Telsonic Telsosplice 3KW - operating instructions.pdf

TRANSLATION OF THE ORIGINALOPERATING INSTRUCTIONS SPLICE MACHINE TELSOSPLICE 3 KW-4 Article number of document: 960000472-en - Version: 1205/01 - 14/04/2014 SPLICE MACHINE TELSOSPLICE 3 KW-4 Important notes about the operating manual Important notes about the operating manual This operating manual must be read carefully and understood before commissioning the product. The operating manual is designed to help you in the most comprehensive possible way to use the product correctly, appropriately, effectively and safely. The operating manual should be given to the users who will be responsible for operating and monitoring the product. Instructions for repairs which exceed the scope of normal maintenance are not included. The product has been constructed in accordance with the recognised technical safety standards. There is still a potential hazard for any user who does not use the system in the proper way. Always keep the operating manual near to where the product is installed. Additional copies can be ordered at any time from your supplier. Please use the article number indicated on the front page when ordering. Modifications to the hardware and software are strictly forbidden without the permission of the manufacturer! Copyright TELSONIC AG, CH-9552 Bronschhofen TELSONIC AG Industriestrasse 6b CH-9552 Bronschhofen Tel +41 71 913 98 88 Fax +41 71 913 98 77 Email: [email protected] Web – www.telsonic.com 2 - 70 © TELSONIC AG Version: 1205/01 - 14/04/2014 SPLICE MACHINE TELSOSPLICE 3 KW-4 Table of Contents Table of Contents 1 General information .................................................................................................................. 7 1.1 Copyright .......................................................................................................................... 7 1.2 Limitation of liability .......................................................................................................... 7 1.3 Warranty conditions ......................................................................................................... 7 1.4 Customer service ............................................................................................................. 7 2 TelsoSplice Product Description ............................................................................................... 8 2.1 General View of TelsoSplice, Table Version .................................................................... 8 2.2 General View of TelsoSplice, Board Version ................................................................... 9 2.3 Description and Use of the TelsoSplice Machine ............................................................ 9 2.4 Information and precautionary measures ...................................................................... 10 2.5 Welding Tong Conformity .............................................................................................. 10 2.6 Permissible ambient conditions ..................................................................................... 11 2.7 TelsoSplice Welding Tong Interfaces ............................................................................ 12 2.8 TelsoSplice Rack Interfaces .......................................................................................... 12 3 Safety and warning instructions .............................................................................................. 14 3.1 Explanation of the safety and warning instructions ........................................................ 14 3.2 General information ....................................................................................................... 15 3.3 Intended Use of the TelsoSplice Welding System ......................................................... 15 3.4 Personnel requirements ................................................................................................. 16 3.4.1 Operating personnel .......................................................................................... 16 3.4.2 Electrical engineer ............................................................................................. 16 3.5 Welding Tong Danger Zone ........................................................................................... 16 3.6 Operational safety .......................................................................................................... 19 3.6.1 Electrical/electronic installation .......................................................................... 19 3.6.2 TelsoSplice Pneumatic Installation .................................................................... 19 3.7 Action in an emergency ................................................................................................. 20 4 TelsoSplice Layout and Mode of Operation ............................................................................ 21 4.1 Functional Diagram of TelsoSplice Welding Tongs ....................................................... 21 4.2 Front Rack TelsoSplice .................................................................................................. 22 4.3 Rear Panel of PLC and Generator SG-22 ..................................................................... 23 4.4 TelsoSplice Pneumatic Unit ........................................................................................... 24 4.5 Layout of TelsoSplice Welding Tongs ............................................................................ 25 4.6 TelsoSplice Operating and Display Elements ................................................................ 26 5 TelsoSplice Initial Commissioning .......................................................................................... 27 5.1 Selection of the TelsoSplice Installation Location .......................................................... 27 5.2 TelsoSplice Set-up and Connection ............................................................................... 27 5.3 TelsoSplice Start-up ....................................................................................................... 28 Version: 1205/01 - 14/04/2014 © TELSONIC AG 3 - 70 ... 32 6.3..........14/04/2014 ......................... 45 10..1 General maintenance .. TelsoSplice ............................... 49 12...........3 Scale Drawing for TelsoSplice Welding Tongs........................................................6 Aligning the Anvil and Anvil Plate .........................................................................................................................................3 Monthly maintenance ................................2 Transport damage ..................... 40 7.................................................................................... Table Version ....................................................................... 46 Spare part drawing-list TelsoSplice DM-745046000-E ...................................................... 54 4 ..........................................................4 TelsoSplice Welding Tongs Set-up Mode ............................................. 31 6..............................................................................................................................6 Pneumatic diagram ............................................................................................................... 47 Spare part list TelsoSplice 745046000 ........................................................................................ 29 6 TelsoSplice Operation ........................................ 40 7......................... Board Version .....3.................................................................................1 Safety Precautions Whilst Operating the TelsoSplice Machine ... 30 6...... 30 6...................2 Resonance unit ...........................................................2 TelsoSplice 3 kW Daily Maintenance .......4 Scale Drawing for TelsoSplice Rack .........................................................................2 Removing the Welding Tongs..........1 Scale Drawing for TelsoSplice Table ..........5 Maintenance of the generator ..............8 Aligning the Gather .......3 Removing the Welding Tong Cover................4.................... 40 7...............................................................................................................................................3......................................... 34 6................ 44 9...... 29 5........3.......1 Disposing of the Welding Tongs ............... 38 6............................5 Changing the Anvil and Anvil Plate ..................................... 42 8 TelsoSplice Service and Faults ...........................................................................................1 Creating Nodes and Sequences .................................................5 Product Specification............................ 45 10...................................................................2 TelsoSplice Switch-on and Operation ............................2 Scale Drawing for TelsoSplice Welding Tongs.........................................3................3 TelsoSplice Welding Tongs Tool Change ..........................70 © TELSONIC AG Version: 1205/01 ................................................ 51 12.................................................4 TelsoSplice Guide Slide Bearing Maintenance .........................................................3............................................ 53 12....1 TelsoSplice Welding Tongs General Tool Change ............... 49 12................................ 31 6.......................... 37 6......................4 Replacing the Sonotrode / Converter ........................ 43 9 Transport .............3............................................................ 45 11 TelsoSplice 3kW-4 Spare Parts ........................................................................................... 40 7....................................... 48 12 TelsoSplice Technical Data ......................7 Changing the Gather .................SPLICE MACHINE TELSOSPLICE 3 KW-4 Table of Contents 5......................................................................... Table Version ...........................2 TelsoSplice Tool Change ......................................... 33 6............... 30 6............................................ 36 6...1 Delivery check ......................................... 28 5........................................ 44 10 Disposal ................. 40 7.................................................... 44 9............................... 39 7 TelsoSplice 3 kW Maintenance ........................................................................4................ 52 12........ 50 12..................................3............. Board Version .......... ............................SPLICE MACHINE TELSOSPLICE 3 KW-4 Table of Contents 12...................14/04/2014 © TELSONIC AG 5 .70 ........................ 56 Version: 1205/01 ..............................................7 Electrical diagram ........................................ 55 Electric diagramm TelsoSplice SE00040_V04 .................. 54 Pneumatic diagram TelsoSplice D000109641-A ........................................................ .... 19 Changing the Anvil / Anvil Plate ......................................................... 36 Fig....................... 49 Fig........................................................................... 18 TelsoSplice US Test Maintenance Screen ........................ 17 Replacing the Sonotrode / Converter ........ 16 Removing the Welding Tong Cover..... 31 Fig....... 8 Rear Panel of PLC / Generator SG-22 ............................... 10 Layout of TelsoSplice Welding Tongs ....... 3 TelsoSplice Welding Tong Interfaces ................................ 14 TelsoSplice Maintenance Screen ....14/04/2014 ................. 9 TelsoSplice Pneumatic Unit ............ 41 Fig......... 25 Scale Drawing for TelsoSplice Rack ...... 50 Fig.. 11 TelsoSplice Operating and Display Elements ............................... 13 TelsoSplice Production Mode Screen ......................... 2 General View of TelsoSplice..... 24 Fig.............. Board Version ................................... Table Version ................................... 1 General View of TelsoSplice............................................. Table Version .......... Table Version ....................................................................................... 26 Fig............ 7 Front Rack TelsoSplice ................................ 21 Fig.................................................. 27 Fig......................................................................... 22 TelsoSplice Table ...... 12 Initial Commissioning of TelsoSplice. 4 TelsoSplice Rack Interfaces .............................................................................. 25 Fig....................... 24 Scale Drawing for TelsoSplice Welding Tongs......................................................................... 23 Fig............................ 22 Fig.................................. 34 Fig..................... 8 Fig............................................ 12 Fig........ 30 Fig................................ 15 Removing the Welding Tongs.. 5 Welding Tong Danger Zone .............................................. 9 Fig... 23 Scale Drawing for TelsoSplice Welding Tongs..................... Board Version ..... 17 Fig... 33 Fig............ 6 Functional Diagram of TelsoSplice Welding Tongs .............................................. 35 Fig........................ Table Version ...................................... Board Version .. 37 Fig.......................... 12 Fig...................................................... 51 Fig................. 32 Fig.........................70 © TELSONIC AG Version: 1205/01 ........................... 52 6 ......... 21 Lubrication of guide slide bearings ....................SPLICE MACHINE TELSOSPLICE 3 KW-4 List of Illustrations List of Illustrations Fig............................... 20 Aligning the Anvil / Anvil Plate ........................................................................................................................................................... fax.2 Limitation of liability All the data and information in this operating manual correspond to the applicable standards and specifications. The operating manual may not be passed on to third parties without the written approval of the manufacturer.14/04/2014 © TELSONIC AG 7 .3 Warranty conditions The warranty conditions are contained in the sales documents. See manufacturer's address on Page 2. drawings. Information on the responsible contacts can be obtained at any time via telephone. NOTICE The data.1 Copyright The operating manual should be treated confidentially.4 Customer service Our customer service department is available to provide technical information. are the state of the art and have been compiled according to long-term knowledge and experience. texts. The manufacturer will not accept any liability for damage resulting from the following points: ■ Non-compliance with the operating manual ■ Improper use of the product ■ Use of untrained personnel ■ Own changes to the product 1. Version: 1205/01 . 1. e-mail or the Internet.SPLICE MACHINE TELSOSPLICE 3 KW-4 General information 1 General information 1. 1. images and other representations contained herein are subject to copyright and industrial protection rights. Any abuse of this will be liable for criminal proceedings. It is only intended for people employed on the machine.70 . The system comprises: ■ TelsoSplice rack plus generator. Table Version 1 Touchscreen / Keyboard 3c Generator 2 Tong housing and welding tongs 3d Pneumatic unit (not visible) 3 TelsoSplice rack comprising: 4 Footswitch 3a Computer unit (PC) 5 TelsoSplice table (size variable) 3b PLC 8 .SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Product Description 2 TelsoSplice Product Description The TelsoSplice splice machine is for splicing (welding) wire strands and is controlled via user software.70 © TELSONIC AG Version: 1205/01 .1 General View of TelsoSplice. Table Version Fig. controller and computer unit ■ Touchscreen ■ Welding tongs The TelsoSplice machine offers the following functions: ■ Control of all welding parameters ■ Direct creation of new data records (nodes and sequences) ■ Maintenance and printing of statistics ■ Data backup ■ Networked operation possible 2. 1: General View of TelsoSplice.14/04/2014 . 2: General View of TelsoSplice.1 second. When the welding sequence is started. the stepper motor moves the gather so that the set weld width is achieved.1 . The high-frequency voltage from the generator is transformed into mechanical vibrations by a piezo-electric converter.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Product Description 2. The anvil moves out and presses the inserted strands against the sonotrode. These vibrations are transmitted from the converter to the sonotrode (resonance unit). The welding time is approximately 0. Board Version 1 Touchscreen 3b PLC 2 Welding tongs 3c Generator 3 TelsoSplice rack comprising: 3d TelsoSplice pneumatic unit (not visible) 3a Computer unit (PC) 2. Board Version Fig. The ultrasound is activated and continues to sound until the set values are achieved.70 .14/04/2014 © TELSONIC AG 9 . The controller monitors and controls the entire welding process.3 Description and Use of the TelsoSplice Machine The TelsoSplice welding tongs are intended exclusively for the ultrasonic welding of wire strands. Version: 1205/01 .2 General View of TelsoSplice. 5 Welding Tong Conformity The press has been designed in accordance with the following EC directives and EN ISO standards: EC directives 2006/42/EC Machinery Directive 2006/95/EC Low Voltage Directive 2004/108/EC Electromagnetic Compatibility Harmonised standards DIN EN 12100:2010 Safety of machinery .Emission standard for industrial environments (EMC) 10 . CAUTION The generator may not be switched on before the resonance unit has been connected to the generator.14/04/2014 .70 © TELSONIC AG Version: 1205/01 .Risk assessment and risk reduction DIN EN 60204-1:2006 Safety of machinery . part 1: General requirements EN ISO 13849-1 Safety of machinery . Electric shock 2.Electrical equipment of machines. High voltages on the HF cable.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Product Description 2.Immunity for industrial environments (EMC) EN 61000-6-4 Generic standard .General principles for design .4 Information and precautionary measures NOTICE Please read the instructions on setting up the product and commissioning.Safety-related parts of controllers EN ISO 13849-2 Safety of machinery . Ignoring them may cause damage to components.Safety-related parts of controllers EN 61000-6-2 Generic Standard . 14/04/2014 © TELSONIC AG 11 .80% (non-condensing) Ambient temperature 10 °C .SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Product Description 2.40 °C Version: 1205/01 .70 .. Direct sunlight. Humidity 20%..6 Permissible ambient conditions Do not set up the product close to sources of heat. heavy dust and mechanical vibrations should also be avoided. 70 © TELSONIC AG Version: 1205/01 . 37-pin (controller) 3 Converter cooling 1a Pneumatic connection: Socket couplers 4 Nameplate PK3 2.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Product Description 2. 4: TelsoSplice Rack Interfaces 12 .5 mm (on underside of welding tongs) 2 Connection of HF cable Binder plug. 4-pin 2.14/04/2014 . 3: TelsoSplice Welding Tong Interfaces 1 Connection of D-Sub.8 TelsoSplice Rack Interfaces Fig.7 TelsoSplice Welding Tong Interfaces Fig. SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Product Description 1 TelsoSplice rack 6 Power lead / Mains plug. pneumatic / electrical systems for welding tongs 4 Compressed air connection 9 Touchscreen / keyboard / mouse connections 5 Pneumatic filter / Water trap 10 Nameplate Version: 1205/01 .14/04/2014 © TELSONIC AG 13 . 3- phase. no plug is supplied for 3x208 V 2 Pneumatic unit 7 HF cable to converter 3 Pressure regulator 8 Connection. type 16.70 . SPLICE MACHINE TELSOSPLICE 3 KW-4 Safety and warning instructions 3 Safety and warning instructions 3. do not touch CAUTION: Toxic vapours NOTICE: Wear ear protection NOTICE: Wear eye protection NOTICE: Wear foot protection NOTICE: Wear hand protection NOTICE: Rescue measures 14 .1 Explanation of the safety and warning instructions NOTICE: For potential material damage or special operating instructions CAUTION: For a potentially dangerous situation which could result in minor physical injuries.14/04/2014 . CAUTION: High voltage CAUTION: Crushing. risk to hands CAUTION: Hot surface.70 © TELSONIC AG Version: 1205/01 . SPLICE MACHINE TELSOSPLICE 3 KW-4 Safety and warning instructions 3. The manufacturer is not liable for any damage resulting from such use. Proper use also includes compliance with the operating instructions and the maintenance instructions. Faults which could impair operational safety must be eliminated immediately! 3. The risk is borne solely by the user. Any use beyond this scope or any other use is deemed improper use.70 .3 Intended Use of the TelsoSplice Welding System The TelsoSplice welding system is intended only for ultrasonic welding of suitable wire strands.2 General information NOTICE Read and understand this operating manual before commissioning components! The components may only be used by people who understand the operating manual and the applicable specifications regarding workplace safety and accident prevention.14/04/2014 © TELSONIC AG 15 . Version: 1205/01 . 1 Operating personnel CAUTION The components may only be operated by trained personnel. 3.14/04/2014 .4 Personnel requirements 3.SPLICE MACHINE TELSOSPLICE 3 KW-4 Safety and warning instructions 3.2 Electrical engineer WARNING Risk of injury if insufficiently qualified. Only carry out connection work on the components when the mains cable is unplugged.4. CAUTION Never reach into the operating area of the welding tongs. Possible damage to property or considerable injury to people 3. hazards can arise for the user if the equipment is not used properly. Nevertheless.70 © TELSONIC AG Version: 1205/01 .5 Welding Tong Danger Zone The welding tongs have been designed in compliance with the currently applicable regulations. The electrical engineer must have been specially trained for this field of work and must know the relevant standards and requirements.4. Risk of fingers getting crushed! 16 . Possible damage to property or considerable injury to people. the user must wear eye protection.14/04/2014 © TELSONIC AG 17 . all operating personnel and any other persons in the vicinity must wear suitable ear protection. 5: Welding Tong Danger Zone 1 Welding tongs 2 Welding tong danger zone 3 Anvil: Moves horizontally and vertically 4 Gather: Moves horizontally CAUTION Ultrasound can generate sound pressure levels in excess of 80 dB. plastic or metal parts may break off. Do not touch! Risk of burning hands Version: 1205/01 . While work is being carried out. CAUTION During welding. the resonance unit becomes hot.70 .SPLICE MACHINE TELSOSPLICE 3 KW-4 Safety and warning instructions Fig. Possible eye injuries CAUTION When working. Possible hearing damage. When working. SPLICE MACHINE TELSOSPLICE 3 KW-4 Safety and warning instructions CAUTION The process of welding wire strands can generate toxic vapours due to the partial melting of cable insulation materials. Risk of breathing difficulties! Vapours If vapours are produced during welding, they must be countered by means of an extraction device. This kind of device can be purchased from TELSONIC AG or from a suitable partner recommended by us. 18 - 70 © TELSONIC AG Version: 1205/01 - 14/04/2014 SPLICE MACHINE TELSOSPLICE 3 KW-4 Safety and warning instructions 3.6 Operational safety 3.6.1 Electrical/electronic installation Only operate the press/generators with the voltage specified on the name plate. The earthing of the components is ensured via the power cable of the press. All work on electrical components must only be performed by a electrical engineer. Ensure that sufficient air circulation is guaranteed for the generator and the controller (heat build- up). When installed in control cabinets, the temperature must not exceed 40 °C. NOTICE All of the statutory safety provisions and regulations in your country must be complied with. In the case of non-observance of these regulations, the manufacturer shall not be liable for damage to property or injury to people. 3.6.2 TelsoSplice Pneumatic Installation NOTICE Compressed air supply maximum 10 bar; operating pressure maximum 7 bar. Work on pneumatic components must only be carried out by qualified personnel. Version: 1205/01 - 14/04/2014 © TELSONIC AG 19 - 70 SPLICE MACHINE TELSOSPLICE 3 KW-4 Safety and warning instructions 3.7 Action in an emergency NOTICE Instructions for first aid and rescue measures Incident Action Electric shock Switch the press off using the EMERGENCY STOP strike button. Pull out the mains plug. Provide first aid. Inform a doctor. Production of smoke, Switch the press off using the EMERGENCY unusual noises, STOP strike button. unusual production of heat Pull out the mains plug. Inform the technical customer service of TELSONIC AG. (For address, see Page 2) Fire in the electrical system Disconnect the mains plug. Use a suitable fire extinguisher to fight the fire. Raise the alarm with the works fire brigade or the local fire brigade. Notify the technical customer service department of TELSONIC AG. (For address, see Page 2) 20 - 70 © TELSONIC AG Version: 1205/01 - 14/04/2014 70 .1 Functional Diagram of TelsoSplice Welding Tongs Fig. 37-pin. D-Sub.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Layout and Mode of Operation 4 TelsoSplice Layout and Mode of Operation 4. 6: Functional Diagram of TelsoSplice Welding Tongs 1 Type of connections 3d Cylinder anvil vertical 1a Electrical cables 3e Cylinder finger protection 1b Pneumatic lines 3f Cooling 2 TelsoSplice rack 3g Converter (resonance unit) 2a Touchscreen and keyboard 4 Power lead rack 2b Computer unit (PC) 5 Compressed air supply 2c PLC 6 HF cable from generator to converter 2d Pneumatic unit 7 Cooling supply air: Tongs and converter 2e TS generator 8 Supply air/waste air cylinder finger protection 3 TelsoSplice welding tongs 9 Supply air/waste air cylinder anvil horizontal 3a Stepper motor 10 Supply air/waste air cylinder anvil vertical 3b Printed circuit board 11 Control cable.14/04/2014 © TELSONIC AG 21 . from controller to welding tong printed circuit board 3c Cylinder anvil horizontal Version: 1205/01 . for example.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Layout and Mode of Operation 4. 22 . If. 7: Front Rack TelsoSplice 1 TelsoSplice rack 3c "EMERGENCY STOP" button 2 Computer unit (PC) 3d Key switch for set-up mode 3 PLC 4 Generator 3a ON/OFF main switch 4a Operating and display elements 3b "RESET" button NOTICE Make sure that the amplitude on the generator is set to 100%.2 Front Rack TelsoSplice Fig.70 © TELSONIC AG Version: 1205/01 .14/04/2014 . the PLC is only able to access a limited amplitude. the amplitude is set to 70%. SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Layout and Mode of Operation 4.3 Rear Panel of PLC and Generator SG-22 Before you can access the rear panels of the controller and generator. to 17 Generator fuses (for values. Fig. to 18 Connection of D-Sub.14/04/2014 © TELSONIC AG 23 . see plate) pneumatic unit 7 Connection of D-Sub. you must first remove the rear panel of the TelsoSplice rack. to welding 16 Rear panel of generator SG-22 tongs 6 Connection of D-Sub. 9-pin. to controller generator 8 Connection of D-Sub. 25-pin. to computer 19 D-Sub covers unit (PC) 9 Connection for TELSONIC qualified 20 Power lead for controller mains supply personnel 10 Mains supply PC / screen 21 Connection of HF cable 11 Fuses 6.70 .3 A 22 Nameplate Version: 1205/01 . 25-pin. 15-pin. 37-pin. 8: Rear Panel of PLC / Generator SG-22 1 Rear panel of PLC 12 Mains connection for rack 2 EMERGENCY STOP connection 13 Fuses 16 A 3 Additional light signal connection 14 Mains supply for generator 4 Footswitch connection 15 Nameplate 5 Connection of D-Sub. compressed air supply 8 Printed circuit board for controlling proportional valve 4 Filter / water trap 9 Proportional valve 5 Valve cluster 10 Terminal strip for welding tongs controller NOTICE The compressed air which is to be used must be available in the following quality classes in accordance with DIN ISO 8573-1: Particle class: > Class 5 Water: > Class 4 Oil: > Class 2 Non-compliance with the DIN ISO 8573-1 standard for compressed air could damage the pneumatic components.70 © TELSONIC AG Version: 1205/01 . 24 .SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Layout and Mode of Operation 4. 9: TelsoSplice Pneumatic Unit 1 Pneumatic box 6 Pressure regulator: Supply valve cluster 4.4 TelsoSplice Pneumatic Unit Fig.14/04/2014 .5 bar 2 Pressure regulator 7 Air regulator supply air cooling 30 l/min 3 Connection. 5 Layout of TelsoSplice Welding Tongs Fig. board version 8 Connection of HF cable 16 Version: 1205/01 .14/04/2014 © TELSONIC AG 25 . 37-pin.70 .SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Layout and Mode of Operation 4. control 15 Release button connection: Welding cable tongs. 10: Layout of TelsoSplice Welding Tongs 1 TelsoSplice welding tongs 9 Connection cooling converter 2 Converter 10 Connection cooling welding tongs 3 Sonotrode 11 Release button for welding process 4 Anvil 12 Green LED indicator: Welding tongs ready 5 Gather 13 Red LED indicator: Process errors 6 Pneumatic connections 14 EMERGENCY STOP connection 7 Connection of D-Sub. 14/04/2014 . 4 "EMERGENCY STOP" button: Shuts down the generator and air supply. you must press the "RESET" button to reset the system.70 © TELSONIC AG Version: 1205/01 . 5 Key switch for set-up mode 6 TelsoSplice / TelsoConfig user software (see software operating manual) 7 Release button for welding process 26 .6 TelsoSplice Operating and Display Elements Fig.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Layout and Mode of Operation 4. 11: TelsoSplice Operating and Display Elements 1 TelsoSplice rack 2 Main switch: Generator / controller / computer unit (PC) 3 "RESET" button: Following switch-on. Secure the main plug with the 2 locking screws. Step 6 Connect the rack power lead to the mains. 5. If there is a keyboard. Version: 1205/01 . make sure that the air outlet openings on the generator / controller remain free. connect this as well. Step 3 Connect the power lead and control cable [8] from the rack [7] to the screen.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Initial Commissioning 5 TelsoSplice Initial Commissioning 5. connect the cable [10] directly to the "footswitch" connection on the rear panel of the controller (you have to remove the rear panel of the rack first).14/04/2014 © TELSONIC AG 27 . Table Version Step 1 Connect the main connection cable [7] (pneumatic/electrical system) from the rack [1] to the welding tongs [11].1 Selection of the TelsoSplice Installation Location When setting up the components. 12: Initial Commissioning of TelsoSplice. Step 2 Connect the HF cable [8] from the rack [7] to the welding tongs [11]. Step 4 If there is a footswitch [9].2 TelsoSplice Set-up and Connection Fig.70 . Step 5 Connect the compressed air to the pneumatic unit. SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Initial Commissioning NOTICE Compressed air supply maximum 10 bar.4 TelsoSplice Welding Tongs Set-up Mode The key switch on the TelsoSplice rack lets you switch from production mode to set-up mode. NOTICE During start-up. Step 3 Check the fastening of the resonance unit. the system will not start up 5. 28 .3 TelsoSplice Start-up Step 1 Check the energy supplies: Mains supply and compressed air supply. Step 4 Check that the EMERGENCY STOP button is released. Step 2 Check the connection cable. together with a prompt to reference the welding tongs. The set-up mode may only be used by trained and authorised personnel. TelsoSplice starts up.14/04/2014 . check the mains voltage on the nameplate. Step 6 Press the "RESET" button to reset the TelsoSplice machine. Possible damage to the generator and controller 5. Work on pneumatic components must only be carried out by qualified personnel.70 © TELSONIC AG Version: 1205/01 . the system is in the EMERGENCY STOP state. Otherwise. Step 8 Press the release button (start button) for the welding tongs or the footswitch until the referencing process for the welding tongs is complete (see operating manual for the TelsoSplice software). Step 5 Turn the main switch to "ON". operating pressure maximum 7 bar. Press the "RESET" button to acknowledge this state. Step 7 The production mode screen appears. NOTICE Before you connect the power cable. Step 9 The splice machine is ready for operation. 4. ■ Welding mode set. the following data are set or displayed: ■ Welding parameters / upper and lower limits defined (quality window). ■ Logs generated. printed out or exported. ■ Statistics generated. Caution: Once the set-up mode is ended. 5. Risk of fingers getting crushed! 5.70 . ultrasonic test.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Initial Commissioning In the set-up mode. manual pressure setting.4.1 Creating Nodes and Sequences See operating manual for TelsoSplice software. printed out or exported. CAUTION Never reach into the operating area of the welding tongs.14/04/2014 © TELSONIC AG 29 .2 TelsoSplice Tool Change See "Maintenance" chapter. the key must be removed. Version: 1205/01 . ■ Maintenance: Manual operation of individual welding tong components. 2 TelsoSplice Switch-on and Operation Fig.70 © TELSONIC AG Version: 1205/01 .14/04/2014 . While work is being carried out. Possible hearing damage. 30 . 6. Step 4 The welding tongs are ready for operation. Step 3 Select the node or sequence to be welded. all operating personnel and any other persons in the vicinity must wear suitable ear protection. Step 2 The production mode screen appears.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Operation 6 TelsoSplice Operation 6.1 Safety Precautions Whilst Operating the TelsoSplice Machine CAUTION Under no circumstances should you reach into the operating area of the welding tong. Possible finger crushing CAUTION Ultrasound can generate sound pressure levels in excess of 80 dB. 13: TelsoSplice Production Mode Screen Step 1 Start up the splice machine as described in the "Initial Commissioning" chapter. SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Operation Step 5 Place the wire strands in the welding tongs and press the release button for the welding process. Fig. 6. the welding tongs must be switched to set-up mode.3. please see the operating manual for the TelsoSplice software. Switch on the system and go to the "Maintenance" screen. Possible finger crushing Version: 1205/01 . 14: TelsoSplice Maintenance Screen CAUTION Maintenance work may only be carried out by trained qualified personnel Possible serious injury to people CAUTION Under no circumstances should you reach into the operating area of the welding tong.70 . chapter: Maintenance Screen. For a description of the "Maintenance" screen.2 bar.14/04/2014 © TELSONIC AG 31 .3 TelsoSplice Welding Tongs Tool Change 6. Set the traversing pressure to a maximum of 0.1 TelsoSplice Welding Tongs General Tool Change Before you can carry out a tool change. Step 2 Disconnect the HF cable [3] from the converter [4].14/04/2014 . Step 4 Loosen the screws [9] of the two brackets [8].SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Operation 6. Table Version Fig. The welding tongs are ready for you to change the sonotrode and tool. follow the steps in reverse order. Step 6 To refit the welding tongs (table version). Step 5 Loosen the screws [10] of the brackets [8]. 15: Removing the Welding Tongs. Step 3 Loosen the screws [6] of the main plug on both sides [5] and remove it from the welding tongs.2 Removing the Welding Tongs. 32 .70 © TELSONIC AG Version: 1205/01 .3. then pull the welding tongs out of the opening and place them on the table. Table Version Step 1 Loosen the 4 screws [2] and remove the cover plate [1]. Step 3 Loosen the screws [5] and remove the cover [4].70 . Step 4 Loosen the screws [7] and remove the cover [6]. Board Version Fig. Board Version Step 1 Disconnect the HF cable [1] from the converter. Step 2 Loosen the screws [3] of the main plug on both sides [2] and remove it from the welding tongs. Version: 1205/01 . 16: Removing the Welding Tong Cover.14/04/2014 © TELSONIC AG 33 .3 Removing the Welding Tong Cover. The welding tongs are ready for you to change the sonotrode and tool.3. follow the steps in reverse order.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Operation 6. Step 5 To refit the welding tongs (board version). Lift up the resonance unit [3. 34 .3. (Tighten the fixing screw to a tightening torque of 3-4 Nm (reference value). Step 9 Now replace the converter [3] or the sonotrode [4].SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Operation 6. Step 8 Use a hexagonal wrench to release the converter [3].70 © TELSONIC AG Version: 1205/01 . Tighten the converter [3] to a tightening torque of 80 Nm. Step 6 Hold the sonotrode [4] by the tip and the converter [3] by the housing. (Tighten the locking screw to a tightening torque of 10 Nm). you first need to move the gather [2] upwards.4] and remove it from the welding tongs. Step 3 Push the gather [2] up by 10 mm and secure it again. but only on the gather side. Step 5 Now loosen the fixing screw [8] (sonotrode clamp). Step 4 Loosen screw [5] and screw [6] and then remove the retaining bracket.4] (sonotrode / converter) from the welding tongs. Step 10 Refit by following the reverse sequence. Step 11 Test the power loss of the resonance unit. The fixing screw does not have to be fully unscrewed and removed. Step 7 Clamp the sonotrode [4] by the clamping surfaces [9] in a vice with aluminium jaws. Step 2 Insert an SW6 hexagon key into the slot [1] and loosen the locking screw of the gather [2].4 Replacing the Sonotrode / Converter Fig. The fixing screw has to be fixed with Loctite 243). 17: Replacing the Sonotrode / Converter Step 1 Before removing the resonance unit [3.14/04/2014 . Maximum power loss at 50% amplitude = < 40 W Maximum power loss at 100% amplitude = < 70 W Fig. Version: 1205/01 . (See chapter: Changing the Anvil and Anvil Plate.14/04/2014 © TELSONIC AG 35 .70 . between the sonotrode and the anvil plate and between the anvil plate and the anvil. Changing the Gather.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Operation Step 12 Make sure that the correct air gap is set between the sonotrode and the gather. Subsequent damages to anvil and sonotrode.) Step 13 Now test the power loss of the resonance unit. 18: TelsoSplice US Test Maintenance Screen NOTICE Never start the ultrasonic test as long as the anvil is extended and located on the sonotrode. Step 9 Either replace the anvil plate or reinsert it so the unused side can be utilised. Step 3 Loosen the screws [2] and remove the cover [1]. 36 . Step 8 Now loosen the screws [8] just enough to remove the anvil plate [7].5 Changing the Anvil and Anvil Plate Fig. 19: Changing the Anvil / Anvil Plate Go to the "Maintenance" screen in set-up mode. 4a] and remove the anvil holder [3] from the welding tongs. Step 1 Press the "UP" button [12] on the controller to move the anvil upwards. Tighten the screw slightly.70 © TELSONIC AG Version: 1205/01 . Step 10 Now you must realign the anvil and the anvil plate. Step 4 Loosen the screws [4.3. Step 2 Press the "OPEN" button [11] on the controller to move the anvil to the home position (retracted). Step 5 Loosen the screw [6] and pull the anvil [5] out of the holder.14/04/2014 . Tighten the screw slightly. Step 6 Clean the surfaces of the holder and the anvil [5]. Step 7 Either replace the anvil or reinsert it so the unused side can be utilised.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Operation 6. Tightening torque of anvil plate screws 3 Nm. B = 0. Step 3 Set the air gap [A] between the anvil and the anvil plate. Tighten the screws [7. To achieve this. To achieve this. Step 5 Now set the air gap [B] between the anvil plate and the sonotrode. Step 4 Reinsert the entire anvil holder [1] into the tongs. 7a] to a tightening torque of 3 Nm and 6 Nm.04 mm. use a 0. A = 0. Version: 1205/01 .04 mm spacer film.6 Aligning the Anvil and Anvil Plate Fig. Tightening torque 20 Nm.04 mm. (See edges [5].) Step 2 Now tighten the screw [3].70 .14/04/2014 © TELSONIC AG 37 . 7a] slightly. Tighten the screws [7.04 mm spacer film.3.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Operation 6. 20: Aligning the Anvil / Anvil Plate Step 1 Align the anvil [2] parallel with the anvil guide [4]. you can use a 0. Step 6 Mount the welding tong cover. Make sure that the lateral surfaces [X + Y] are congruent (parallel). 14/04/2014 . Step 2 Loosen the screws [4] and remove the finger protection [3].SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Operation 6.3. Step 3 Loosen the screw [6] slightly and pull the gather [5] up and away.7 Changing the Gather Step 1 Loosen the screws [2] and remove the cover [2]. Step 4 Clean the mounting surfaces. 38 .70 © TELSONIC AG Version: 1205/01 . Step 4 Check the air gap (0. Tightening torque 10 Nm.3.8 Aligning the Gather Step 1 Either replace the gather [1] or reinsert it so the unused side can be utilised. Step 2 Press the gather [1] gently onto the sonotrode [2].SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Operation 6.02 mm) between the gather and the sonotrode. Step 3 Tighten the fastening screw of the gather.70 . Version: 1205/01 . Tighten the fastening screw of the gather slightly.14/04/2014 © TELSONIC AG 39 . making sure that the grooves [3] are correctly centred. 3 Monthly maintenance ■ Check the pneumatic unit. ■ Check the connecting cables of the individual components. 7.14/04/2014 . 7. 7. ■ Clean the sonotrode surface. gather and anvil. Damage to the keyboard membrane and LCD displays.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice 3 kW Maintenance 7 TelsoSplice 3 kW Maintenance 7. Possible serious injury to people CAUTION Maintenance work may only be carried out by trained qualified personnel Possible serious injury to people NOTICE Never use caustic cleaning agents to clean the keyboard and the displays of the of the controller or of the generator.1 General maintenance CAUTION Always disconnect all electrical and pneumatic energy sources before starting any maintenance work.4 TelsoSplice Guide Slide Bearing Maintenance The guide slide bearings must be maintained and lubricated as indicated below: 40 .70 © TELSONIC AG Version: 1205/01 .2 TelsoSplice 3 kW Daily Maintenance ■ Keep the welding tongs clean. Step 3 Before you can lubricate the guide slide bearings of the anvil holder (image B).000 operations TELSONIC AG by quoting: Anvil (complete inspection) Article No.8 in that order.14/04/2014 © TELSONIC AG 41 . you must first disassemble the components numbered from 1 . Step 5 Reassemble the components by proceeding in reverse order.000 .SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice 3 kW Maintenance Slide bearing type: Interval: Lubricant: Horizontal guide slide bearings: 50.15 in that order. you must first disassemble the components numbered from 11 . Step 4 Lubricate the Y surfaces of the guide slide bearings on both sides. 21: Lubrication of guide slide bearings Step 1 Before you can lubricate the guide slide bearings of the gather (image A). 485101100 Fig.70 . Version: 1205/01 .000 welding Molykote DX Anvil and gather processes Can be ordered from Vertical guide slide bearings: 150.150. Step 2 Lubricate the X surfaces of the guide slide bearings on both sides. Risk of damage to guide slide bearings! 7.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice 3 kW Maintenance NOTICE Only use the specific lubricant recommended by the manufacturer. Otherwise the generator does not require maintenance.70 © TELSONIC AG Version: 1205/01 .14/04/2014 . 42 . Damage to the keyboard membrane and LCD displays.5 Maintenance of the generator NOTICE Never use caustic cleaning agents to clean the keyboard and the displays of the of the controller or of the generator. Clean the generator as required. 70 .14/04/2014 © TELSONIC AG 43 .SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Service and Faults 8 TelsoSplice Service and Faults A list of possible error messages can be found in the operating manual for the TelsoSplice / TelsoConfig software. Version: 1205/01 . 1 Delivery check Before commissioning the components.2 Transport damage The delivery company is responsible for any damage which occurs in transit. We must be notified immediately of any damage to. In the event of any discrepancy in the items supplied. if necessary. as well as during internal transport.70 © TELSONIC AG Version: 1205/01 .SPLICE MACHINE TELSOSPLICE 3 KW-4 Transport 9 Transport NOTICE Damage through incorrect transport! Incorrect transport will cause considerable property damage.14/04/2014 . check whether the components listed in the delivery note are complete and undamaged. any components supplied by us. please contact our customer service. A complete report which exactly describes the damage must be submitted to the delivery company. or loss of. the damaged consignment will be replaced. 44 . take care and observe the symbols on the packaging. Where goods have been supplied on a free house or CIF (Cost Insurance Freight) basis by TELSONIC AG or a subsidiary. > When unloading the packages on delivery. 9. Falling. This must be confirmed by forwarding a copy of the above-mentioned report. and the costs reclaimed from the relevant transport insurance. the report forms the basis for any claim for damages. crushing of feet. 9. CAUTION Move heavy components with the intended transport aids. The electrical and electronic parts should be sent to a licensed electrical scrap dealer in your region.70 . 10.SPLICE MACHINE TELSOSPLICE 3 KW-4 Disposal 10 Disposal NOTICE The components must be disposed of in accordance with the statutory requirements in your country. reuse 10. Version: 1205/01 .2 Resonance unit The resonance unit should be sent to a concessionary scrap metal dealer in your region.1 Disposing of the Welding Tongs Remove the electrical and electronic parts of the welding tongs. Environmental pollution.14/04/2014 © TELSONIC AG 45 . The mechanical parts should be sent to a licensed scrap metal dealer in your region. 46 .14/04/2014 .SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice 3kW-4 Spare Parts 11 TelsoSplice 3kW-4 Spare Parts See the spare parts drawing and list of spare parts on subsequent pages.70 © TELSONIC AG Version: 1205/01 . 47 .01.5 > 3 > 6 > 30 > 120 > 400 > 1000 D 23. 36 available as from Rev.04mm 175 155 160 45 140 © TELSONIC AG I 180 170 I K K A B © Telsonic AG L L A Copyright reserved! Oberflächenbehandlung / finish meu Massstab / scale mm C X Erstellt / constructed 14. 6 .2012 - Geändert / modified 21.2 ± 0.14/04/2014 B (2:1) TelsoSplice 3kW-4 Spare Parts 72 70 105 Spaltmass an den Aussenseiten ~0.1 ± 0. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 X (1 : 1) A A (2:1) A Spaltmass ~0.01. 120 .2013 shu Index Abmasse in mm für Nennmassbereiche Schweisszange TelsoSplice 3kW-4 Zeichnungs Nr Genauig .5Nm 90 © Telsonic AG 36 Pos.01... 1000 . noch an Dritte weitergegeben werden.05mm Amboss horizontal öffnen Amboss horizontal schliessen 80 clearance ~0.02mm 3Nm 110 45 clearance on the outside ~0.2013 shu Format / format Blatt Nr / sheet No Geprüft / checked Werkstoff / material Gewicht / weight 13...1 ± 0.0Nm open Anvil horizontal close Anvil horizontal 120 6Nm Schallschutz öffnen 20Nm open protection B B 115 90 Kühlung Schallschutz schliessen cooling close protection Kongruent ±0.05 congruent ±0. 400 .70 .2012 shu .. 603 H H Spaltmass ~0... The recipient herby acknowledges these rights and assures the use of this document only for the purpose it was delivered.10.. Zuwiderhandlung ist strafbar und wird strafrechtlich verfolgt.0Nm 140 10Nm 141Ncm 35 6Nm 40 45 F C (2:1) F 6Nm 5 80 10 15 20 150 25 G 30 3.3 ± 0. 3 .5 ± 0.D vorhanden Pos.0Nm 55 145 SPLICE MACHINE TELSOSPLICE 3 KW-4 E 32Ncm Loctite 222 80Nm E 50 140 3... Es darf ohne unsere ausdrückliche Genehmigung weder kopiert..01.0Nm Amboss vertikal öffnen Amboss vertikal schliessen open Anvil vertical close Anvil vertical 140 80 C C 85 90 95 Version: 1205/01 .525 kg A1 3/3 Benennung / description Artikel Nr / part No 745046000 M Allgemeintoleranzen für Längenmasse DIN ISO 2768-1 E 21.05.2012 shu Anzugsdrehmomente D200531 E Ähnlich wie D200110 Status Freigegeben Plotdatum 30..8 ± 1.11.603 Glue with Loctite Nr. 2000 m (mittel) ± 0.. vervielfältigt oder verwertet. 36 ab Rev..05mm 3. D Sichern mit Loctite Nr.2013 1 2 3 4 5 6 7 8 9 10 11 12 similar to status print date Dieses Dokument ist unser geistiges Eigentum.05 3. clearance ~0.2013 shu 1:2 - 22.04mm We reserves all rights in this document and it's subject matter.2 C 30.02mm D 10Nm 100 D 60 65 3. drawing No index keitsgrad 0. 30 . 00 pce 80 671586055 Anvil tip TS "PLUS" and 3kW-4 X 1.00 pce 20 677050450 Gearwheel TS incl.9 1199390 X 1. item no RT/qty UOM spare part wear part 5 740046046 Spindel set TS X 1.14/04/2014 .telsonic.00 pce 145 921029000 Converter SE 50/30-6 A X 1.00 pce 140 980008827 Wire splicing sonotrode TE 20 8827 X 1.com Industriestrasse 6b Switzerland Fax +41 71 913 98 77 www. M3x4 AT-80 0004 8633 X 1.00 pce 105 366005105 Magnetic tape for MLFK08 L=26mm 11 099144 X 1.5 09.00 pce 65 677050030 Bracket TelsoSplice X 1.00 pce 70 740046045 Sound protection cap TS X 1.00 pce 25 677050465 Tooth belt Synchroflex 6T2.00 pce 75 606464001 Socket Cap Screw M 6 x 16 Grade 12. Resource Description Ext.00 pce 35 677050412 Slide carriage gather tip TS "PLUS" X 1.00 pce 175 888001391 Short stroke cylinder ADVC-63-20-I-P 188290 X 1.00 pce 85 677050211 Moving carriage anvil tip TS "PLUS" X 1.00 pce 110 888007086 Short stroke cylinder ADVC-16-10-A-P 188124 X 1.00 pce 155 673120073 Stepper motor gear X 1.1831.00 pce 180 440466000 Fan 24 V DC 40x40x20mm SU KD2404PKS2G X 1.00 pce 95 677050251 Guide to moving carriage anvil tip TS "PLUS" X 1. +41 71 913 98 88 [email protected] pce 120 973120060 Anvil cover TS X 1.00 pce 170 366005200 Magnet sensor linear MLFK08T7105/N25X 10149985 X 1.00 pce 60 677050020 Mini roadbed DFC 4 15-P-GF 189453 X 1.00 pce 150 735080151 Board weldunit TS X 1.00 pce 160 673120060 Stepper motor incl.00 pce 10 690010100 Bearing 9 x 26 x 8 629.2ZR X 1.00 pce 90 671586030 Anvil plate TS 12mm 11 waves X 1.5 / 317.com 48 .telsonic.00 pce 50 745046045 Guide plate for TelsoSplice 1.00 pce 100 677050230 Moving carriage anvil vertical TS X 1.00 pce 115 677050220 Guide plate anvil horizontal TS X 1.00 pce 30 677050150 Gather support TS X 1.00 pce 45 671586050 Gather tip TS "PLUS" X 1.70 © TELSONIC AG Version: 1205/01 .2012 Item 745046000 Splice Head TelsoSplice 3kW-4 Page 1 of 1 Pos.00 pce TELSONIC AG 9552 Bronschhofen Tel.00 pce 15 677050440 Spindle gather tip TS X 1.00 pce 72 677050565 Window for sound protection cap X 1. Encoder X 1.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice 3kW-4 Spare Parts Spare part list Date 06.00 pce 55 360106000 Proximity switches IFFM 08P37A6/L 10142952 X 1.00 pce 36 677050413 Threaded bushing X 1.12.00 pce 40 888007316 Insert Gather TS X 1.5206 X 1. 1 Scale Drawing for TelsoSplice Table Fig.14/04/2014 © TELSONIC AG 49 . 22: TelsoSplice Table A B C D Table 2 m 835 2000 1000 592 Table 1.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Technical Data 12 TelsoSplice Technical Data 12.9 m 835 915 915 88 Version: 1205/01 .70 .2 m 835 1220 915 203 Table 0. SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Technical Data 12.14/04/2014 .2 Scale Drawing for TelsoSplice Welding Tongs.70 © TELSONIC AG Version: 1205/01 . 23: Scale Drawing for TelsoSplice Welding Tongs. Table Version Fig. Table Version 50 . 24: Scale Drawing for TelsoSplice Welding Tongs.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Technical Data 12.3 Scale Drawing for TelsoSplice Welding Tongs.70 . Board Version Version: 1205/01 . Board Version Fig.14/04/2014 © TELSONIC AG 51 . 4 Scale Drawing for TelsoSplice Rack Fig.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Technical Data 12. 25: Scale Drawing for TelsoSplice Rack 52 .70 © TELSONIC AG Version: 1205/01 .14/04/2014 . 5 kg Weight of welding tongs. 50 . board version: 13.40 mm² at 6 bar 0. PC) Frequency: 20 kHz Power 3 kW Amplitude accuracy: +/.14/04/2014 © TELSONIC AG 53 . controller. table version: 12.5 kg Interfaces: Converter: Connector socket.5 Product Specification.2 mm² . 10 mm Strand cross section: 0. TelsoSplice TelsoSplice welding tongs Frequency: 20 kHz Power: 3 kW Voltage: 24 V Maximum current consumption: 2A Maximum compressed air supply: 10 bar Maximum operating pressure: 7 bar Compressed air quality: Oil-free: DIN ISO 8573-1 Cylinder force at 6 bar: 1750 N Cylinder force at 7 bar: 2040 N Feeding area (stroke.2 mm² .3% under load Mains supply: 3 x 400 V / 230 V ±15%.SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Technical Data 12. D-Sub 37-pin male connector) TelsoSplice rack (generator.70 . opening): 19 mm. 4-pin.60 Hz Electrical inputs and outputs: See electrical diagram Current consumption: 3 x 8 A RMS Protection class: IP 20 Weight: 70 kg Version: 1205/01 . for HF cable Binder plug Pneumatic system / controller Main plug (socket coupler.45 mm² at 7 bar Weight of welding tongs. SPLICE MACHINE TELSOSPLICE 3 KW-4 TelsoSplice Technical Data Monitor: SVGA TFT touchscreen PC: 80 GB hard disk / 21 GB RAM.5 kg Weight of TelsoSplice plus board version with 85 kg rack: Permissible ambient conditions: Humidity: 20% .5 kg rack: Table 2 m: Approx.70 © TELSONIC AG Version: 1205/01 . 133. 3x RS232.6 Pneumatic diagram See appendix 12.2 m: 125 kg / 133. 50 kg Complete TelsoSplice system: Weight of TelsoSplice plus table version with Table 1.80% Ambient temperature: 15°C – 35°C 12.14/04/2014 . Interfaces: front: 2x USB / rear: 2x LAN.7 Electrical diagram See appendix 54 . 4x USB.5 kg Table weight: length 2000 mm: Approx. 1x VGA Tables: Table weight: length 1220 mm: 38. 05. 18.70 .05. Tag Name -1Z14 A 1 Typ: 1 675841515 Tag Name 1 2 gez.5-150Y4 4 2 -150Y5 2 12 14 12 CPASC1-M1H-X-P-2.01.2008 mkl gesehen 07.01 3 3 TelsoSplice Technical Data OUT x ø6 Version: 1205/01 . A B C D ADVC-63-20-A-P ADVU-12-15-P-A cooling DZF-4-15-P-GF kühlen anvil vertical anvil horizontal noise protection Amboss vertikal Amboss horizontal Schallschutz -1A24 -1A47 -1A78 Festo No.5 anvil horizontal converter cooling 2 -150Y1 on: close / off: open 2 12 82 (4) 1 3 (K12) main valve (K14) 12/14 1 5 82/84 3 (X12) ø6 © TELSONIC AG -1Z23 ø6 L 1 2 12/14 5 CPASC1-VI 1 3 4 2 82/84 4 2 4 2 4 2 LR-1/8-D-O-7-MICRO ø8 Index Änderungs-Nr.2012 mkl Gefertigt aus: Maßstab Benennung Dok-Art: Teile-Nummer: MS4-LFR-1/8-D7-E-R-M-WR-Z Pneumaticbox TelsoSplice 15m D000109641 DINA3 A B C D 55 .2012 mkl Blatt-Nr: Freigabe 07. Anz. CH_SY.14/04/2014 P E 2 GR-QS-4 MPPE-3-1/8-10-010-B -1V23 -1Z71 ø4 ø4 ø6 ø4 1 SPLICE MACHINE TELSOSPLICE 3 KW-4 3 CPASC1-M1H-N-P-2.02.05.5-150Y2 4 2 -150Y3 -150Y6 12 4 2 2 10 14 10 14 1 anvil vertical anvil horizontal CPASC1-M1H-M-P-2.5 on: down / off: up on: close / off: open (N14) (N12) noise protection 14 84 5 1 3 w 12/14 1 5 82/84 3 (M14) x EXT ø6 ø4 ø4 CPASC1-M1H-K-P-2.102074. 0 4 .56 . 2 0 0 7 P r o c e s s e d o n : 19 . 2 0 0 8 E di t o r : CB Version: 1205/01 .0 6 .14/04/2014 .70 Ele c t r ic dia gr am TelsoSplice Technical Data Cus t omer : T el s oni c CH P l a n t d e s i gn a t i o n : T els o Splic e SPLICE MACHINE TELSOSPLICE 3 KW-4 D r a w i n g nu m b e r : SE000 40 _ V 0 4 C ommis sion : in t er nal CAD : s e e ele c t r ic al V 4R1 © TELSONIC AG M a nu f a c t ur e r C li en t : T e l s o ni c C H Pr o jec t name : S p l i c e w e l di n g: T e l s o S p l i c e Mak e : T e l s o ni c A G Type : T el s o Spli c e In s t a l l a t i o n : R ep onsible f or pr o je c t : ac Cr ea t e d on : 0 2. 2 0 0 8 Shee t: 1 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä. CB 16 . CB 19 . TelsoSplice Technical Data Version: 1205/01 .14/04/2014 SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r .0 4 . 2 0 0 7 T el s oni c CH E le c t r ic dia gr a m numb e r : Ge ä.Nu m b e r : Plant (=) = O v er vie w in t e r n al Loc a t ion (+) + Gez. SE 0 0 0 4 0 _ V 0 4 Ne x t: 4 57 .0 6 .70 . gr e e n .gr e en BN / GN 45 w hi t e .y e l l o w . CB 2 6 .b l a c k PK / BK 12 r e d.b l a c k Y E / GN / B K 16 y ello w .GN 60 br o wn-r ed-black BN / RD / BK 30 y e l l o w .b r o w n .b r o w n .0 4 .r e d.Nr .r e d GY /RD SPLICE MACHINE TELSOSPLICE 3 KW-4 9 black BK 40 p i nk .y e l l o w WH/ YE 46 y e l l o w .blue Y E / BU 2 br o wn BN 33 gr e e n .r e d WH/RD 54 gr e y .Nr .r e d PK / RD 10 viole t VT 41 gr e y .b r o w n .p i nk WH / PK 50 gr e e n .bla c k BU / BK © TELSONIC AG 13 w hi t e .b l a c k G Y / BN / BK 24 br o wn-r ed BN / R D 55 w hi t e .blue BN / BU 53 w hi t e .p i nk .b l a c k W H / GN / B K 19 w hi t e .w hi t e BK / W H 31 gr e en.blu e RD / BU 43 blue .gr e e n PK .gr e e n G Y / GN 58 br o w n .bla c k Y E / BN / BK 22 br o w n.bla c k BN / BU / BK 28 y e l l o w .br o w n YE / BN 47 gr e y .b l u e .gr e e n .b l u e PK / BU 8 red RD 39 gr e y .p i nk . SE 0 0 0 4 0 _ V 0 4 Ne x t: 5 Version: 1205/01 .p i nk YE / PK 61 b l a c k .58 .br o w n G Y / BN 49 w hi t e .b l a c k GY /RD 11 g r e y .14/04/2014 . W ir e c olor Si W i r e .bla c k BU / RD / BK 18 gr e y .gr e y .b r o w n . 2 0 0 8 Shee t: 4 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä. CB 19 .gr e e n YE/ GY 59 w hi t e .b l u e WH / BU 52 y ello w .0 6 .b l a c k PK / BN / BK 26 br o wn-black BN / BK 57 w hi t e .70 D IN 4 710 0 C o l o r c o d e W i r e .g r e y WH/GY 48 blue .b l u e G Y / BU 7 blue BU 38 p i nk .b l a c k W H / PK / BK 25 w hi t e .b l a c k W H / BN / BK 15 w hi t e . 2 0 0 7 T el s oni c CH E le c t r ic dia gr a m numb e r : Ge ä.g r e e n W H / GN 44 r ed-black RD / BK 14 br o w n.bla c k Y E / BK 6 p i nk PK 37 gr e y .b l a c k WH / BK 56 p i nk .b l a c k GN / B N / B K 20 p i nk .br o w n.Nu m b e r : Plant (=) = C olour c o d e in t e r n al Loc a t ion (+) + Gez.b l a c k W H / BU / BK 27 g r e y .b l a c k G Y / PK / BK 17 w hi t e .b r o w n PK / BN 51 w hi t e . W ir e c olor Si 1 w hi t e WH 32 y ello w .b l a c k W H / RD / BK 29 p i nk .b l a c k GN / B K 5 gr e y GY 36 y ello w .blue GN / B U Si Date Pr o jec t / plant Shee t c ont ent s O r d e r .b l a c k W H / G Y / BK 23 w hi t e .r e d GN / R D TelsoSplice Technical Data 3 gr e en GN 34 y ello w -r e d YE/RD 4 y ello w YE 35 gr e e n .blue .r e d .p i nk G Y / PK 42 p i nk .b l a c k W H / Y E / BK 21 w hi t e . TelsoSplice Technical Data Version: 1205/01 . CB 16 .Nu m b e r : Plant (=) = Plan t and lo c a t ion de signa t ion in t e r n al Loc a t ion (+) + Gez.0 4 .14/04/2014 SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r . 2 0 0 8 Shee t: 5 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä. 2 0 0 7 T el s oni c CH E le c t r ic dia gr a m numb e r : Ge ä.0 6 .70 . SE 0 0 0 4 0 _ V 0 4 Ne x t: 15 59 . CB 19 . 0 4 .Nu m b e r : Plant (=) = A1 C on t r oll er SP C in t e r n al Loc a t ion (+) + O1 Gez. CB 19 .0 6 . SE 0 0 0 4 0 _ V 0 4 Ne x t: 20 Version: 1205/01 . 2 0 0 8 Shee t: 15 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä.70 TelsoSplice Technical Data SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r .60 .14/04/2014 . CB 16 . 2 0 0 7 T el s oni c CH E le c t r ic dia gr a m numb e r : Ge ä. 0 6 .14/04/2014 SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r . SE 0 0 0 4 0 _ V 0 4 Ne x t: 21 61 . 2 0 0 7 T el s oni c CH E le c t r ic dia gr a m numb e r : Ge ä. CB 19 .70 . TelsoSplice Technical Data Version: 1205/01 .0 4 .Nu m b e r : Plant (=) = A1 C onne c t or SP C / X 20 in t e r n al Loc a t ion (+) + O1 Gez. 2 0 0 8 Shee t: 20 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä. CB 17 . 0 4 . CB 16 .70 TelsoSplice Technical Data SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r .14/04/2014 .62 .Nu m b e r : Plant (=) = A1 C o n n e c t o r S P C / X 21 in t e r n al Loc a t ion (+) + O1 Gez. 2 0 0 8 Shee t: 21 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä. CB 19 .0 6 . 2 0 0 7 T el s oni c CH T ongs E le c t r ic dia gr a m numb e r : Ge ä. SE 0 0 0 4 0 _ V 0 4 Ne x t: 22 Version: 1205/01 . 2 0 0 8 Shee t: 22 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä.14/04/2014 SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r .0 4 .70 . SE 0 0 0 4 0 _ V 0 4 Ne x t: 23 63 . TelsoSplice Technical Data Version: 1205/01 . CB 19 . CB 16 .Nu m b e r : Plant (=) = A1 C onne c t or SP C / X 2 2 in t e r n al Loc a t ion (+) + O1 Gez. 2 0 0 7 T el s oni c CH P n e um a t i c E le c t r ic dia gr a m numb e r : Ge ä.0 6 . 64 .0 4 . CB 16 . 2 0 0 8 Shee t: 23 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä.14/04/2014 . 2 0 0 7 T el s oni c CH Gener a t or E le c t r ic dia gr a m numb e r : Ge ä.0 6 .70 TelsoSplice Technical Data SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r .Nu m b e r : Plant (=) = A1 C onne c t or SP C / X 23 in t e r n al Loc a t ion (+) + O1 Gez. SE 0 0 0 4 0 _ V 0 4 Ne x t: 24 Version: 1205/01 . CB 19 . 14/04/2014 SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r . TelsoSplice Technical Data Version: 1205/01 .0 6 .0 4 .70 .Nu m b e r : Plant (=) = A1 C onne c t or SP C / X 2 4 in t e r n al Loc a t ion (+) + O1 Gez. 2 0 0 8 Shee t: 24 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä. SE 0 0 0 4 0 _ V 0 4 Ne x t: 25 65 . 2 0 0 7 T el s oni c CH Signali s a t i on E le c t r ic dia gr a m numb e r : Ge ä. CB 19 . CB 16 . 14/04/2014 . 2 0 0 7 T el s oni c CH Footswitch E le c t r ic dia gr a m numb e r : Ge ä. 2 0 0 8 Shee t: 25 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä. CB 16 .70 TelsoSplice Technical Data SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r .Nu m b e r : Plant (=) = A1 C onne c t or SP C / X 25 in t e r n al Loc a t ion (+) + O1 Gez.0 4 .0 6 . CB 19 . SE 0 0 0 4 0 _ V 0 4 Ne x t: 26 Version: 1205/01 .66 . TelsoSplice Technical Data Version: 1205/01 . CB 16 .0 6 . CB 19 .0 4 . 2 0 0 8 Shee t: 26 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä.70 .14/04/2014 SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r .Nu m b e r : Plant (=) = A1 C onne c t or SP C / X 2 6 in t e r n al Loc a t ion (+) + O1 Gez. SE 0 0 0 4 0 _ V 0 4 Ne x t: 10 0 67 . 2 0 0 7 T el s oni c CH PC-R S232 E le c t r ic dia gr a m numb e r : Ge ä. CB 16 .0 6 .Nu m b e r : Plant (=) = A1 T ongs in t e r n al Loc a t ion (+) +O2 Gez. SE 0 0 0 4 0 _ V 0 4 Ne x t: 15 0 Version: 1205/01 .70 TelsoSplice Technical Data SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r . CB 19 .68 . 2 0 0 7 T el s oni c CH E le c t r ic dia gr a m numb e r : Ge ä.14/04/2014 . 2 0 0 8 Shee t: 10 0 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä.0 4 . CB 2 0 . 2 0 0 8 Shee t: 15 0 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä. 2 0 0 7 T el s oni c CH E le c t r ic dia gr a m numb e r : Ge ä.Nu m b e r : Plant (=) = A1 P n e um a t i c b o x in t e r n al Loc a t ion (+) +O3 Gez.14/04/2014 SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r .0 4 . SE 0 0 0 4 0 _ V 0 4 Ne x t: 69 . CB 16 . TelsoSplice Technical Data Version: 1205/01 .0 6 .70 . 0 6 . CB 2 0 . CB 2 0 .70 Page over view A dditional f ield Plant (=) Loc a tion (+) Page Designation 1 Designation 2 Si Rev. Dat e TelsoSplice Technical Data SPLICE MACHINE TELSOSPLICE 3 KW-4 © TELSONIC AG Si Date Pr o jec t / plant Shee t c ont ent s O r d e r .Nu m b e r : Plant (=) = in t e r n al Loc a t ion (+) + Gez.14/04/2014 . 2 0 0 8 T el s oni c CH E le c t r ic dia gr a m numb e r : Ge ä. 2 0 0 8 Shee t: 1 S p l i c e w e l d i n g: T e l s o S p l i c e Ge ä.0 6 . SE 0 0 0 4 0 _ V 0 4 Ne x t: Version: 1205/01 .70 .