Ultrasonic Sewing Machine
S400
Operation Instructions
Operation Instructions of S400 Ultrasonic Sewing Machine
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Contents I. Application...............................................................................................3
II. Technical parameters ..............................................................................3
III. Installation conditions ...........................................................................4
IV. Structural diagram .................................................................................4
V. Description of pressure operation...........................................................5
VI. Operation of ultrasonic generator .........................................................5
VII. Operation of control center .................................................................9
VIII. Common faults and fault elimination methods................................13
Operation Instructions of S400 Ultrasonic Sewing Machine
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I. Application S400 ultrasonic sewing machine (welding machine) is applicable to flat sewing machine’s sewing of nylon cloth, PVC, PU, TPU, TC cloth, non-woven fabric and other thermoplastic cloth. Ultrasonic working head generates high frequency vibration to make cloth interface fused, so needles and threads are not needed; the interface has no needle holes and it can realize completely seamless effect. According to product demand, especially punctiform plastic welding, e.g. welding of both ends of clothing zippers, it is smokeless, tasteless and odorless, so the machine is a set of environment-friendly production equipment in demand at present. If auxiliary processing devices are installed, the processing quality can be controlled and the production rate can be enhanced.
II. Technical parameters Power supply voltage
AC220V 50Hz-60Hz
Rated power
1000W
Rated current
7A
Ultrasonic frequency
35KHz
Jointing width
1-5mm
Jointing speed
1-10m/min
Working air pressure
3-8kg/cm2
WxLxH
1300x600x1100mm
Net Weight
99kgs
Operation Instructions of S400 Ultrasonic Sewing Machine
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III. Installation conditions 1. Power supply: AC220V 50Hz-60Hz 2
2. Cross section of electric wire: aboveφ2mm 3. Compressed air supply: 8kg/cm2 4. Air leakage switch: 15A
5. Power line must have good earth connection.
IV. Structural diagram
1. Air filter assembly 2. Main power switch 3. Main air leakage switch 4. Ultrasonic run 5.Ultrasonic current display 6.Ultrasonic power switch 7.Ultrasonic alarm display 8. Power indicator light
9. Pressure
controller of press wheel 10 Control center 11. Pressure indicator of press wheel 12. Upper press wheel 13. Ultrasonic converter 14. Left and right pedals 15. Upper cylinder column Operation Instructions of S400 Ultrasonic Sewing Machine
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V. Description of pressure operation 1. Adjustment of air pressure: turn the pressure adjusting handle and make pressure gauge indicate to 0.4-0.6Mpa. 2. Pressure adjustment of upper press wheel: operate the left pedal and adjust the pressure of press wheel 9; observe the pressure indicator 11 of press wheel and the pressure indication shall be 0.5-2kg/cm2; if the fabric is thinner, the pressure shall be 0.5kg/cm2; if the fabric is thick, the pressure shall be 2kg/cm2.
VI. Operation of ultrasonic generator 1. Working environment Indoor use, humidity: ≤85%RH; ambient temperature: 0℃～40℃ Machine size: 252*195*424 (including the parts outside chassis) A sufficient space (not less than 150mm) shall be available around the machine to dissipate heat and insert and pull out the aviation plug. The bold-face part is very important, so it must be complied with, or else it may easily damage the machine or cause an accident. When there is any abnormal noise or electric meter indication rises abnormally, please shut off power supply immediately and then find the fault reason. Aviation Plug
Alarm
Fuse Current
Power Supply Fan
Ultrasonic Run
Front Panel Diagram
Operation Instructions of S400 Ultrasonic Sewing Machine
Tuning Screw
220V
Back Panel Diagram
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2. Unpacking After receiving the goods, unpack and check control panel and machine surfaces whether there is damage, and check the fittings of the machine whether there is looseness that may be caused in transportation process. If there is any damage, the transportation company shall be notified immediately. The packing material shall be kept well to maintain its original state in order to facilitate investigation. 3. Power supply Warning: before power supply is connected, make sure the switch is OFF (0). A power supply connected to the ground shall be used as vibration source to prevent electric shock. 4. Line connection before use of power supply Before using the power supply, the aviation plug at the back of chassis shall be connected. The electrode plate connected with the shell of vibrator is grounding electrode and the others are high voltage electrodes. The connection principle of 4-core aviation plug on the chassis is shown as follows: 4 is connected with high voltage electrode of vibrator and 1 is connected with grounding electrode of vibrator. 1 and 2 of 2-core aviation plug are connected with external run switch. The transducer and power supply have been debugged to normal state in a professional way for matching with each other, so the transducer can not be changed at will. + Transducer
1
4
2
3
Operation Instructions of S400 Ultrasonic Sewing Machine
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External Run Switch 1
2
The driving power supply has certain frequency tracking function, with high reliability and low electric power consumption, but the ultrasonic processor must be in resonance condition. So it must be tuned before starting the machine for the first time. 5. Tuning When the machine works, the fan must be checked to make sure it runs. Before starting the machine, make sure external run switch and ultrasonic run switch are in pop-up state (the two switches are connected in parallel). Before working for the first time or after installing new transducer, amplitude transformer and tool head, the machine shall be tuned, i.e. make the whole ultrasonic system in optimum state, of which specific representation is that current indication is minimum when the vibration is strongest (it varies when adjusting tuning screw). There is a frequency modulation screw at the back of chassis and the screw is composed of two parts, namely long and thin tuning screw and butterfly fixing screw cap. After completion of tuning, the butterfly cap shall be tightened. ①The tool head shall be in no-load state (the vibrator is in the air and not in the solution). ⑥ Make sure external run switch and ultrasonic run switch are in pop-up state before starting the machine. Turn on power switch and ultrasonic run switch, here the end surface of the vibrator feels vibrating. ③ After the ultrasonic run switch is turned on, if the alarm indicator Operation Instructions of S400 Ultrasonic Sewing Machine
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lamp is on, please adjust the frequency modulation knob back and forth and turn on the ultrasonic run switch repeatedly; find approximate position of tuning screw by coarse adjustment till no alarm is given. ④ If the requirement of coarse adjustment in step 2 is met, please adjust the frequency modulation knob back and forth till the indication of current indicator is minimum, and the end surface of vibrator has the strongest vibration when lightly touching it by hand. ⑤ If tuning screw is adjusted to the innermost position from outermost position and alarm indicator lamp is on all the time, there are three cases as follows: tuning exceeds setting value, current indication exceeds setting value or the temperature of high power tube in the chassis is excessively high, or shut the machine down and check each copper sheet tin soldering point of the vibrator whether there is cold solder joint, and check mechanical part whether there is looseness or damage. Each section of the vibrator can be dismantled successively to test and judge the faulty section by exclusive method. Or else please contact with technical service department of our company for help. 6. Power control Shown as follows, changing the position of the plug pin on ZJS-500-PCB-TL circuit board in the chassis can change the output power of transducer, but the output power of transducer can not be excessively high, or else the vibrating system may be damaged. Capacitor Capacitor
Capacitor
Low Middle High
Operation Instructions of S400 Ultrasonic Sewing Machine
Transformer
Transformer
Power control
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7. Cooling The temperature of transducer can not exceed 80℃, or else the transducer must be equipped with a force fan for cooling; moreover, close attention shall be paid to the heat quantity transferred through tool head and amplitude transformer. 8. Main parts Ultrasonic vibration source (driving power supply): convert 50-60Hz power supply into high-power and high-frequency (15kHz-100kHz) power supply and supply to transducer. Transducer (controller, transducer): convert high frequency electric energy into mechanical vibration energy. Amplitude transformer: connect and fix the transducer and tool head and magnify the amplitude of transducer and transmit it to tool head. Tool head (lead-in rod): transfer mechanical energy and pressure to working substance, and magnify the amplitude. Connecting bolt: connect the above parts tightly.
VII. Operation of control center 1. After starting, the system will display the information about the manufacturer, and 4 seconds later, will display the language selection page, shown as follows:
Operation Instructions of S400 Ultrasonic Sewing Machine
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Chinese
2. In the language selection page, press “English” button to enter Chinese homepage.
Pls enter 2222 ，adjust the speed(the best speed for you:1.5m/min)
3. Press Set button to enter password entry page. Please enter the password
Cancel
Homepage
OK
Press password display frame, and input keyboard will pop up; after entering different passwords, press OK button to enter different pages. The password list is shown as follows: Changeable
password
set in factory 2222 4. User parameter
Operation Instructions of S400 Ultrasonic Sewing Machine
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Operation Instructions of S400 Ultrasonic Sewing Machine
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Press “←” or “→” buttons to turn pages up or down. “1、Forward speed: Press the key to set the forward speed of the roller; 2、Backward speed: Press the key to set the backward running speed of the roller; 3、Micro-backward speed”and“7、Micro-backward delay”: Press these keys to set the length of micr-backword. 4、Fan in delay:” The key is used to set the time that the hot air gun transversly arrives to the roller position;(Note: The word “Fun” should be “Gun”) 5、Fan out delay”: The key is used to set the time that the hot air gun transversly leaves from the roller position; (Note: The word “Fun” should be “Gun”) 7 、 User password”: The user can set the user Paramete password according his need.
Operation Instructions of S400 Ultrasonic Sewing Machine
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VIII. Common faults and fault elimination methods
Phenomena
Faults
Fault elimination methods
① Ultrasonic power switch is ① Replace the switch; No ultrasonic wave
② Close the ultrasonic
damaged;
② Ultrasonic power switch is power switch; ③
not closed; ③
Transducer
wire
Reconnect
the
is transducer wire or tighten
disconnected;
it;
④ Ultrasonic generator is ④ Repair the ultrasonic damaged. ①
Air
generator. supply
is
not ① Connect air supply; ② Replace the solenoid
connected; ②
Solenoid
valve
is valve; ③ Check mechanical part;
Upper press wheel has no damaged; action
③
Mechanical
part
is ④ Regulate the pressure
blocked;
or replace the pressure
④ Pressure regulating valve regulating valve; fails to regulate the pressure ⑤ Replace the cylinder. or is damaged. ⑤ Cylinder is damaged. ① Chain jackscrew is loose; ② Wheels do not rotate
Synchronous
belt
①
Tighten
the
chain
is jackscrew;
broken or loose;
② Replace or tighten the
③ Main board has no output;
synchronous belt;
④ Driver is damaged.
③ Replace main board; ④ Replace the driver.
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