWARE

EXIT

WDTH ENC

HGT ENC

(VAL)

PR READ

SEEK

(VAL)

(VAL)

(VAL)

Transducer Configuration Screen: This screen allows control of information feedback devices on the actuator. Press one of the following options for this screen: WIDTH ENCODER To toggle width encoder on/off HEIGHT ENCODER To toggle height encoder on/off PRESSURE READING To toggle pressure reading transducer on/off SEEK To toggle on/off seek function. This pulses ultrasonic energy to the stack prior to each weld in order to allow the system to tune to stack frequency. EXIT To return to System Configuration. See page 41



AMTECH SEQUENCE RESET OPTIONS SCREEN STEPS

MENU CONFIGURE (PASSWORD) NEXT NEXT SEQ ERR

EXIT

DBL CLK

DBL CLK

(VAL)

SEQ ERR

(VAL)

(VAL)

Sequence Error Screen: When a weld error occurs while running in Sequence mode, options are available for when the system is reset. This screen allows for setting these options. The double click functions are applicable only when the controller is equipped with a remote reset button. Press one of the following options for this screen: DOUBLE CLICK (ALLOW) To toggle between allow and not allow a double click input. DOUBLE CLICK (OPTION) To toggle between double click options as follows: Restart – to restart sequence from step 1 To Next- to move to the next step of the weld sequence. SEQUENCE ERROR To toggle between sequence options which apply after a weld error is cleared. Restart- to restart the sequence from step 1. Reweld- to reweld the same step in the sequence. EXIT To return to System Configuration. See page 41



AMTECH SCREEN STEPS

MENU DIAGNOSTIC (PASSWORD)

EXIT INIT SERIAL

TOUCHPANEL CYCLES

PROGRAM RUNNING Tick Count: (val) Height: (val) Width: (val)

TOTAL WELDS: (val) Software Version: (val)

Diagnostic Screen: This screen allows access to operating system settings and information. Press one of the following options for this screen: INITIALIZE To reinitialize the controller for software upgrades or in the unlikely event of a system failure. An option of partial or full initialization will be presented. A partial initialization will save all presets and sequences stored in the controller library.

A full initialization will not save all presets and sequences stored in the controller library. SERIAL To set baud rate and test serial communications. See page 45 TOUCH PANEL To go through a series of steps which recalibrate the touch panel. This is a factory set calibration that should not need adjustment. CYCLES To set options for automatic actuator cycling used for testing. See page 46 EXIT To return to Run Mode. See page 7



AMTECH SERIAL PORT DIAGNOSTICS SCREEN STEPS

MENU DIAGNOSTIC (PASSWORD) SERIAL

EXIT

SEND PO

RECVE PO

COM DATA

(BAUD)

SEND P1

RECVE P1

BARCODE

Serial Port Diagnostics Screen: This screen is to setup test and move data between two controllers or a controller and a PC. The button functions are described below. For precise instructions on how to save/ transfer preset and sequence information see page 55. Press one of the following options for this screen: SEND PO To send 10,000 “U” characters to Port 0 as test transmission RECEIVE PO Allows message typed on PC (hyperterminal) to be displayed on touchscreen. COM DATA Allows sending of stored Preset or Sequence information to Port 0. SEND P1 To send 10,000 “U” characters to Port 1 as test transmission. RECEIVE P1 Allows message typed on PC (hyperterminal) to be displayed on touchscreen. BARCODE To initialize Port 1 to receive barcode data. BAUD To set baud rate value for Port 0. (Port 1 baud is fixed at 9600 ) EXIT to return to Diagnostics. See page 44



AMTECH CYCLES SCREEN STEPS

MENU DIAGNOSTIC (PASSWORD) CYCLES

EXIT

CYCLES

CONTINUE STOP

RUN

CYCLES LEFT: (VALUE)

Cycles Screen: This screen allows automatic cycling of the weld actuator for a designated number of cycles. This feature is used for test purposes. Press one of the following options for this screen: CYCLES To set the number of cycles to be completed. See page 47 CONTINUE To continue the actuator cycling after initiating a stop command without resetting the counter. RUN To start actuator cycling. STOP To stop actuator cycling EXIT to return to Diagnostics. See page 44



AMTECH (DESCRIPTION) (VALUE) SCREEN STEPS

7

4

MULTIPLE PATHS LEAD TO THIS SCREEN

8

5

9

6

1 2 3

0 . <

ENTER

CLEAR

+10%

-10%

Typical Keypad Entry Screen: A number of touchscreen menu paths lead to a numerical entry keypad screen similar to that shown above. Generally the current variable and its value are displayed at the top of the screen. Note that some screens do not contain the 10% keys. Press one of the following options for this screen: NUMERIC KEYPAD To enter a new value. +10% or -10% To increment the current setting by plus or minus 10 percent. CLEAR To undo the value you entered. CLEAR then ENTER To return to settings and leave the previous value unchanged. ENTER To save the new value and return to previous screen.


AmTech Product Manual- Touchscreen Controller Maintenance: The controller is designed for a long service life. In the event the system malfunctions, many of the internal components (Modules) are replaceable as a unit. If a particular module has failed, it should be replaced or repaired at our facility or in the field by a qualified AmTech trained technician.

Before you begin to disassemble any parts of the controller, ensure that it is turned off, and the main power is disconnected. Wait at least two minutes to allow capacitors to discharge. High voltage is present in the power supply. Do not operate with the cover removed. High line voltages exist in the ultrasonic power supply module. Common points are tied to circuit reference, not chassis ground. Therefore, use only non-grounded, battery-powered multimeters when testing these modules. Using other types of test equipment can present a shock hazard. The controller contains components that can be degraded or damaged by electrostatic discharge. Always use a grounded wrist strap and use a grounded work area when handling or servicing the controller. The following pages provide descriptions and means to identify replaceable components.

Do not cycle the welding system if either the RF cable or converter is disconnected. Power Supply Cover: The cover is held in place with seven screws, three on each side of the case and one on the rear. Lift the rear of the cover up to remove it. The cover must be in place when the system is operating due to fan-forced ventilation design. Circuit Boards and Modules: Replaceable modules are shown in Figure 1. Be sure to note ribbon cable and connector orientation prior to removing components for maintenance or replacement. The cooling fans use identical wiring harnesses, with one tying back the ‘extra’ lead length. Make note of any wiring paths if you are removing a module, before you disassemble. In some cases, there are several possible paths, but one preferred location. Be especially careful with harnesses and wires that go between the two portions of the case, as they can be pinched by the metal case if miss-routed. Cleaning the Equipment: Air is continuously drawn into the controller. Periodically disconnect the unit from power, remove the cover and vacuum out any accumulated dust and debris. Remove material adhering to the fan blades and motor, transistors, heat sinks, transformers, circuit boards, cooling intake vents, and exhaust ports. External covers may be cleaned with a damp sponge or cloth using a solution of mild soap and water.


AmTech Product Manual- Touchscreen Controller Touchscreen Controller- Top view with cover removed:

Ad FDi

3

vanced unction p Switches

5

Front bezel showand rotated 90 de

Figure 1


Under

2

1

n g

8

7

6

4

9

14

11

13

10

12

detached


Item Component Part No (20 kHz) Part No (40kHz) 1 Ultrasonic Power Supply Module 106-251 (3300w)

106-218 (4400w) 106-252

2 Line Filter Module 106-236 106-236 3 DC Power Module 106-253 106-253 4 Cooling Fans 106-226 106-226 5 Touch Screen 104-278 104-278 6 LCD Controller 104-280 104-280 7 Display Board 104-279 104-279 8 Front Panel Board UOA00011 UOA00011 9 Power Switch 106-247 106-247 10 Power Reset Board U1A00004 U1A00004 11 IO Board U0A00009 U0A00009 12 CPU Board U0A00010 U0A00010 13 Motor Control Board (Splicers) 105-068B - 14 Pneumatic Kit See Special Info

Instruction Set See Special Info Instruction Set

Table 1

Table 1

Components: The following paragraphs describe touchscreen controller internal components (Modules) and their function. and may be used to locate and identify components. Figure 1

In Figure 1 a 20 kHz controller is shown. The 40 kHz controller is similar.


AmTech Product Manual- Touchscreen Controller Ultrasonic Power Supply Module- generates ultrasonic energy at the resonant frequency of the Converter-Booster-Horn Stack. The Ultrasonic Power Supply Module contains five main circuits as follows: •

•

•

• • • • •

•

• •

• •

•

•

320VDC Power Supply: converts AC line voltage to +320VDC for the output power devices.

FET bridge- switches the 320 vdc into ultrasonic pulses at the resonant frequency.

Output circuit – matches the impedance of the output power device to the Converter-Booster-Horn Stack; and provides feedback to the Control circuit.

Control circuits: perform the following functions:

Provide drive signal to output power device. Determine true percentage of ultrasonic power used over a range of amplitudes. Allows control of the resonant frequency. Control starting amplitude.

System Protection Monitor (SPM) and AutoTune with Memory (AT/M) circuit do the following:

Provide overload protection for the Ultrasonic Power Module. Store operating frequency of last weld (frequency memory) and use the stored frequency as a starting point for the next weld. Check and update frequency memory on start-up. Provide switch-selective starting ramp times (Start).

Line Board Module- performs the dual function of providing RFI filtering for the line voltage input to the power supply, and controlling the electrical current surge to the ultrasonic Power Supply Module at power up until the inrush current limiter relay engages. The filtering also blocks ultrasonic signals from entering the AC main line. Additionally, the Line Board contains a soft start circuit module which limits the effects of current inrush. DC Power Module- rectifies, filters, and regulates the AC voltages from the Line Transformer into DC voltages for the CPU Board. These two circuits are described below:

5VDC output: provides +5VDC for the analog and digital circuitry on the CPU Board.

24VDC output: provides +24VDC for the CPU Board control signal and user I/O voltage. The DC Power Supply is mounted to the rear of the Power Supply case. It is mounted so it will swivel up to service the DC Power Supply, Line Board, and fuses.


AmTech Product Manual- Touchscreen Controller I/O Board- provides a standard interface for automation and is accessed on the rear of the power supply. It gives the customer the ability to make their own interface for automation or special control and/or special reporting needs. It is mounted to the CPU Board on standoffs, and is connected to the rear of the controller case by its end panel. CPU Board- controls the following functions of the Power Supply: • • • • • • • •

Responding to start and stop signals Responding to alarm and reset signals Responding to user input from the front panel Activating and monitoring ultrasonics Provides information for Front Panel Displays Generate alarms Activate printing Control communications

This board mounted to the bottom of the power supply box on standoffs and is connected to the rear of the controller case by its end panel. To access this board removal of the I/O Board is required. The system software eproms reside in sockets u15 and u3 as shown in Figure 2. The battery backup ram (BBRAM ) is located next to the eproms and saves stored information when power is removed from the system.

Figure 2

Instruction Set for Touchscreen Controller - Page 52 o

BBRAM
U15 U3
f 61

AmTech Product Manual- Touchscreen Controller Front Touchscreen Panel and Bezel Assembly- is held by four upper screws which are accessible from inside the enclosure and four lower screws which are accessible from outside the enclosure through the ventilation slots in the bezel. Removal of the front bezel allows access to the following components which are housed inside it: • Touchpanel- The sensing element which provides the user interface with the controller. •

•

•

•

•

•

•

•

LCD screen- The visual display through which instructions are communicated to the user. It is mounted directly behind the touchpanel.

Display Board- Contains the video control circuits for the LCD Screen. This board is mounted directly behind the LCD controller.

Front Panel Board- Houses the alarm beeper and the four diagnostic lights which are located to the right of the touchscreen on the front bezel.

Power Switch and Power Reset Board- the power reset board is directly plugged into the power switch. In the event power is disconnected from the control, the reset board circuit requires that the power switch be pressed to return to the off position and pressed again to return to power on state.

Motor Control Board- contains the control circuit for controlling actuators which are equipped with a stepper motor driven gather mechanism. Pneumatic Kit- refer to the Special Information Instruction Set. Advanced Function Switch Select Once you connect external controls to the power supply, you can set the following Advanced Functions using the Switch Select block:

Seek - Provides options for controlling, monitoring, and storing operating frequency.

Amplitude control - Allows for varying amplitude (50% - 100%) via external controls or keeping the amplitude fixed.

Select Start - Provides four starting ranges. Select start allows the power supply to ramp amplitude to accommodate different converter and load requirements.

Memory - Stores horn frequency at end of each weld.

Refer to Table 2 for switch settings.


AmTech Product Manual- Touchscreen Controller Advanced Function Switch Select Table

Function Options Set Toggles... Seek Seek on power up - Checks horn

frequency upon power up and stores it in memory.

1 – On (Default) 1 – Off

Auto Seek - Checks horn frequency once each minute, timed from the last activation of ultrasonics.

2 – On 2 - Off (Default)

Auto Seek Duration - Indicates the length of time the Auto Seek function is active.

3 – On (standard) 3 – Off (short, Default)

Store at End of Weld - Updates horn frequency memory at the end of each weld.

4 – On 4 – Off (Default)

Amplitude Control

Variable - Front panel adjustment of amplitude (50% to 100%) Note: Pin 6 must be on or Amplitude Control will not work.

6 - On (Default)

Start Short - Sets ramp time to 10 ms. 7 - Off (Default) 8 – Off (Default)

Medium - Sets ramp time to 35 ms. 7 – On 8 – Off

Standard - Sets ramp time to 80 ms. 7 – Off 8 – On

Long - Sets ramp time to 105 ms. 7 – On 8 – On

Table 2 See Figure 1 for switch location

Figure 3



Saving / Transferring Preset and Sequence Information: Equipment required: • •

•

•

•

•

•

•

Standard IBM PC Null Modem cable. A computer running Windows HyperTerminal and a standard RS232 serial port. Other computers may be configured to work but will require additional instructions. An AmTech TouchScreen Controller version 5.03.00 or later. It must be configured and ready to run.

Download Procedure:

Connect the PC to the touchscreen controller (connection P105) with the Null Modem cable. Note the PC COM port because it will be required for setting HyperTerminal. Do not start the controller at this time.

From the PC, start HyperTerminal (Usually in the Accessories program menu folder). Setup a HyperTerminal connection (File, New Connection). Use the default settings with the following changes:

Set Phone Number: Direct to Com 1 (or Com 2 as available) In Configure set:

Bits per second 19200 (Default for TouchScreen) Data bits 8 Parity None Stop bits 1 Flow control None

In Settings set Emulation: VT52

Save and connect with the new connection Turn on touchscreen controller. HyperTerminal view window should show: UUIA1 :020000030900F2 :02000000C740f7 :0100000100FE This is the touchscreen’s sign on to an attached serial port. It is always sent when the control starts to tell any waiting device that the COM port is active. If you do not see this sign on or the characters are unusual check the settings. The baud rate may have been changed or if there is no display check the Null Modem cable and COM port assignment.


AmTech Product Manual- Touchscreen Controller •

•

•

•

•

•

•

•

•

From the touchscreen controller go to the Serial Port Diagnostics Screen. (Menu> Diagnostic > Password> Serial). Check the BAUD rate at the lower right corner of the screen. It must match the Bits per second used in HyperTerminal. From the PC HyperTerminal go to Transfer, Capture Text. It is recommended that the data be stored on a floppy disk in the A: drive. A file name a:\tsdata.txt or similar can be used. Use a .txt extension.

From the touchscreen controller press COM DATA. When the next screen appears press PRESETS or SEQUENCE to upload the data to the PC HyperTerminal. When all data has been sent to the PC go back to Transfer, Capture Text and Stop. This will close the file with data stored.

Upload Procedure:

The captured text file contains all the information required to return the data back to any waiting touchscreen controller. Assuming the HyperTerminal setup was saved, load that setup to start the system. If you have not saved the setup you can use the above steps to setup a new HyperTerminal session.

IMPORTANT: Leave the controller at the RUN screen. From the PC, use the Send Text File (instead of Capture Text) to upload the file to the controller.

Controller to Controller:

The PC is required only to store the data. If desired, two touchscreen controllers can be attached via the Null Modem cable and the data sent directly from one controller to another. The BAUD rate must be identical, there is no other setup.



Figure 4

Figure 4

Figure 4

Encoder Board Calibration Encoder board calibration is factory set and generally does not need to be changed. Any calibration required due to tool wear or adjustment is built into the controller software and may be accomplished using touchscreen commands. If a new encoder board is installed, it will be necessary to calibrate Height and Width as follows. If a new width encoder belt is installed, follow the procedures for Width only. Calibrate Height • •

•

•

•

From the controller, lower the horn (step reference- Menu >Maintain >Height > Horn) Remove appropriate components on the actuator to locate and remove (if necessary to allow access) the actuator board. With digital voltmeter measure dc voltage at test point R14 ( ) to ground. The 9 pin connector should be used as the ground point. Voltage should read + 0.150 vdc. If not turn voltage the HGT ZERO potentiometer (

) until the voltmeter reads + 0.150 vdc. (The voltage must be positive) From the controller raise the horn (step reference- Horn).


AmTech Product Manual- Touchscreen Controller Height Span Adjustment • • •

• • •

• •

Position a 1mm shim on the weld surface of the tip/horn. From the controller lower the horn (step reference- Menu >Maintain >Height > Horn) From the controller calibrate the height (step reference- Calibrate). The controller will reset the zero point and the anvil arm will move up. Position a 6mm shim on the weld surface of the tip/horn. From the controller lower the horn (step reference- Horn) Verify that the height reads 6mm. Adjust the HGT CAL (Figure 4) potentiometer until a reading of 6mm is obtained. Repeat above steps until the height reads 6mm without adjustment at the previous step. From the controller exit the calibration screen (step reference- Exit)


AmTech Product Manual- Touchscreen Controller File Attachments:

Description File Controller User Screen Hierarchy V1A50247-01 Controller External Connections J1A00111-00

Table 3

File attachments are included at the end of this Instruction Set.


AmTech Product Manual- Touchscreen Controller Alphabetical Index: Advanced Function Switch ........................................................................................................... 53 Advanced Weld Settings Screen................................................................................................... 14 Afterburst Time............................................................................................................................. 14 Amplitude ..................................................................................................................................... 11 Batch ............................................................................................................................................. 11 Cleaning ........................................................................................................................................ 48 Components .................................................................................................................................. 50 Cooling Delay ............................................................................................................................... 33 Cooling Duration .......................................................................................................................... 33 Cooling Screen.............................................................................................................................. 33 Cycles.............................................................................................................................................. 8 Cycles Screen................................................................................................................................ 46 Diagnostic Screen ......................................................................................................................... 44 Endnotes........................................................................................................................................ 61 Energy ........................................................................................................................................... 11 File Attachments ........................................................................................................................... 59 Formula Adjustment Screen ......................................................................................................... 39 Graph/Wires/Data Toggle............................................................................................................... 7 Height Calibration Screen............................................................................................................. 22 Height Encoder ............................................................................................................................. 42 Hold Time ..................................................................................................................................... 14 Initialize ........................................................................................................................................ 44 Low Air Alarm Screen.................................................................................................................. 40 Maintenance.................................................................................................................................. 48 Maintenance Counters And Limits Screen ................................................................................... 25 Maintenance Menu Screen............................................................................................................ 19 Menu Options Screen...................................................................................................................... 9 On Alarm ...................................................................................................................................... 36 Password Changing Screen........................................................................................................... 38 Password, Initial.............................................................................................................................. 9 Preset Library Screen.................................................................................................................... 18 Preset Menu Screen....................................................................................................................... 15 Preset Name Screen ...................................................................................................................... 16 Presets ............................................................................................................................................. 8 Pressure Reading........................................................................................................................... 42 Pressure Units ............................................................................................................................... 32 Printing Screen.............................................................................................................................. 24 Reweld .......................................................................................................................................... 36 Run Screen ...................................................................................................................................... 7 Saving / Transferring Preset and Sequence Information .............................................................. 55 Seek Reading ................................................................................................................................ 42 Select Actuator Screen.................................................................................................................. 37 Sequence Error Screen.................................................................................................................. 43


AmTech Product Manual- Touchscreen Controller Sequence Library Screen .............................................................................................................. 30 Sequence Menu Screen ................................................................................................................. 27 Sequence Name & Edit Screen ..................................................................................................... 28 Sequence Steps Screen.................................................................................................................. 29 Serial Port Diagnostic Screen ....................................................................................................... 45 Sonic Generator Screen................................................................................................................. 23 Splice Drawing Screen.................................................................................................................. 17 Splice, Make New......................................................................................................................... 15 Squeeze Time................................................................................................................................ 14 System Configuration Screen ....................................................................................................... 32 System Configuration Screen (Next) ............................................................................................ 36 System Configuration Screen (Next, Next) .................................................................................. 41 Teach Mode Setup Screen ............................................................................................................ 34 Teach Mode, Auto ........................................................................................................................ 34 Teach Mode, Standard .................................................................................................................. 34 Teach Toggle .................................................................................................................................. 7 Transducer Configuration Screen ................................................................................................. 42 Trigger Pressure ............................................................................................................................ 11 Weld Limits Screen....................................................................................................................... 26 Weld Mode Screen........................................................................................................................ 13 Weld Mode, Energy ...................................................................................................................... 13 Weld Mode, Energy with Height Compensation.......................................................................... 13 Weld Mode, Height....................................................................................................................... 13 Weld Mode, Time ......................................................................................................................... 13 Weld Pressure ............................................................................................................................... 11 Weld Settings Screen .................................................................................................................... 11 Width............................................................................................................................................. 11 Width Adjustment Screen ............................................................................................................. 21 Width and Height Adjustment Screen .......................................................................................... 31 Width Encoder .............................................................................................................................. 42 Wire Size....................................................................................................................................... 32 Endnotes: 1 Not available on Advanced Terminator. 2 Usable only when encoder(s) are set to on.


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AMTECH 2032 Manual soldadora ultrasónica cable