Operating Instructions Us-Generator SG-22-XXX-3

OPERATING INSTRUCTIONS
US-GENERATOR
SG-22-XXX-3
TELSONIC AG
Industriestrasse 6b
CH-9552 Bronschhofen
Tel +41 (71) 913 98 88 Fax +41 (71) 913 98 77
Email main@telsonic.com Internet www.telsonic.com
Article number: 950 002 100 Version: 950 002 100

Operating instructions US-Generator
SG-22-XXX-3
Foreword
These operating instructions describe the SG-22-XXX-3.
The operating instructions are to be given to people who will be responsible for the
operation and monitoring of the unit.
These operating instructions include the details concerning installation and operation
necessary to the operator.
Any descriptions of activities, which do not require any special knowledge, have been
omitted.
No instructions have been given for repairs that exceed the normal maintenance.
The unit has been constructed in accordance with the acknowledged standards on
safety techniques. Despite this, there are dangers for any user who does not use it in
the proper way.
Copyright
TELSONIC AG, CH-9552 Bronschhofen
2 - 25 ©TELSONIC AG 04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

SG-22-XXX-3
List of contents
1 Introduction .................................................................................. 7
1.1 Notes ................................................................................ 7
1.2 Designation ........................................................................ 7
1.3 Symbol and Character Explanation ........................................ 7
1.4 Proper Intended Use ............................................................ 8
2 Safety Instructions......................................................................... 9
2.1 General .............................................................................. 9
2.2 Take Particular Care ............................................................ 9
2.3 Choice of Operating Personnel .............................................. 9
2.4 Notes on the Electrical/ Electronic Installation ....................... 10
2.5 Operation ......................................................................... 10
3 Product description ...................................................................... 11
3.1 Generator Set Up .............................................................. 11
3.1.1 Front view ............................................................. 11
3.1.2 Rear view .............................................................. 11
3.2 Description....................................................................... 12
3.2.1 Fully automatic frequency regulation ......................... 12
3.2.2 Displays and operating elements............................... 12
3.2.3 Manual Operation ................................................... 12
3.2.4 Protection circuits................................................... 12
3.2.5 Mains voltage variation ........................................... 12
3.2.6 Normal output during the Start-up phase ................... 12
3.2.7 Electronic selection of amplitude............................... 12
4 Operating and display elements ..................................................... 13
4.1 Front Face........................................................................ 13
5 Initial commissioning .................................................................... 15
5.1 Set Up and Connections..................................................... 15
6 Operation ................................................................................... 17
6.1 Normal Operation .............................................................. 17
6.1.1 Switching on ......................................................... 17
6.1.2 US-Test................................................................. 18
6.1.3 Frequency automatic and regulation of amplitude........ 18
6.2 The Overload Switch Off.................................................... 19
6.2.1 Overload with MPS-2 .............................................. 20
6.2.2 Overload with MPS-4 .............................................. 20
6.3 The Load Display .............................................................. 21
6.4 The Output Measurement Interface ..................................... 21
04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 3 - 25

SG-22-XXX-3
7 Technical data............................................................................. 23
7.1 Generator SG-22-1000-3 ................................................... 23
7.2 Generator SG-22-2000-3 ................................................... 23
7.3 Generator SG-22-3000-3 ................................................... 23
7.4 Generator SG-22-5000-3 ................................................... 24
7.5 Generator SG-22-6500-3 ................................................... 24
7.6 Generator SG-22-1000-3-36 .............................................. 24
8 Disposal, Recycling ...................................................................... 25
4 - 25 ©TELSONIC AG 04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

SG-22-XXX-3
List of figures
Fig. 3-1, Front view ................................................................ 11

Fig. 3-2, Rear view ................................................................. 11
Fig. 4-1, Operating and Display Elements Front Face ................... 13
Fig. 5-1, Set Up and Connections ............................................. 15
Fig. 6-1, Amplitude and mode selection ..................................... 17
Fig. 6-2, US-Test .................................................................... 18
Fig. 6-3, Frequency range ........................................................ 18
Fig. 6-4, Overload LED ............................................................ 19
Fig. 6-5, Load display .............................................................. 21

SG-22-XXX-3
1 Introduction
1.1 Notes
These operating
instructions should be
read and particularly
observed before
unpacking and
commissioning the unit.
The unit should only be
used by people who have
been entrusted with the
operating instructions
and the valid regulations
about work safety and
accident prevention.
1.2 Designation
The exact designation for the generator is
Ultrasonic Generator SG-22-XXX-3 (1000 to 6500W)
Abbreviated in these operating instructions as
SG-22-XXX-3
1.3 Symbol and Character Explanation

In the operating instructions the following terms or characters are used
for particularly important details:
Note on the risk of injury to people or the risk

CAUTION
of damaging machine parts.
NOTE Special information or operating instructions.

SG-22-XXX-3
1.4 Proper Intended Use

The SG-22-XXX-3 is intended exclusively for operation in TELSONIC
welding units.
Any other unauthorized use does not count as the proper intended use.
The manufacturer is not responsible for any damage resulting from this.
The user is solely responsible for the risk.
Observance of the operating instructions and of the inspection and
maintenance conditions comes under the heading of proper intended
use.
8- 25 ©TELSONIC AG4-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

SG-22-XXX-3
2 Safety Instructions
2.1 General
The construction of the SG-22-XXX-3 corresponds to the current state
of technique and is operationally safe.
Our Quality Assurance routinely tests the individual structural
components as well as the complete unit.
The unit should only be used in a trouble-free state for its intended
purpose and in full awareness of safety and risk while observing the
operating instructions!
Remedy (have remedied) any disorders, which might affect the safety
of operation!
2.2 Take Particular Care

When the unit is put into operation read through the present operating
instructions carefully.
Any lack of knowledge about operation and maintenance could cause
damage to the unit.
Always keep the operating instructions to hand where the unit is
installed.
Modifications, additions or conversions, which might affect safety, are
strictly forbidden without the permission of the manufacturer.
2.3 Choice of Operating Personnel

Work on the unit can only be carried out by authorized personnel.
Only use trained or instructed personnel and clearly establish the
competence of the personnel to operate, equip, maintain and service!
Work on the electrical equipment of the unit should only be done by a
qualified electrician or by an instructed person under the guidance and
supervision of a qualified electrician in accordance with the rules of
electrical technique.

SG-22-XXX-3
2.4 Notes on the Electrical/ Electronic Installation
Only carry out work on the peripherals

CAUTION
when the mains cable is unplugged.
Only operate the unit at the alternating voltage with neutral conductor
shown on the nameplate and fit the mains connection cable used for
this with earth wires.
Work on the electrical units or operating media should only be carried
out by a qualified electrician or by instructed personnel. Only use
voltage insulated tools for this.
Holding the plug remove from mains socket.
Country specific, legal safety conditions must

be observed here!
CAUTION Should these conditions not be observed, the
manufacturer denies any liability for damage to
people or materials!
2.5 Operation
Make sure that there is sufficient air circulating around the unit in order
to avoid any internal build-up of overheat.

SG-22-XXX-3
3 Product description
3.1 Generator Set Up
3.1.1 Front view
Fig. 3-1, Front view
2
4
1
1 Generator module - Handles 4 Fixing screws

2 Operating and indicating 5 Carrying handles
elements
3 Housing 6 Front plate
3.1.2 Rear view

Fig. 3-2, Rear view
1.1
5
3
2
1 Mains fuses 230V 3 25 Pole Sub-D Connection to MPS-4

1.1 Control fuse 24V 4 15 Pole Sub-D Connection to MPS-2/3
2 Mains cable 5 HF-Connection

SG-22-XXX-3
3.2 Description
The unit contains a generator of the most up to date design from the
series SG-22 with amplitude set to ± 2% in the load range from idle to
full load. The mains voltage variation should not exceed the rate of ±
15%.
3.2.1 Fully automatic frequency regulation

The unit has a fully automatic frequency regulation which ensures
automatic correction for load variations. This means the Sonotrode will
operate exactly at their resonance frequency for optimum welds.
3.2.2 Displays and operating elements

All displays and operating elements can be seen arranged on the front
plate (Fig. 3-1, Front view). For remote control and operation
surveillance with the generator control unit CU-1 all functions are
optionally fed to a plug on the back of the device (Fig. 3-2, Rear view).
3.2.3 Manual Operation

For critical Sonotrodes, for example with several resonance frequencies
in the operating range of regulation, the automatic adjustment can be
switched to "MANUAL" to enable manual equalization. The automatic
regulation still remains in service, however with a smaller range of
regulation, so that small changes can still be stabilized without trouble.
The current operating frequency can be read off at a bar display as a
standard value.
3.2.4 Protection circuits

The generator has protection circuits which make it completely secure
against short circuits and idling. When the maximum possible output is
exceeded it switches off and indicates the overload on the
"OVERLOAD" display.
3.2.5 Mains voltage variation

With nominal voltage the generator supplies the 1.2 times of the
typically normal output. Therefore the normal generator output at
100% amplitude is guaranteed even with mains voltage variations of ±
15%.
3.2.6 Normal output during the Start-up phase

During the Start-up phase of the ultrasonics the unit supplies in the first
50 ms about 150% of its normal output. Large Sonotrodes are charged
very quickly and have short loading times.
3.2.7 Electronic selection of amplitude

In the standard version the amplitude can be selected on the generator
front in steps of 70%, 80%, 90% and 100%. With an electronic
default value from a controller the generator selection must definitely
be set to 100%.

SG-22-XXX-3
4 Operating and display elements

4.1 Front Face
Fig. 4-1, Operating and Display Elements Front Face
4
5 3
6
8
12 13 11 14 10 1
1 Operation display 8 Positive deviation of the set

frequency
2 LED-bar Output 9 Negative deviation of the set
frequency
3 Overload display 10 Selection switch AUTO / MANUAL
MODE
4 Amplitude selection 11 US-Test Key
5 Green LED = selected amplitude 12 Red LED: Blinks for
equalization request (RE
TUNE)
6 Set frequency (Nominal 13 Retuning in MANUAL MODE
frequency)
7 Frequency deviation display in 14 Green LED: Optimum
kHz equalization

SG-22-XXX-3

SG-22-XXX-3
5 Initial commissioning
5.1 Set Up and Connections
Fig. 5-1, Set Up and Connections
3 5
4
2
Connection to controller MPS-4 with 25 pole Sub-D 3, or MPS-2/3 with

15 pole Sub-D 4, connect HF-cable from press with plug 5. Connect
mains cable 2 with power supply 230V, respectively 3 x 400/230 V
with neutral conductor for generators over 3’000 W.

SG-22-XXX-3

SG-22-XXX-3
6 Operation
6.1 Normal Operation
6.1.1 Switching on
Fig. 6-1, Amplitude and mode selection
1 1. For normal operation

4 select the amplitude
100% on graded
switch 4.
2 2. Set the frequency to

„AUTO“ using
switch 10.
10

SG-22-XXX-3
6.1.2 US-Test
Fig. 6-2, US-Test
3 3. When the US-TEST

key 11 is activated
the LOAD bar display
2 should display less
than 15%.
11 2
Fig. 6-3, Frequency range
4 4. The frequency
display 7 should lie
within the range of
±0.5 kHz of the
nominal frequency.
7
6.1.3 Frequency automatic and regulation of amplitude

The unit is at the right frequency when the display on the generator
"LOAD" bar display 2 is at minimum. The indication is directly
proportional to the losses and the loading ratios on the converter. With
an uncharged Sonotrode the displayed value should not under any
circumstances be more than 15%. The exact loss value is displayed by
pressing the Test button (on the controller unit) in the MPS-4 / MPS-2/3
Display.

SG-22-XXX-3
6.2 The Overload Switch Off

The internal monitoring circuits switch off the ultrasonic when there are
abnormal loading ratios for more than 120 ms.
Fig. 6-4, Overload LED
5 The overload LED

"OVERLOAD" 3 on the
front plate indicates this
3 state.
The LED display is initiated when the switching times are less than
120ms. The overload signal still prevails at the moment of switch off,
so the LED display gives an indication of whether, with very short weld
times, the required amplitude has been reached.
The overload LED will switch off at the next US-Start cycle.
The percentage load displayed on the LED-bar

NOTE corresponds with the load displayed on the
MPS-control-unit.
The exact output load can be read from the control display, or
determined by evaluation of the analogue output signal as described in
section 6.4.

SG-22-XXX-3
6.2.1 Overload with MPS-2

If the control of the generator is carried out via the MPS-2 controller
the ultrasonics will have already been switched off after 100 ms in the
event of an overload and the following message will appear on the
display:
Controller Display
MPS-2 OVERLOAD => KEY 0
Further welding is only possible after the overload occurrence has been
acknowledged by pressing key 0.
If there is overload only at the switching off moment, then the display
shows the message:
OVERLOAD WARNING
and further welding is possible without acknowledgement.
6.2.2 Overload with MPS-4

If the control of the generator is carried out via the MPS-4 controller
the ultrasonics will have already been switched off after 100 ms in the
event of an overload and an appropriate message will appear on the
display. Working with rotary table: if the operating mode "Automatic"
is not selected, further welding can only take place after
acknowledgement with the F1 key.

SG-22-XXX-3
6.3 The Load Display

Fig. 6-5, Load display
6 The percentage bar

display 2 on the
generator will only
correspond exactly with
the indicated ultrasonic
output if:
- the operation is at
2 100% amplitude and
- AUTO-TUNING 10
is functioning or with
MANUAL-TUNING the
green LED LOCKED 14
is displayed.
10 14
With reduced amplitude the bar display must

always be multiplied by the amplitude
NOTE
reduction factor to determine the effective
actual output.
The exact output load can be read from the control display, or
determined by evaluation of the analogue output signal as described in
section 6.4.
With significantly reduced amplitude the overload display can trip even
before the 100% mark of the load display is reached.
6.4 The Output Measurement Interface

The output measurement interface is connected in between generator
and control and determines the actual output emitted. The output signal
is 0 - 10 V corresponding to 0 to 100% of the nominal output. The
signal is available on the control plug on the rear side. The evaluation
and display of the output is done by the microprocessor unit.

SG-22-XXX-3

SG-22-XXX-3
7 Technical data
7.1 Generator SG-22-1000-3
Mains Voltage / Frequency....................................230 V, ±15%, 50/60 Hz
Input Current ..................................................................................... 8 Aeff.
Operating Frequency...................................................................... 20 kHz
Output Power ............................................................................ 1'000 Weff.
Amplitude ....................................................................... stabilized to ±2%
Dimensions 19“ 4 height units WDH ........................ 510 x 440 x 220 mm
................................................................................ 20.1 x 17.4 x 8.7 inch
Weight (with / without housing) ..................................approx. 22 / 14.5 kg
.................................................................................................48.5 / 32 lb

Mains Voltage / Frequency....................................230 V, ±15%, 50/60 Hz
Input Current ................................................................................... 10 Aeff.
................................................................................ 20.1 x 17.4 x 8.7 inch
..............................................................................................56.2 / 38.6 lb

Mains Voltage / Frequency................3x400/230 V/N/PE, ±15%, 50/60 Hz
Input Current ............................................................................... 3 x 8 Aeff.
................................................................................ 20.1 x 17.4 x 8.7 inch
..............................................................................................61.7 / 45.2 lb

SG-22-XXX-3

Mains Voltage / Frequency............... 3x400/230 V/N/PE, ±15%, 50/60 Hz
Input Current.............................................................................. 3 x 15 Aeff.
Output Power............................................................................. 5'000 Weff.
Amplitude........................................................................ stabilized to ±2%
Dimensions 19“ 8 height units WDH.........................510 x 440 x 400 mm
............................................................................... 20.1 x 17.4 x 15.8 inch
Weight (with housing) .............................................approx. 45 kg / 99.2 lb

Mains Voltage / Frequency............... 3x400/230 V/N/PE, ±15%, 50/60 Hz
Input Current.............................................................................. 3 x 18 Aeff.
Dimensions 19“ 12 height units WDH.......................530 x 570 x 590 mm
............................................................................... 20.9 x 22.5 x 23.3 inch
Weight (with housing) ........................................approx. 62.5 kg / 137.8 lb
7.6 Generator SG-22-1000-3-36

Mains Voltage / Frequency................................... 230 V, ±15%, 50/60 Hz
Input Current......................................................................................8 Aeff.
Dimensions 19“ 4 height units WDH.........................510 x 440 x 220 mm
................................................................................. 20.1 x 17.4 x 8.7 inch
Weight (with / without housing)...................................approx. 22 / 14.5 kg
..................................................................................................48.5 / 32 lb

SG-22-XXX-3
8 Disposal, Recycling
Generators, which have reached the end of their life cycle, can be
disposed according to the local rules concerning the disposal or
recycling of electronic scrap, which are in force. You will receive
further particular information at your local authority.
For more detailed information, please contact your supplier or visit our
website for further contacts www.telsonic.com.

Auftrags-Nr: Ersatz für: Ersetzt durch: Gezeich. 29.11.99 Ge
Aenderungen: STEUERANSCHLUSS GENERATORSERIE SG-22-XXXX-3
GENERATOR CONTROL SERIES SG-22-XXXX-3 TELSONIC Geprüft
Gesehen
Blatt 1 von 2 Blätter

ULTRASONICS 3 - 20 - 51226
Auftrags-Nr: Ersatz für: Ersetzt durch:
TELSONIC
Gezeich. 29.11.99 Ge
Aenderungen: Geprüft
STEUERANSCHLUSS GENERATORSERIE SG-22-XXXX-3
Gesehen
GENERATOR CONTROL SERIES SG-22-XXXX-3
Blatt 2 von 2 Blätter
ULTRASONICS 3 - 20 - 51226

Operating Instructions Us-Generator SG-22-XXX-3

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OPERATING INSTRUCTIONS

Article number: 950 002 100 Version: 950 002 100

2 - 25 ©TELSONIC AG 04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 3 - 25

4 - 25 ©TELSONIC AG 04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

Fig. 3-1, Front view ................................................................ 11

04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 5 - 25

1.3 Symbol and Character Explanation

Note on the risk of injury to people or the risk

NOTE Special information or operating instructions.

04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 7 - 25

1.4 Proper Intended Use

8- 25 ©TELSONIC AG4-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

2.2 Take Particular Care

2.3 Choice of Operating Personnel

04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 9 - 25

2.4 Notes on the Electrical/ Electronic Installation

Only carry out work on the peripherals

Country specific, legal safety conditions must

10- 25 ©TELSONIC AG4-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

1 Generator module - Handles 4 Fixing screws

3.1.2 Rear view

1 Mains fuses 230V 3 25 Pole Sub-D Connection to MPS-4

04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 11 - 25

3.2.1 Fully automatic frequency regulation

3.2.2 Displays and operating elements

3.2.3 Manual Operation

3.2.4 Protection circuits

3.2.5 Mains voltage variation

3.2.6 Normal output during the Start-up phase

3.2.7 Electronic selection of amplitude

12- 25 ©TELSONIC AG4-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

4 Operating and display elements

1 Operation display 8 Positive deviation of the set

04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 13 - 25

14- 25 ©TELSONIC AG4-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

Connection to controller MPS-4 with 25 pole Sub-D 3, or MPS-2/3 with

04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 15 - 25

16- 25 ©TELSONIC AG4-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

1 1. For normal operation

2 2. Set the frequency to

04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 17 - 25

3 3. When the US-TEST

Fig. 6-3, Frequency range

6.1.3 Frequency automatic and regulation of amplitude

18- 25 ©TELSONIC AG4-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

6.2 The Overload Switch Off

5 The overload LED

The percentage load displayed on the LED-bar

04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 19 - 25

6.2.1 Overload with MPS-2

6.2.2 Overload with MPS-4

20- 25 ©TELSONIC AG4-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

6.3 The Load Display

6 The percentage bar

With reduced amplitude the bar display must

6.4 The Output Measurement Interface

04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 21 - 25

22- 25 ©TELSONIC AG4-SG-22-xxxx-3-e.DOC 03.06.2004 LOL

7.2 Generator SG-22-2000-3

7.3 Generator SG-22-3000-3

04-SG-22-xxxx-3-e.DOC 03.06.2004 LOL ©TELSONIC AG 23 - 25

7.4 Generator SG-22-5000-3