Models 2050 2055 2096 20khz Welding Presses

Model 2050
Model 2055
Model 2096
I N S T R U C T I O N M A N U A L
WARNING
SAFETY PRECAUTIONS
READ BEFORE INSTALLING OR USING THE EQUIPMENT
Our systems have been designed to assure maximum operator safety.
However, no design can completely protect against improper usage. For
maximum safety and equipment protection, observe the following warnings at
all times and read all applicable instruction manuals carefully before you
attempt to operate any equipment.
– The equipment has safety devices that require both hands to be on the
palm buttons until the horn contacts the work piece. Do not defeat or
modify these safety devices.
– Do not use with foot switch or other means of actuation unless alternate
means of pinch-point protection is provided.
– High voltage is present in the equipment. Disconnect plug before removing

cover or servicing.
– Make sure equipment is properly grounded with a 3-prong plug. Before

plugging in equipment, test outlet for proper earth grounding.
– High voltage potential may be present in the converter as a result of

temperature changes. Do not touch the converter contact unless you first
short both pins or the button to the converter case with an insulated tool.
– Never squeeze or grab a vibrating horn.
– Do not modify horn configurations.
– 20 kHz, 30 kHz and 40 kHz ultrasonic welders operate above normal

audibility for most people. Ear protection is recommended.
– Do not affix any device to any portion of the horn.
Sonics & Materials, Inc.

Corporate Headquarters
53 Church Hill Road • Newtown, CT 06470 USA

203.270.4600 • 800.745.1105 • 203.270.4610 fax
www.sonics.com • [email protected]
Information contained in this manual is subject to change without notice. Sonics & Materials, Inc. is not responsible for any typographic errors.
© Sonics & Materials, Inc. 2012 Printed in U.S.A. Rev 9-12
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INSTRUCTION MANUAL • 2050 / 2055 / 2096 1

TABLE OF CONTENTS
IMPORTANT SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Manual Change Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
OVERVIEW OF ULTRASONIC PLASTICS ASSEMBLY . . . . . . . . . . . . . .5
What is Ultrasonics? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Principal of Ultrasonic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Ultrasonic Assembly Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
GLOSSARY OF ULTRASONIC TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . .7
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Setting Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Control Panel (2050 Press) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Controls (2055 Press) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Controls (Model 2096) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
INITIAL EQUIPMENT SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Assembling and Mounting Converter, Booster and Horn . . . . . . .15
Horn and Fixture Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Positive Stop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
FINE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Booster Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Re-Establishing Proper Booster/Horn Interfaces . . . . . . . . . . . . .22
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Repairs / Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Draining Air Filter Bowl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Pressure Switch Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Upper Limit Switch (Model 2096) . . . . . . . . . . . . . . . . . . . . . . . . .28
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Limitation of Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
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IMPORTANT SERVICE LITERATURE
The system supplied with this instruction manual is constructed of the finest
material and the workmanship meets the highest manufacturing standards. It
has been thoroughly tested and inspected before leaving the factory and
when used in accordance with the procedures outlined in this manual, will
provide you with many years of safe and dependable service.
NOTE: Please read
carefully before operating MANUAL CHANGE INFORMATION
the equipment, then We continually strive to be at the forefront of the latest electronic
forward to your service developments by adding circuit and component improvements to our
department. equipment as soon as they are developed and tested.
Sometimes, due to printing and shipping requirements, we cannot incorporate

these changes immediately into printed manuals. Hence, your manual may
contain new change information. Change information, if any, is located in the
Appendix.
We reserve the right to make any changes in the design or construction of our
equipment at any time, without incurring any obligation to make any change
whatsoever in units previously delivered.
The technical data and schematics in the manual are for informational
purposes only and may not reflect the current configuration being shipped
from our factory. Upon formal request, complete and up-to-date information
can be provided from the factory free of charge.
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UNPACKING AND INSPECTION
Before unpacking the equipment, check the shipping carton for any visible
damage. If you see any, be sure to follow the procedures described below
under “Visible Loss or Damage.” Otherwise, proceed to remove the
equipment from the carton. Before disposing of any packing material, check
it carefully for small parts. Then perform a visual inspection of the equipment
to detect any evidence of damage which might have occurred during
shipment. Check the following:
NOTE: We recommend
keeping all carton(s) and
packing material in case it 1. all components against the enclosed packing list,
2. all module plug-in units,

might be necessary to
3. all wire plug-in connections.

move the equipment, or to
ship it for repair.
The equipment was carefully packed and thoroughly inspected before leaving
our factory. All units are tested and checked for problems prior to shipping. It
is asked that when a problem does occur that all parts and components be
inspected for damage (especially when the unit is not in working order when
received). Responsibility for safe delivery was assumed by the carrier upon
acceptance of the shipment. Claims for loss of damage sustained in transit
must therefore be made upon the carrier, as follows:
VISIBLE LOSS OR DAMAGE

Any external evidence of loss or damage must be noted on the freight bill or
express receipt, and signed by the carrierʼs agent. Failure to adequately
describe such external evidence of loss or damage may result in the carrierʼs
refusal to honor a damage claim. The form required to file such a claim will
be supplied by the carrier.
CONCEALED LOSS OR DAMAGE

Concealed loss or damage means loss or damage which does not become
apparent until the merchandise has been unpacked. The contents might have
been damaged in transit due to rough handling even though the container
may not show external damage. When the damage is discovered upon
unpacking, make a written request for inspection by the carrierʼs agent within
48 hours of the delivery date. Then file a claim with the carrier since such
damage is the carrierʼs responsibility. The form required to file such a claim
will be supplied by the carrier. Do not destroy packing materials, or move
material from one location to another before the carrier makes their
inspection.
If the system or any unit is damaged, notify “Sonics.” “Sonics” will arrange for
repair or replacement of damaged equipment without waiting for the claim
against the carrier to be settled, provided a new purchase order is issued to
cover the repair or replacement costs. Should any damage, shortage or
discrepancy exist, please notify us immediately.
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INTRODUCTION
Models 2050, 2055 and 2096 are 20 kHz precision pneumatic actuators used
for ultrasonic plastics assembly. The 2050 and 2055 are benchtop presses,
and the 2096 can be mounted on a bridge or rigid structural member for use
with automated systems. All three models can be supplied with the following
GX-Series power supplies:
■ GXT . . . . . . .Weld by digital time
■ GXE . . . . . .Weld by digital time and/or constant energy
■ GXL . . . . . . .Weld by digital time, constant energy and/or distance*
*Available with Models 2050 and 2096 only.
All models are also compatible with E and F Series power supplies.
OVERVIEW OF ULTRASONIC PLASTICS

ASSEMBLY
WHAT IS ULTRASONICS?
Ultrasonics refers to vibrational waves with a frequency above the human
audible range which is usually above 18,000 cycles per second (Hz).
PRINCIPLE OF ULTRASONIC ASSEMBLY

The basic principle of ultrasonic assembly involves conversion of high
frequency electrical energy to high frequency mechanical energy in the form
of reciprocating vertical motion which, when applied to a thermoplastic,
generates frictional heat at the plastic/plastic or plastic/metal interface. In
ultrasonic welding, this frictional heat melts the plastic, allowing the two
surfaces to fuse together; in ultrasonic staking or insertion, the controlled flow
of molten plastic is used to capture or lock another material in place (staking)
or encapsulate a metal insert (insertion).
ULTRASONIC ASSEMBLY SYSTEMS

“Sonics” ultrasonic assembly systems are generally composed of the fol-
lowing major elements: a power supply, converter, booster, horn, pneumatic
press/actuator and holding fixture, as detailed in the diagram on the next
page. A review of this diagram will help you understand the basic elements
involved in the assembly process and their relation to each other.
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“SONICS” ULTRASONIC ASSEMBLY SYSTEMS
50/60 Hz
Electrical power
Generates ultrasonic electrical energy

Power Supply/Generator
(15/20/40 kHz)
Ultrasonic
electrical energy
Actuator/Press
Provides compressive force

and mounting for Converter,
Booster, Horn assembly
Converter
(Stack) Transforms ultrasonic electrical energy

to ultrasonic mechanical vibrations
Ultrasonic Vibrations
Booster
Increases or decreases amplitude
Horn
Contacts and transfers vibrational
energy to plastic part
Holding Fixture
Aligns and supports part
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GLOSSARY OF ULTRASONIC TERMS
POWER SUPPLY/GENERATOR – The solid state power supply converts

standard 50/60 Hz electrical power to 15,000 Hz, 20,000 Hz, 30,000 Hz or
40,000 Hz (15/20/30/40 kHz) electrical energy (depending on frequency of
model purchased).
ACTUATOR/PRESS – The pneumatic actuator provides compressive force

and mounting for the converter, booster, and horn assembly. The benchtop
press consists of a base assembly, column and actuator (head).
CONVERTER – The converter changes the high frequency electrical energy

supplied by the power supply to high frequency mechanical vibrations.
BOOSTER – Successful ultrasonic welding often depends on having the right

amplitude at the horn face. Often it is not possible to design a horn which has
both the necessary shape and required gain (ratios of input amplitude to
output amplitude). Therefore, a booster is placed between the converter and
the horn to either increase or decrease the amplitude of the horn. In addition
to changing/maintaining the amplitude, the booster provides support and
alignment in the welding system. (See page 19 for booster selection.)
HORN – The horn is a tuned component of the system which comes in

contact with the parts to be assembled. The horn 1) transfers the ultrasonic
vibrations produced from the converter to the parts being welded, and 2)
applies necessary force to the assembly while the material resolidifies.
HOLDING FIXTURE – The holding fixture or nest assures proper alignment

and support of the parts being assembled.
MODEL 2050 MODEL 2055 MODEL 2096
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INSTALLATION
ELECTRICAL POWER
The press is powered by the power supply. Consult your power supply
instruction manual to determine power specifications.
AIR SUPPLY
The press requires a source of dry, filtered (5 micron), oil-free, compressed
air capable of supplying a constant line pressure of 85 psig. (586 kPa / 6 bar)
at a minimum capacity of 2 CFM.
Do not connect the press SETTING UP

to an air source supplied The press should be installed in a clear, uncluttered location that is free from
by a compressor lubricated excessive dirt, dust, corrosive fumes, and temperature and humidity ex-
with synthetic oils or oils tremes. The selected installation site should be near the electrical power and
containing phosphate air supply sources and away from any equipment that generates abnormally
esters or chlorinated hydro- high electrical transients. Observe the following additional instructions when
carbons. This type of installing the press:
a. The press should be placed on a sturdy, level table or bench capable of

lubricant may cause the air
supporting a minimum of 500 pounds (227 kg).

filter to malfunction, and
b. Allow at least 6 inches (152.4mm) at the rear of the press for cable
the plastic bowl to rupture.
connections.
KEY COMPONENTS AIR CONNECTION

(in rear of Press)
PRESSURE SPEED CONTROL KNOBS

NOTE: If the power supply GAUGE
is to be run continuously, REGULATOR
air cooling of the converter HEAD DOWN SWITCH
and horn is required. Use
clean, dry compressed air CONVERTER
filtered down to 5 microns HOUSING DOOR
(supplied to converter CONVERTER HOUSING
with converter, booster &
fitting).
horn (stack) assembly
PALM BUTTONS
EMERGENCY STOP
BUTTON
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CONNECTIONS
When making the initial connections, make sure all electrical power is
disconnected.
1. Connect the air supply source to the press air connection located at the
rear of the press head, using a hose having a minimum inside diameter of
1/8 inch (3 mm).
NOTE: Do not strain or
kink the cables. When
going around corners, A 1/4 NPT threaded female elbow connector is provided to attach your air
allow as wide a bend as line service. Connectors are typically an instant (push-to-connect) plastic
possible. Do not run the tube fitting or a male sleeve lock type quick connect fitting.
cables parallel to any
power line within a distance MODEL 2050
of less than 1 foot
(304.8mm).
CONNECTOR
MODEL 2055
(AND 2096)
AIR
CONNECTOR
(IN REAR)
2. Connect the RF and base (actuating) cables of the press to the power
supply. (Consult your power supply instruction manual for details.)
3. Check with your electrician if you have any wiring questions.
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OPTIONS
A Linear Encoder is available as an option on Models 2050 and 2096. The
Linear Encoder allows distance-controlled welding in incremental and
absolute modes.
The Linear Encoder is supplied with a 9-pin male connector that connects to
a matching 9-pin female connector on the FDL power supply (factory
installed).
LINEAR ENCODER
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OPERATING PROCEDURES
CONTROL PANEL (2050 PRESS)

Located above the converter housing on the 2050 press are the following
controls:
1. SPEED CONTROL knobs allow regulation of the velocity at which the

horn descends and returns (stroke speed).
These controls are factory adjusted for average operating conditions.

When minor adjustments are necessary, be sure to adjust in small
degrees.
Excessive velocity may be Pull the red ring out to release and push in to lock setting.
The left knob, labeled "UP," controls the return speed - turn the knob
unnecessary and harmful
clockwise to slow the speed, counterclockwise to increase speed.

to the system.
The right knob, labeled "DOWN," controls the descending speed – turn the
knob clockwise to slow the speed, counterclockwise to increase speed.
2. PRESSURE REGULATOR with corresponding gauge that allows

regulation of the (air) pressure with which the horn contacts the part(s). Pull
the knob to make adjustments, and then push in to lock setting when
desired pressure is displayed on the gauge. Once pulled, turning the knob
clockwise increases pressure, and turning it counterclockwise decreases
pressure.
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3. HEAD DOWN switch. Simultaneously depressing the Head Down switch
and the left Palm button allows the head to move down under gauge
pressure. Release the Head Down switch and the left Palm button and the
head will remain in the down position. To retract the head, press the right
Palm button. The Head Down switch is for set-up purposes only – these
actions do not cause ultrasonics to be activated.
CONTROLS (2055 PRESS)

Located at the top rear of the 2055 press are the following controls:
1. PRESSURE REGULATOR with corresponding gauge that allows

regulation of the (air) pressure with which the horn contacts the part(s). Pull
the knob to make adjustments, and then push in to lock setting when desired
pressure is displayed on the gauge. Once pulled, turning the knob clockwise
increases pressure, and turning it counterclockwise decreases pressure.
PRESSURE
REGULATOR
PRESSURE
GAUGE
AIR FILTER
BOWL
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2. SPEED CONTROLS
The velocity at which the horn descends and returns can be adjusted via
the two small threaded screws located at the top of the press as shown
below. These controls are factory adjusted for average operating con-
ditions. If a minor adjustment is necessary, adjust in small degrees.
Turn the Descend Speed Control screw clockwise to slow the descend
speed, counterclockwise to increase the speed. Turn the Return Speed
Excessive velocity may be
Control screw clockwise to slow the return speed, counterclockwise to

unnecessary and harmful
increase speed.
to the system.
DESCEND
SPEED
CONTROL
RETURN
SPEED
CONTROL
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CONTROLS (2096 ACTUATOR)
The velocity at which the horn descends and returns can be adjusted via the
speed controls. These controls are factory adjusted for average operating
conditions and should not require further adjustment. However, if a minor
adjustment is necessary, adjust in small degrees. Turn clockwise to slow the
extend speed, and counterclockwise to increase the return speed.
The speed controls are 2 small threaded screws located at the top of the
actuator and behind the air cylinder as shown below.
The top screw controls the extend speed - turn it clockwise to slow the speed,
counterclockwise to increase the speed. The bottom screw controls the return
speed - turn it clockwise to slow the speed, counterclockwise to increase
speed.
EXTEND SPEED
CONTROL
RETURN SPEED
CONTROL
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14 INSTRUCTION MANUAL • 2050 / 2055 / 2096

INITIAL EQUIPMENT SETUP
ASSEMBLING AND MOUNTING CONVERTER, BOOSTER,

AND HORN
If the converter, booster, and horn are not already assembled, follow these
instructions:
1. Clean the mating surfaces of the converter and booster, as well as the
Never tighten the horn to threaded stud and hole. Check that the stud is tight (see recommended
the booster using the torque requirements on page 15).
2. Hand assemble the converter and booster together. Using spanner

housing door as the upper
wrenches as shown below, tighten until snug. Then, using a torque wrench,
wrench as this may cause
tighten to 25-35 foot-lbs. (34-47 newton-meters).

damage to the booster
and/or converter.
Do not force or overtighten.
CONVERTER/BOOSTER
3. Clean the mating surfaces of the booster and horn, as well as the threaded
stud and hole. Check that the stud is tight. (See recommended torque
requirements on next page.)
4. Hand assemble the horn to the booster. Using a spanner and an open-
ended wrench as shown below, tighten securely. Then, using a torque
wrench, tighten to 25-35 foot-lbs. (34-47 newton-meters).
Do not overtighten.
CONVERTER/BOOSTER/HORN
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5. Using the 3/16" (4.7 mm) T-handle wrench provided, loosen (turn
counterclockwise) the two cap screws on the hinged converter housing
and open the door.
6. Place the converter / booster / horn assembly (stack) in the housing with
the horn facing down. Fit the male brass button on the top of the converter
NOTE: When performing into the female brass fitting in the bottom of the contact block assembly
housing, and gently push the assembly up and in so that the booster
mounting ring rests on the lower support ridge.
any of the operations
described on this page and
pages 16-17, DO NOT turn
on the power supply. CONVERTER / BOOSTER /
HORN ASSEMBLY
BRASS BUTTON
BOOSTER RING
Never tighten the horn to

the booster using the
7. Close the converter housing door and tighten (turn clockwise) the two
housing door as the upper
socket head cap screws until they are snug. Do not tighten the horn to the
wrench as this may cause
booster using the door as a clamp. Hand-forcing the horn on and off in this
damage to the booster
manner can twist wires in the converter and cause a failure. If the horn is
and/or converter.
not correctly oriented to the part, re-position the stack assembly by

loosening the converter housing cover and rotating the stack.
RECOMMENDED TORQUE REQUIREMENTS

Component Foot-Lbs. Newton-Meters
NOTE: If you do not close Converter / Booster 25 - 35 34-47
the housing door once the Booster / Horn 25 - 35 34-47
Stud 45 61
assembly is in place, the
Tips 25 - 35 34-47
assembly can fall out.
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

HORN AND FIXTURE ALIGNMENT (MODELS 2050 & 2055)
For maximum productivity, the clearance between the horn and the part
should be at a minimum. However, adequate clearance should be provided to
enable easy loading and unloading of the part from the holding fixture. The
maximum stroke distance is 4" (101.6 mm). Ensure that the horn does not
contact the part when the head is close to the limit of its down travel distance.
Otherwise, the horn may not have sufficient distance to travel downwards to
Support the head before
achieve a full depth of weld. Set welding height as follows:

releasing the column
clamps so that it cannot
crash down or fly up. First, position the holding fixture loosely on the machine base using 3/8-16
Ignoring this warning might screws. Then, place the part to be welded in the fixture.
1. Prepare to loosen the column clamps, but be sure to hold onto the head
result in injury and/or
assembly firmly as it can move rapidly up or down with heavy tooling once
damage to the equipment
the clamps are released. While holding the head assembly, loosen the two
and part being welded.
column clamps (counterclockwise) and move the head up or down as

required. Then tighten the column clamps.
2. Using the PRESSURE REGULATOR (turn counterclockwise) and

corresponding gauge, set the air pressure to zero.
3. Loosen the column clamps once again and manually lower the head until
the horn contacts the part. Tighten the clamps.
4. Loosen the cap screws on the converter housing door and gently rotate the
head and horn as required to ensure proper horn-to-part alignment.
PRESSURE GAUGE
PRESSURE REGULATOR
HEAD DOWN SWITCH
COLUMN
CLAMPS
BASE PLATE
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

5. Lock the two column clamps, tighten the converter housing door screws,
and then tighten the fixture on the base plate.
6. Check for proper mating of fixture, parts, and horn. If the horn and part are
not in parallel contact, shim the fixture or adjust leveling screws as
required.
7. Set the PRESSURE regulator to a reading of 20 psig (140 kPa/1.4 bar) on

the pressure gauge. (Turn the PRESSURE knob clockwise.)
8. To check that the horn and parts are properly aligned, the horn needs to be
lowered. Depress the Head Down switch and the left Palm button to lower
the horn (as described on page 12). If the horn and parts are not sufficiently
aligned, then repeat steps 4 through 8. However, if you are working with
small, delicate parts, then fine adjustments can be made using the positive
NOTE: For maximum stop adjustment knob as explained below.
safety and productivity, HORN AND FIXTURE ALIGNMENT (MODEL 2096)
The operation of the 2096 actuator is controlled by the automated system.
adjust the clearance
Rotate the stack assembly as required to ensure proper horn-to-part

between the horn and the
alignment. Check for proper mating of the fixture, parts and horn. If the horn
part to a minimum that will
and part are not in parallel contact, shim the fixture or adjust leveling screws
still allow ease of loading
as required.
and unloading.
To check that the horn and parts are properly aligned, the horn needs to be
lowered. If necessary, shim the fixture or adjust the leveling screw again. Fine
adjustments can be made using the positive stop adjustment knob as
explained on the next page.
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

POSITIVE STOP ADJUSTMENT
The positive stop is set to limit the downward travel of the horn to
approximately 75%. Readjustments may be required. Coarse adjustment of
the clearance between the face of the horn and part should be made using
the elevation control. Fine adjustment should be made using the positive stop.
MODELS
2050 & 2055
KNURLED
THUMBSCREW
POSITIVE
STOP
ADJUSTMENT
KNOB
The positive stop adjustment knob is located offset from the converter
housing. Turning the knob clockwise will decrease downward travel distance.
Turning the knob counterclockwise will increase the downward travel dis-
tance. Rotate the knurled thumbscrew to lock and unlock the positive stop.
A different positive stop is available for oversize horns. Contact factory for
details.
MODEL 2096
POSITIVE
STOP
ADJUSTMENT
KNOB
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

OPERATION
ACTUATION
MODELS 2050 & 2055
Each 2050 and 2055 press is equipped with two maintained anti-repeat (non-
tie-down) palm buttons, one located on the left and one on the right side of
the base of the press. Both palm buttons must be pressed simultaneously to
activate the press to cycle the welder. To operate the press, follow these
simple steps:
The equipment has safety
devices that require both
1. Depress both black palm buttons simultaneously.

hands to be on the palm
2. Once the horn comes in contact with the part, the pressure switch closes
buttons until the horn
and the ultrasonics are activated, release the palm buttons. If you release
contacts the workpiece. Do
the buttons before contact is made, the head will immediately return to its
not defeat or modify
“home” position.
these safety devices.
MODEL 2096
The operation of the 2096 actuator is controlled by the automated system. A

four-wire actuation cable is provided which ties into the output side of a PLC,
or other system-controlling device. Momentary two-wire closure from a dry
source will initiate the welderʼs cycle. For more information, refer to the power
supply manual and the included wiring diagrams.
NOTE: Power supply EMERGENCY STOP

cannot be shut off once the MODELS 2050 & 2055
To abort the 2050 or 2055 press during welding, simply press the red
weld cycle has started.
EMERGENCY STOP button located at the front center of the press base.
Termination of cycle can
Once the EMERGENCY STOP button has been depressed, the head will
only be achieved by using
retract and return to its “home” position. Simply rotate the EMERGENCY
the EMERGENCY STOP
STOP button clockwise 1/4 turn to release the press for further operation.
button.
MODEL 2096
For the 2096 actuator, a four-wire actuation cable contains two normally
closed wires which control the emergency stop function. For more
information, refer to the power supply manual and the included wiring
diagrams.
Do not use with a

footswitch unless alternate
means of pinch-point
protection is provided.
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

FINE ADJUSTMENTS
BOOSTER SELECTION
The first step in optimizing welding conditions is to select a booster which will
provide the necessary amplitude. For parts one inch (25.4mm) in diameter or
greater, start with a moderately high amplitude booster such as a gold. For
smaller parts, start with a green booster. Determine optimum amplitude by
welding a few parts, and repeat the procedure with boosters giving higher or
lower amplitude. If there appears to be little or no difference, use the booster
NOTE: Consult the
giving the highest amplitude.

Applications Manual or call
our Applications Lab for
proper booster selection. Seven standard boosters, color coded or engraved for ease of identification,
are available either to increase or decrease the amplitude.
BOOSTER
O-Ring Mount Rigid Mount
(standard) (optional)
Color Part No. Part No. Gain Amplitude Effect
Black BHN15TBK BHNR15BK 2.50 Increase

High gain boosters, such Silver BHN15TSI BHNR15SI 2.00 Increase
Gold BHN15GD BHNR15GD 1.50 Increase

as silver and black in
Brown BHN15BR BHNR15BR 1.25 Increase

combination with high gain
horns can result in the horn
Green BHN15GR BHNR15GR 0 No Change

cracking or failing.
Purple BHN15PU BHNR15PU 0.75 Decrease
Blue BHN15BU BHNR15BU 0.50 Decrease
PRESSURE
During the welding process, sufficient pressure should be applied to the part
so that the mating surfaces contact each other. If the pressure is too low, the
process will run inefficiently causing unnecessarily long weld time cycles,
marking of the parts or poor welding. If the pressure is too high, the horn may
stop vibrating, the part(s) might fracture, or the power supply might overload.
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

RE-ESTABLISHING PROPER BOOSTER / HORN
INTERFACES
To re-establish proper interfaces, follow these instructions:
1. Using open-ended wrenches, separate the booster from the horn. Clean
each item and then examine interfaces for irregularities (scoring).
2. If irregularities are present, remove the stud.

NOTE: Contact between
3. Tape a sheet of 400 grit emery cloth to a smooth, flat surface. (Do not use
the booster and horn
coarser than 400 grit.)

should be parallel. When
encountering symptoms
4. Grasp the lower portion of the booster or horn and move it across the
such as loud noises or
emery cloth. To ensure proper lapping, a) hold the part straight, b) apply
tuning difficulties, examine
light downward pressure, and c) move in one direction only in a figure 8

the booster / horn
pattern.
interfaces for parallelism,
Repeat the figure 8 pattern once more.

corrosion, galling or foreign
deposits. Also check the
integrity and tightness of
the stud.
DO NOT use anything

coarser than 400 grit
5. Then, rotate the booster or horn 1/3 of a turn in a clockwise direction and
emery cloth.
then repeat step 4.
6. Repeat step 5.
7. Using wire brush, clean stud, then replace securely. Tighten new stud to
the recommended torque specifications on page 15.
Machining of booster / horn

may alter the ability to tune
the component to the
system. System inoperation
may occur.
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MAINTENANCE
REPAIRS / SERVICE
If problems are encountered, contact our Service Department as follows:
Phone: 1-800-745-1105 • 1-203-270-4600 ext. 343 or 366
Fax: 1-203-270-4610
E-Mail: [email protected]
NOTE: If packing unit for
It is suggested that a system in need of repair be sent back to the factory, with
return shipment, DO NOT
a written description pertaining to the nature of the problem.

use styrofoam “peanuts.”
Always contact the factory for return authorization before shipping any
instrument. Include date of purchase, model number, and serial number. For
units not covered by the warranty, a purchase order should be forwarded to
avoid unnecessary delay. Care should be exercised to provide adequate
packing to insure against possible damage in shipment. The system must be
sent with all transportation charges prepaid and return method of shipment
indicated.
DRAINING THE AIR FILTER BOWL

Periodically check the Air Filter Bowl for any moisture and/or condensation,
and drain as necessary.
AIR FILTER
BOWL
To drain, simply unscrew the knurled brass fitting at the bottom of the bowl.
Drain any collected moisture, and then replace the fitting.
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COVER REMOVAL
MODEL 2050 COVER REMOVAL

To remove the side panel cover:
a. Maintain air pressure and unplug the power supply from the electrical
Always disconnect the source.
b. Loosen and remove the 2 Phillips pan head screws on the back of
power supply from the
the cover.
electrical source before
c. Loosen and remove the 2 socket head cap screws at the bottom of
removing covers.
the cover.
d. Loosen column clamps.
e. Raise head as shown below to bottom of column cap.
PAN HEAD
SCREWS
COLUMN
CAP
CAP SCREWS
Do not operate press f. Slide the cover back and then lift it up and off.
without covers in place.
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To remove the pinch point cover:
a. Loosen and remove the coverʼs 4 screws - 2 on each side of the cover.
PINCH POINT
COVER
SCREWS
b. Pull the cover to the front and then pull it down and off as shown below.
MODEL 2055 COVER REMOVAL

To remove the side panel cover:
a. Maintain air pressure and unplug the power supply from the electrical
source.
b. Loosen and remove the 4 Phillips pan head screws - 2 on the top of the
Always disconnect the
cover and 2 on the bottom. (See photo on the next page.)

power supply from the
electrical source before
removing covers.
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PAN HEAD
SCREWS
Do not operate press
PRESSURE SWITCH ADJUSTMENT

For systems mounted in the normal vertical position with downward travel, no
adjustment should be necessary. The minimum trigger pressure is factory set
NOTE: Pressure switch is at 4-7 psig.
However, if the minimum trigger pressure requires recalibration or re-

factory set and should not
adjustment, the pressure switch can be accessed and adjusted.

be adjusted unless
FOR MODELS 2050 & 2055: To access the pressure switch, it is first
authorized by Sonics
necessary to remove both the side panel cover and the pinch point cover as
Service Department.
described above (for either the model 2050 or 2055 press). Then, observe the
following procedure:
1. Loosen the jam nut holding the 1/4-20 cap screw in place.
MODELS 2050 &

2055
Do not operate press

PRESSURE
SWITCH
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2. Rotate the small, knurled, threaded rod upward until the Pressure Switch
closes.
3. Next rotate the cap screw down until the Pressure Switch opens.
4. Rotate cap screw down one turn past the Pressure Switch open position.
5. Tighten the jam nut to lock cap screw in position.
6. Replace pinch point cover and the side panel cover and position securely.
7. Plug the power supply into the electrical source and cycle the welder..
The press is now set to trigger at the minimum trigger pressure of 4-7 psig.
A press actuating in an upward or horizontal direction should be set to trigger

at a minimum of 8-10 psig. Lower values may affect trigger performance
where false triggering may be observed.
FOR MODEL 2096:
1. Maintain air pressure and unplug the power supply for the electrical source.
2. Remove the actuator cover and loosen the jam nut holding the 8-32 cap
screw in place
3. Rotate the cap screw counter-clockwise (up) until the Pressure Switch
closes. Then rotate the cap screw clockwise (down) until the Pressure Switch
opens.
4. Rotate cap screw clockwise (down) one turn past the Pressure Switch
open position.
6. Replace the cover, plug the power supply into the electrical source and
cycle the welder.
The press is now set to

trigger at the minimum
MODEL
trigger pressure of 4-7 psig.

2096
A press actuating in an
upward or horizontal
direction should be set to
trigger at a minimum of 8-10
psig. Lower values may
PRESSURE
affect trigger performance
SWITCH
where false triggering may

be observed. Top of Converter
Housing
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UPPER LIMIT SWITCH
The optional Upper Limit Switch is used as a safety interlock in automation to
prevent the movement of material handling equipment (indexing) when the
horn is down. It also initiates the movement of material handling equipment
when the horn is up.
UPPER LIMIT SWITCH
The Upper Limit Switch is factory set and should be suitable for all
applications. If for some reason you need to readjust it, observe the
following procedure:
1. Maintain air pressure and unplug the power supply from the electrical
source.
2. Remove the actuator cover.
3. Loosen the jam nut holding the 8-32 cap screw in place.
4. Rotate the cap screw counter-clockwise (down) until the Upper Limit
Switch closes.
6. Replace the cover and screws.
The Upper Limit Switch is now set.
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
28 INSTRUCTION MANUAL • MODEL 2050/2055

WARRANTY
Sonics & Materials, Inc., hereinafter referred to as "Sonics", warrants its products
for a period of one year from the date of original shipment against defects in
materials and workmanship under normal installation, use and maintenance as
described in the operating instructions which accompany such equipment.
During the warranty period, Sonics will, at its option, as the exclusive remedy,
either repair or replace without charge for material and labor, the part(s) which
prove upon our examination to be defective, provided the defective unit is
returned to us properly packed with all transportation charges F.O.B. Sonics
dock, Newtown, CT. Warranty period on equipment rentals that are converted to
purchase are deemed to have commenced on the date of original rental
equipment shipment.
Ultrasonic plastics welding horns constructed of titanium or aluminum are

guaranteed against defects for a period of one year from date of shipment.
Sonics will repair or replace a cracked or defective horn once without charge, if
failure occurs within the warranty period.
Ultrasonic plastics welding horns constructed of steel are guaranteed against

defects for a period of ninety days from date of shipment. Sonics will repair or
replace a cracked or defective steel horn once at a charge of 50% of the original
purchase price, if failure occurs within the warranty period.
Ultrasonic metal welding horns constructed of titanium or steel are guaranteed

against defects for a period of one year from date of shipment. Sonics will repair
or replace a cracked or defective horn once without charge, if failure occurs
within the warranty period.
Sonics warrants its ultrasonic converters for a period of one year from date of
shipment with a one-time replacement if a converter proves to be non-repairable.
When customer site service is required, all travel, living and related expenses will
be billed at cost. In-warranty service labor time (including travel time) at the
customers facility is provided Monday through Friday (excluding holidays) from
8:00 am to 5:00 pm. Any in-warranty service time requested outside of these
days and hours will be billed at 150% of Sonics current rate per hour for such
site service work.
LIMITATION OF WARRANTY
This warranty does not apply to items subject to normal wear and tear or, to
equipment or tooling which has been subject to unauthorized repair, misuse,
abuse, negligence or accident. Misuse includes operation of equipment with
tooling that is not qualified for the equipment or tooling not properly installed on
the equipment.
Equipment which, in our judgment, shows evidence of having been used in

violation of operating instructions, or which has had the serial number altered or
removed, will be ineligible for service under this warranty.
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

For components and parts not manufactured by Sonics but included in Sonics
manufactured equipment, this warranty shall be limited to the warranty as given
to Sonics by said original component or part manufacturer.
Ultrasonic horns supplied by Sonics are manufactured to exacting specifications

and are tuned to vibrate at a specific frequency. Using an out-of-tune horn will
cause damage to the equipment and may result in warranty nullification. Sonics
assumes no responsibility for converters, horns or fixtures not supplied by
Sonics or for consequential damages resulting from their usage.
Ultrasonic converters showing signs of excessive heat or contamination, such as

but not limited to, oils and moisture, are not covered by this warranty.
Warranty does not apply to ultrasonic horns quoted as prototype, experimental

or of unusual design which, in our judgment are more likely to fail in use.
Warranty does not apply to re-sharpening of ultrasonic blade type cutting or

slitting horns.
Warranty does not apply to knurl pattern wear on ultrasonic plastics and metal
welding horns and tips.
Warranty does not apply to ultrasonic horn or tip face wear when used with
plastics that are molded with fillers, such as but not limited to, glass or talc.
This warranty does not apply to ultrasonic plastics welding equipment, horns or
fixtures where metal-to-metal tooling contact time is in excess of 250
milliseconds.
This warranty does not apply to used or re-built equipment.
This warranty is non-transferable.
Data supplied in Sonics instruction manuals has been verified and validated and
is believed adequate for the intended use of the equipment. If the equipment or
procedures are used for purposes other than those specified herein, confirmation
of their validity and suitability should be obtained in writing from Sonics.
Otherwise Sonics does not guarantee results and assumes no obligation or
liability.
This warranty is in lieu of any other warranties, either express, implied, or

statutory. Sonics neither assumes nor authorizes any person to assume for it any
other obligation or liability in connection with the sale of its products. Sonics
hereby disclaims any warranty or merchantability or fitness for a particular
purpose. No person or company is authorized to change, modify, or amend the
terms of this warranty in any manner or fashion whatsoever. Under no
circumstances shall Sonics be liable to the purchaser or to any other person for
any incidental or consequential damages or loss of profit or product resulting
from any malfunction or failure of this Sonics product.
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

APPENDIX
2050 LAYOUT
FRONT VIEW
Dimensions are shown in inches and millimeters,

i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

APPENDIX
2050 LAYOUT SIDEVIEW

i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

APPENDIX
2050 EXPLODED ASSEMBLY DRAWING
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

APPENDIX
2055 LAYOUT
FRONT VIEW

i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

APPENDIX
2055 LAYOUT SIDEVIEW

i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

APPENDIX
2055 EXPLODED ASSEMBLY DRAWING
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

APPENDIX
BASE LAYOUT

i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •

APPENDIX
OPTIONAL STAND-ALONE
MOUNTING HUB LAYOUT

i.e., 11/2 (38.1) signifies 11/2" (38.1mm)
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Models 2050 2055 2096 20khz Welding Presses

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Models 2050 2055 2096 20khz Welding Presses

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Models 2050 2055 2096 20khz Welding Presses

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Model 2050

– High voltage is present in the equipment. Disconnect plug before removing

– Make sure equipment is properly grounded with a 3-prong plug. Before

– High voltage potential may be present in the converter as a result of

– Never squeeze or grab a vibrating horn.

– Do not modify horn configurations.

– 20 kHz, 30 kHz and 40 kHz ultrasonic welders operate above normal

– Do not affix any device to any portion of the horn.

Sonics & Materials, Inc.

53 Church Hill Road • Newtown, CT 06470 USA

© Sonics & Materials, Inc. 2012 Printed in U.S.A. Rev 9-12

INSTRUCTION MANUAL • 2050 / 2055 / 2096 1

IMPORTANT SERVICE LITERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

UNPACKING AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

INSTRUCTION MANUAL • 2050 / 2055 / 2096 2

Sometimes, due to printing and shipping requirements, we cannot incorporate

INSTRUCTION MANUAL • 2050 / 2055 / 2096 3

2. all module plug-in units,

3. all wire plug-in connections.

VISIBLE LOSS OR DAMAGE

CONCEALED LOSS OR DAMAGE

INSTRUCTION MANUAL • 2050 / 2055 / 2096 4

■ GXT . . . . . . .Weld by digital time

■ GXE . . . . . .Weld by digital time and/or constant energy

■ GXL . . . . . . .Weld by digital time, constant energy and/or distance*

*Available with Models 2050 and 2096 only.

OVERVIEW OF ULTRASONIC PLASTICS

PRINCIPLE OF ULTRASONIC ASSEMBLY

ULTRASONIC ASSEMBLY SYSTEMS

INSTRUCTION MANUAL • 2050 / 2055 / 2096 5

Generates ultrasonic electrical energy

Provides compressive force

(Stack) Transforms ultrasonic electrical energy

Increases or decreases amplitude

INSTRUCTION MANUAL • 2050 / 2055 / 2096 6

POWER SUPPLY/GENERATOR – The solid state power supply converts

ACTUATOR/PRESS – The pneumatic actuator provides compressive force

CONVERTER – The converter changes the high frequency electrical energy

BOOSTER – Successful ultrasonic welding often depends on having the right

HORN – The horn is a tuned component of the system which comes in

HOLDING FIXTURE – The holding fixture or nest assures proper alignment

MODEL 2050 MODEL 2055 MODEL 2096

INSTRUCTION MANUAL • 2050 / 2055 / 2096 7

Do not connect the press SETTING UP

a. The press should be placed on a sturdy, level table or bench capable of

supporting a minimum of 500 pounds (227 kg).

KEY COMPONENTS AIR CONNECTION

PRESSURE SPEED CONTROL KNOBS

INSTRUCTION MANUAL • 2050 / 2055 / 2096 8

3. Check with your electrician if you have any wiring questions.

INSTRUCTION MANUAL • 2050 / 2055 / 2096 9

INSTRUCTION MANUAL • 2050 / 2055 / 2096 10

CONTROL PANEL (2050 PRESS)

1. SPEED CONTROL knobs allow regulation of the velocity at which the

These controls are factory adjusted for average operating conditions.

clockwise to slow the speed, counterclockwise to increase speed.

2. PRESSURE REGULATOR with corresponding gauge that allows

INSTRUCTION MANUAL • 2050 / 2055 / 2096 11