Kobra EX II USC3 en v7b

Operating- and Maintenance Manual
Ultrasonic welding machine
KOBRA EX 2
H auptstraße 95
No. 964731 Rev. 7 D–35435 Wettenberg
http:// w w w . s u t . b i z
DECLARATION OF CONFORMITY 1
SAFETY 2
DESCRIPTION OF THE MACHINE 3
TRANSPORTATION / INSTALLATION 4
SETUP 5
MAINTENANCE 6
DISTURBANCES AND TROUBLE-SHOOTING 7
TOOL CHANGE AND MAINTENANCE 8
SHUTDOWN 9
ADDENDUM 10
NOTES 11
Manufacturer: Schunk Sonosystems GmbH
Hauptstraße 95
D-35435 Wettenberg
Tel: +49 (0) 6 41 / 803 - 0
Fax: +49 (0) 6 41 / 803 – 250
http://www.sut.biz
STAPLA Ultrasonic
Type of machine:
welding machine
KOBRA EX 2
2010
Year of construction:
December 10
Date of issue:
Revision-Informations:
Rev. No. Modified by Modifications Page Datum
2 C. Wohlfahrt General Modifications / 04.09.04
3 C. Wohlfahrt Chapter Safety modified 10-16 20.09.04
6 M. Weiß Changing name to Schunk Sonosystems 18.09.07
7 M. Weiß Data sheet PLC added 81 18.10.08
7 V.Wagner Air consumption added 34 11.05.09
8 C. Wohlfahrt Maintenance plan added 61 14.10.10

Dear user,
Thank you very much that you have decided to buy the ultrasonic welding machine from SCHUNK.
This operating manual is a guideline for the operation and the maintenance of the machine. It will help
you to integrate the machine efficiently into your production process. This operating manual is primarily
addressed to the operator, the set-up man as well as the maintenance personnel, but also to all other
persons who will ensure the operation of the machine.
Please respect and follow all safety advices when operating the machine, in order to avoid damages
and injuries. The safety advices contained in this operating manual have to be observed for any
handling of the machine and should always be available.
Please make yourself familiar with the maintenance manual, in order to find easily and quickly the
relevant chapters in case of a disturbance.
Kindly note that any disrespect of the maintenance advices could lead to serious physical damage and
partial damages of the machine or of other equipments.
For the faultless operation of your welding machine it is necessary to use only SCHUNK spare parts
and tools. Kindly note that otherwise SCHUNK will not be able assume any guaranteeing.
If you have further questions regarding the product or concerning this operating manual, please
address yourself to our service department or contact your local SCHUNK representative office.
Any duplication, reproduction, translation and distribution of this document is only permitted by the
written consent of the SCHUNK Sonosystems GmbH.
Your SCHUNK Team
SCHUNK SONOSYSTEMS GmbH, Hauptstraße 95, D-35435 Wettenberg http://www.sut.biz 5

STRUCTURE OF THIS OPERATING MANUAL
The structure of this operating manual enables the user to find the requested subjects easily. The
chapters are arranged according to the installation of the machine. By having a look to the table of
contents you can quickly find and consult the respective subjects.
The specific security instructions of the system are compiled in chapter 1.
CONTACT INFORMATION
For help in case of any disturbance of the machine, for the ordering of spare parts or for the answering
of further questions concerning this machine, please contact our service department:
SCHUNK Sonosystems GmbH

Hauptstraße 95
D-35435 Wettenberg
Tel: +49 (0) 6 41 / 803 –0
Fax: +49 (0) 6 41 / 803 – 250
Email: STAPLA@Schunk-Group.com
Internet: http://www.sut.biz
When requesting information, please always define the type of machine and let us know the respective
serial number. You will find these pieces of information on the type plates of the machine and of the
ultrasonic controller.

1 DECLARATION OF CONFORMITY ...............................................................................12
2 SAFETY..........................................................................................................................13
2.1 Warning advices and symbols............................................................................................................... 13
2.2 Additional warning symbols .................................................................................................................. 13
2.3 Machine design and operation .............................................................................................................. 14
2.4 General advices and warnings .............................................................................................................. 15
2.5 Safety instructions.................................................................................................................................. 16
2.6 Overview of the standard scope of supply........................................................................................... 17
2.7 Use according to the specifications ..................................................................................................... 17
2.8 Sources of danger and residual dangers ............................................................................................. 18
2.9 Authorised operators.............................................................................................................................. 18
2.10 Safety arrangements ........................................................................................................................... 18
2.11 Emergency-stop key button (optional).............................................................................................. 19
2.12 Functional testing of the emergency-stop key button .................................................................... 19
3 DESCRIPTION OF THE MACHINE................................................................................20

3.1 General ..................................................................................................................................................... 20
3.1.1 Functional description .................................................................................................................... 20
3.1.2 Workpieces .................................................................................................................................... 20
3.1.3 Explanation of the employed special terms ................................................................................... 21
3.2 Basic elements of ultrasonic welding................................................................................................... 22
3.3 Scope of supply ...................................................................................................................................... 24
3.4 Technical Data ......................................................................................................................................... 25
3.5 Dimensions .............................................................................................................................................. 25

3.5.1 Ultrasonic controller ....................................................................................................................... 25
3.5.2 Welder............................................................................................................................................ 26
3.5.3 Emission figures............................................................................................................................. 27
3.5.4 Indications regarding the sound levels .......................................................................................... 27
3.6 Welder ...................................................................................................................................................... 28
3.7 Safety system – Explosion proofness .................................................................................................. 28
3.8 Ultrasonic controller ............................................................................................................................... 29

3.8.1 Overload protection........................................................................................................................ 29
3.9 Tools (Sonotrode and anvil)................................................................................................................... 30

3.10 Drive...................................................................................................................................................... 31
3.11 Pneumatic............................................................................................................................................. 32
3.12 Interfaces.............................................................................................................................................. 32
3.13 Tools ..................................................................................................................................................... 33

3.13.1 Sonotrodes..................................................................................................................................... 33
3.13.2 Anvils.............................................................................................................................................. 33
4 TRANSPORTATION/INSTALLATION ...........................................................................34
4.1 Packaging ................................................................................................................................................ 34
4.2 Storage / Transportation ........................................................................................................................ 34
4.3 Shipment / Intercompany transportation.............................................................................................. 34
4.4 Checking of the delivery......................................................................................................................... 34
4.5 Connected loads ..................................................................................................................................... 35
4.6 Compressed air supply .......................................................................................................................... 35
4.7 Place of installation / Place of operation .............................................................................................. 36
4.8 Ambiance conditions.............................................................................................................................. 36
4.9 Installation of the welding machine ...................................................................................................... 36

4.9.1 Assembly - mechanical .................................................................................................................. 36
4.9.2 Assembly - electrical ...................................................................................................................... 36
4.10 Disassembly......................................................................................................................................... 37
4.11 Setup for initial operation ................................................................................................................... 37
5 SETUP ............................................................................................................................38
5.1 General ..................................................................................................................................................... 38
5.2 Welding position ..................................................................................................................................... 38
5.3 Table of parameters (Standard values for left-/right-cut) ........................................................................ 39
5.4 SETUP Mode / Settings on the controller before the initial operation .............................................. 40
5.4.1 Date and time................................................................................................................................. 40
5.4.2 Language ....................................................................................................................................... 40
5.4.3 Counters ........................................................................................................................................ 41
5.4.4 Peripherals ..................................................................................................................................... 41
5.4.5 Adjustment of the tools .................................................................................................................. 42
5.4.5.1 Left- and right-cut tooling ............................................................................................................ 43
5.4.5.2 Double-cut tooling (optional)....................................................................................................... 44
5.4.5.3 Tooling without cut...................................................................................................................... 45
5.4.6 Ultrasonic test ................................................................................................................................ 46
5.4.7 Calibration of the height measurement.......................................................................................... 47
5.4.8 Process Control ............................................................................................................................. 48
5.5 TEACH mode (Individual weldings) ...................................................................................................... 49

5.5.1 Welding parameters....................................................................................................................... 49
5.5.2 Calling of programmes................................................................................................................... 50
5.5.3 Processing of programmes............................................................................................................ 50
5.5.4 Generation of programmes............................................................................................................ 50
5.5.5 Storage of programmes ................................................................................................................. 50
5.6 TEACH Mode (Sequences) ..................................................................................................................... 51

5.6.1 Generation of sequence ................................................................................................................ 51
5.7 Influencing factors regarding the welding result ................................................................................ 52
5.8 Evaluation of the welding quality .......................................................................................................... 52
6 OPERATION...................................................................................................................53
6.1 Daily starting ........................................................................................................................................... 53
6.2 Preparations ............................................................................................................................................ 54
6.3 Welding .................................................................................................................................................... 55
6.4 Completion of the welding ..................................................................................................................... 55
6.5 Operational controls on the welder and the system cable ................................................................. 56
6.5.1 Emergency-stop key button (optional) ........................................................................................... 56
6.5.2 START ........................................................................................................................................... 56
6.6 Operational controls on the ultrasonic controller ............................................................................... 57
6.7 OPERATE Mode ...................................................................................................................................... 59

6.7.1 Alarm.............................................................................................................................................. 59
7 DISTURBANCES AND TROUBLE-SHOOTING ............................................................60

7.1 General maintenance.............................................................................................................................. 60
7.2 Examples of wear on the weld tools (sonotrode and anvil) ............................................................... 60
7.3 Maintenance plan .................................................................................................................................... 61
7.4 Maintenance documentation.................................................................................................................. 63
7.5 Pneumatic service unit ........................................................................................................................... 64

7.5.1 Empty the condensate tank ........................................................................................................... 64
7.5.2 Changing the filter cartridge........................................................................................................... 64
7.6 Trouble-shooting..................................................................................................................................... 65
7.6.1 General .......................................................................................................................................... 65
7.6.2 The values are not within the tolerance zone ................................................................................ 66
7.7 Contact persons and address of the service department .................................................................. 67
8 SERVICE AND MAINTENANCE ....................................................................................68

8.1 Installation and removal of the oscillating system.............................................................................. 68
8.1.1 Dismounting of the limit stop.......................................................................................................... 68
8.1.2 Opening the rear wall..................................................................................................................... 69

8.1.3 Detaching the oscillating system ................................................................................................... 71
8.1.4 Removal of the oscillating system ................................................................................................. 71
8.1.5 Disassembly of the oscillating system ........................................................................................... 72
8.1.6 Assembly of the oscillating system ................................................................................................ 73
8.2 Adjustment of the anvil .......................................................................................................................... 74
8.3 Adjustment of the welding depth limit stop and the welding positions............................................ 74
8.4 Replacement of the height sensor ........................................................................................................ 75
8.5 Installing/removing the fork ................................................................................................................... 77
8.6 Adjustment of the fork............................................................................................................................ 80
8.7 Replacing the drive unit ......................................................................................................................... 81
9 SHUTDOWN ...................................................................................................................82
9.1 Disconnection ......................................................................................................................................... 82
9.2 Final shutdown........................................................................................................................................ 82
9.3 Disassembly ............................................................................................................................................ 82
10 APPENDIX...................................................................................................................83
10.1 Spare part drawings ............................................................................................................................ 83
10.2 Certificate of explosion proofness .................................................................................................... 84
10.3 Data sheet PLC-Adapter (optional).................................................................................................... 87

10.3.1 Pin definition .................................................................................................................................. 87
10.3.2 Connection values ......................................................................................................................... 87
10.3.3 Signal description:.......................................................................................................................... 87
11 NOTES.........................................................................................................................89

LIST OF ILLUSTRATIONS:
Figure 1: Operation of the machine (shown without balancer) 14
Figure 2: Standard scope of supply (overview) 17
Figure 3: Emergency-stop key button (optional) 19
Figure 4: Schematic construction of the elements relevant for the osciallation 22
Figure 5: Scope of supply 24
Figure 6: Dimensions of the ultrasonic controller 25
Figure 7: Dimensions of the welder (without system cable) 26
Figure 8: Welder with inserted tube 28
Figure 9: Front view of the ultrasonic controller 29
Figure 10: Overload protection on the rear wall 29
Figure 11: Schematic illustration of the tools 30
Figure 12: Cooling unit with filling tube (A) for the welding with right-hand cut tools 30
Figure 13: Cooling unit with filling tube (A) for the welding with left-hand cut tools 30
Figure 14: Welding space and fork 31
Figure 15: Rear wall of the ultrasonic controller 37
Figure 16: Welding position 38
Figure 17: Table of wall thickness / Thickness of the feeler gauge 42
Figure 18: Insertion of the tube 55

Declaration of Conformity 1
1 DECLARATION OF CONFORMITY

Safety 2
2 SAFETY
Please carefully and completely familiarize yourself with the content of this
operating manual before starting the operation of this machine or carrying out
maintenance and reparation works.
2.1 Warning advices and symbols
The following warning advices and symbols will inform you about possible risks and dangers when
operating the machine:
Information: Informs about actvities and situations.
Advice: Advises against situations which may lead to damages.
Caution: Warns of situations which may lead to physical injuries

of operators, technical staff or other persons within the
environment of the machine.
Danger: Warns of situations which may lead to serious

injuries or accidents with fatal consequences for
operators, technical staff or other persons
within the environment of the machine.
2.2 Additional warning symbols

Ear protection: Imposes wearing of ear protection.
Danger: Warns of dangerous electrical voltage.
Danger: Warns of dangerous movements which can lead

to squeezing of hands or fingers.

Safety 2
2.3 Machine design and operation
This machine is determined for the operation on a fixed location. For maintenance and reparation
purposes the access should be ensured from all sides.
The safety concept of the machine presupposes that the machine is controlled by a single
operator. This applies also for the adjustment of the machine. Every other person in the
environment of the machine may be an additonal safety risk for the operation and the
maintenance of the machine!
Figure 1: Operation of the machine (shown without balancer)

Safety 2
2.4 General advices and warnings
Please observe the country-specific safety instructions as well as the safety regulations of your
company. All instructions contained in these advices regarding the initial operation and the
maintenance have to be met.
The owner is responsible for the training of the machine operators and the maintenance personnel. The
training course has to comprise at least the following subjects: Type of machine, danger areas, safety
regulations, function of the individual machine components, correct operation of the machine.
All maintenance, service and possible reparation works on the electrical parts of the machine can only
be carried out by qualified and skilled electrical personnel.
You may only use the machine for purposes according to the specifications, see 1.6.
Modifications of the machine will cause the loss of the EC-Conformity (CE) and of the explosion
proofness certificate.
Please familiarise yourself with all safety regulations and accident-prevention measures before
operating this machine and observe them for your own protection.
This operating manual presupposes a system-specific training of the operators before they work with
this machine. This operating manual also presupposes that the technical personnel disposes of an
appropriate training and observes the accident-preventing measures when operating the machine.

Safety 2
2.5 Safety instructions
• Please always use the respective protective devices defined for each particular application!
• Avoid getting in touch with the welding tools (sonotrode and anvil) during the welding process.
• Make sure that there are no solvents or vapours in the air when starting the machine and during its
operation (e.g. resulting from manufacturing processes within the environment of the machine).
• Vapours and gases emerging from the welding process may represent a health risk. Please avoid
the inhalation of such vapours and gases.
• In order to avoid accidents and damages caused by a second person, please keep the direct
environment of the machine under surveillance and limit the access to the working area!
• Please take particularly care that the machine is in proper condition during the operation.
• Only carry the machine and its components on the grips determined for this purpose.
• For safety reasons a welding cycle may only be activated, if the tube has been inserted correctly;
special processes regarding the setup of the machine are excluded from this procedure.
• Maintenance and reparation works may only be effected by qualified personnel that has been
especially trained according to the valid safety regulations.
• Special regulations and work instructions can be necessary because of your respective
manufacturing process. The disregard of these instructions and regulations can cause accidents
with serious physical injuries or financial damages. The observation of these regulations may
probably avoid drastic consequences!
• Persons with cardiac pacemakers are not allowed to stay in the direct environment of the ultrasonic
welding machine. As the high-frequent ultrasonic vibrations may have an influence on cardiac
pacemakers, danger of life will result from a dismounted or damaged screen.
• The machine may only be used together with a personal noise protection device.
• Maintenance and reparation works may only be carried out in a non-hazardous area.

Safety 2
2.6 Overview of the standard scope of supply
Figure 2: Standard scope of supply (overview)
• Welder withSystem cable and integrated emergency-stop key button (optional)

• Ultrasonic controller
2.7 Use according to the specifications
The machine is designed for seal-welding and cutting of copper-tubes. The range of application are gas
impinged compounds, especially in the domains of refrigeration and freezing. The weldability of the
material is the precondition for using the machine. Furthermore, the shape and the quality of the tube
have an influence on the welding.
Any other use diverging from this description as well as a divergent application is not in accordance
with the conception of this system. Therefore, it is prohibited. Also the ultrasonic generator (controller)
may only be applied on this system. Any kind of abuse of the machine and of the components, too, may
cause unknown danger for the operators and casual bystanders.

Safety 2
2.8 Sources of danger and residual dangers
Danger! The danger of violent contusions exists within the whole area
of the Welder and between the welding tools (sonotrode and
anvil)!
Danger! Welder: High-voltage within the housing!

Ultrasonic controller: High-voltage within the housing!
Danger! If the machine is operated according to the safety regulations

(see 1.4, 1.5), risks of injury can be excluded to the greatest
possible extent. If the safety regulations are not strictly
observed, this may cause injuries!
2.9 Authorised operators
This machine has to be operated exclusively by trained personnel.

The operators have to be particularly informed about the sources of danger and the residual dangers
mentioned under chapter [1] by trained personnel.
The safety instructions of the manufacturer (see 1.4) have to be observed.

2.10 Safety arrangements
Device Position Function

Number of devices
on the machine
Emergency-stop key 1 Integrated into Complete disconnection of the
button system cable machine.
(optional)
Set-Up key-operated 1 On Controller- After the actuation of this switch by the
switch Frontplate set-up person, modifications on the
machine can be carried out within the
SETUP mode, in order to change the
tools for example.
Danger: Potential danger of injuries when the key-

operated switch is in the SETUP-position!

Safety 2
2.11 Emergency-stop key button (optional)
Figure 3: Emergency-stop key button (optional)
2.12 Functional testing of the emergency-stop key button

During the operation the function of the emergency-stop key button can always be tested by the
operating personnel.
The control of the machine as well as all pneumatic actuators are disconnected (electrically and
pneumatically), the fork goes into initial state (open).
After having actuated and unlocked the emergency-stop key button, you have to switch on the
ultrasonic controller once again.
Advice: The weld joint of the tubes may be defective after the
functional testing of the emergency-stop key button!

Description of the machine 3
3 DESCRIPTION OF THE MACHINE
3.1 General
3.1.1 Functional description

A great number of metallic materials with melting points below approx. 700 °C can be welded with each
other without direct supply of heat or bonding agents by using ultrasound.
The stability of the compound depends on the qualities of the material, the parameters determined by
the device, the design of the joint surfaces, the position of the weldment joint, the shape and the design
of the welding tools as well as the use according to the specifications by the operator.
Therefore, it is in any case essential to determine the weldability of the respective material as well as
the optimal working conditions necessary for this purpose, the operating parameters and the optimal
geometry of the tools in the SCHUNK application laboratory.
The welding is effected by the activation of vibration energy which welds the material without adding
any other resources.
The generation of the ultrasonic oscillation results from piezoceramic disks. The vibration generator
(converter) receives the supply voltage from a generator, the ultrasonic generator. The mechanical
oscillation amplitude is passed over mechanically and is transmitted to the sonotrode. The shape of the
sonotrode's working surface is adapted to the welding conditions.
3.1.2 Workpieces
Copper as well as its weldable alloys are used as welding materials (workpieces).
The application limits of the system result from the size of the workpieces, the dimensions of the
welding surfaces as well as from the properties of the materials.

3.1.3 Explanation of the employed special terms

Welder Module for the fixture of the ultrasonic oscillating system and the application of
the welding load
Oscillating system Converter, booster and sonotrode (horn)
Converter Converter of electrical energy into mechanical vibration
Booster Component of the oscillating system for the amplification or the reduction of
the converter's amplitude
Sonotrode Main welding tool and top welding space delimitation
Anvil Bottom welding space delimitation and supporting surface for parts
Serration Structure of the working-surfaces of the welding tools which fixes the tube
Welding space Welding area which is delimited by the sonotrode and the anvil
Fork Lifting unit and support for the anvil
Ultrasonic controller Control unit of the welding process
System cable Contains the pneumatic and electric connecting cable between the welder and
the ultrasonic controller
Amplitude Mechanical vibration deflection of the sonotrode

Zero point Place on which no longitudinal vibrations occur within the sonotrode
Pressure converter Electronical control element of the air pressure that is integrated within the
ultrasonic controller
Welding method Determined by welding parameters which are set as standard or test
parameters.
Welding parameters Energy, time or compression
Welding energy Energy in wattseconds (Ws) which is required for the welding wird
Welding time Duration of the ultrasonic exposure during the welding
Trigger time Time between the start signal ("anvil up") and the activation of the ultrasound
Afterpulse Short activation of the ultrasound in order to release the tube and to clean the
sonotrode after the welding activity

3.2 Basic elements of ultrasonic welding
In order to obtain an optimum welding result, it is very important to adapt the electronical and
mechanical components to each other. Figure 4 shows the schematic construction.
A) Sonotrode
B) Booster
C) Converter
D) Anvil
E) Welding part (tube)
F) Ultrasonic controller
(electrical control)
G) Power supply connection
Figure 4: Schematic construction of the elements relevant for the osciallation
The feed frequency of 50 or 60Hz is converted into 20 kHz by the ultrasonic controller. The converter
transforms this electrical energy into mechanical vibration energy. In this context the mechanical
vibration frequency corresponds to the electrical frequency of the ultrasonic controller of 20kHz. The
booster that is placed between the sonotrode and converter and serves as a transformation device for
the amplitude.
The following welding parameters determine the quality of the ultrasonic weld joint:
• Amplitude of the sonotrode

• Welding pressure (working pressure)
• Energy
• Compression
• Welding time
Furthermore, kindly note that the use according to the specifications as well as the wear-out of the tools
(abrasion) will have a considerable influence on the results.

Geometry, wall thickness and material quality are decisive for the input data.
If the customer buys the welding machine directly from the manufacturer, it will be adapted according to
the tube used by the customer, and the respective parameters will be stored within the ultrasonic
controller.
Information:
If the material and/or the tube had changed, the parameters
have to be redetermined.
Before modifying your parameters, please verify the new
material regarding its suitability for the welding process or for
the welding machine. The SCHUNK service will be glad to
advise you.
The welding load is obtained by a cylinder integrated into the welding machine. At the same time the
pressure converter integrated into the ultrasonic controller provides the working pressure.
In order to obtain an optimum welding result, the welding is effected until the final height is achieved.
Simultaneously, the welding time and energy are used as test parameters. In any case, the weldings
have to be subjected to a quality control, and the welding parameters have to be adapted, if necessary.
The working-surfaces of the welding tools (sonotrode and anvil) have special structures. They have an
influence on the welding quality. As the working-surfaces are subjected to general wear-out, they have
to be checked regularly and to be replaced according to a specified cycle or to be exchanged after
wear-out.
The amplitude measured by a fine needle (test gauge) corresponds to the half mechanical deflection of
the sonotrode. The welding will be effected by the mechanical vibrations of the sonotrode's working-
surfaces.
If the amplitude is set too high, this may lead to the overstressing of the welding material and to the
destruction of the tools. An amplitude that is set too low will generally cause a worse welding quality
and manifests itself among other things by a prolongation of the welding time. This will lead to an
enhanced development of heat and thus to a reduced service life of the tools.

3.3 Scope of supply
A) Welder with oscillating system and wiring

B) Ultrasonic controller (generator with control unit) with 4 keys for the key-operated switch
C) Operating and maintenance manual
D) Pneumatic maintenance unit consisting of a manually operated shutdown valve, a pressure regulating
valve with manometer, a water separator and coarse/fine filter with connecting hose
E) Maintenance and adjusting tools (in a roll-up pocket) consisting of:
- 1 set hexagon spanners
- 1 hook spanner
- 2 spanner wrenches
- 1 set feeler gauge tape
- 1 setting gauge
Figure 5: Scope of supply

3.4 Technical Data
Welding method: Metal welding by ultrasound, vibration frequency 20 KHz

Design: Oscillating system clamped into the welder by a special fixture
Vertical motion via a pneumatic cylinder
Starting of the welding procedure per starter push-button
Weight of the welder 19 kg (inclusively grips and system cable)
inclusively the oscillating
system:
Dimensions of the welder: 517 x 225 x 246 mm (inclusively handle, without system cable)
Weight of the ultrasonic 17 kg
controller:
Dimensions of the controller: 450 x 135 x 445 mm (without handles)
3.5 Dimensions
3.5.1 Ultrasonic controller
Figure 6: Dimensions of the ultrasonic controller

3.5.2 Welder
Figure 7: Dimensions of the welder (without system cable)

3.5.3 Emission figures
The machine is characterised by high environmental acceptability, because the ultrasonic welding
process does not require any supplementary operating agents in addition to the electric power supply
and the pneumatic compressed air supply.
3.5.4 Indications regarding the sound levels
The sound level generated by the machine depends on the characteristics and the shapes of the
workpieces. For common materials and shapes, this sound level amounts to 112 dB (A) in 1 m distance
and at 1.6 m operating height.
Depending on the properties of the workpieces, the sound level may considerably exceed
110 dB (A). In such cases you have to proceed according to the requirements of the industrial safety.

3.6 Welder
Figure 8: Welder with inserted tube

The welding machine KOBRA EX 2 seals copper tubes gas-tight by means of ultrasound and (optionally)
separates them within the same working operation. The tubes should have an outside diameter of at least
2 mm and should not exceed 12.5 mm.
.
3.7 Safety system – Explosion proofness
This machine is designed for the use within environments exposed to explosions of
category II 3 G (cf. Explosion proofness certificate, see chapter 9)
In the rear part of the welder, a certain amount of air per time unit flows into the
purging space where it generates a defined overpressure.
The amount of air which has flown in escapes on the defined orifices on the periphery
of the sonotrode (primarily below the sonotrode).
This overpressure prevents dangerous gases from penetrating into the housing.

3.8 Ultrasonic controller
The ultrasonic controller contains the electric power supply of the ultrasonic generator as well as the
control elements for the machine.
Additionally, it contains all necessary elements, in order to modify and adapt the weldings according to
the conditions. By turning the control button, you can move the marker on the display over the menu
items. You can select the highlighted menu item in its function by pressing the button. If the data fields
are marked, the turning of the control button will change these figures. By pressing this button, they will
be stored. Then, the cursor will be released.
Figure 9: Front view of the ultrasonic controller
3.8.1 Overload protection
Figure 10: Overload protection on the rear wall
A) Safety fuse 2 Ampere - Operating voltage

B) Safety fuse12,5 Ampere - Power module

3.9 Tools (Sonotrode and anvil)
The manufacturer has adapted the sonotrode to the used oscillation frequency. Modifications
concerning the height and the masses will lead to the breakdown of the whole system and may cause
damages!
A) Sonotrode
B) Anvil
A
B
Figure 11: Schematic illustration of the tools
The welding tools are adapted to the respective application:
Figure 12: Cooling unit with filling tube (A) for the Figure 13: Cooling unit with filling tube (A) for the
welding with right-hand cut tools welding with left-hand cut tools

3.10 Drive
Figure 14: Welding space and fork
A) Pneumatic driven fork: The vertical movement of the fork closes the welding space
Caution: For safety reasons during welding, only insert the

specific tube between the welding tools and never use
steel pins or similar materials!

3.11 Pneumatic
The oscillating system of the welder consisting of the sonotrode, the booster and the
convertor is located in a housing of which the interior space is rinsed thoroughly by
air.
The purging air is introducted by a separate air hose (blue). The pressure of this hose
is monitored by the control unit (ultrasonic controller).
The amount of the air flowing into the purging space is determined by an air regulator.
The dynamic pressure in front of the air regulator is used in order to actuate a
pressure switch with 2 start-valves within the ultrasonic controller.
This pressure switch transmits an electric start signal to the control system, if
a) the gas pressure is > 6 bar (4 bar pressure switch on) and
b) the dynamic pressure is > 1.5 bar (purging air available).
The electric signal will only start a welding cycle, if 20 sec have passed by after the
activation of the respective programme within the ultrasonic controller (e.g. when the
supply voltage is connected).
The time period of 20 sec is preset by a time lag relay which is always restarted on
the press switch after the pressure has fallen below 4 bar.
.
The preset hysteresis provokes a switching-on at 4 bar and a switching-off at >3.4
bar.
An additional hose (green) supplies the 24V-valve within the purging space with the
working pressure for the cylinder which presses the anvil mounted on the fork against
the sonotrode.
3.12 Interfaces
On the rear wall of the ultrasonic controller a RS-232 interface is available (see 5.4.4).

3.13 Tools
3.13.1 Sonotrodes
Application Order number
LEFT-cut
103 573 46
RIGHT-cut
103 573 45
NO-cut
130 573 47
DOUBLE-cut
103 575 41
*
3.13.2 Anvils
Application Order number
LEFT-cut
103 575 94
RIGHT-cut
NO-cut
103 575 95
LEFT-cut, round
* 103 575 98
RIGHT-cut, round
*
DOUBLE-cut
103 575 93
*
* = optional for special applications

Transportation/Installation 4
4 TRANSPORTATION/INSTALLATION
This operating and maintenance manual acts on the assumption that the measures described in this
chapter are carried out by particularly trained qualified personnel with appropriate knowledge and
instruction regarding the accident prevention regulations.
4.1 Packaging
The packaging materials have to be kept in store for later shipment or the final shutdown of the
machine.
4.2 Storage / Transportation
If the machine is not used for a longer time period (> 1 week), we recommend to disassemble and store
it.
The machine has to be stored in a location that must be dry and dust-free.
We recommend the following procedure to you before storing the machine:

• Clean the machine at the place of operation.
• Make sure that corrosions cannot occur at the place of storage. If there is the danger of corrosion,
we recommend to wrap the machine into moisture-absorbing materials.
4.3 Shipment / Intercompany transportation
When transporting the machine, please take care to protect it against shiftings and falls. The weight of
the complete welding unit (excluding spare parts or additonal tooling) is around 36 kg, therefor the
safety regulations of your company for the transport of heavy parts apply.
4.4 Checking of the delivery
Please check the completeness of the delivery by means of the shipping note (see 3.3).

4.5 Connected loads
Mains supply: 230 ±15% VAC 50/60Hz single phase/grounded
Power consumption: Max. 3000 W
Fuse protection: 16 A
Compressed air supply in front of 6.5-10 bar, dry, oil-free

the maintenance unit:
Air consumption: approx. 20 l/min. at 6 bar (excluding cooling air)
Air consumption of cooling ~180 l/min at 6,5 bar
~160 l/min at 5,5 bar
4.6 Compressed air supply
Working pressure on the machine (behind the maintenance unit):
− 6 bar constantly
Information: If the minimum working pressure is under-run, the functioning

of the welding machine as well as the welding result will be
affected!
Information: If there is water within the compressed air, this will lead to the
destruction of the pressure converter as well as of all other
pneumatic and electronic components installed within the
ultrasonic controller. Therefore, the compressed air
maintenance unit has to be inserted between the ultrasonic
controller and the compressed air supply!
Caution: Risk of injury due to not properly fastened pneumatic

hoses. Pay attention when plugging hoses!

4.7 Place of installation / Place of operation
Danger: The ultrasonic controller must not be installed

within a potentially explosive environment!
The conceptual design of the machine's components acts on the assumption that the machine is
installed and used in a weatherproof location.
For maintenance and reparation purposes, the access of the machine should be possible from all
sides.
We recommend the suspension of the welder on a cable control (balancer). Please take care that the
machine is always fixed in its position.
4.8 Ambiance conditions
Ambient temperature: min. [°C] - 10

max. [°C] + 40
Higher temperatures can reduce the service life of the welding
machine, because there may be a lack of lubricants etc.
Relative air humidity: min. [%] 10

max. [%] 90
The machine may only be used at a maximum height of 1000m above sea level. It may only be used in
a non-dewed condition.
4.9 Installation of the welding machine
Please inform the delegated safety officer about the receipt of the machine and coordinate with him the
installation procedure of the machine.
4.9.1 Assembly - mechanical
The welder can be held manually. If you use them frequently, we recommend to disburden the operator
by making use of an appropriate cable control (balancer) on the welder.
4.9.2 Assembly - electrical
The distance of the controller and the machine is limited to approx. 10 meters due to the given length of
the cables.

Figure 15: Rear wall of the ultrasonic controller

A) Place the end of the system cable into the angle support on the rear wall of the ultrasonic
controller determined for this purpose and tighten the fastening nut.
B) Then, connect the big cylindrical connector to the socket "HF-out" (High Frequency) and lock the
connection with the knurled nut. Please take care that the nut is screwed down completely.
C) Insert the Sub-D connector into the respective socket and lock with its two screws. (A little flat
screwdriver will be necessary!)
D) The pneumatic hoses identified by colours are connected to the respective ports.
E) The power supply lead is firmly connected to the ultrasonic controller. Put the mains lead into a
socket of a single-phase grounded supply mains with an alternating voltage of 230 ±15%V. Take
care that the housing of the ultrasonic controller is connected to the ground by the ground contact
of the plug.
Danger of voltage!
Please take care that the ultrasonic controller cannot be abused as surface
for putting down objects (e.g. for drinks)!
Please pay attention to the fact that an extension cable of more than 10 m length
which does not have an adequate conductor cross-section will cause an
inadmissible voltage drop. Thus, it can affect the operativeness of the whole system!
4.10 Disassembly
For disassembly of the machine, please proceed in the reverse order of the process described above.
4.11 Setup for initial operation
The SCHUNK SONOSYSTEMS company has already installed the basic settings of the machine.
Thus, the machine is ready for operation after the installation.

SETUP 5
5 SETUP
5.1 General
SCHUNK SONOSYSTEMS has adjusted the machine to the tube samples provided
in advance by the customer.
If you have not sent any samples to us in advance, SCHUNK SONOSYSTEMS will
set up the machine according to your indications.
In this case, the SCHUNK laboratory, however, kindly requests you to forward
samples, in order to be able to determine the optimal parameters for your operation
and to suggest adjustments or improvements, if necessary.
The anvil and the sonotrode have to be placed in the correct position for welding and
have to be fixed.
Please consider that the sonotrode, the booster and the converter have to be in
resonance. Modifications of the sonotrode require an adaptation of the resonance by
the manufacturer.
If SCHUNK SONOSYSTEMS has not installed any setup, please inform yourself
about the most important appropriate standard parameters for the welding part or
contact the manufacturer.
Please define the part number within the TEACH mode (see 5.5) or select an existing
number with an established set of parameters. Adequate test weldings should be
carried out.
5.2 Welding position
A) Compressor
B) Compressor tube
C) Cu-Filling tube according
to the specification
(solded)
D) Welding area
E) Filling valve
F) Min. distance 90 mm
G) Filter
H) Radiator
Figure 16: Welding position

SETUP 5
5.3 Table of parameters (Standard values for left-/right-cut)
Diameter of the tube (mm): 6.00 6.00 6.35 6.35 3.00
Wall thickness (mm): 1.00 0.75 0.60 0.75 0.55
Gap dimension (mm): 0.90 0.65 0.55 0.65 0.50
Pressure (bar) 4.20 - 4.60 4.20 - 4.60 4.20-4.40 4.20-4.40 4.20 - 4.60
Amplitude (µ
µm) 20 - 24 20 - 24 ~23µ ~23µ 20 - 24
t1 (s) max. 2 0.80 - 1.20 0.80 - 1.20 ~0.80 ~0.80 0.80 - 1.20
t2 (s) max. 1 0.20 - 0.35 0.20 - 0.35 0.20 - 0.35 0.20 - 0.35 0.20 - 0.35
Final height (mm), measued with ~0.80 ~1.00

~1.30 ~1.00 ~0.70
caliper
Information: Due to variations concerning the copper qualities, the wall

thicknesses, the diameters of the tubes and the tolerances
within the production, the parameters have to be adapted
individually to the respective product, if necessary.
Regarding the determination of parameters not listed in the table, please contact SCHUNK
SONOSYSTEMS.

SETUP 5
5.4 SETUP Mode / Settings on the controller before the initial operation
Information: This mode of operation requires key 3!
After the key has been turned to SETUP, the SETUP

mode is activated. The SETUP menu illustrated on the
left hand side will appear.
5.4.1 Date and time

The current date and time can be set. They are used for
the printout of the welding statistics (optional).
5.4.2 Language
The desired language for the texts shown in the display
can be set here. After having opted for a language, all
texts will be displayed in the selected language.
The following languages have been preset as standard

languages:
• German
• English

SETUP 5
5.4.3 Counters
The service-counter should be used, in order to display
the welding position which has to be modified each time
after the completion of 4000 weldings (see 8.4).
Furthermore, it can be used as display for the periodical
check of the machine.
In order to reset the service-counter, please select the

value and confirm it by pressing the control button two
times.
The permanent counter counts the total number of welds

of the machine and cannot be reset.
The air-shutdown shows the delay time in which the air

will be cut off, if the machine is not used. A maximum
value of 60 min. can be set.
5.4.4 Peripherals
Here you can select the connected peripheral equipment.
Printer:
The weld data from each weld is exported to the
connected printer via the RS-232 port. It is also possible
to connect a PC with a terminal program to collect the
data.
PC:
If selected, a PC with the SCHUNK Sigma Data Software
can be connected to the DATAPACK port for statistical
process control.

SETUP 5
5.4.5 Adjustment of the tools
Information: This adjustment has to be carried out, if mechanical shiftings

have been effected during the exchange of the sonotrode and
the anvil or new tools have to be adjusted.
If the start signal has been actuated, the anvil will close.
No ultrasound will be activated.
The height measured during this process is indicated.
The anvil must not touch the sonotrode, when the welder
is closed.
Therefore, the tooling gaps must be set before the initial
operation.
After the command to start the process has been given,
the welding tools will close and the gap dimensions
between anvil and sonotrode can be adjusted.
X
X
X
B (0,4mm) B (0,25 - 0.30mm)
Gaps on left- and right-cut tooling Gaps on tooling without cut Gaps on double-cut tooling
(optional)
Figure 17: Table of wall thickness / Thickness of the feeler gauge

SETUP 5
5.4.5.1 Left- and right-cut tooling

Distance between the cut-anvil-sonotrode:
Loosen the 2 set screws (A) on both sides by means of a

hexagon spanner (SW4) and adjust the gap between the
sonotrode and the anvil (B) by a feeler gauge 0.40 mm
(C) in lateral direction.
The feeler gauge has to be in a slightly fixed position, but
you should still be able to withdraw it by hand.
Then, tighten the set screws (A) on both sides and

perform a calibration of the height (see 4.4.8).
Take care that the oscillating system is firmly clamped

after this adjustment of the gap!
X
B (0,4mm)
Setting the height dimension (limit stop) between

anvil and sonotrode:
The height limit stop (gap X) is adjusted according to the

employed wall thickness of the tube.
For a wall thickness of the tube of 0.75 mm, please use a

feeler gauge of 0,65 mm.
In this case, the final height amounts to 0.95 – 1.05 mm

(i.e. ~ 1.00 mm).
For a wall thickness of the tube of 1 mm, please use a

feeler gauge of 0.9 mm.
In this case, the final height amounts to 1.20 - 1.30 mm

(i.e. >1.20 mm)
• Please loosen the fixing screws (D) of the limit stop

on both sides by means of a hexagon spanner
(SW3).
• Then, adjust the minimum distance by means of a
hexagon spanner (SW4) using the adjusting screw
(E) below the anvil.
After this procedure, tighten the fixing screws (D) and
perform the calibration of the height (see 4.4.8).

SETUP 5
5.4.5.2 Double-cut tooling (optional)
Distance between the cut-anvil-sonotrode:
Loosen the 2 set screws (A) on both sides by means of a

hexagon spanner (SW4) and adjust the gaps between
the sonotrode and the anvil (B) by a feeler gauge 0,25-
0,30mm in lateral direction.
The feeler gauge has to be in a slightly fixed position, but
you should still be able to withdraw it by hand.
Then, tighten the set screws (A) on both sides and

perform a calibration of the height (see 5.4.7).

X
B (0,25 - 0.30mm)




(i.e. ~ 1.00 mm).


(i.e. >1.20 mm)

(SW3).
perform the calibration of the height (see5.4.7).

SETUP 5
5.4.5.3 Tooling without cut
Loosen the 2 clamping set screws on both sides by

means of a hexagon spanner (SW4) and adjust the
sonotrode centralized above the anvil.
Then, tighten the set screws on both sides and perform a

calibration of the height (see5.4.7).

X



(i.e. ~ 1.00 mm).


(i.e. >1.20 mm)

(SW3).
perform the calibration of the height (see5.4.7).

SETUP 5
5.4.6 Ultrasonic test

This test checks the power dissipation of the oscillating
system in idle position. The power dissipation is
considered as a criteria for the mechanical and electrical
operativeness of the oscillating system.
If the values are > 100W, the oscillating system should
be checked and probably exchanged (see 8.1).
For the duration of the operation, ultrasound is activated.

There will be no mechanical movement of the drive.
This function has to be executed after each setting or

adjustment of the oscillating system's components, in
order to make sure that there is no mechanical contact
between the vibrating and the stationary parts and that
the oscillating system has been correctly installed by
using the right parts.

SETUP 5
5.4.7 Calibration of the height measurement

Information: Prior to height calibration, a prompt is diplayed to confirm if the
machine is equipped with “standard anvil” or “round type anvil”.
After the exchange of the tooling or the height sensor

(see 7.5), a calibration of the absolute height measuring
system will be necessary.
When activated, the calibration programme prompts the

user to insert a feeler gauge of 1 mm height between the
anvil and the sonotrode. The feeler gauge needs to be
placed in the welding position, i.e. on the limit stop.
When the start button has been pressed, the tooling will
close over the feeler gauge, and the programme will store
the value.
The process needs to be repeated with a 2 mm – feeler
gauge.
In doing so, please take care that the tools are contacted
by both feeler gauges!

SETUP 5
5.4.8 Process Control

Here you can change from "single welds" to "sequential
welds" and vice versa.
Single welds are individual welds which can be carried

out with the same or different parameter sets.
Useful application:
Refridgerator-manufacturing with one weld per device,
which means same tube diameter always. Therefor, only
one parameter set has to be chosen at the beginning of
the manufacturing process or shift.
Sequences are consecutive welds within a stored cycle.
A sequence can be composed of both different and

identical sets of parameters (see 4.6).
Useful application:
Refridgerator-manufacturing with three different welds
per device, which means different tube diameters.
In this case, a sequence should be composed of three
different parameter sets, which are then welded
consecutively per device.

SETUP 5
5.5 TEACH mode (Individual weldings)
Information: This mode of operation requires keys 2 or 3!
After having turned the key to TEACH, the TEACH mode

is activated.
5.5.1 Welding parameters
The following activities can be executed:

• Setting of the welding parameters
• Execution of test weldings
• Setting of the tolerances of the test parameters
• Storage of the welding parameters
• Calling of the stored values
• Overwriting of the stored values

SETUP 5
[Tube-number]:
This is the denomination under which the welding
parameters for a certain product are stored. This number
can be arbitrary within the limits of an acceptable input.
The setting of the amplitude is done in steps between 0

(no vibration), 20µm (minimum vibration) and 30µm
(maximum vibration). This input represents a set value
(specification). The effective power curve is shown as a
diagram under [POWER].
The time t1 defines the welding time until the height for
switching over has been achieved. When the height for
switching over has been reached, the time t2 will be
started. As the switch-height, the height-value determined
under 5.4.5 has to be used.
The measured values like final height, time and energy

which have been collected in a fixed clock pulse during
the welding are reference values for the Quality
Assurance.
The required tolerance zone is determined by a test
welding.
For this purpose, call the data field TEST PARAMETERS
within the menu TEACH.
After the welding, the measured height is displayed in

mm, the time in seconds and the energy in Ws with their
respective tolerance zones.
The measured limit values can still be adapted
afterwards.
5.5.2 Calling of programmes Mark the [Tube-number] and press the rotary control.
Afterwards, the turning of the rotary control will enable
you to call the different sets of parameters
5.5.3 Processing of programmes It is not possible to delete sets of parameters. However,

existing sets of parameters can be modified after having
been called and can be restored with other values.
Alternatively, they can be overwritten by other data.
5.5.4 Generation of programmes After having called a programme by selecting [Tube-

number], all fields of the parameters can be accessed
and be filled with values. After that, they can be used
within a welding programme.
5.5.5 Storage of programmes After the generation of the welding programme, it will be
stored by selecting another [Tube-number]. Then, you will
be able to recall it with the stored values.

SETUP 5
5.6 TEACH Mode (Sequences)
5.6.1 Generation of sequence If the "sequence-welding" has been selected as process

within the SETUP mode (see 4.4.4), the sequence
programmes can be generated within the TEACH mode.
Sets of parameters which have been generated before as

individual weldings are assigned to the welding positions
1-5.
After the generation of the welding programme, it will be

saved by selecting "STORE".

SETUP 5
5.7 Influencing factors regarding the welding result
The aforementioned parameters have a considerable influence on the weld joint. If

the welding results are bad, you have to check the following points:
• Is the structure of the anvil worn out? (Is the part clamped optimally by the anvil?)
• Are the welding tools clean?
• Are the welding tools undamaged?
• Are the sonotrode, the booster and the converter firmly bolted together?
• Does the ultrasonic controller switch off during the welding process?
• Do the material properties of the parts to be welded vary (wall thickness,

diameter, roundness)?
• Is the working-surface of the sonotrode worn out, i.e. does it still have the
required geometric shape?
• Does the sonotrode become hot?
• Was the correct set of parameters assigned to parts to be welded?
• Was a welding error indicated?
• Are the parts to be welded clean?
• Was the minimum distance to the soldering joint kept?
• Was the tube correctly fed in rectangular direction?
• Did the soldering process take too much time (Thus, the properties of the tube
can modify in such a considerable way that there will be no seal weld)?
5.8 Evaluation of the welding quality
For the evaluation of the welding quality, the consistency of the tube (keeping of the
specified impression values) is considered.
The energy consumed during the welding as well as the final height of the welds are
also important indicators.
If the amount of energy is too low, the solidity of the weld joint will suffer. If the
amount of energy is too big, the weld joint will be imprecise. The material is
unintentionally displaced, the part can take an undesirable shape.
Please only modify one parameter and check its effects during several sample-
weldings.

Operation 6
6 OPERATION
Information: The welding machine may only be used by trained and

adequately qualified personnel!
6.1 Daily starting
For the daily starting, the ultrasonic controller is switched on by pressing the button
labelled ON.
Before starting the welding activities, please make sure that:

• The respective tools and parameters are set.
• The cable and hose connections between the welder and the ultrasonic controller
as well as the air hose are connected.
• The ultrasonic controller is switched on. The green signal lamp on the front panel
lights.
• The key-operated switch is in the positon "OPERATE".
In order to adjust the machine, please pay attention to chapter 4.
In order to avoid dangerous situations, please observe the

following:
1) The ultrasonic controller has to be installed in an non-hazardous area, seperated
from the welding location - in which explosive gases cannot occur.
2) The ultrasonic controller has to be supplied with air by means of the maintenance
unit. The minimum gas pressure which is indicated on the maintenance unit has
to be 6 bar, so that a flow of at least 58 l/min is ensured for the "purging" of the
welding apparatus. An internal pressure control device prevents the machine
from starting at a pressure below 1.5 bar.
3) After the disconnection of the machine or after the shutdown of the "purging air",
a new start will only be possible after a time period of 20 sec. The delay time is
controlled by a time lag relay.
4) When starting the machine, the parameters of the standard values (see 4.3) have
to be observed:

Operation 6
5) The machine used for the welding must have the following type plates:
Type plate on the welder:
Kobra Ex 2
Schunk Sonosystems GmbH
D-35435 Wettenberg/Germany
Minimum Flow: 58 l/min.
Minimum Purging Time: 20 seconds
Serial-No.:2 3 3 _ _ _ Date: _ _ _ _
Welding Tool Kobra Ex 2 for Controller Kobra Ex 2
II 3 G EEx nPL II (C4H10)

PTB 02 ATEX 2172 X
Type plate on the ultrasonic controller:
Model: Kobra Ex 2
Schunk Sonosystems GmbH
Pressure: 4,5 bar min. 6,5 bar max.
D 35435 Wettenberg/Germany Power: 200-240 VAC/10A/50-60Hz
Located in a non hazardous area only!
Serial-No.:C _ _ _ Date: _ _ _ _
Controller Kobra Ex 2 for Welding Tool Kobra Ex 2
Part of: PTB 02 ATEX 2172 X
6.2 Preparations
• Please identify the work piece you would like to weld
• Enter the sequence-number at the ultrasonic controller: press the button

<OPERATE> -, select <Sequence-No.>; press the button
• Is the welding zone limit stop set correctly?

The welding shall be effected in an area with slight abrasion of the sonotrode and
the anvil! If necessary, the stopper has to be displaced according to the raster!
• Do the welding tools get in touch by the air pressure?

Check the network pressure on the maintenance unit
• Check the setting of the welding parameters

Operation 6
6.3 Welding
Caution: Please always use the assigned protective equipment!

Neither touch the welding tools nor the workpiece!
Avoid breathing in the welding vapours!
1) Put the system into the welding position.
2) Insert the parts to be welded.
3) Press the two start key buttons. The tools will close if both of the key buttons
are pressed simultaneously.
4) If possible, please observe the welding data and the messages possibly
appearing on the display of the ultrasonic controller.
Figure 18: Insertion of the tube
Correct Incorrect
6.4 Completion of the welding
1) Check the messages on the ultrasonic controller, if the signal transmitter is heard
and the welding error lamp lights up.
2) The welding will be immediately finished, the welding tools will open directly.
3) Remove the welder from the weld joint.
4) Check the workpiece according to your preset standard values.
Caution:
Possible danger to burn yourself on the tube!

Operation 6
6.5 Operational controls on the welder and the system cable
6.5.1 Emergency-stop key button (optional)
The emergency-stop key button is integrated within the system cable (see 1.10).
After the activation of the emergency-stop key button, the ultrasound as well as the
movement of the workpiece are simultaneously switched off. Thus, the control of the
machine and all pneumatic actuators are disconnected (electrically and
pneumatically).
The unlocking of the emergency-stop key button is done by turning it in the direction
of the arrow.
6.5.2 START
The weld is started with a two-button right-and-left-hand safety release.
Before the triggering of the welding, the parts to be welded have to be positioned
correctly (see figure on page Figure 18: Insertion of the tube55).
The welding programme is executed according to the settings within the ultrasonic
controller.

Operation 6
6.6 Operational controls on the ultrasonic controller
The ultrasonic controller provides the energy for the welding and controls the process
flow.
A) Display The display shows the menus mentioned above as well as the error messages
which have been described in chapters 6.7.1 and 7.6.2. In addition, statistic
evaluations of the welding results can be displayed here (also graphically).
B) LED Main power The yellow LED shows the availability of control voltage within the ultrasonic
controller.
C) LED Welding error The red LED will flash up, if the specified limit values have not been kept during
the last welding activity.
In this case, please observe the error messages on the display.
The pressing of this key button switches off the ultrasonic controller and thus the
D) Key button whole system. For secure switch-off, please pull the mains plug!
"machine switched
off" (black)
The pressing of this key button turns on the operating voltage of the machine and
E) Illuminated key is the precondition to obtain the operativeness.
button "machine
switched on" (white)
F) Single-hand rotary- The turning of this control button moves the cursor (the highlighted area) on the
control button display. In addition, the turning of this control button will modify the values in the
data fields, if they have been selected before.
The pressing of this control button leads to the selection of the marked menu or a
marked data field.
Furthermore, the pressing of this control button (in the field OK) will store the
modified values.
A F C D E B

Operation 6
G) Function selector You can select 4 different modes of operation by pressing the key-operated switch
switch (SETUP, TEACH, QC and OPERATE).
This selector switch has been designed as key-operated switch with 4 functions. 3
different keys belong to the switch. With key no. 1 you can select the menus
OPERATE and QC, with key no. 2 you can choose OPERATE, QC and TEACH,
and with key 3 you will be able to select all 4 control positions.
Settings which may influence the welding activity, can only be effected by key 2
(TEACH) or by key 3 (TEACH und SETUP).
We presuppose that only the set-up man will be in possession of keys 2 and 3.
Depending on the position of the key-operated switch, different sub-programmes
can be called by the control button.
Switch position of keys 1, 2 or 3 on OPERATE (welding)

This position is selected, if the machine is used for production.
The permanent counters only function in this switch position. The measured
values are compared to the limiting values of the tolerance zone and possible
alarm messages are shown.
Switch position of keys 1,2 or 3 on QC (Quality Control)

This switch position is accessible by means of all keys (like the "OPERATE"
mode).
Switch position of keys 2 or 3 on TEACH

In this switch position the data of the welding programmes can be modified and be
set up.
Switch position of key 3 on Setup

In this switch position only system settings and calibrations are carried out.
A F C D E B

Operation 6
6.7 OPERATE Mode
Information: This mode of operation requires keys 1, 2 or 3!
By turning of the key you will have access to the menu

„OPERATE“, where the welding procedure can be started
by pressing the two key buttons on the welder.
In this position, the operator can call the set values

specified and stored for the parts by using in the part-
number or the sequence-number of the welding
workpiece.
In addition, the number of weldings is shown on the

display. After the selection of the respective field, the
counter can be reset at zero by pressing the control
button two times.
If the values measured during the welding are not within

the specified limits, the part will be defined as "reject", an
alarm message will appear and an acoustic signal will be
emitted. This signal can be deleted by means of the
control button.
After the selection of "POWER" the last welding will be

illustrated graphically.
6.7.1 Alarm
If a value is outside of the preset tolerance limits, an
acoustic and optic alarm will be emitted after the welding
process.
The measured actual value and the set value as well as
the tolerances (limiting values) of the parameter by which
the alarm has been activated will be displayed.
After you have checked the reasons for the alarm, it has
to be cancelled.
The alarm is cancelled manually by confirming with
<OK>. and by pressing the control button afterwards.
Information: Before making further weldings, please check the reason for
the error message!

Disturbances and trouble-shooting 7
7 DISTURBANCES AND TROUBLE-SHOOTING

Information: It is decisive to adjust the welding tools carefully and
precisely, in order to obtain good welding results!
7.1 General maintenance
When What Who

Daily • Clean the system with a cloth. Operator
• If necessary, please lubricate the Service-personnel
Proceedings which have
mechanics of the welder.
to be executed at each
tooling change: • Please check, if all screws of
the oscillating system are
tightened and screw them down,
if necessary.
• Change weld position (see 8.3)
The indication Service-personnel
„SERVICE-CHECK“ or • Please examine, if there are any or skilled electrical
proceedings to be cracks or marks on the welding personnel
carried out after approx. surface of the sonotrode and
4000 welding activities: replace it, if necessary.
• Please check, if there are any
cracks or marks on the welding
surface of the anvil and replace
it, if necessary.
7.2 Examples of wear on the weld tools (sonotrode and anvil)
Worn Sonotrode surface, cutting Worn Sonotrode surface, cutting Broken sonotrode due to wrong
edge washed out edge washed out weld position (see 8.3)
Worn anvil, cutting edge washed Worn anvil, cutting edge washed Worn anvil, cutting edge and
out out serration washed out

7.3 Maintenance plan
Date Subject Responsible
Daily
• Clean welding area with bristle brush
Operator
• Daily maintenance
Weekly
(or after approx.
10.000 welds) • Check fork backlash (A), next check Service-Personnell
cutting gap (B) (see 5.4.5)
• Check height value (see 5.4.5)

Service-Personnell
Biannually • Weekly maintenance

(or after approx.
300.000 welds) • Remove drive unit, clean and grease Service-Personnell
(see 8.7)
Replace spring and spring pot Service-Personnell

Order-No: SET Spring 10519877
• Check and adjust fork backlash

(see 8.6)
Service-Personnell
• Aspirate vent openings on ultrasonic

controller
Do not use compressed air! Operator
• Check and clean pneumatic service

unit (see 7.5) Service-Personnell

Date Subject Responsible
Annually • Biannual maintenance

(or after approx. Service-Personnell
600.000 welds) • Replace Set KA
Order-No: SET KA - 10519878
Five-yearly • Annual maintenance

(or after approx. Service-Personnell
3.000.000 • Replace Set K5
welds) Order-No: SET K5:
- KOBRA EL: 10519879
- KOBRA EX: 10519880

7.4 Maintenance documentation
Use the list below to document maintenance and tool changes!
No. Part-No. Order-No. Date Remarks
10
11
12
13
14
15
16
17
18
19
20

7.5 Pneumatic service unit
You absolutely have to observe the following servicing

instructions!
Only dry, oil-free air must be used! Severe electrical
damage and bodily harm can occur when air, water,
particles and/or oil gets into the welding machine! Drain
Caution: and clean the pneumatic service unit on a daily basis to
avoid liquid to transfer into the welding machine and
causes any machine or any components damage!
Furthermore the controller, converter and welding quality
can be damaged by humidity, oil, water or particles.
A B
3
1
2
Figure 1 Pneumatic service unit (similar)
7.5.1 Empty the condensate tank

- Daily condensate separator by
- Condensate level approx. 10mm below the filter element (1)
- Loosen the drainage screw (2).
- The condensate will flow out
or
Daily condensate separator automatically
7.5.2 Changing the filter cartridge

- Exhaust the unit
- Push the unlock slide (3) in direction of the arrow
- Turn the filter bowl anti clockwise and pull it away from the unit
- Turn the filter plate anti clockwise
- Replace the filter cartridge (grasp the new filter only at the lower end).
- Assembly in reverse order
- Check position (locking pin / recess in the housing)
- The unlocking slide must be heard clicked in
Only Water or suds (max. + 60°C)and petroleum ether may be used as

cleaning agent

7.6 Trouble-shooting
7.6.1 General
Observation / Message Possible reason Measures
The “machine on” button lamp The emergency-stop key button is Unlock the emergency-stop key
does not light: pressed. button.
The ultrasonic controller is switched off. Switch on the ultrasonic controller.
The main power lamp does The mains plug is unplugged. Plug in the mains plug.
not light: The fuse 2A is defective (see 3.8.1). Exchange the fuse 2A.
SERVICE-CHECK: The number of weldings has exceeded Carry out the service or change the
the preset limit of the counter. welding position.
Delete the message by resetting the
counter.
Insufficient welding results: The oscillating system has not been Tighten the screws.
screwed down according to the
specifications.
The properties of the workpieces have Re-determine the parameters.
changed.
The sonotrode and/or the anvil is/are Exchange the sonotrode and/or the
worn out. anvil.
Leakage: The tools are dirty or worn out. Use clean material.
Wrong selection of parameters Select the appropriate set of
parameters.
The properties of the workpieces have Re-determine the parameters.
changed.
The tube is incorrectly inserted. Insert the tube according to the
specifications.
The supply pressure to the The supply by the compressed air Please check the compressed air
welder is too low: ductwork system is insufficient. ductwork system an get it repaired.
Impossibility to switch on the The emergency-stop key button is Unlock the emergency-stop key
controller: pressed. button.
The mains plug is unplugged. Plug in the mains plug.
The safety fuse 2A is defective (see Exchange the saftety fuse 2A.
3.8.1).

Oberservation / Possible reason Measures

Message
The frequency is too low: The high-frequency cable is defective. Get the high-frequency cable
replaced by the SCHUNK service.
Sonotrode is defective. Replace
Oscillating system not properly Retighten

screwed.
Connect
The high-frequency cable is not
connected.
Message „OVERLOAD“: The oscillating system is defective. Please check and get it replaced by
the SCHUNK service.
The power supply is too high. Modify the parameters "Amplitude"
or "Pressure."
The display remains dark: The display is defective. Get it replaced by the SCHUNK
service.
No ultrasound: The high-frequency cable is defective. Get it replaced by the SCHUNK
service.
Oscillating system defective. Replace.
Amplitude set to zero Set to normal value.
7.6.2 The values are not within the tolerance zone

Observation / Message Possible reason Measures
The amount of energy is too Defect on the oscillating system Please check, if the tool is
low [E]: worn out.
The energy is outside of the tolerance limits. Examine the tolerance limits.
Has the height of the welding part changed? Re-determine the parameters.
The gap dimension is too big. Correct the gap dimension.
Wearout of the sonotrode and/or the anvil Adjust the limit stop.
Examine the tolerance limts,
re-determine the parameters.
The material is dirty. Use clean material.
The amount of energy is too The load is too big for the sonotrode (material, Please re-determine the
high [E]: parameters). parameterss
[H2] too low: The supplied energy is bigger. Check the parameters.
The height of the parts has changed. Adapt the limiting values.
The limit stop is positioned too low. Check the gap dimension.
[H2] too high: The supplied energy is insufficient. Check the parameters.
The height of the parts has changed. Adapt the limiting values.
The limit stop is positioned too high. Check the gap dimension.
The height is not reached / the height sensor Examine the height sensor
is defective. and replace it, if necessary.

7.7 Contact persons and address of the service department
SCHUNK Sonosystems GmbH

Hauptstraße 95
D-35435 Wettenberg
Tel.: +49 (0) 6 41 / 803 - 0 (Headquarter)
Fax: +49 (0) 6 41 / 803 - 250

Tool change and maintenance 8
8 SERVICE AND MAINTENANCE
Information: The activities described in chapter may only be carried out by

skilled personnel. For operators it is prohibited to carry out these
activities!
8.1 Installation and removal of the oscillating system
Caution: In order to install and to remove the oscillating system,

the rear wall of the welder has to be opened.
As a defined seal of the housing is the precondition for
the explosion proofness characteristics of the welder,
only qualified personnel may mount the rear wall, in
order to ensure that the cross section of the openings for
the outgoing air remains unaltered.
8.1.1 Dismounting of the limit stop The limit stop should be dismounted for
adjustment purposes.
After unscrewing the upper fastening screw (A),
the complete component assembly can be pulled
off.

8.1.2 Opening the rear wall
Detach the rear wall by removing the screws (A)
on the opposite sides.
Then, remove backwards the rear cover of the

housing (B).
Information: In order to dismount the rear cover easier, the system cable
including the pneumatic hoses can be removed!

Danger: Mechanical forces on the converter may generate

electrical tensions. Please do not touch any of the
contacts!
Pull off the red-coloured HF (high frequency)-cable (C) as

well as the black-coloured one (D). Please touch both
cables only in the insulated zones.
Plug both contacts (C) and (D) of the converter cable into
each other (short circuit). Thus you will avoid an
undesired charging caused by the mechanical load of the
oscillating system.
Then, separate all connecting cables and pneumatic

hoses. In order to pull off the valve connector, the bracket
(E) has to be pressed.

8.1.3 Detaching the oscillating Loosen the sets crew shown in the illustration on
the left on both sides.
system
8.1.4 Removal of the oscillating system
Push the vibration system backwards in direction of

the arrow and pull it out of the housing.

8.1.5 Disassembly of the oscillating
system
In order to avoid damages, the oscillating system

has to be clamped into a vice with protection jaws.
You can now loosen the screwed connections
between the sonotrode, the booster and the
converter by means of the hook spanner
contained in the scope of supply.

8.1.6 Assembly of the oscillating

system
The reassembly and the installation have to be
done in reverse order!
In order to avoid damages, the oscillating system
has to be clamped into a vice with protection jaws
(see above).
In order to brace the components, please use the
hook spanner contained in the scope of supply.
• Slightly lubricate the coupling surfaces of the

sonotrode, the booster and the converter.
• Hand-screw the connecting bolts on both
sides completely into the booster, then turn
back 1 turn.
• Mount sonotrode and converter and tighten
with hook spanner.
A torque of approx.120Nm has to be kept.
Push the oscillating system into the correct

position.
Take care that the abutting surfaces on the anvil

and the sonotrode are planar.
Screw down slightly the lateral set screws.
Then, you have to adjust the tools and calibrate

the height (see 4.4.5)
Advice: The safe operativeness of the oscillating system requires a
torque of approx. 120Nm on the screwed connections within
sonotrode, booster and converter!

8.2 Adjustment of the anvil

The anvil is pinned into its optimal position. Therefore, it
cannot be set or be adjusted.
You must only take care that the supporting surfaces are
clean during the assembly.
8.3 Adjustment of the welding depth limit stop and the welding
positions
In order to adjust the welding depth limit stop and the

welding positions, only loosen both of the fastening
screws, adjust the position and tighten the fastening
screws.
In order to obtain a constant wearout of the welding tools,

the sonotrode should be used on 4 positions.
• Put the limit stop on the front position (Position 1)

• After the completion of 4.000 weldings, the sonotrode
should be turned 180° (Position 2).
• After the completion of 8.000 weldings, the sonotrode
should be turned 180° and the stopper should be
moved to the rear position (Position 3).
• After the completion of 12.000 weldings, the
sonotrode should be turned 180° (Position 4).
• Each time the sonotrode has accomplished 16.000
weldings, repeat the above process until the tools are
worn-out and should be replaced.

8.4 Replacement of the height sensor
First of all, the rear wall has to be removed (see 8.1.2).
Then, loosen the screw of the side wall on both sides as

shown in the illustration on the left.
Lift the base plate and remove it by pulling slightly in the

direction of the arrow.
Take the connecting cable of the height sensor out of the

guide notch.
Slightly press the support of the sensor (C) inwards,

loosen the fastening screw of the sensor (B) by a
hexagon spanner (SW3) and take out the support of the
sensor (C).
Attention: The spring (D) has initial tension!

Loosen the cable socket (E) and pull the sensor (F)
out of its support. If necessary, the pin (G) must be
knocked-out.
The installation is done in reverse order. In

proceeding this way, please take care that the rear
surface of the sensor is planar with the step (H).
After the installation of the height sensor, a

calibration of the height measurement system will be
necessary (see 5.4.7).

8.5 Installing/removing the fork
Loosen the mounting screw of the drive unit on both

sides, as shown.
Lift drive unit slightly and pull backwards to remove.

Remove plug screws M12x1,25 (A) on both sides.
Loosen clamping screws (B) und (C) on both sides.
Push pin (D) outwards.
Remove fork towards front, as shown.

When installing, take care that the bearing surfaces
of the fork as well as the slide blocks (E) and the
spring (F) are well greased and sit in their appropriate
positions.
When pushing the fork inwards, take care that the

spring (F) is not tilted.
Push fork inwards and push slide blocks in the

mounting positions.
Mount pin (D) and adjust fork (see 8.6).

8.6 Adjustment of the fork
To centralize the fork within the housing, slightly

tighten screws (A) on both sides in order to achive a
similar gap (B) on both bearing sides of the fork.
(Standard value for the feeler gauge is 0,40-
0,60mm).
Slightly tighten screws (C) on both sides in order to

achive a central position of the fork within the
housing.
Adjust the fork to achive a smooth and play-free

motion during closing. The fork must open itself via
the spring-load.
If necessary, mount drive unit and back panel.
After adjustment of the fork, the gaps of the tooling

need to be adjusted (see 5.4.5).

8.7 Replacing the drive unit
Remove rear wall (see 8.1.2).
Loosen the screws in the side walls on both sides, as

shown.
Lift drive unit slightly and pull backwards to remove.
For assembly, proceed in reverse order

Shutdown 9
9 SHUTDOWN
9.1 Disconnection
A permanent disconnection of the welding machine can be done by pressing the

OFF- switch of the ultrasonic controller (see 6.6) and by cutting off the ultrasonic
controller's network connection.
9.2 Final shutdown
After the final shutdown of the ultrasonic welding machine, you have to store the
components of the machine in their respective original packagings in a dry and
dustfree place, if possible.
9.3 Disassembly
At the end of its service life, the welding machine is disassembled and professionally
disposed.

Appendix 10
10 APPENDIX
10.1 Spare part drawings

Appendix 10
10.2 Certificate of explosion proofness

Appendix 10

Appendix 10

Appendix 10
10.3 Data sheet PLC-Adapter (optional)
Definition & Signal diagrams Version

The PLC interface, which is integrated into every Schunk CONTROLLER, serves as a communication interface
to common PLC’s and therfore allows the external control of the welder.
The signals are provided on a 15-pin SUB-D Socket, which is mounted in an adapter on the back of the
controller (optional).
10.3.1 Pin definition
Sub-D 15-pin Status Direction Function

5,13 High activ OUT READY
6 +24V OUT +24V
2 GND OUT Ground
10.3.2 Connection values
Input Voltage: +24V (>20V)

Max. Input Current: 10 mA
Max. Collector-Emitter-voltage: 70V
Max. Collector Current: 50 mA
Output Voltage: +24V max. 1A
10.3.3 Signal description:
READY When welding has started, the READY contact is opened indicating that the machine is
busy. When all welds are completed and the machine is READY again, the contact closes.
In case of an alarm, the READY-contact remains opened, until the alarm is cleared.
Alarm messages because of fatal system errors (Power module, Linear table etc.)
may not be reset by external signals, since resetting these type of errors may
possibly result in severe damage of the machine !

Appendix 10
Schematics of 15-pin Sub-D-Socket

Notes 11
11 NOTES

Notes 11

Notes 11

Notes 11

Operating- and Maintenance Manual
Ultrasonic welding machine Kobra EX 2

Kobra EX II USC3 en v7b

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Operating- and Maintenance Manual

Ultrasonic welding machine

DESCRIPTION OF THE MACHINE 3

DISTURBANCES AND TROUBLE-SHOOTING 7

TOOL CHANGE AND MAINTENANCE 8

Tel: +49 (0) 6 41 / 803 - 0

Fax: +49 (0) 6 41 / 803 – 250

Rev. No. Modified by Modifications Page Datum

2 C. Wohlfahrt General Modifications / 04.09.04

3 C. Wohlfahrt Chapter Safety modified 10-16 20.09.04

4 C. Wohlfahrt General Modifications / 01.11.04

5 C. Wohlfahrt General Modifications / 10.01.06

6 M. Weiß Changing name to Schunk Sonosystems 18.09.07

7 M. Weiß Data sheet PLC added 81 18.10.08

7 V.Wagner Air consumption added 34 11.05.09

8 C. Wohlfahrt Maintenance plan added 61 14.10.10

Your SCHUNK Team

SCHUNK SONOSYSTEMS GmbH, Hauptstraße 95, D-35435 Wettenberg http://www.sut.biz 5

The specific security instructions of the system are compiled in chapter 1.

SCHUNK Sonosystems GmbH

SCHUNK SONOSYSTEMS GmbH, Hauptstraße 95, D-35435 Wettenberg http://www.sut.biz 6

2.2 Additional warning symbols .................................................................................................................. 13

2.3 Machine design and operation .............................................................................................................. 14

2.4 General advices and warnings .............................................................................................................. 15

2.5 Safety instructions.................................................................................................................................. 16

2.6 Overview of the standard scope of supply........................................................................................... 17

2.7 Use according to the specifications ..................................................................................................... 17

2.8 Sources of danger and residual dangers ............................................................................................. 18

2.9 Authorised operators.............................................................................................................................. 18

2.10 Safety arrangements ........................................................................................................................... 18

2.11 Emergency-stop key button (optional).............................................................................................. 19

2.12 Functional testing of the emergency-stop key button .................................................................... 19

3 DESCRIPTION OF THE MACHINE................................................................................20

3.2 Basic elements of ultrasonic welding................................................................................................... 22

3.3 Scope of supply ...................................................................................................................................... 24

3.4 Technical Data ......................................................................................................................................... 25

3.5 Dimensions .............................................................................................................................................. 25

3.6 Welder ...................................................................................................................................................... 28

3.7 Safety system – Explosion proofness .................................................................................................. 28

3.8 Ultrasonic controller ............................................................................................................................... 29

3.9 Tools (Sonotrode and anvil)................................................................................................................... 30

SCHUNK SONOSYSTEMS GmbH, Hauptstraße 95, D-35435 Wettenberg http://www.sut.biz 7

3.13 Tools ..................................................................................................................................................... 33

4.2 Storage / Transportation ........................................................................................................................ 34

4.3 Shipment / Intercompany transportation.............................................................................................. 34

4.4 Checking of the delivery......................................................................................................................... 34

4.5 Connected loads ..................................................................................................................................... 35

4.6 Compressed air supply .......................................................................................................................... 35

4.7 Place of installation / Place of operation .............................................................................................. 36

4.8 Ambiance conditions.............................................................................................................................. 36

4.9 Installation of the welding machine ...................................................................................................... 36

4.11 Setup for initial operation ................................................................................................................... 37

5.2 Welding position ..................................................................................................................................... 38

5.3 Table of parameters (Standard values for left-/right-cut) ........................................................................ 39

5.5 TEACH mode (Individual weldings) ...................................................................................................... 49

SCHUNK SONOSYSTEMS GmbH, Hauptstraße 95, D-35435 Wettenberg http://www.sut.biz 8

5.6 TEACH Mode (Sequences) ..................................................................................................................... 51

5.7 Influencing factors regarding the welding result ................................................................................ 52