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11/27/2018 CR4 - Thread: Error Frequency on Sonobond Ultrasonic Welder
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calpark Error Frequency on Sonobond Ultrasonic Welder

Active Contributor 06/20/2014 2:03 PM
Join Date: Jun 2014

Posts: 11 I recently purchased a Sonobond Ultrasonic Welder for Plastics (MP3512 w/ Generator SL35-900).
After setting it up with the compressed air system and a voltage converter (I'm in the US), I turned the generator on. On the
display, I got an "ERROR FREQUENCY."
I thought it was because I hadn't connected the horn yet, but even with the horn on, I still got the error. (I was told that I was
using the correct horn, too). I made sure the RF cable was plugged in and that there were no visible cracks on the horn,
booster, and transducer/converter.
After I got "error frequency," I pressed CLR and proceeded to press the dual safety switch. The actuator came down like it was
supposed to and I heard a sound, but the machine still said error frequency and my two plastic pieces were nowhere near
welded.
Can anyone tell me why I'm getting error frequency and how I should fix it? I'm debating if I should replace my horn, booster, or
converter since there might be defects that I can't see.
Thank you!
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#1 "Re: Error Frequency on Sonobond Ultrasonic Welder" by gringogreg on 06/20/2014 2:35 PM (score 1)
gringogreg Re: Error Frequency on Sonobond Ultrasonic Welder

Guru 06/20/2014 2:35 PM
1. Did you contact Sonobond Tech Support?

2. You say that you needed a voltage converter for US. Is the machine configured for European line frequency (50 Hz)? Can
you change this configuration for US 60Hz?
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WJMFIRE Re: Error Frequency on Sonobond Ultrasonic Welder In reply to

Guru 06/20/2014 3:11 PM
That's probably the issue.
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It's highly likely that the machine uses the AC frequency to establish it's ultrasonic frequency.
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calpark Re: Error Frequency on Sonobond Ultrasonic Welder In reply to

Join Date: Jun 2014

Posts: 11
The machine says "Connected loads: 230 V 50-60Hz." I thought this meant that the machine could run on either frequency..So
I though I only needed to change the voltage.
Crabtree Re: Error Frequency on Sonobond Ultrasonic Welder In reply to

Guru 06/20/2014 5:21 PM
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calpark Re: Error Frequency on Sonobond Ultrasonic Welder

06/21/2014 12:00 AM In reply to
Join Date: Jul 2007

Wal
Location: Commissariat de Re: Error Frequency on Sonobond Ultrasonic Welder
06/21/2014 12:42 AM In reply to
Police, Nouvions, occupied
France, 1942.
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calpark
Good Answ ers: 76
Re: Error Frequency on Sonobond Ultrasonic Welder
06/21/2014 12:52 AM In reply to
#
Wal Re: Error Frequency on Sonobond Ultrasonic Welder
06/21/2014 1:31 AM In reply to
#
06/23/2014 2:10 PM In reply to #
bigg Re: Error Frequency on Sonobond Ultrasonic Welder In reply to

Guru 06/20/2014 10:57 PM
Join Date: Jun 2010

Posts: 1290
Your use of 'voltage converter' suggests something other than a simple transformer. Exactly how are you converting the
Good Answ ers: 102 voltage?

Active Contributor 06/21/2014 12:07 AM
Join Date: Jun 2014

Posts: 11
I'm using one of those black, boxy transformers. Looks kind of like this:
#
Active Contributor 06/21/2014 12:58 AM
Join Date: Jun 2014

Posts: 11
I studied a bit more, and I think the box I use is just a transformer..
#
bigg Re: Error Frequency on Sonobond Ultrasonic Welder In reply to #
Guru 06/21/2014 9:10 AM
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Posts: 1290
Can you power it somewhere temporarily on 230V without the transformer - just to go/no-go the power supply?
Good Answ ers: 102
#
calpark Re: Error Frequency on Sonobond Ultrasonic Welder In reply to #
Join Date: Jun 2014

Posts: 11
Thanks bigg. Yeah I need to go/no-go the power supply, the generator, and the vibration system. I tested the transformer, at
least voltage is right.
Can you let me know other ways to power it on 230V?
#
bigg Re: Error Frequency on Sonobond Ultrasonic Welder In reply to #
Guru 06/24/2014 8:57 AM
Join Date: Jun 2010

Posts: 1290
Let's step back. The machine needs 230V, 50-60 Hz. You have 120V, 60 Hz available, so you are using a step-up transformer
Good Answ ers: 102 to get 230V, right?
My suggestion was simply to take the machine to a location (if you are in the US, surely there's a 230V supply available
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Wal Community
Re: Error Frequency Search Community
on Sonobond Ultrasonic Welder In reply to #
Guru 06/24/2014 9:30 AM
An elimination process...
How different could one transformer derived 230V source be from another?
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welderman Re: Error Frequency on Sonobond Ultrasonic Welder
Guru 06/21/2014 7:04 AM
These systems have a fairly high Q which means that you may have to tune your power supply to match the frequency of your
transducer, or suffer a major drop in power output.
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#
Wal Re: Error Frequency on Sonobond Ultrasonic Welder In reply to #
Guru 06/21/2014 8:11 AM
You'd think that would have been sorted by the manufacturer if they were supplied as a system.
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#
06/23/2014 2:24 PM In reply to #
#
welderman Re: Error Frequency on Sonobond Ultrasonic Welder
Guru 06/21/2014 7:53 AM
You should also check to make sure that your 3000 watt step-up/down transformer can supply the required peak current for
your welder.
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#
Guru 06/21/2014 8:09 AM
Transformer would have smoked or that breaker would trip (you would hope) if it wasn't upto the job.
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welderman Re: Error Frequency on Sonobond Ultrasonic Welder In reply to #
Guru 06/21/2014 12:05 PM
Your suggestions of "thinking and hoping" are not materially contributing to this thread.
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#
Guru 06/21/2014 11:37 PM
When sorting a problem you have to make some assumptions if there isn't any evidence to the contrary.
This is part of the problem elimination process.

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Location: Phnom Penh An under rated transformer gets hot and if there are any protective devices that are over rated for that which they are protecting
Posts: 4019 then smoke is inevitable in an overload situation.
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Not sure why you took umbrage to my thoughts and hopes.
I am assuming that the transformer pictured was part of the kit supplied by the manufacturer and is properly rated for purpose. I
also hope that the breaker shown on it was correctly sized.
OP's the only one here who could tell us for sure, short of folk here googling the plasticwelder mentioned and checking its rated
power. OP has a manual.
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06/22/2014 5:19 PM
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Guru
The fact that this is a welding machine implies that the peak current can be substantially higher than the RMS current. This can
explain why an after-market voltage transformer and/or its protection device might not function the way you think it does. If the
Join Date: Sep 2007
Posts: 1601
transducer frequency does not correspond to the oscillator frequency, the observed ultrasonic vibration amplitude will be out of
Good Answ ers: 57 specification. I know these things because I have built and diagnosed many ultrasonic welders. If you haven't, then the evidence
you refer to, doesn't exist.
#
Join Date: Jun 2014

Thanks Wal and welderman! Actually right after I turned on the power, the generator said error frequency.... I did nothing except
Posts: 11
turning on power... So do you guys think the machine has kinds of sensor that can detect the defects of parts? Then I press
clear error message button, and press start. The error frequency appeared again 2~3 sec later after the horn coming down.
I am thinking maybe instead of frequency unmatching, some parts breaks and the machine can tell that? Because at the very
first moment, there is no power supplied.
Can anyone help analysis this situation? Thanks!
#
NAWONUSA Re: Error Frequency on Sonobond Ultrasonic Welder In reply to #
Participant 08/08/2014 3:37 PM
Join Date: Aug 2014

Hello,
Posts: 1
That unit is manufactured by Rinco Ultrasonics, you can call Rinco USA and they will be much more help to you than
SONOBOND ever will. http://www.rinco-usa.com/en/contact.htm
The unit does a self test on start up and if the frequency varies too much, you'll get an error.It will error again if you press clear
as it checks the frequency on every cycle.From what you're describing, It sounds like either the transducer / booster or output
board is no good, but no real way to tell without more testing.
If you are in the LA area, we would be happy to take a look at it in our facility in Van Nuys www.nawonusa.net . We sell and
service all kinds of ultrasonic welders, including those.
#
gringogreg Re: Error Frequency on Sonobond Ultrasonic Welder
Guru 06/21/2014 9:38 AM
I'm not sure why comments 6,8,9, and 11 were considered "off topic" They seem to me to be very pertinent to Calpark's
problem. He has indeed been in contact with Sonobond, but the information he received was vague at best.
My initial thought that the problem might be due to the input power frequency seems to have lead this discussion off in the
wrong direction.
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#
Join Date: Jun 2014

First of all, thread starter is a girl. Lol..
Posts: 11
Thanks for everyone's discussion. I need to check every part in order to know where is the problem. If the power generator can
provide 35KHz output, then I would say power is fine and proceed to converter.
But I have 2 questions,
1, How to check the generator output? With the error existing, will the generator have output or not?
2, If the generator is fine, how to check converter? Any way to measure the mechanical frequency?
Thanks all for help!
#
Guru 06/23/2014 9:14 PM
I would ask Sonobond to repair the unit. If you can't do that, I would determine whether the transducer is piezoelectric or
magnetostrictive. You also need to determine whether the power supply is fixed frequency or auto-tune. The simplest systems
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are fixed frequency. To tune these you need to measure the impedance of the transducer, and tune for the lowest impedance
Good Answ ers: 57 (highest current). This should all be explained in your manual. Where are you located?
#
Rorschach Re: Error Frequency on Sonobond Ultrasonic Welder
Guru 06/24/2014 8:10 AM
I'm reading between the lines here but I'm assuming this unit originally came from europe and is being used in the US (or vice
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identify which mains frequency it is being fed. further I would suggest you might look into using a resonant filter on the mains to
cleanup much of the hash on the line that might be throwing the generator a curveball. beyond that I'd contact Sonobond and
pay one of their techs to come fix it. Community
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Rorschach Re: Error Frequency on Sonobond Ultrasonic Welder
Guru 06/24/2014 9:40 AM
Another possibility is that if this is an old unit, it may be that the electrolytic capacitors in the system may have aged and are
no longer working properly. if so, replacing all of the electrolytic cans with new units of the same rating may be in order.
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#1 "Re: Error Frequency on Sonobond Ultrasonic Welder" by gringogreg on 06/20/2014 2:35 PM (score 1)
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bigg (3); calpark (10); Crabtree (1); gringogreg (2); NAWONUSA (1); Rorschach (2); Wal (6); welderman (5); WJMFIRE (1)
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11/27/2018 CR4 - Thread: Error Frequency on Sonobond Ultrasonic Welder

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calpark Error Frequency on Sonobond Ultrasonic Welder

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Comments rated to be "almost" Good Answers:

gringogreg Re: Error Frequency on Sonobond Ultrasonic Welder

1. Did you contact Sonobond Tech Support?

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WJMFIRE Re: Error Frequency on Sonobond Ultrasonic Welder In reply to

That's probably the issue.

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calpark Re: Error Frequency on Sonobond Ultrasonic Welder In reply to

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Crabtree Re: Error Frequency on Sonobond Ultrasonic Welder In reply to

calpark Re: Error Frequency on Sonobond Ultrasonic Welder

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bigg Re: Error Frequency on Sonobond Ultrasonic Welder In reply to

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calpark Re: Error Frequency on Sonobond Ultrasonic Welder In reply to

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Can you let me know other ways to power it on 230V?

Join Date: Jun 2010

This is part of the problem elimination process.

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Can anyone help analysis this situation? Thanks!

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But I have 2 questions,

Thanks all for help!

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