Ultrasonic Hand-Held Welders
for Plastic Assembly

Welds, Spot Welds, Stakes, and Inserts
Here are two 500-watt hand-held ultrasonic welders for plastics assembly; a 20-kHz, Model H-520 and a 40-kHz, Model H-540. These compact and portable units are rugged, reliable, and easy to operate. They are designed specifically for welding, staking, inserting, and spot welding applications (see descriptions of applications).

The lightweight hand pieces are ideally suited for manual operations with low volume production requirements or for assembling parts with difficult to reach weld areas. The units consist of an ultrasonic power supply and a 1.5-lb hand gun. The 20-kHz hand guns are supplied with integral 1/2" diameter titanium front drivers with replaceable flat face tips. Other standard tips are available for various applications (see chart on page 54 for tip information). In addition, custom tips can be designed for specific applications. The 40-kHz hand gun is supplied with a removable horn designed specifically for each customer’s requirements.

Most manual applications can be performed with the 20-kHz model. However, the higher frequency and lower amplitude of the 40-kHz system makes it ideal for welding small assemblies that require gentler action. The hand gun systems operate at a standard 120 volts or optional 220 volts nominal input voltage.

The power supply features autotune circuitry which eliminates the need to retune the system each time it is turned on or when the horn/tip is changed. It also regulates the line voltage and provides constant amplitude throughout the welding process. The welders contain a microprocessor-based programmable timer for weld times from 0.1 to 9.9 seconds. Another function of the microprocessor is digital amplitude control. All of these beneficial features yield a more precise and repeatable cycle. Once set up, the user only needs to apply the tip of the hand gun to the parts being assembled and depress the switch on the gun’s housing to operate the welder.

These 500-watt welders contain two overload protection circuits, one for the power supply and the other for the converter. The systems overload circuit protects the power supply from exceeding its maximum wattage. The advanced converter protection circuit is designed to protect against excessive voltage or current caused by the application. With a response time of less than 2 micro-seconds, these circuits instantaneously prevent internal component damage to the power supply and converter.
Ultrasonic Welder Specs

Power Supply / Hand Gun
Model H520/CV52
Power Supply / Hand Gun
Model H540/CV54
Frequency/Power: 20 kHz: 500 watts
50/60 Hz regulated between 95-135 volts or 190-65 volts
Input Voltage: Standard 120 volts or optional 220 volts
Weld Time: 0.1-9.9 seconds
Dimensions: 8.5 in. H x 13.5 in. W x 7.5 in. D
(216 mm H x 340 mm W x 190 mm D)
Weight: 10 lbs (4.5 kg)
Hand Gun Specs:
Dimensions: 1.9 in. (48.3 mm) D, 7.6 in. (193 mm) L (with standard tip)
Weight: 1.5 lbs (0.68 kg)
Horn: Integral with threaded end to accept replaceable tips
Material: Titanium
Tip: Standard- 1/2" (12.7 mm) diameter flat faced titanium tip (see chart below for other tip configurations)
Cable Specifications: Hardwired into hand gun. Optional detachable cable available
Lengths: 10 ft. standard, optional 15 ft. or 25 ft. available
Frequency/Power:40 kHz: 500 watts
Input Voltage: Standard 120 volts or optional 220 volts
50/60 Hz regulated between 95-135 volts or 190-65 volts
Weld Time: 0.1-9.9 seconds
Dimensions: 8.5 in. H x 13.5 in. W x 7.5 in. D
(216 mm H x 340 mm W x 190 mm D)
Weight: 10 lbs (4.5 kg)
Hand Gun Specs:
Dimensions: 1.9 in. (48.3 mm) D, 7.6 in. (193 mm) L (without horn)
Weight: 1.5 lbs (0.68 kg)
Horn: Supplied and priced separately
Material: Titanium or aluminum
Cable Specifications: Hardwired into hand gun. Optional detachable cable available
Lengths: 10 ft. standard, optional 15 ft. or 25 ft. available
(Order horn and tip separately)

Pricing and Purchase on Abbeon.com.

Standard Titanium Tips for
½ " Diameter Horn (thread size ¼- 28)
Flat tip 1/2" diameter
Spot welding tip— specify material thickness
Staking tip— high profile, solid flared stake, specify boss diameter
Staking tip— low profile, solid flared stake, specify boss diameter
Staking tip— high profile, conical boss, spherical head, specify boss diameter
Staking tip— low profile, conical boss, spherical head, specify boss diameter
Staking tip— hollow boss, specify diameter
Overweight tip (machine to 3.5 grams) for special applications
Knurled tip— male coarse, medium or fine (specify)
Knurled tip— female coarse, medium or fine (specify)
Inserting tip with pilot (specify insert size) SAE
Staking/Spot Welding Tips Standard threaded tips available for staking and spot welding are listed below.
Ordering Information (Specify tip required using code letter)
Examples: Staking Tip "A" indicates a tip used for staking a 1/32" solid boss with a high profile flared head. Spot Welding Tip "SA" indicates a tip used for spot welding 1/32" thick material. Flat, knurled and custom faced tips are available.

Pricing and Purchase on Abbeon.com.
Staking (see pricing above)
Tip Code Letter Hollow
Boss
Plastic Boss
Diameter		 Standard Boss
Flare Stake		 Conical Boss
Spherical Stake
Inches mm High
Profile		 Low
Profile		 High
Profile		 Low
Profile
1/32 0.793 A G AA GG —
1/16
1.587
 B H BB HH —
3/32
2.381
 C I CC II —
1/8
3.175
 D J DD JJ R
5/32
3.969
 E K EE KK S
3/16
4.762
 F L FF LL T
Spot Welder



Material Thickness


Tip Code Letter
Inches mm
1/32 0.793 SA
3/64 1.190 SB
1/16 1.587 SC
5/64 1.984 SD
3/32 2.831 SE
7/64 2.778 SF


Inserting (Specify SAE or Metric)
Insert
Size		 Inside
Diameter
of Insert		 Pilot Diameter
of Tip
(Dim. A-inches)		 Insert
Size		 Inside
Diameter
of Insert		 Pilot Diameter
of Tip
(Dim. A-inches)
SAE METRIC
4 - 40 0.088 0.078 2.5 x 0.45 0.079
0.069
6 - 32 0.106 0.096 3 x 0.5 0.097
0.087
8 - 32 0.133 0.123 3.5 x 0.6 0.114
0.107
10 - 24 0.147 0.137 4 x 0.7 0.129
0.119
10 - 32 0.160 0.150 5 x 0.8 0.165
0.155
1/4 - 20 0.200 0.190 6 x 1 0.195 0.185
1/4 - 28 0.211 0.201 8 x 1.25 0.265 0.255
5/16 - 18 0.262 0.252 Pricing and Purchase on Abbeon.com
Optional Accessories
Manual Press is available for assembling parts where production volume does not justify more expensive pneumatic presses. Provides a more controlled motion of the welder than is possible by just holding the hand gun, resulting in more consistent assemblies. This unit is available with foot switch or cam actuation. The trigger handle is removed from the hand gun housing when foot switch actuation is used.

Model SD-M500 for 20 kHz and 40 kHz.

Pricing and Purchase on Abbeon.com
Features
  • CV20 Ultrasonic Hand Gun Collar Adapter
  • 0 to 18" Vertically Adjustable Head
  • ½" Steel Tooling Plate
  • 6" Throat Depth
  • 3" Head Stroke
  • Spring Return Lever Arm
  • Angle Iron Column Supports
  • Through Holes for Work Bench Mounting
  • Adjustable and Positive Stroke Stop Block
  • X-Y Pattern Nest Fixture Mounting Holes on 47/16" and 7" Centers

Pneumatic Press is similar in style to the Manual Press. Contains dual anti-tie down palm buttons, a pressure regulator, and a pneumatic timer with all the required controls. Model SD-P500 for 20 KHz & 40 KHz (Call for pricing)
Stapler attachment is ideally suited for sealing low production rate clam-shell packages. Supplied with two sealing patterns, the standard is a medium diamond knurl on one end and a coarse diamond knurl on the other.
Model CV00523 for 20 kHz
Model CV00543 for 40 kHz

Pricing and Purchase on Abbeon.com
Pistol Grip A lightweight ergonomic device that simply slips onto the hand guns. The operator activates the ultrasonics by pulling on the “trigger”.
Model CV00524 for 20 kHz
Model CV00544 for 40 kHz

Pricing and Purchase on Abbeon.com.
Questions or Orders —
Call  800/922-0977   8am – 4pm Pacific Time