盛新超声科技（苏州）有限公司

GW User’s Manual
IQS Document Control Software

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Content

1 Introduction ........................................................................................ 3

2 Product Dimension & Parameters ..................................................... 4

3 Transportation & Installation ............................................................ 5

4 Equipment Debugging ........................................................................ 7

5 Connection .......................................................................................... 21

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1 Introduction
1.1 Read before use
Before using this equipment, please read and familiarize yourself with this manual; the purpose of this
manual is to provide you with clear and efficient operating instructions. The examples listed are intended
to make you understand its basic operations intuitively and concisely.
“Tips”: Prompt important information to facilitate your understanding and operation.
“Attention”: Remind you to pay attention to some safety precautions.
“Warning!”: Safety Reminders to help you to avoid possible hazards-used together with "Attention".

Safety Warning Electric Shock Warning Hearing Protection Crush Warning

1.2 IQS I Overview

iQS-GW- HMI operating system interface, compatible with GW-A/S series software plastic ultrasonic
welding machine, human-machine interface tools can make it more convenient for you to manage and
control the ultrasonic welding process. Applicable frequency range 15KHz, 20KHz category models.

1.3 Key Features

DSP single-chip microcomputer: to handle the ultrasonic welding process
Wide-screen touch screen: easy to program, all welding machine parameters can be set through menu
Concise and human-machine interface: convenient parameter setting and ideal interactive interface
Data storage: record and store the working parameters and welding data
Program editing: welding program editing and storing records
Workpiece identification record: USB barcode scanning & QR code to identify welding record

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2 Product Dimension & Parameters

GW-A/S Plastic Welding Series (Cylinder driven type)

Specifications

MODEL GW-AS1530 GW-SS1530 GW-AS2020 GW-SS2020 GW-AS3510 GW-SS3510

Delay Time Delay Time Delay Time

Trigger mode Delay Time Delay Time Delay Time
/Position / Position / Position
welding welding welding welding welding welding
time/welding time/welding time/welding time/welding time/welding time/welding
Welding mode
energy/ energy/ energy/ energy/ energy/ energy/
Max. Power absolute position Max. Power absolute position Max. Power absolute position
Power(W) ≤3000W ≤3000W ≤2000W ≤2000W ≤1000W ≤1000W
welding welding welding
welding time/welding welding time/welding welding time/welding
Weld quality time/welding energy/ time/welding energy/ time/welding energy/
setting energy/ absolute energy/ absolute energy/ absolute
Max. Power position/Max. Max. Power position/Max. Max. Power position/Max.
Power Power Power
Language 1) Chinese 2) English

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3 Transportation & Installation

This operation manual is specially written for the operators of ultrasonic welding machine. Please be sure
to put this operation manual and equipment together and ensure the readability of the manual. Operating
and using the equipment according to the operating manual can avoid unnecessary operating errors and the
need for maintenance. Due to the improvement and update of production technology, we reserve the right
to modify this manual.

Attention
Please read and understand this operation manual before using the equipment,
so that it can be used as a reference in subsequent operations.

Read this operation manual carefully, especially the safety part, to avoid the
danger caused by wrong operation.

Check
Check if the packaging and equipment are in good condition.
Open the box after signing the receipt to check if the equipment is damaged
(Including the control box, the fuselage, and the operating part)
Tip! If the equipment is damaged, please inform the freight forwarder.

3.1 Reliable transportation aids and materials

It is best to use a forklift of suitable size to transport this equipment. The two fork legs of the forklift need
to maintain a proper distance from the center focus of the jack to transport the equipment.

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3.2 Lifting equipment (For models with hoisting rings)

The lifting ring is used to connect the lifting device. This equipment can only be transported under the
conditions of an ambient temperature of -25°C~+55°C-the equipment can be exposed to the environment
up to 70 °C within 24 hours

3.3 Equipment placement

Be sure to place the device on a flat and stable ground. Install the device in a clean and tidy environment
to extend the service life. The initial setting is set at 20°C.

Installation Specifications
Ambient Temperature 10-45℃
Air Humidity 30-70% max. 95% non-condensing

Placement Requirements Length 1000mm/Width 800mm

Minimum ground load 150Kg

3.4 Electronic Connection

Before powering on the power connection, please make sure that the "nameplate" of the device is
consistent with the received manual!

This equipment needs to be connected to a reliable grounding device and an independent power supply
connection. Do not cut off the power without the normal shutdown of the equipment during the operation,
which may cause damage to the equipment parameters.

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Compressed air source (Cylinder type): the compressed air source entering this equipment should be kept
dry and the previous stage water and gas separated. (Max operation air pressure 0.65Mpa, Min 0.2Mpa)

4 Equipment Debugging
4.1 Preparation
Check if the equipment is placed smoothly
Check the accessories and external auxiliary parts used
Power connection confirmation, power type detection
Reconfirm the air supply connection and air pressure detection
Adjust the input air pressure
Clean the surface of the welding work area

4.2 HMI Interface

Cylinder driven type using AST-070AHS-7’’ display.
The HMI interface after power on is shown as below:

① ② ③ ④

① Function parameter
② Language -Chinese
③ Monitoring data
④ Language ‐ English

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4.3 Function Parameter

“① Function parameter key”: the mechanical parameters of the equipment

(Password:1324)

(Note! The mechanical parameters are the basic parameters of the equipment,
and the corresponding rack assembly settings cannot be modified arbitrarily!!!)

4.4 Calibration and instruction

Click “③ Monitoring data” key: to enter to GW series data monitoring interface:

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4.4.1 State display area

Program number/State display:

Press the button to enter the formula management: to set the formula number & data

Code scanning & Compilation information Display:

USB connection with the scanner, input the product code (bar code or QR-code) information,
display after complication.

State & data display:

Ultrasonic Power (KW)

Ultrasonic Frequency (Khz)

Amplitude (range: 10-100%)

4.4.2 Welding function area

Ultrasonic welding mode

Welding mode: Welding time & Welding energy & Max power (for GW-A series)
Welding time & Welding energy & Absolute position (for GW-S series)

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Welding time: to set the welding time (Sec)

Welding Energy: to set the welding energy (J)

Max power: to set the maximum welding power (Kw)

Absolute position: to set the position where the ultrasound stops (mm)

(Note: Any welding mode will be monitored by ultrasonic protection. When the ultrasonic wave
is overloaded during the welding process, an alarm will be displayed, and the machine will stop.
When this alarm occurs-please check the setting parameters)

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Ultrasonic trigger mode

Trigger mode: Delay time (for GW-A series)

Delay time & Trigger position (for GW-S series)

Delay time: the period before the ultrasound starts & after the horn goes down (Sec)

Trigger position: to set the position where the ultrasound starts (mm)

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Example: Trigger mode: Delay time

Welding mode: Welding time

Machine under “Auto” mode

Press two start buttons to start
Horn going down
Delay time
Welding time
Cooling time
End

Cooling time: the cooling time after the ultrasound stops

4.4.3 Dynamic data area

Real-time data

Current depth (mm)

Current pressure (Kgf)

Descent rate (mm/s)

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4.4.4 Function operation area

Film rolling: to set number of intervals (0-100pcs) & rolling time (0.15-99.99sec)
Output port: (CN7/15+, 16- )
(startup>Automatic Run-Welding completes>Counting>Roll film starts
>Roll film counts>Roll film stops.) *Press the emergency button to stop roll film

(Note: If the interval number is “0”, it means the interval count function is closed & will run the
roll film each time. In manual mode, roll film function is disabled.)

4.4.5 Operation Keyboard

Frequency test: ultrasound stack frequency test button

Sonic test: ultrasound trigger test button

State reset button

Quality Assurance: welding data quality control

Welding counts & reset button: Click “Reset” to clear the count to zero

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Auto/Manu switch button

QA ON/OFF button

QA Panel:

Welding time

Relative position*Invalid

Max power

Welding energy

Peak pressure*Invalid

Absolute position

(Note: QA Management information will be displayed after the normal welding under QA)

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Welding time (set: upper limit time>lower limit time)

QA displays after welding: actual welding time
0(Off): welding time disabled
1(Pass): upper limit time> welding time >lower limit time
2(NG): upper limit time < welding time / lower limit time > welding time

Relative position (set: upper limit depth>lower limit depth) *Invalid

QA displays after welding: actual welding depth
0(Off): welding depth disabled
1(Pass): upper limit depth>relative position >lower limit depth
2(NG): upper limit depth < relative position / lower limit depth > relative position

Max power (set: upper limit power>lower limit power)

QA displays after welding: actual max power
0(Off): welding power disabled
1(Pass): upper limit power> max power >lower limit power
2(NG): upper limit power < max power / lower limit power > max power

Welding energy (set: upper limit energy>lower limit energy)

QA displays after welding: actual welding energy
0(Off): welding energy disabled
1(Pass): upper limit energy > welding energy >lower limit energy
2(NG): upper limit energy < welding energy / lower limit energy > welding energy

Peak pressure (set: upper limit pressure>lower limit pressure) *Invalid

QA displays after welding: actual peak pressure
0(Off): peak pressure disabled
1(Pass): upper limit pressure > peak pressure >lower limit pressure
2(NG): upper limit pressure < peak pressure / lower limit pressure > peak pressure

Absolute position (set: upper limit position>lower limit position)

QA displays after welding: actual welding position (position where welding stops)
0(Off): welding absolute position disabled
1(Pass): upper limit position > absolute position >lower limit position
2(NG): upper limit position < absolute position / lower limit position > absolute position

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4.5 Set initial welding parameters

Main parameter:
Welding air pressure: adjust the operating air pressure of the cylinder
Trigger mode: select ultrasonic trigger mode
Welding mode: select ultrasonic welding mode

Initial data setting

Auto mode, test run
Check welding data, product inspection
Modify welding data
Test run
Check welding data, product inspection
Test run
OK

(Note: The air pressure, amplitude, trigger method, and welding mode will ultimately affect the
welding data and final welding result. The debugging of the machine requires experience and
patience.)

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4.6 Test
iQS GW Welding process(auto)

Start buttons / Connect wire to start

Sound proof shield on

Welding horn down

Pre-vibration on *Invalid

Trigger mode

Welding mode Function Infrared protection

Cooling

QA record
Data record

Return Sound proof shield off

Film rolling

Whole cycle completes

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4.6.1 Set welding parameters per needs

1 Select trigger mode: Delay time/trigger position

2 Select welding mode: Welding time/energy/power/absolute position

3 Set cooling time

4 Set welding amplitude

5 Switch to Auto mode

6 Press start buttons to start welding

(Note: Set the welding parameters per different product’s needs)

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4.7 Formula management & Data Records

Formula management: press this button to enter the formula management

Display: Current formula No. & Current formula mode

Select the formula you want to store:

Press Read Formula to read the formula according to the access number and overwrite the
currently used formula data.
Press Save Formula to store the currently used formula data according to the access number
and overwrite the previous data.

Data monitoring area: to view the parameter data under the formula management, includes
formula number, trigger mode, welding mode, cooling time, amplitude.

(Note: attention must be made to the matching of the welding head when using the formula data,
otherwise it is only for reference.)

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Data record

Data-1 Safety take out the portable dish

Data-2 Clear data
Data-3 Save to USB

(Note: After each welding, the data will be automatically stored in sequence. Document format:
csv)

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5 Connection
5.1 Adapt USB scanner
To support data recording, the USB port can be adapted to the following external barcode scanner:

① Honey well 1900GHD

② Code CR1400-DP
③ Datalogic Gryphon 4430/GD4400
④ Infoscan/fs36-1413w / fs36-1415w

21X-S Control box front panel USB Port:

21X-S Control Box Port:

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21X-S Control box CN4-rack position detection encoder port:

CN4 DB-15M (Mother base)

1 +5V Brown

3 CHB Gray

4 CHA Green

9 GND White

10

11 CHB/ Pink

12 CHA/ Yellow

13 MIL10-S2LE0005PA

14

15

0.005

TYPE: MIL10-S2LE0005PA(2018)
TYPE: PM-B-03-0D-T-10 / PS-B-0300(2019)

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21X-S Control box CN5-rack control connection port:

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21X-S Control Box CN7-external control and accessories connection port:

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21X-S Control box rack lifting motor control connection (SY-17(4P) female base
Body motor connection: Adaptable to SY-17 (4P):

AC 220V
1-> L
1-> N

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