Kobra-III Operating Manual Rev 4.0 en COMPRESSED

Operating Manual
English - Translation -
Kobra-III (Ex)
Machine No. 1234567-89

1234567-89
Year of manufacture 04/2020
04/2020
Schunk Sonosystems GmbH  +49 (0) 641 8 03 - 0

Hauptstraße 95 Fax +49 (0) 641 8 03 - 250
35435 Wettenberg  Service +49 (0) 641 8 03 - 300
Rev 4.0
 sonosystems@schunk-group.com
Germany www.schunk-sonosystems.com
Kobra-III (Ex) Operating Manual - Translation -
General instructions
IMPORTANT!
THIS GUIDE APPLIES TO BOTH KOBRA-III AND KOBRA-III EX IN THE

VERSIONS
¬ BASIC
¬ ADVANCE
¬ ADVANCE-SEQUENCE
PRIOR TO STARTUP CAREFULLY READ THE OPERATING MANUAL OF THE

MACHINE TO FAMILIARIZE YOURSELF WITH THE SYSTEM.
THE OPERATING MANUAL MUST BE ACCESSIBLE FOR THE OPERATORS AT

ANY TIME!
KEEP THE OPERATING MANUAL IN A SAFE PLACE FOR FUTURE USE
THE OPERATING MANUAL CONTAINS ALL AVAILABLE OPTIONS.

THESE ARE NOT NECESSARILY AN INTEGRAL PART OF THE DELIVERED
MACHINE!
YOU WILL FIND THE COMPLETE VERSION OF THE OPERATING MANUAL ON

THE ATTACHED USB-STICK.
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4.0 4.0 © Schunk Sonosystems GmbH
Contents
General instructions 2
Contact Information 9
1. Safety instructions 10
1.1 Presentation of hazard-related information 10
1.2 Types of hazards 12
1.3 Personal protective equipment 14
1.4 Higher-level safety instructions 15
1.4.1 Maintenance and assembly works 16
1.5 Machine design and operation 17
1.6 General information and warnings 18
1.7 Safety instructions 19
1.8 Scope of delivery 21
1.9 Intended use 23
1.10 Limits of use 23
1.11 Hazard sources and residual risks 24
1.12 Approved operators 25
1.13 Safety devices 26
1.14 Emergency stop button 27
1.15 Checking the emergency stop button for correct functioning 27
2. Machine Description 28
2.1 General information 28
2.1.1 Description of functions 28
2.1.2 Workpieces 28
2.1.3 Explanation of technical terms 29
2.2 The fundamentals of ultrasonic welding 31
2.3 Technical data 33
2.4 Dimensions 34
2.4.1 Welding gun for tubes with a maximum diameter of 7 mm 34
2.4.2 Ultrasonic controller 35
2.4.3 Emission values 37
2.4.4 Sound level information 37
2.5 Welding gun 38
2.6 Safety system ‒ Ex protection 39
2.7 Electrical specifications 41
2.8 Data concerning excess pressure encapsulation 41
2.9 Ultrasonic controller 42
Front 43
© Schunk Sonosystems GmbH 1234567-89

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Rear 45
Reset / Start button (Pos. 26) 46
2.10 Welding tools (sonotrode and anvil) 47
2.10.1 Sonotrodes set 48
2.10.2 Anvils set 49
2.11 Drive unit 50
2.12 Pneumatic system 52
2.13 Interfaces 52
2.14 Spare parts list 53
2.14.1 Overview of basic mechanical parts manual depth stop (basic version) 53
2.14.2 Overview of basic mechanical parts manual depth stop (basic version) 56
2.14.3 Overview of basic mechanical parts, motorized depth stop (full version) 59
2.14.4 Overview of basic mechanical parts, motorized depth stop (full version) 62
2.14.5 “Zero-point” support 65
2.14.6 Sealing of anvil support, stroke 7 mm 66
2.14.7 Sealing of anvil support, stroke 12 mm 67
2.14.8 Stop left and right 68
2.14.9 Set of replacement snap fasteners with slot and latch spring 69
2.14.10 Flat cage guidance system ASSY (order no. 10921229) 70
2.14.11 ASSY pneumatic valve 2x3/2 way valve (order no. 10830114) 71
2.14.12 ASSY pneumatic valve 5/2 way valve (order no. 10842474) 71
2.14.13 Pressure switch 72
3. Transport and installation 73

3.1 Packaging 73
3.2 Storage / Transport 73
3.3 Shipment / Company-internal transport 73
3.4 Connected loads 74
3.5 Compressed-air supply 75
3.6 Place of use / place of operation 76
3.7 Space requirement of the machine 76
3.8 Ambient conditions 77
3.9 Installation requirements 77
3.9.1 Protection classes 77
3.10 Installation of the welding machine 78
3.10.1 Mechanical assembly 78
3.10.2 Assembly ‒ electrical system 78
3.10.3 Assembly ‒ pneumatic system 79
3.11 Power supply connection 80
3.11.1 Electrical connection 80
3.11.2 Description of connections 81
3.11.3 Pneumatic connection 83
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3.12 Dismantling 85
3.13 Commissioning 85
4. Setup 86
4.1 General information 86
4.2 Welding position 87
4.3 Start parameters table (guide values for left / right-cutting tools) 88
4.4 Setup mode 90
Tool selection 92
4.4.1 Setting the tools 94
4.4.1.1 Setting double cut 96
4.4.1.2 Setting the right or left cutting anvil 98
4.4.1.3 Setting the not-cutting anvil 99
4.4.1.4 Setting the round right or left cutting anvil 100
4.4.1.5 Calibration 101
Error message 103
4.4.1.6 Calibration with test pin (Order no. 10855491) 104
Error message 105
4.5 Teach mode 106
Overview 106
Adjusting limit stop Basic Version 108
Help menu 114
4.5.1 Options menu 115
4.5.1.1 Setting the counter 117
Parameterising further counters 122
Air shut-off 122
Error configuration 123
4.5.1.2 Machine setup 125
4.5.1.3 Edit sequences 126
Creating new sequence 128
Editing sequence 129
Delete sequence 131
4.5.1.4 Import or export of welding parameter sets 132
4.5.1.5 Import or export of sequences 134
4.5.1.6 Export of logbook files 136
4.5.2 Creating new parameter set 138
4.5.2.1 Tube name 140
4.5.2.2 Comment 140
4.5.2.3 Tube diameter 141
4.5.2.4 Tube wall thickness 141
4.5.2.5 Automatic tube detection / start parameters selection (option) 142
4.5.3 Loading or deleting a parameter set 144
5. Operation 145

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5.1 Daily start-up 145

5.2 Controls 147
5.2.1 Start button 147
5.2.2 Emergency stop button 147
5.3 Control elements on the ultrasonic controller 148
5.3.1 Main switch with emergency stop function 149
5.3.2 Controller ON button 149
5.3.3 Controller OFF button 149
5.3.4 Key switch 150
5.3.5 USB port 150
5.3.6 Calibration unit 150
5.4 Switching the device on or off 151
Switching on 152
Switch-off 153
5.5 Welding 154
5.5.1 Correct insertion of the tube 155
5.5.2 LED enabling and start button 156
5.5.3 Welding strategy 157
5.6 Production mode 159
5.6.1 Production mode overview 159
5.6.1.1 Export of logbook files 165
5.6.1.2 Loading welding parameters 167
Loading welding parameters 169
Loading sequence 171
5.6.1.3 Operator counter 174
6. Changing tools 175

6.1 Safety information on changing tools 175
Preparation for changing the oscillator unit 177
6.2 Disconnect the system cable from the welding module 179
6.3 Open housing 180
Variant: handle on the side 180
6.4 Dismantling the oscillator unit 184
6.4.1 Sonotrode replacement 186
6.4.1.1 Dismantling the sonotrode 186
6.4.1.2 Installing new sonotrode 187
6.4.2 Converter change 187
6.4.3 Mounting the vibrator unit 190
6.5 Installation of the oscillator unit 191
6.6 Anvil changing 197
6.7 Setting the limit stop welding position 199
6.8 Assembling welding module 200
6.9 Connect welding module with system cable 202
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6.10 Replacing the sealing of the anvil support (10.40, 60.1000 and 60.1010) 203
6.11 Changing left limit stop (70.10) and limit right stop (70.20) 204
6.12 Support spring, zero-point bearing (20.20) 206
7. Maintenance 208
7.1 After each tool change 210
7.1.1 Calibration 210
7.2 During each sonotrode change 211
7.3 Annual examination 212
7.3.1 Emergency stop button 212
7.3.2 Purging air monitoring 212
7.3.3 Pressure test - proportional valve 213
7.3.4 Amplitude measurement 214
7.3.5 Cleaning the electronics and pneumatic section of the machine 215
7.3.6 Large maintenance 215
7.4 Electronic controller 216
7.4.1 Error analysis in the control system 218
7.4.1.1 Maintenance tasks 219
Filter mat at the fan 219
Condensate in the filter of the maintenance unit 219
8. Decommissioning and disposal 220

8.1 Decommissioning 220
8.2 Shutdown 220
8.3 Dismantling and disposal 220
9. Annex 221
9.1 Versions 221
Top handle 221
Side handle (left) 222
Side handle (right) 222
Support handle (order no. 10881226) 223
Twin handle (order no. 10881482) 224
Twin top handle (order no. 10875492) 225
Single handle (left with suspension) (order no. 10891436) 226
Single handle (right with suspension) (order no. 10903047) 226
Top handle with side trigger (order no. 10913810) 227
9.1.1 Suspension, vertical 228
9.1.2 Suspension, horizontal 229
9.2 ASSY 360° Rotation device (order no. 10914363) 231
9.2.1 Assembly of the rotation device 232
9.2.2 Disassembly of the rotation device 233
9.2.3 Stops for the rotation 234
9.3 Overview Drawings 235

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10. Options 238

10.1 Barcode Scanner (Order no. 10878736) 238
10.1.1 Functions 238
10.1.2 Activating the barcode scanner function 239
10.1.3 Definition of barcode scan functions 240
10.1.4 Example 1 241
10.1.5 Further settings 242
10.1.6 Example 2 243
10.2 Dongle versions 244
10.2.1 Dongle no. 134 - Set Kobra-III Sequences (order no. 10877431) 244
10.2.2 Dongle no. 135 - Set Kobra-III Start Parameters - APR (order no. 10877432) 245
10.2.3 Dongle no. 136 - Set Kobra-III PLIS-Interface - order no.: 108 774 33 245
10.3 Set monitor 17“ (2nd parallel monitor) (Order No. 10877568) 246
10.4 External emergency stop box (order no. 10589624) 246
10.5 Uninterruptible Power Supply (optional) 247
Back-UPSTM BK500EI 500VA (APC) 247
10.5.1 Function/general points 247
10.5.2 Hardware installation 247
10.5.2.1 Electrical connections 248
10.5.2.2 Plugging X7.1/X7.1 UPS into another socket 250
10.5.3 Software installation 251
10.5.3.1 Before installing PowerChute Personal Edition 251
10.5.3.2 Installation steps 251
10.5.4 Further information 251
10.6 Calibrating and measuring device case Kobra III (order no. 10884834) 252
10.7 Recommended tools 252
11. Pneumatic circuit diagram 253
12. Electric circuit diagram 255
13. Appendix 280

13.1 Wacker Safety data sheets 280
13.2 APC UPS 280
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Contact Information
Please contact our customer service department should there be a fault with the
machine, for ordering replacement parts or if there are any further questions
regarding this machine.
Schunk Sonosystems GmbH

Hauptstrasse 95
D-35435 Wettenberg, Germany
Tel. + 49 (0) 641 / 803 – 0
Fax + 49 (0) 641 / 803 – 250
Hotline: + 49 (0) 641 / 803 – 300
E-mail: sonosystems@schunk-group.com
Internet: http://www.schunk-sonosystems.com
When contacting us, it is very helpful if you can readily provide the information
regarding the machine type along with the relevant serial number(s). The infor-
mation can be found on the rating plate.

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1 Kobra-III (Ex) Operating Manual - Translation -
Safety instructions
1. Safety instructions
Please familiarise yourself thoroughly and completely with this manual before
starting to work with this machine or performing maintenance or repair tasks.
1.1 Presentation of hazard-related information
Representation / Structure
Signal word
Type and source of the hazard
Possible consequences if not complied with
→ Measures for hazard avoidance
Symbol, signal word and type of hazard
DANGER
If this signal word is used death or severe bodily injuries will occur if the appro-
priate precautionary measures are not complied with.
WARNING
If this signal word is used, injury or material damage, or also risk of injury,
accident and health impairment can occur, if the appropriate precautionary
measures are not complied with.
CAUTION
If this signal word is used minor, reversible bodily injuries can occur, if the
appropriate precautionary measures are not complied with.
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ATTENTION
This signal word is only used if health impairments cannot occur. This signal
word is shown without symbol because degree of danger is low.
The possible consequences of failure to comply can be malfunctions and mate-
rial damage, e.g. on the machine or on the workpiece.
Recommendation
This symbol is used for an application recommendation.

Important information concerning for an understanding of the device or for
i optimized operating procedures.
The possible consequences of failure to comply can be material damage, e.g.

on the machine or on the workpiece.
Precaution
→ Handling instruction or precautionary measure to avert the hazard.

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Safety instructions
1.2 Types of hazards
Warning signs indicating the type of hazard
General warning sign
Attention symbol in conjunction with signal words DANGER,

WARNING, CAUTION.
Also used as general warning sign.
Warning ‒ high voltage
Warning ‒ dangerous voltage on electrical components.
Possible consequences may include death or serious injury (personal injury).
Warning of hot surfaces
Risk of burns on hot surfaces.
Possible consequences may include minor or serious injuries (personal injury).
Warning ‒ hand injuries
Risk of injury to the hands from crushing; risk of injury from sharp edges or
cutter units.
Possible consequences can be minor or severe injuries (personal injury)
Warning ‒ pointed objects
Risk of injury from objects with sharp edges, especially on sharp-edged com-
ponents such as needles, blades or automatic cutters.
Possible consequences may include minor or severe cut injuries or stab injuries
(personal injury)
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Mandatory signs for required procedure:
Observe the manual
Carefully read the operating manual prior to the use of the machine
→ Adhere to the operating steps

→ Avoiding accidents or failures due to improper operaition
Disconnect the mains plug
Disconnect from the mains before performing repair and maintenance tasks
on electrical components.
Possible consequences may include death or serious injury from electrical vol-
tage (personal injury).

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Safety instructions
1.3 Personal protective equipment
Use of the following personal protective equipment is mandatory when operating

the system:
Use ear protection
Use suitable ear protection: for work where there is a noise hazard
Possible consequences of non-compliance may include irreversible damage to

the hearing system (personal injury).
Use eye protection
Use suitable eye protection: for protection against mechanical,

thermal, chemical and electrical hazards.

the eyes (personal injury).
Use hand protection
Use suitable hand protection:

for protection against harmful effects of a mechanical and thermal nature

the hands (personal injury).
Use protective footwear
Use suitable safety shoes:

to protect the feet against external harmful effects and that protect again
slipping
Possible consequences of non-compliance may include irreversible irreversible

damage (personal injury).
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Safety instructions
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1.4 Higher-level safety instructions
The ultrasonic welding system has been designed and built in accordance with
the basic safety requirements of the EC Machinery Directive.
Dangers can emanate from the ultrasonic welding system, if the ultrasonic wel-
ding system is improperly used by untrained persons, or if it is not used as in-
tended, or if safety instructions are not followed.
WARNING
Untrained persons at the the ultrasonic welding system.
Danger of injury and material damage
→ Only trained persons are allowed to operate the ultrasonic welding system
WARNING
None-intended use of the ultrasonic welding system.
→ Permitted is only the intended use of ultrasonic welding system

(see „1.9 Intended use“)
→ The specified capacity limits must be complied with

(see „2.7 Electrical specifications“).
WARNING
Touching energised parts
Fatal electrical shock when the housing is open.
→ Do not open the housing with power supply connected

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Safety instructions
DANGER
Danger of explosion
Death or serious injury
→ Do not open the housing in an explosive atmosphere
WARNING
Danger of explosion
Injury and property damage
→ Do not operate the machine with damaged housing parts!

If the purging air escapes in the wrong place, there is no explosion protec-
tion.
1.4.1 Maintenance and assembly works
During maintenance and assembly works lubricants are used. The SILICON-PASTE
P (order no. 10354243) to install the tools.
Contact with lubricant:
i Information on safe and proper handling of the lubricants used can be found in
the attached safety data sheets (see „13.1 Wacker Safety data sheets“).
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Safety instructions
1
1.5 Machine design and operation
This machine is intended for use at a fixed location. Ensure that the machine can
be accessed from all sides for maintenance and repair tasks.
The safety concept for the machine is based on one-person operation. This also
applies to setting up the machine. Any further person in the vicinity of the
machine may present an additional safety risk!
Fig. 1: Usual operation of the machine with vertical suspension

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Safety instructions
1.6 General information and warnings
Please observe the country-specific safety instructions and safety regulations of

your company. All instructions contained therein regarding putting a machine
into service and performing maintenance tasks must be complied with.
The owner is also responsible for the training of machine operators and main-
tenance personnel. This training must include at least instruction in the following
topics: type and use of machine, danger zones, safety regulations, function of
individual machine components, and correct operation of the machine.
Any tasks involving maintenance, servicing or repair work are to be performed

only after the machine has been switched off and disconnected from the mains.
Otherwise, the owner is responsible for implementing special sequential proce-
dures accordingly so as to avoid accidents and damage to the equipment.
Only a trained and qualified electrician is permitted to perform tasks involving

the maintenance, servicing or repair of electric system components.
The machine must be used only for the purpose intended, see „1.9 Intended
use“.
Modifications to the machine will render the EC conformity (CE) and EX conformi-
ty null an void.
Before starting to work with this machine, familiarise yourself with all safety
regulations and accident prevention measures and comply with these to protect
yourself.
This operating manual is based on the assumption that machine operators have
been trained system-specifically. This manual is based on the assumption that
technical personnel have received appropriate technical training and that they
work with this machine in compliance with the accident prevention measures.
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Safety instructions
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1.7 Safety instructions
¬ The machine is suitable for use in the zone EX II 3G Ex pzc [ic] IIA T3 Gc. Only
use the machine for the welding of copper tubes.
¬ Please always use the protective devices intended for the relevant
application!
¬ Avoid making contact with welding tools (sonotrode and anvil) while welding
is in progress.
¬ Ensure that the welding tools can never touch.
¬ Please note that the initial start of the machine (flushing for approx. 10
seconds) must be carried out in the safe area, outside of the hazardous area.
There may be no solvents or fumes in the air (e.g., due to manufacturing
processes in the vicinity of the machine) before switching on the machine
and while it is in operation.
¬ Vapours and gases as a result of welding tasks may present a health risk.
Avoid inhaling such vapours or gases.
¬ Monitor the immediate vicinity of the machine and restrict access to the
direct vicinity of the machine to one person!
¬ It is extremely important to ensure that the machine is in proper condition
while it is in operation.
¬ Do not use the machine if parts of the housing are damaged.
¬ Before every start-up check that the purging air escapes in the area around
the sonotrode.
¬ Carry the machine or its components using only the handles.
¬ For reasons of safety, a welding cycle may be initiated only if the part to be
welded or workpiece has been correctly inserted; special procedures when
setting up the machine are excepted from this.
¬ Maintenance and repair tasks must be performed only with the energy
supply disconnected and by accordingly trained and qualified personnel who
are complying with the applicable safety regulations.
¬ Setup, maintenance and service work may only be carried out outside the
potentially explosive area.

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Safety instructions
¬ It may become necessary to set out special instructions and work guidelines
due to your specific manufacturing process. Failure to comply with these
instructions and guidelines may result in accidents causing severe physical
injury or leading to financial damage. By complying with these provisions,
drastic consequences may be avoided.
¬ For persons with active Class III implants there is a risk relative to EMI (elec-
tromagnetic interference) relative to the welding module and the controller.
At activation of the opened assemblies (for service applications) access is
prohibited to this group of persons!
¬ The wearing of personal hearing protection is mandatory when operating
the machine.
¬ The welding gun is equipped with an electrical safety monitor. To a great
extent, this prevents an inadvertent triggering of the welding process when
there is no part to be welded inserted.
¬ Use only original spare parts for the Kobra-III welding system. Failure to use
genuine parts will result in the loss of the EC conformity (CE) and ex-confor-
mity as well as the loss of the guarantee.
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1.8 Scope of delivery
Fig. 2: Scope of delivery (assembly stand is not included)
¬ Welding gun incl. oscillator system

¬ System cable
¬ Monitor
¬ Ultrasonic controller (generator with control unit)
including 4 keys for the key-switches
¬ Operating and maintenance instructions
¬ Pneumatic maintenance unit comprising a manual shut-off valve,
pressure control valve with pressure gauge, water trap, and a coarse/fine
filter incl. connecting hose

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Safety instructions
¬ Maintenance and adjustment toolkit (in pocket tool roll), consisting of:
• Tubular hexagon box spanner 6/7 mm
• Tubular hexagon box spanner 10/13
mm
• Silicone paste
• Hexagon screwdriver
• Allen key
• Hook spanner
• Measuring gauge 0,3 mm
• Measuring gauge 0,4 mm
• Feeler gauge
• Calibration pin
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1.9 Intended use
The machine is designed for seal welding and the cutting of copper tubes. Appli-
cation areas include gas-pressurised joints particularly in the area of cooling and
refrigeration applications.
The material must be weldable for the machine to be used. The shape and struc-
ture of the part to be welded further influence the welding result.
Tubes should have an outer tube diameter of at least 2 mm and 7 mm at the

most, optionally 10 mm, with a maximum wall thickness of 0.5 - 1 mm.
The quality of copper tubes used should be consistent with the Y35 grade in
accordance with EN12735-2.
Any possibility of use or application that deviates thereof is not in conformity

with this system conception and therefore prohibited. Likewise, the ultrasonic
generator (controller) may only be used for this system. Any type of misuse of
the machine or its components may result in unknown dangers to operators and
innocent bystanders.
Improper use of, or unauthorised technical changes to, the machine by the custo-
mer will result in the loss of the warranty.
WARNING
None-intended use of the ultrasonic welding system.
→ Only the intended use of ultrasonic welding system is permitted.
→ The specified capacity limits must be complied with.
1.10 Limits of use
Welding or cutting other material or solid material is not permitted.

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Safety instructions
1.11 Hazard sources and residual risks
DANGER
An increased risk of injury exists in the entire vicinity of the welding gun as
well as between the welding tools (sonotrode and anvil).
Crushing of the fingers and hands,

squeezing or severing of fingers
→ Wear protective gloves, work carefully
DANGER
High voltage in housing (welding gun, ultrasonic controller)
Fatal electrical shocks
→ Only operate the machine with the housing closed and not damaged
→ Never operate the machine without the cover mounted
→ Only operate the controller with the housing closed
→ Only operate the controller outside of the Ex zone
DANGER
Failure to comply with the safety regulations
Failure to strictly comply with safety regulations may result in injuries.
→ The risk of injury is ruled out to the extent possible, if the machine is used in
compliance with safety instructions given in this operating manual.
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DANGER
For persons with active Class III implants there is an EMI (Electromagnetic
Interference) risk relative to the welding module and the controller.
Malfunctions of cardiac pacemakers and cardioverter defibrillators
→ At activation of the opened assemblies (for service applications) access is

prohibited to this group of persons!
1.12 Approved operators
Only trained personnel may operate this machine.

Trained personnel are to especially point out „1.11 Hazard sources and residual
risks“ to operating personnel.
Compliance with safety instructions given by the manufacturer (see „1.6 General
information and warnings“ and „1.7 Safety instructions“) is mandatory.
WARNING

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Safety instructions
1.13 Safety devices
Device Qty on Position Function

on the
machine
Emergency stop 1 Integrated in Complete deactivation
button the welding of machine.
gun
Key switch 1 On the control- After the machine setter
Setup mode ler front panel has used this key,
changes to the machine,
such as tool changes,
can be made in setup
mode.
Main switch 1 On the control- Complete deactivation
ler front panel of machine incl. dis-
connection from mains.
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1.14 Emergency stop button
Fig. 3: Emergency stop button
1.15 Checking the emergency stop button for correct functioning
The operating personnel can check the emergency stop button for correct func-
tioning any time during machine operation.
The operating voltage of the control component and the drive unit will be isola-
ted (electrically and pneumatically) during this process.
The ultrasonic controller must be switched on again following the activation and
release of the emergency stop button.
The tube weld joint may be flawed, if the emergency stop button has been
i checked for correct functioning while welding was in progress.

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Machine Description
2. Machine Description
2.1 General information
2.1.1 Description of functions
Many metal weld materials with melting points below approx. 700°C can be
joined by ultrasonic welding without the direct supply of heat or adhesive.
The welded joint strength depends on material properties, device-specific para-

meters, the design of joint surfaces, the location of the weld seam, the type and
design of welding tools, as well as the proper application of methods ensured by
the operator.
For this reason it is necessary to determine the weldability of the relevant ma-
terial, the corresponding optimum work conditions, the operating parameters,
as well as the optimum tool geometry for the welding operation in the SCHUNK
SONOSYSTEMS application laboratory.
Welding occurs thorough introducing oscillation energy. This welds materials

without the addition of auxiliary materials.
Piezo-ceramic discs are used to generate ultrasonic vibration. A generator, re-

ferred to as "ultrasonic controller", is used to supply the vibration generator
(converter) with voltage. The vibration amplitude is transmitted via mechanical
means and transferred to the sonotrode. The shape of the sonotrode work sur-
face has been adapted to the welding conditions.
2.1.2 Workpieces
Materials to be welded (workpieces) include copper and weldable copper alloys.
Application limits of the system include the size of the workpieces, the size of
surfaces to be welded, as well as material properties.
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Machine Description
2
2.1.3 Explanation of technical terms
Module used to accommodate the ultrasonic

Welding gun
oscillator system and apply the welding force
Oscillator
Converter, booster and sonotrode
system
Used to convert electrical energy

Converter
into mechanical vibration
Oscillator system component

Booster used to amplify or reduce the amplitude
provided of the converter
Main welding tool and upper welding space

Sonotrode
limit
Anvil Lower welding space limit and part holder
Welding Welding area delimited by the sonotrode

space and anvil
Mounting of the guide drive module and the

Anvil support
anvil
Stop Contact release for welding process
Ultraschall-
Control unit for welding process
Controller

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Machine Description
Accommodates the pneumatic and electrical

System cable connection strands between the welding gun
and the ultrasonic controller
Calibration
For calibrating the machine
pin
Calibration
Calibration unit (optional)
unit
Mechanical vibration displacement of

Amplitude
sonotrode
Point at which no longitudinal vibration

Zero point
occurs within the sonotrode
Maintenance unit/pressure Electronic air pressure control unit; inte-

regulator grated into ultrasonic controller
Is determined by the welding parameters

Welding method which are set out as specifications or test
parameters.
Welding parameters Time (t1 and t2), pressure and amplitude
Energy required for welding, expressed in

Welding energy
watt-seconds (Ws)
Duration of the ultrasonic effect while wel-

Welding duration
ding is in progress
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Machine Description
2
2.2 The fundamentals of ultrasonic welding
In order to achieve optimum welding results, it is essential that the electronic and
mechanical components have been adapted to each other.
Fig. 4 shows the schematic structure.
A. Sonotrode
B. Booster
C. Converter
D. Anvil
E. Part to be welded
(tube)
F. Ultrasonic cont-
roller (electrical
control system)
G. Mains connection
Fig. 4: Schematic structure of the vibration-relevant elements
The input frequency of 50 or 60 Hz is converted into approx. 20 kHz by the ultra-

sonic controller. The converter transforms this electrical energy into mechanical
vibration energy, whereby the mechanical vibration frequency of the oscillation
system corresponds to the electrical frequency of the ultrasonic controller of
approx. 20kHz. The booster between the sonotrode and the converter serves as
an amplitude transformation device.
The following welding parameters determine the quality of the ultrasonically

welded joint:
¬ Sonotrode amplitude
¬ Welding pressure (operating pressure)
¬ Energy
¬ Welding height
¬ Welding duration
¬ Deposited metal

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Machine Description
Please be advised that also the material qualities, proper use and tool wear will
significantly affect the results.
Geometrical features, wall thickness and the material quality are crucial data
points for making settings.
When the welding machine was purchased from the factory, it is adapted, if
necessary, to the customer's part to be welded with the relevant parameter
settings saved in the ultrasonic controller.
In the event of changes to the material and/or geometrical features of the

part to be welded, then the relevant parameter settings will have to be
i re-determined.
Prior to changing your parameter settings please check whether the new mate-
rial is suited to the welding process and/or the welding device.
SCHUNK SONOSYSTEMS customer service will be happy to provide advice.
The pressure transducer integrated in the ultrasonic controller reduces the sup-
ply pressure to the required working pressure.
In order to achieve optimum welding results, welding continues until a specified

final height is reached, while the welding duration and welding energy are used
as test parameters. The quality of welding results must be checked in any case
and the welding parameter settings should be adjusted if necessary.
The welding tool work surfaces (sonotrode and anvil) are specially textured. This
texture affects the welding quality. These work surfaces are subject to wear and
tear and must be checked and replaced at regular intervals or if they are worn.
The amplitude, which can be determined, for instance, with the aid of a dial
comparator (dial gauge), corresponds to 50% of the mechanical sonotrode
displacement. The welding operation is performed as a result of the mechanical
vibrations of the sonotrode work surfaces.
If the amplitude is set too high, the weld material may become overstrained and
the tools may break. When the amplitude is set too low, this generally adversely
affects the quality of the weld and is indicated by a longer welding duration,
among other factors. This in turn leads to an increased build-up of heat, which
will also reduce the service life of the tools.
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Machine Description
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2.3 Technical data
Ultrasonic metal welding,

Welding method
oscillation frequency approx. 20 kHz
Oscillator system clamped into
welding gun with the aid of a special
Configuration receptacle
Vertical movement via pneumatic cylinder
Start of welding procedure via Start button
Weight of welding gun incl.

< 10,6 kg
oscillator system:
519 x 77 x 247 mm
Welding gun dimensions:
(incl. handles, without system cable)
Weight of ultrasonic controller: 20 kg
Controller dimensions 450 x 195 x 435 mm (without handles)

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Machine Description
2.4 Dimensions
2.4.1 Welding gun for tubes with a maximum diameter of 7 mm
Detailed drawings, see „9.3 Overview Drawings“
max. 3 Nm
Fig. 5: Dimensions ‒ welding gun (one-hand guidance without system cable)
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Machine Description
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2.4.2 Ultrasonic controller
Fig. 6: Dimensions ultrasonic controller

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Machine Description
Fig. 7: Dimensions of ultrasonic controller basic version
Fig. 8: Dimensions of ultrasonic controller with calibration unit (explosion-proof version)
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Machine Description
2
2.4.3 Emission values
This machine offers a high degree of environmental compatibility because no

additional consumables, apart from the supply of voltage and compressed-air,
are required for the ultrasonic welding process.
2.4.4 Sound level information
The sound level generated by the machine is dependent on the properties and
shapes of the workpieces. The wearing of personal hearing protection is man-
datory when operating the machine.
i Compliance with specifications set out by occupational health and safety regu-
lations is required.

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Machine Description
2.5 Welding gun
Fig. 9: Welding gun with inserted tube Fig. 10: Welding gun with inserted tube - top view
The Kobra-III welding machine is used for sealing copper tubes in a gas-tight man-
ner by applying ultrasound and cutting the tube in the same work step. The outer
tube diameter should be at least 2 mm and 7 mm at the most, optionally
10 mm, with a maximum wall thickness of 1 mm for tools that do not cut tubes.
The quality of copper tubes used should be consistent with the Y35 grade in
accordance with EN12735-2. The specification for the maximum tube diameter
that can be processed is dependent on the welding tool used, the wall thickness
and the quality of the tube material.
The Kobra-III welding machine has the possibility of:
¬ welding and cutting copper tubes with an outer diameter from Ø 2 mm to Ø

7 mm (optional Ø 10 mm) and a wall thickness of 0.5 mm to 1.0 mm.
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Machine Description
2
2.6 Safety system ‒ Ex protection
This machine is designed for use in class EX II 3G Ex pzc [ic] IIA T3 Gc explosive
environments of. This temperature class is adhered to if correctly handled and
with the correct setting of the welding parameters according to specification.
With faulty machine settings or operation, which lead to extremely long welding
times or to an extremely high energy input, the surface temperature of the tools
can temporarily rise above the specified temperature. The machine operator or
setter is responsible for checking the correct settings required for that.
The EX zone 2 area can be an area of up to max. 800 mm diameter around the
welding area.
Fig. 11: Safety area - explosion protection
Pos. Designation
1 Zone 2
2 Safe area

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Machine Description
In the rear part of the welding gun, limited by a nozzle, a specific quantity of air
per time flows into the interior and generates an excess pressure of min. 0.25
mbar (excess pressure encapsulation). Before operating the machine, make sure
there is no explosive gas in the welding gun, by flushing min. 5 times interior
volume with fresh air for 10 sec. when starting.
The inflowing air quantity exits at the front at defined openings on the perimeter
of the sonotrode. This excess pressure prevents harmful gases from penetrating
into the housing. In addition, the outflowing purging air in the area of the tools
generates a safe area.
Signaling and operating elements that are not in the enclosed area are protected
by zener barriers.
Modifications to the machine will render the EC conformity (CE) and EX conformi-
ty null an void.
DANGER
Air outlet has been sealed or modified
Explosion hazard! Risk of injury!

Without air escaping the plant is no longer explosion-proof, since this ensures
that no explosive mixture is present in the plant and in the welding area.
→ Do not press buttons

→ Retreat from the explosive area immediately
→ Silencers must be checked for function
i The escaping air also cools the tools.

The lack of cooling also reduces the service life of the tools!
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Machine Description
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2.7 Electrical specifications
230 ± 10% VAC, 50/60 Hz

Supply
single-phase-zero, grounded (PE)
Control voltage 24 V (DC)
Ultrasonic continuous power 3000 W
Frequency approx. 20100 Hz
Welding duration max. 3 seconds
2.8 Data concerning excess pressure encapsulation
Excess pressure encapsulation Excess pressure > 0.25 mbar
Purge time at least 10 seconds
Volume flow at 5 bar a. 150 l/min

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Machine Description
2.9 Ultrasonic controller
The ultrasonic controller consists of the power supply for the ultrasonic generator
and the control elements for the machine.
It also includes all elements required for altering and adjusting the welding ope-
rations according to the conditions.
DANGER
Explosive atmosphere
Danger of explosion! Danger of injury!
→ Do not set up the ultrasonic controller in a potentially explosive areas.
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Machine Description
2
Front
1 2
5 4 3
Fig. 12: Front view ‒ ultrasonic controller
6 1 2
5 4 3
Fig. 13: Front view of ultrasonic controller with calibration unit

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Machine Description
Pos. Label Designation
Key switch
Pos.: : Setup mode
1 MODE
Pos.: : Production mode
Pos.: : Teach mode
MAIN
2 Main switch "O / I" with emergency stop function
SWITCH
3 USB USB port
4 OFF Button "O" Control Off
5 ON Button "I" Control On
6 Calibration unit (optional)
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Machine Description
2
Rear
1 2 3 4 5 6 7 8 9 10 11 12 13
30
29
28
27
26 25 24 23 22 21 20 19 18 17 16 15 14
Fig. 14: Electronic controller - rear
1 19 Reserved
2 18 Touch screen interface
3 5 Reserved
4 12 Customer interface (hand shake)
5 6 Reserved
6 15 Maintenance unit supply
7 7 External emergency stop / reset box, option
8 P1 Compressed air outlet regulated (0-6 bar)
9 P Compressed air supply of maintenance unit 6.5 bar
10 P2 Supply pressure (6.5 bar)
11 Silencer, exhaust air
12 Fan and filter mat
13 RF RF socket

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Machine Description
14 Connection to power supply
15 8 Monitor mains supply 230V
16 9 UPS supply 230V
17 F1 Fuse (M2A) for power suppyl units T1, T2
18 USB USB port
19 LED for disk access
20 LED supply voltage On
21 PC-USB Double USB interface (mouse, keyboard)
22 PC-LAN1 Ethernet 1
23 PC-LAN2 Ethernet 2
24 PC-DVI DVI interface for monitor
25 PC-COM1 COM1 interface (RS232)
26 PC-I/0 Reset / Start button
27 4 I/O interface PLC (reserve)
28 3 RS232/0 interface
29 2 Reserved
30 1 Control cable of Kobra-III module
Reset / Start button (Pos. 26)

Reboots the PC. To be used only in special cases if PC does no longer respond.
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Machine Description
2
2.10 Welding tools (sonotrode and anvil)
The sonotrode has been adapted to the applied oscillation frequency at the
factory. Any change may cause damage and would render the entire system
inoperable.!
A. Sonotrode
B. Anvil
B A
Fig. 15: Schematic representation of the welding tools
The welding tools are configured for the relevant application:
Fig. 16: Cooling device with filler tube (A) for welding Fig. 17: Cooling device with filler tube (A) for welding
with right-hand cutting tools with left-hand cutting tools

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Machine Description
2.10.1 Sonotrodes set
Application Order number
Left cutting 10853682
Right cutting 10853629
Both sides cutting 10872298
Not cutting 10853713
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Machine Description
2
2.10.2 Anvils set
Application Order number
Left cutting 10853613
Right cutting 10853613
Both sides cutting 10872297
Not cutting 10853711
Left cutting round 10918641
Right cutting round 10918641

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Machine Description
2.11 Drive unit
Fig. 18: Welding room and anvil support
Pneumatically moved anvil support (A)
The vertical movement closes the welding space.
WARNING
An increased risk of injury exists in the entire vicinity of the welding gun as
well as between the welding tools (sonotrode and anvil).
Danger of injury! Crushing of the hands/fingers! Separating the fingers! Burns!
→ Wear protective gloves, work carefully
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Machine Description
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ATTENTION
Tool break due to non-intended parts to be welded
Material damage, e.g. on the machine or on the workpiece.
→ For reasons of safety only place the provided part(s) to be welded between
the welding tools and never steel pins or similar materials!

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Machine Description
2.12 Pneumatic system
The working pressure of the ultrasonic controller is controlled by a transducer

according to the set of parameters.
A pneumatic hose within the system cable is used to supply the solenoid valves in
the welding gun with the controlled working pressure for the cylinder. It pushes
the anvil mounted on the anvil support against the sonotrode and thus applies
the force required for the welding.
Pressure Colour Marking

Pressure supply transparent tube P
Normal pressure blue hose P2
Controlled pressure red hose P1
2.13 Interfaces
There are several interfaces at the back side of the ultrasound controller (see
„Rear“).
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Machine Description
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2.14 Spare parts list
2.14.1 Overview of basic mechanical parts manual depth stop (basic version)
Opening dimension 7 mm
Fig. 19: Overview of basic mechanical parts, opening dimension 7 mm

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Machine Description
Pos. Qty. Designation Order no.

10 1 ASSY main body, complete 10952868
20 1 ASSY zero-point support, complete 10820070
30 1 ASSY oval piston, complete for 10 mm lift 10819753
40 1 ASSY piston cover, complete 10819953
50 1 ASSY Anvil support, opening dimension 7 mm 10952131
ASSY cover, complete
60 1 10953001
vertical suspension lift 10 mm
70 1 ASSY stop, complete 10820197
80 1 ASSY motor connection Kobra-III 10857522
90 1 Intermediate plate 10853339
100 1 ASSY Sheet metal element right, complete 10842494
110 1 ASSY Sheet metal element left, complete 10842499
120 1 ASSY pneumatic valve 2x3/2 way valve 10830114
130 1 ASSY pneumatic valve 5/2 way valve 10842474
150 1 Plug holder, complete 10851291
160 1 ASSY attachment body, complete 10830662
170 1 Lower cover, complete 10853404
180 1 Cop cover, complete 10853403
190 1 ASSY position sensor, complete 10827205
200 1 Sonotrode cover 10842555
210 1 Fibroflex foil 10843543
220 1 Plate 10921400
230 1 Plate 10921390
240 4 Coupling 10823649
1010 2 EJOT-Delta-PT 10725386
1020 1 Logic elements OS-PK-3 10841989
1030 1 Plug Straight 4WA (Ini cable) 10354894
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Machine Description
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1040 1 Socket 2 pins 10574511
2000 8 Filister head screw 10758138
2010 6 Cylinder screw 10924473
2020 8 Oval-head screw 10591506
2060 1 Nut 10823023
2080 1 Set screw 10951701
i The respective serial number of the anvil support is located on its underside.

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Machine Description
2.14.2 Overview of basic mechanical parts manual depth stop (basic version)
Fig. 20: Overview of basic mechanical parts, opening dimension 12 mm
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50 1 ASSY Anvil support, opening dimension 12 mm 10952164
60 1 10953053
100 1 ASSY Sheet metal element right, complete 10842494
110 1 ASSY Sheet metal element left, complete 10842499
210 1 Fibroflex foil 10843543
220 1 Plate 10921390
230 1 Plate 10921400
240 4 Coupling 10823649
1010 2 EJOT-Delta-PT 10725386

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Machine Description

1040 4 Socket 2 pins 10574511
2000 8 Filister head screw 10758138
2060 1 Nut 10823023
2080 1 Set screw 10951701
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Machine Description
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2.14.3 Overview of basic mechanical parts, motorized depth stop (full version)
Fig. 21: Overview of basic mechanical parts, motorized depth stop, opening dimension 7 mm

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Machine Description

ASSY Anvil support, complete,
50 1 10952131
opening dimension 7 mm
60 1 10953001
100 1 Sheet metal element right, complete 10842494
110 1 Sheet metal element left, complete 10842499
210 1 ASSY motor stop 10820243
220 1 Plate 10921400
230 1 Plate 10921390
240 4 Coupling 10823649
1010 2 EJOT-Delta-PT 10725386
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Machine Description
2
1040 1 Socket 2 pins 10574511

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Machine Description
2.14.4 Overview of basic mechanical parts, motorized depth stop (full version)
Fig. 22: Overview of basic mechanical parts, motorized depth stop, opening dimension 12 mm
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2
ASSY Anvil support, complete,
50 1 10952164
opening dimension 12 mm
60 1 10953053
100 1 Sheet metal element right, complete 10842494
110 1 Sheet metal element left, complete 10842499
210 1 ASSY motor stop 10820243
220 1 Plate 10921390
230 1 Plate 10921400
240 4 Coupling 10823649
1010 2 EJOT-Delta-PT 10725386

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Machine Description

1040 4 Socket 2 pins 10574511
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Machine Description
2
2.14.5 “Zero-point” support
Fig. 23: Support spring zero point bearing
Asm. Pos. Qty. Designation Order no.

20 1 ASSY zero-point support 10820070
20 20 1 Support spring 10782733
20 2020 2 Cylinder screw 10685492

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Machine Description
2.14.6 Sealing of anvil support, stroke 7 mm
Fig. 24: Sealing of anvil support, stroke 7 mm

10 40 1 Fibroflex foil 10827320
10 60 1 Sheet metal element 10860844
10 2030 4 Oval-head screw 10690123
60 1000 1 Fibroflex foil 10849253
60 1010 1 Fibroflex foil 10947580
60 2000 2 Oval-head screw 10690123
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Machine Description
2
2.14.7 Sealing of anvil support, stroke 12 mm
Fig. 25: Sealing of anvil support, stroke 12 mm

10 40 1 Fibroflex foil 10827320
10 2030 6 Oval-head screw 10690123
60 1000 1 Fibroflex foil 10855809
60 1010 1 Fibroflex foil 10849253
60 2000 2 Oval-head screw 10690123

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Machine Description
2.14.8 Stop left and right
Fig. 26: Stop left and right

70 10 1 Limit stop, left 10837769
70 20 1 Limit stop, right 10837770
70 2030 4 Oval-head screw 10685455
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Machine Description
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2.14.9 Set of replacement snap fasteners with slot and latch spring
Fig. 27: Replacement snap fastener with slot
Designation Order no.

Set of replacement snap fasteners with slot and latch spring 10917586

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Machine Description
2.14.10 Flat cage guidance system ASSY (order no. 10921229)
Fig. 28: Flat cage guidance system ASSY
Size Pos. Pcs. Designation Order no.

50 10 1 Flat cage guidance system on request
50 1000 14 Needle roller on request
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Machine Description
2
2.14.11 ASSY pneumatic valve 2x3/2 way valve (order no. 10830114)
Fig. 29: ASSY pneumatic valve 2x3/2 way valve
2.14.12 ASSY pneumatic valve 5/2 way valve (order no. 10842474)
Fig. 30: ASSY pneumatic valve 2x3/2 way valve

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Machine Description
2.14.13 Pressure switch
1
Fig. 31: Pressure switch
Pos. Designation
1 Pressure switch
WARNING
Inclined or incorrectly set pressure switches
→ The two pressure switches are safety-relevant components and may only be
adjusted and replaced by Schunk Sonosystems. Failure to adhere will result
in the loss of the EC conformity (CE) and ex-conformity as well as the loss of
the guarantee.
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Transport and installation
3
3. Transport and installation
Specially trained qualified personnel who possess the appropriate knowledge and
have been instructed in accident prevention regulations are to execute all measu-
res described in this chapter.
3.1 Packaging
The machine must be packed dry and protected from the atmospheric influences.
The packaging materials should be stored for later shipment and/or for machine
shutdown.
3.2 Storage / Transport
Should the machine not be used for an extended period, dismantling and storage
of the machine is recommended.
The machine should be stored at a dry and dust-free location.
The following procedure is recommended for placing the machine into storage:
¬ Clean the machine at the place of use.

¬ Please ensure that the conditions at the place of storage do not promote
the formation of corrosion. If this cannot be excluded, we recommend using
moisture-absorbing materials for wrapping the machine.
3.3 Shipment / Company-internal transport
Please ensure that all components have been secured against shifting and falling
for the purpose of transport. The overall weight of the system (without replace-
ment parts or additional tools) is approx. 36 kg:
¬ Welding gun incl. oscillator system 9 kg

¬ System cable 6 kg
¬ Ultrasonic controller 20 kg
¬ Monitor with stand 3.5 kg
For this reason, the general safety regulations of your company shall apply.

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Inspection on delivery
You need to inform us about damages and missing parts immediately and have
the shipping company confirm this on the delivery documents.
Please check the shipment on delivery and compare with the delivery note to
verify completeness (see „1.8 Scope of delivery“).
3.4 Connected loads
230 ± 10% VAC, 50/60 Hz

Connection to power supply
single-phase-zero, grounded (PE)
Power consumption: max. 4000 VA
Fusing: 16 A
6.5-10 bar,
dry, oil-free,
Compressed air supply to the
compressed air quality in accordance with
maintenance unit:
ISO 8573.1
Purity Class 2.4.1.
Air consumption rate: Max. approx. 150 l/min at 6 bar
Setting value of maintenance

6.5 bar
unit
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3.5 Compressed-air supply
The working pressure on the machine (displayed on the maintenance unit) must
always be 5.5 bar!
WARNING
Pneumatic hoses that are not properly fastened
Risk of injury!
→ Ensure that they have been fitted firmly.
ATTENTION
Underranging the minimum working pressure
Functional impairment of the welding machine and of the welding result!
→ Comply with the prescribed minimum working pressure!
ATTENTION
Water or oil in the compressed air
Destruction of the pressure converter integrated in the ultrasonic controller, as

well as of the other pneumatic and electronic components!
→ Insert the compressed air maintenance unit between ultrasonic controller

and compressed air supply!

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3.6 Place of use / place of operation
DANGER
Danger of explosion!
The ultrasonic controller, monitors, barcode scanner and external emergen-

cy stop box must not be installed and operated in a potentially explosive
environment!
The design of machine components is based on the assumption that the machine
would be set up and operated at a location that is protected against the effects of
weather.
The machine should be accessible from all sides to enable the performance of
maintenance and repair tasks.
We recommend suspending the welding gun from a spring-loaded tool balancer

to prevent posture-induced damage. Ensure that the tool balancer is correctly
secured in position at all times.
Adequate and appropriate on-site lighting for the machine must be available at
the place of machine operation. (To this end, comply with occupational health
and safety regulations and company-internal specifications)
3.7 Space requirement of the machine
The installation surface of the machine is 74 mm x 519 mm (W x L) for the version

handle at top, see „Fig. 117: Top handle“, without system cable:
The installation surface of the controller is 450 mm x 550 mm (W x D) with
handles and calibration unit.
An adequate clearance must be provided for the system cable.
Operating personnel needs additional space.
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3.8 Ambient conditions
Ambient temperature: min. [°C] + 10

max. [°C] + 40
The service life of the welding
machine may be reduced due to
lubricant failure, etc., as a result of
high ambient temperatures
Rel. atmospheric humidity max. [%] 85
non-condensing
Only operate the machine in a defrosted state.
3.9 Installation requirements
Requirements on the installation location:
¬ closed, dry production facility

¬ solid, dry and level floor
¬ dust-free environment
¬ drip and splash-free environment
¬ no open liquids and oils in the machine area
¬ no mechanical manufacturing and chips in the surrounding region
¬ Ensure that no solvents or fumes are present in the air before switching on
the machine and while it is in operation.
3.9.1 Protection classes
The welding head IP42 and the ultrasonic controller IP40 meet the protection
class.
The aforementioned installation location requirements are to be satisfied to

guarantee trouble-free operation of the machine.

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3.10 Installation of the welding machine
Please notify the safety officer in charge regarding the anticipated arrival of the
machine and coordinate execution of machine installation with the safety officer.
3.10.1 Mechanical assembly
The machine is delivered ready assembled. It can be put into operation as soon
as electrical and pneumatical connections have been established.
i The welding gun can be held by hand. To avoid posture problems for the opera-
tor, the machine must be fastened on a suitable counterbalancing element.
3.10.2 Assembly ‒ electrical system
The distance of the controller from the machine is limited to about 4 meters due
to the given cable lengths (variant with system cable length 6 m).
Formation of loops to ensure sufficient mobility of the system cable is required

for proper operation.
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3.10.3 Assembly ‒ pneumatic system
The maintenance unit should be installed only vertically, as shown below.
Fig. 32: Maintenance unit
ATTENTION
The maintenance unit is part of the safety chain!
Shutting down or reducing the supply pressure is only permitted after previous-
ly removing of the welding device from the explosive area!

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3.11 Power supply connection
3.11.1 Electrical connection
A qualified electrician needs to connect the ultrasonic welding system to the

electrical supply network.
The mains voltage and the maximum current consumption must be adhered to.
DANGER
Mains connection ultrasound control:

Non-compliance with regulations and rules, faulty installation
Fatal electrical shock in case of incorrect connection to electrical supply

network!
¬ Connection to electrical supply network only by qualified electricians

¬ Comply with rules and regulations
¬ Ultrasonic control: observe mains voltage and maximum power
consumption
Mains connection, 230 V type

Voltage / network 230 VAC ±10 %, N, PE, 50/60 Hz
Power consumption max. 16 A
Main fuse 16 A
Mains connector Schuko plug according to CEE 7/4
Mains connection, 220 V type

Voltage / network 220 VAC ±10 %, PE, 50/60 Hz
Power consumption max. 16 A
Main fuse 16 A
Mains connector Schuko plug according to CEE 7/4
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3.11.2 Description of connections
D G A I H C
B G J H E E F
Fig. 33: Rear panel of the ultrasonic controller
A. Install protective conductor (green-yellow wire).
B. Hook the end of the system cable in the provided support bracket at the rear
panel of the ultrasonic controller and tighten the retaining nut.
C. Then connect the RF plug to the RF jack and secure the connection by tigh-
tening the knurled nut. Ensure that the nut is tightened until the limit stop is
reached.
D. Plug the 25-pin Sub-D connector (XS1) into the corresponding socket no. 1
and secure with two screws. (Small flat-head screwdriver required!)
E. Connect the marked pneumatic hoses with the accordingly marked connec-
tion points (P1, P2).
F. The mains cable is permanently connected to the ultrasonic controller. Insert

the mains plug into a single-phase, earthed mains socket outlet with 230V
AC (±10%).

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G. ¬ Connect the 15-pin Sub-D connector (XS18 interface 10“ touch monitor) to
the socket No. 18 and secure with two screws.
Connect the USB connector is to the PC (Touch).
¬ Connect the DVI connector to the PC and secured with two screws
H. P is used to supply the compressed air from the maintenance unit. Connect
the main valve of the maintenance unit to socket No. 15 and secure with the
bracket.
I. External emergency stop box (option):

Connect the round plug to socket No. 7 and secure with the rotary ring.
J. Ethernet connection for data exchange via network
i In case of applications with external emergency stop box, if not ordered from
the factory, disconnect and insulate the internal red bridge at socket No. 7.
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3.11.3 Pneumatic connection
The connection is established via the compressed air mains at the installation
location.
Marking
Pressure supply transparent tube P
Normal pressure blue hose P2
Controlled pressure red hose P1
Supply pressure (mains 6.5 - 10 bar

side)
Pressure connection of 6.5 bar
machine
Compressed air quality: according to ISO 8573.1 class

2.4.1

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DANGER
Fatal electrical shock if energised surfaces are touched
→ Ensure that the ultrasonic controller is not misused as a storage area (e.g.
for beverages).
DANGER
Bending and deformation the system cable
Risk of injury
Impairment of the operation of the entire system
→ Please note that the system cable must not be bent or deformed!
→ The minimum bending radius of max. 300 mm must be ensured!
→ The system cable must not be twisted!
→ Do not store any loads on the system cable!
Extension cables for the connection to the 230V mains longer than 10 m can
i cause unacceptable voltage drops if the conductor cross section is insufficient!

The functionality of the entire system can be affected. The length of the exten-
sion cable should be less than 10 m.
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3.12 Dismantling
Dismantling is carried out in reverse order of the sequence described under

„3.10 Installation of the welding machine“.
3.13 Commissioning
The basic settings of the machine were already made by Schunk Sonosystems at
commissioning.
Commissioning takes place by switching on the main switch on the ultrasonic

controller, see „5.4 Switching the device on or off“.
The first start parameters can be found in the guide values table, see „4.3 Start
parameters table (guide values for left / right-cutting tools)“.
They shall only be used for initial welding tests and must be adapted to the
respective requirements such as material quality, wall thickness, tube diameter,
tolerances and the desired target values (max. tightness or maximum tool life).
The machine is ready for operation after it has been accepted by the
manufacturer.

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Setup
4. Setup
4.1 General information
Factory-set values are based on the supplied sample parts and empirical values
for the respective material. The selected starting values are usually in the lower
average range to ensure that tools and the welding system do not sustain da-
mage. After checking the strength, tightness and other test values, the welding
parameters must be adapted to the desired requirements.
If SCHUNK SONOSYSTEMS was unable to make any settings, please contact the
SCHUNK SONOSYSTEMS service department to obtain the appropriate essential
standard parameter settings suitable for the part to be welded
(see „Contact Information“).
If SCHUNK SONOSYSTEMS was not provided with your samples, then the machine
is set according to internal specifications.
If this is the case, please provide the SCHUNK SONOSYSTEMS laboratory with
sample parts in order to determine the optimised parameter settings suitable
for your process and to be able to suggest adjustments and improvements if
necessary.
Please keep in mind that the sonotrode, the booster and the converter must be
in resonance. Changes made to the sonotrode require new resonance tuning at
the factory.
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4.2 Welding position
A. Compressor
B. Compressor tube
C. Cu filler tube ac-
cording to specifi-
cations (brazed)
D. Welding area
E. Filler valve
F. Min. distance
90 mm
G. Filter
H. Heat exchanger
Fig. 34: Welding position
i
If the minimum welding distance of 90 mm to the soldering joint on the pipe is
not maintained, leakage rates can increase due to influences of the soldering
process!

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Setup
4.3 Start parameters table (guide values for left / right-cutting tools)
Tube diameter (mm) 6,35 6,35 6,00 6,00 6,00
Wall thickness (mm) 0,75 0,60 1,00 0,75 0,50

Gap width between
tools (mm) 0,54 0,35 0,89 0,56 0,24
(closed)
*)
Pressure (bar) 3,20 2,90 3,80 3,20 2,60
Amplitude (µm) 25 24 25 25 24
t1 (s) 1,50 1,50 1,50 1,50 1,50
t2 (s) 0,16 0,20 0,15 0,16 0,26
Target height mm (measured
1,05 0,84 1,40 1,05 0,70
with vernier calliper)
*) max. adjustable pressure 5 bar
Fig. 35: Gap width between tools (mm) (closed) Fig. 36: Welded tube (target height)
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It may become necessary to adjust parameter settings according to the indivi-

i dual product during production due to different qualities of copper, wall thick-
nesses, tube diameters and tolerances.
Please contact SCHUNK SONOSYSTEMS to determine parameter settings for

dimensions not listed in the table.
Make sure to select the welding position so that the tube always remains
i completely within the welding tools during the welding process (guide value:
welding positions 2 to 8 for a tube with a diameter of 6 mm).
If the tubes exits the welding surfaces, this can result in untight welded joints.

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Setup
4.4 Setup mode
The following values are used for illustrative purposes and do not guarantee
i accuracy.
Fig. 37: Setup mode overview
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Operation Function Explanation
A test pin can be used here to

Calibration of height
calibrate the height measuring
measuring system
system.
Moving the anvil Moving the anvil up or down
Test sound check Control of the amplitude of the

button sonotrode
The currently selected tool is

displayed here. Pressing the
Display and selec- button opens a selection menu
tion of the current for the corresponding tools, see
tool „Tool selection“
If the tool has been changed, it
will prompt for calibration.
Checking purging air Checking the proper function of

monitoring the purging air
Setting a new value for the

Changing the depth height of the depth stop.
stop height The depth stop motor moves
accordingly.
Display of non-edited height

Current height value
sensor value
The welding position sensor

Current welding
provides the current welding
position
position (1-9).
Current value of the Display of non-edited sensor

depth stop motor value of the depth stop motor.

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Setup
Tool selection
Fig. 38: Tool selection
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Setup
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Aktion Funktion Erklärung
Left cutting Selection of the left cutting anvil
Selection of the right cutting

Right cutting
anvil
Selection of the both sides cut-

Both sides cutting
ting anvil
Not cutting Selection not cutting
Selection of the left cutting

Left cutting round
round anvil
Selection of the right

Right cutting round
cutting round anvil
Cancel selection with ESC or

Query confirm with Enter

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Setup
4.4.1 Setting the tools
WARNING
Shearing of the fingers between anvil and sonotrode
Severing of fingers
→ Never reach your fingers into the area of moving parts
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¬ if necessary, switch on the device, see „5.4

Switching the device on or off“
→ turn the key to the left to the setup
mode
→ The tool to be set must be displayed on the

screen. or
→ if necessary, convert to the selected tool,

see „6. Changing tools“
→ Press the height adjustment button
→ Adjust height to 1 mm and confiirm with the

green checkbox.
→ Wait until the anvil has moved to the end

position (counter of the depth stop motor
comes to a stop)
→ Press the close tools button

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Setup
4.4.1.1 Setting double cut
i If double cutting is selected, the after-burst will be activated automatically and

deactivated when switching to another tool.
→ Follow the instructions under „4.4.1 Setting

the tools“
→ Enable release by contact of the test pin
with the tool and the limit stop (drive
without anvil!)
→ Confirm with start button
→ Machine closes
→ Insert anvil as shown in the picture
→ The term „FRONT“ must be visible at the

front
→ Screw in the cylinder screws on the anvil

support (do not tighten!)
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→ For screwing, insert the feeler gauge
0,30 mm on the right side (on the side of
the clamping screws) between anvil and so-
notrode until the end of the anvil and lightly
press the anvil in the upper area against the
sonotrode (see picture)
→ Tighten screws on the anvil support
→ Check the gap on both sides with a feeler
gauge 0.30 mm. The feeler gauge must be
completely inserted on both sides.
→ Tighten screws with torque wrench (10 Nm)

→ Check the gap again on both sides with the
feeler gauge 0,30 mm
→ To open the machine click the marked

button

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Setup
4.4.1.2 Setting the right or left cutting anvil
The anvil is adjustable.
i
The standard adjustment of the gap is 0,40 mm ± 0,05 mm.
If the tube diameters are smaller, the anvil can be adjusted to other cross
sections.

the tools“

→ In set-up mode set the motorized depth

stop to 1,25 and close tools. Now set the
cutting gap between sonotrode and anvil to
0,40 mm using a feeler gauge.

0,40 mm between anvil and sonotrode until
the end of the anvil and lightly press the
anvil in the upper area against the sonotro-
de (see picture)
→ Tighten screws on the anvil support with
10 Nm
→ Check the gap with a feeler gauge 0.40 mm.
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4.4.1.3 Setting the not-cutting anvil

the tools“

support and tighten.

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Setup
4.4.1.4 Setting the round right or left cutting anvil
The anvil is adjustable.
i The standard adjustment of the gap is 0,40 mm ± 0,05 mm.

If the tube diameters are smaller, the anvil can be adjusted to other cross
sections.

the tools“

→ In set-up mode set the motorized depth

stop to 1,25 and close tools. Now set the
cutting gap between sonotrode and anvil to
0,40 mm using a feeler gauge.

0,40 mm between anvil and sonotrode until
the end of the anvil and lightly press the
anvil in the upper area against the sonotro-
de (see picture)
→ Tighten screws on the anvil support with
10 Nm
→ Check the gap with a feeler gauge 0.40 mm.
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4.4.1.5 Calibration
Use the calibration pin with black button (order no. 10839062) to calibrate with
left/right cutting edge and without cutting edge.
i For calibrating with double cutting edge use the calibration pin with red button
(order no. 10872031).
The two pins are only used in connection with the calibration unit. If the cali-
bration unit is not available, use the calibration pin from the tool kit (order no.
10855491).
ATTENTION
Incorrect insertion of the calibration pin
Malfunctions and material damage on the machine or on the workpiece.
→ Ensure the correct position of the respective calibration pin for all
calibrations!
WARNING
Insertion of the calibration pin
Danger of crushing fingers
→ Never reach your fingers into the area of moving parts

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Setup
¬ If necessary switch on the device (e.g. after

changing the tools) see „5.4 Switching the
device on or off“
→ Confirm info with a click on the button
→ Turn the key to the left to setup mode
→ The current welding postion must be set to

Pos. 1, (see„6.7 Setting the limit stop wel-
ding position“)
→ Start calibration by clicking on the button
(button lights up red)
→ Follow the instructions on the screen
→ Carry out three additional calibration steps

with different positions of the calibration pin
following the instructions on the screen
→ Press the start button when the green light
lights up!
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→ Calibration was successful (green check

mark)
Error message
→ Calibration has been cancelled manually

→ inserted calibration pin is defective
→ Diagnosis has not been performed correctly

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Setup
4.4.1.6 Calibration with test pin (Order no. 10855491)
The calibration pin is only used if it is not an Ex-version and as a result no calibra-
tion unit is available.
¬ Switch on the device, see „5.4 Switching the

device on or off“
→ Confirm info with a click on the button
→ Turn the key to the left to setup mode
→ Start calibration by clicking on the button

→ Place the calibration pin at the cutting edge
of the anvil

→ Enable welding by contact of the test pin
with the tool and the limit stop
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→ Press the start button as soon as the green

light lights up
→ Machine closes
→ Carry out two additional calibration steps

with different positions of the calibration pin
following the instructions on the screen
→ Press the start button when the green light
lights up!
→ Calibration was successful (green check

mark)
Error message
→ Calibration has been cancelled manually

→ inserted calibration pin is defective
→ Diagnosis has not been performed correctly

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Setup
4.5 Teach mode
Overview
Tube, welding and quality parameters can be set and managed in this dialogue.
The set parameter values will be used in the next test weld.
The input fields are accessed by clicking on the corresponding field.
Fig. 39: Teach mode overview
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Information on designation and

Tube designation
description of the current wel-
Comment
ding parameter set
Time after which the switchover

Switching time t1 height must be reached at the
latest.
Time after which the tube

Welding duration t2 is welded after reaching the
switchover height.
Pressure with which the

Working pressure
machine closes.
Amplitude of the sonotrode

Amplitude in μm
during dry running
A weld will be identified as

Final height toleran-
defective if the limits are not
ce value
reached or exceeded.
Total welding durati- A warning is output if the limits

on tolerance value are not reached or exceeded.
Energy tolerance A warning is output if the limits

value are not reached or exceeded.
Height of the limit stop: the

Limit stop machine cannot move further
down during the next welding

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Setup
Adjusting limit stop Basic Version

The thickness of the welded tube is adjusted by means of the height of the limit
stop (see „Fig. 36: Welded tube (target height)“
In the basic version this is done manually using the setting screw under the cover
at the bottom of the machine.
¬ Switch to teach mode
¬ Create new parameter set or load existing

parameter set
¬ Query to suggest welding parameters

Enter Yes
ESC No
¬ When loading existing parameters check

correct setting of the limit stop
¬ confirm with the green checkbox
¬ Switch to setting mode

¬ Press the close tools button
¬ Enable by contact of the test pin with the
tool.
Press the start button as soon as the green
light lights up
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¬ When the welding gun is closed, subtract
the displayed value from the value to be set
¬ Activate measuring system by clicking on the
button (∆ 0.00 mm)
¬ Remove the screws of the cover at the

bottom of the machine with allen wrench
(WAF 2.5)
¬ Loosen counter nut with socket wrench

(WAF 13)
¬ Turn adjusting screw with Allen key

(WAF 4) to the left or to the right until the
desired value is set (= calculated setting
dimension Δ)
¬ set value
(here, the value adds up from 0.40 mm to
0.80 mm figure 1)
¬ Tighten counter nut

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Setup
¬ Press the Open Tools button

¬ Carry out diagnostics on welding position 1
(the limit stop position is adopted by the
diagnosis)
¬ Calibration: follow the instructions on the
screen
¬ Adjust welding position
¬ Adjust Teach Mode
¬ Carry out test welding
¬ Measure welding height of the welded tube

(see Abb. 34: Geschweißtes Rohr (Zielhöhe).
¬ enter the real welding height
¬ save
¬ To enter the measured value press „Enter“

and enter the measured value.
¬ repeat these steps from point „adjusting“

until the final height has been reached.
¬ Tighten the screws of the cover at the

bottom of the machine with allen wrench
(WAF 2.5)
i After each adjustment of the limit stop, a calibration must be carried out!
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Submenus
Options menu Import welding data, parame-

(see „4.5.1 Options terise sequences and other
menu“) settings
Create new parame-

ter set Create new parameter set with
(see „4.5.2 Creating default values.
new parameter set“)
Load a parameter
set Select a parameter set to be
(see„4.5.3 Loading loaded from existing parameter
or deleting a para- sets
meter set“)
The current parameter set can

Save parameter set
be saved.
Display tube Here you can find the properties

parameters of the tube to be welded.
Display of the current date and

Date and time
time

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Setup
After welding:
Aktion Funktion Erklärung
After welding and pressing the

flashing memory button, the
Save after welding window will appear asking you
to enter the measured welding
dimension.
Cancel selection with ESC or

Selection
acknowledge with Enter
Entry of the measured welding

Keyboard
dimension
After a welding the measured

Display height graph power and height values can be
displayed as a graph.
Display tube The properties of the tube to be

parameters welded can be seen here.
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The following symbols apply to all menus
Confirm the action to be

Confirm
performed
End Exit input field
¬ Help display
Help (see „Help
¬ Select language
menu“)
¬ User manual
Exit Exit menu
Save Save the data

1234567-89 Rev 4.0 Rev 4.0 113
Setup
Help menu
Language Select the language
Call up the operating

User manual
instructions
i The actions to be performed can also be confirmed with a double-click!
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Setup
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4.5.1 Options menu
Fig. 40: Options menu

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Setup
Set counter (see

„4.5.1.1 Setting the Parameterise different counters
counter“)
Machine setup
(see „4.5.1.2 Machi- various machine settings
ne setup“)
Edit
sequences Re-create, edit or delete
(see „4.5.1.3 Edit sequences
sequences“)
All welding results can be vie-

View log book
wed in the logbook.
Import or export
welding parameter
sets Import or export welding para-
(see „4.5.1.4 Import meter sets from any directories
or export of welding
parameter sets“)
Import or ex-
port sequences
Import or export sequences
(see „4.5.1.5 Im-
from any directories
port or export of
sequences“)
Export logbook files

Export logbook files to arbitrary
(see „4.5.1.6 Export
directories
of logbook files“)
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4.5.1.1 Setting the counter
Here you can parameterise or reset to 0 various counters. The operation counter
cannot be reset. If the threshold is 0, the respective counter is not monitored.
The (stop) setting disables the machine if the next weld count is reached.
Fig. 41: Setting counter menu - Stop

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Setup
With the set (warning), a warning that the set value has been reached is
issued when reaching the count value.
Fig. 42: Setting counter menu - Warning
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Setting alarm or warning

Setting thresholds
threshold
Resetting counter Reset counter to 0
Service counter
Set or reset the service counter
alarm
Welding position Set or reset welding position

counter alarm counter
Sonotrode counter
Set or reset sonotrode counter
alarm
Anvil counter alarm Set or reset anvil counter
Operation counter Counts the number of welds
Switch between
Stop
stop and warning
Switch between
Warning
stop and warning
Parameterising Parameterise further counters

further counters after a certain number of errors,
(see „Parameterising e.g. automatic air shutdown or
further counters“) shutdown

1234567-89 Rev 4.0 Rev 4.0 119
Setup
You can enter the keyboard input by clicking on the respective counter field. Here
can enter manually the desired alarm threshold.
Fig. 43: Keyboard input alarm thresholds
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Displays the entered alarm

threshold
(...... is output for all counters)
Input keyboard To enter the values
Forward counter Sets higher value
Reverse counter Sets lower value

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Setup
Parameterising further counters
Fig. 44: Parameterise further counters
Air shut-off
Parameterization of the automatic air shut-off:
Setting the time that may pass

after the last welding until the
Parameterise air
supply air is shut off.
shut-off
If 0 is set, the supply air will stay
on.
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Error configuration
Here you can configure the handling of the pressing dimension, welding duration,
welding dimension and energy errors.
You can set for each error whether it should be analysed or ignored. Errors to be
analysed are displayed in green, errors to be ignored in grey.
If "... error is analysed" has been selected, the number of errors is counted. The
machine stops after the set number of errors within the set number of welds
(e.g.: the machine stops after 15 errors if 15 errors have occurred within 30
welds).
If "... error is not analysed" has been selected, the errors are displayed but the
machine continues running.

1234567-89 Rev 4.0 Rev 4.0 123
Setup
Enter the number of errors that

is allowed before stopping the
Setting the counter
machine
(via keypad)
Number of total Entering the total welds via

welds keypad
Resetting counter The error counter is reset.
Do not analyse
Welding dimension errors will
welding dimension
be ignored
errors
Consider welding dimension

Analyse welding
errors when analysing the last
dimension errors
error
Do not analyse wel- Welding duration errors will be

ding duration errors ignored
Consideration of welding dura-

Evaluate welding
tion errors in the evaluation of
duration errors
the last errors
Do not analyse wel- Welding energy errors will be

ding energy errors ignored
Analyse welding Consider welding energy errors

energy errors when analysing the last errors
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4.5.1.2 Machine setup
Input of various machine settings
Entering a password is required. The setup menu appears after the password has
been entered correctly.
Fig. 45: Machine setup

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Setup
4.5.1.3 Edit sequences
Fig. 46: Edit sequences
Sequences can be re-created, edited or deleted here. By double-clicking on the

above welding parameter sets of the sequence, you can view its parameters.
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Sequence display Display of the current sequence
Sequence name Name of the selected sequence
Display of the selected tube

parameters by clicking
Creating a new se- Creating an empty sequence if a

quence (see „Crea- valid sequence name has been
ting new sequence“) entered before.
Editing sequen-
Editing the currently selected
ce (see „Editing
sequence in another dialogue
sequence“)
Delete sequence
Deleting currently selected
(see „Delete
sequence
sequence“)

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Setup
Creating new sequence
Enter the sequence name
Fig. 47: Enter the sequence name
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Editing sequence
Fig. 48: Editing sequence

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Setup
Selection opposition,
Selection of position
removing by double-click
Sequence name Name of the sequence
Insert welding Inserting a welding parameter

parameters set at the marked position
Removing the selected wel-

Removing welding
ding parameter set from the
parameters
sequence
Selecting the desired welding

Designation of wel-
parameter set
ding parameter set
Pasting by double-clicking
Display of the welding para-

Display of welding
meters of the selected welding
parameters
parameter set
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Delete sequence
Fig. 49: Delete sequence
Enter Confirm
ESC Cancel

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Setup
4.5.1.4 Import or export of welding parameter sets
Here you can store welding parameter sets on external data carriers or load them
from the data carriers. The welding parameters that can be used by the Kobra-III
are displayed on the left side, all welding parameters in the currently selected
directory are displayed on the right side.
Fig. 50: Import or export of welding parameter sets
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Changing file path Change of the file path
All selected welding parameter

Exporting welding
sets are copied from the selec-
parameter sets
ted directory.
All welding parameter sets of

Selecting all welding
the Kobra-III and the selected
parameter sets
directory are selected.
All selected welding parameter

Import welding pa-
sets are copied from the selec-
rameter sets
ted directory.
Deleting welding All selected welding parameter

parameter sets from sets in the selected directory are
external memory deleted.

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Setup
4.5.1.5 Import or export of sequences
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Exporting sequences All selected sequences of wel-

from welding para- ding parameter sets are copied
meter sets to the selected directory.
Selecting all se- Selects all sequences of welding

quences of welding parameter sets of the Kobra III
parameter sets and the selected directory.
Importing sequences All selected sequences of wel-

from welding para- ding parameter sets are copied
meter sets from the selected directory.
Deleting sequences
All selected sequences of wel-
of welding parame-
ding parameter sets in the selec-
ter sets from exter-
ted directory are deleted.
nal memory

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Setup
4.5.1.6 Export of logbook files
Logbook files can be exported to any directories here.

The logbook files generated by the Kobra-III are displayed on the left side, all
logbook files in the currently selected directory are displayed on the right side.
Fig. 51: Export of logbook files
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Export of logbook All selected logbook files are

files copied to the selected directory.
Selects all logbook files of

Selecting all logbook
the Kobra III and the selected
files
directory.
Deleting log fi- All selected logbook files in

les from external the selected directory will be
memory deleted.

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Setup
4.5.2 Creating new parameter set
Fig. 52: Create new parameter set
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Setup
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Function Explanation
Operation
Changing the name

of a weld Editing the current parameter
(see „4.5.2.1 Tube name
name“)
Changing the com-

ment of a weld
Editing the current comment
(see „4.5.2.2
Comment“)
Linking optional image files with

Changing the user the current welding parameter
image of a weld set. These can be displayed, for
example, before each weld.
Editing tube
diameter Entering the outer tube
(see „4.5.2.3 Tube diameter
diameter“)
Editing tube wall

thickness
Entering the tube wall thickness
(see „4.5.2.4 Tube
wall thickness“)
Automatic determination of the

Automatic tube diameter and wall thickness of
detection a tube.
(see „4.5.2.5 Auto- Prerequisite is a supply pressu-
matic tube detection re of min. 6.5 bar and a round,
/ start parameters smooth cut tube end (option).
selection (option)“ This function is not available in
the basic version.

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4.5.2.1 Tube name
Entering the tube name
Fig. 53: Entering the tube name
4.5.2.2 Comment
Entering the description of the current welding parameter set
Fig. 54: Entering the comment
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4
4.5.2.3 Tube diameter
Entering the tube diameter
Fig. 55: Enter the tube diameter
4.5.2.4 Tube wall thickness
Entering the tube wall thickness
Fig. 56: Entering the wall thickness

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4.5.2.5 Automatic tube detection / start parameters selection (option)
The current welding position must be adjusted to Pos. 1! (see „6.7 Setting the
limit stop welding position“)
Fig. 57: Automatic tube detection, right cutting
In order to be able to determine the tube diameter and the tube wall thickness,
the relevant tube must be inserted into the welding space. The reference welding
position should be set. The tube can be pressed against the side of the cutting
edge. But it must not be on the cutting edge.
The automatic tube detection can be cancelled by clicking on this

button.
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Setup
4
Prerequisite is at least 6.5 bar supply pressure and a round, smooth cut tube end.
Always carry out the measurement in stop position 1. If the tube rests correctly
against the limit stop, the measurement is released by the signal lamp (orange
light) and the start button must be pressed.
Automatically calculated values can also be edited manually at any time.
If the tubes are very thick, the automatic tube detection no longer works relia-
bly because they cannot be completely squeezed.
i Due to fluctuating results depending on thickness, diameter and hardness, the

tube detection is not an accurate measurement but only an aid to be able to
start the teaching process with unknown tubes!

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4.5.3 Loading or deleting a parameter set
Fig. 58: Loading or deleting a parameter set
Selection of the wel- Selecting the required welding

ding parameter set parameter set
Deleting welding Deleting the currently selected

parameters welding parameter set
Loading welding Loading the currently selected

parameters welding parameter set
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5. Operation
i Only instructed and appropriately qualified personnel may operate the welding
system.
5.1 Daily start-up
Before commissioning, check there is no condensate in the filter of the main-

tenance unit (visual inspection), drain if necessary.
The daily start-up occurs by switching on the ultrasonic controller by means of

the ON button and the main switch to ON.
Prior to commencing welding operations ensure that:
¬ Check the complete system whether it is not damaged.

¬ The welding tools are to be checked for wear, damage, correct fit, etc.
¬ Cable and hose connections between the welding gun and the ultrasonic
controller have been made and the compressed-air hose is connected.
¬ The ultrasonic controller is switched on and the white indicator light on the
front panel is lit.
¬ The key switch is in operating mode .

To set up the machine, please observe „4. Setup“.

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Operation
Compliance with the following information is required to avoid hazardous

situations:
1. The ultrasonic controller must be installed in an non-explosive area where

explosive gases etc. are not possible.
2. A maintenance unit must be used to supply the ultrasonic controller with air.
The minimum supply pressure indicated on the maintenance unit must be 6.5
bar
3. The start parameters adapted to the requirements by tests must be observed

during commissioning (see „4.3 Start parameters table (guide values for left /
right-cutting tools)“).
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5.2 Controls
5.2.1 Start button
The welding is started by the start button on top of the welding gun.
The part to be welded must be correctly positioned prior to initiating the welding
operation (see „Correct insertion of the tube“).
The welding program is executed according to the ultrasonic controller settings.
5.2.2 Emergency stop button
The emergency stop button is integrated in the machine (see „1.14 Emergency
stop button“) (optional: separate emergency stop button).
After activating the emergency stop button, the ultrasound, as well as the work-
piece movement are switched off simultaneously. In this process the machine
controller, as well as all pneumatic actuators are disconnected from the mains
(electrically, as well as pneumatically).
Turn the emergency stop button in the direction of the arrow to unlock it.
The emergency stop button is installed in a position where an accidental release

is avoided as far as possible.

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5.3 Control elements on the ultrasonic controller
Fig. 59: Control elements on the ultrasonic controller
Key switch
Pos.: : Setup mode
1 MODE
Pos.: : Production mode
Pos.: : Teach mode
MAIN
2 Main switch "O / I" with emergency stop function
SWITCH
3 USB USB port
4 OFF "O" button Control Off
5 ON "I" button Control On
6 Calibration unit (optional)
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5.3.1 Main switch with emergency stop function
The welding installation is switched on or off by pressing the main switch.
Turning on the machine at the main switch establishes the energy supply for the
complete controller slide-in incl. generator.
Turning off the machine at the main switch disconnects the energy supply for the
complete controller slide-in incl. generator.
The main switch has emergency stop functionality.
The 0-position is lockable (additional lock).
Before operational switching off using the main switch, you need to operate the
"OFF" button and shutdown the computer.
5.3.2 Controller ON button
After operating this button, the operating voltage for the machine is switched on,
which is required to establish operational readiness. The integrated lamp lights
up upon activation.
5.3.3 Controller OFF button
Press this button to switch off the ultrasound controller and not the computer
system.
Please disconnect the mains plug to safely shut down the system.

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5.3.4 Key switch
You can use the key switch 3 to select different operating modes:
Setup mode ¬ Setting up and testing the system
Production mode ¬ Call-up of saved data sets

¬ Production with quality monitoring
Teach mode ¬ Creating, calling up and changing the welding

parameters or welding data
¬ Special functions
5.3.5 USB port
Welding parameters and logbook data can be exchanged e.g. via the USB port.
5.3.6 Calibration unit
The height measuring system must calibrated with a test pin as required and at
each tool change.
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5.4 Switching the device on or off
Fig. 60: Switching the device on or off
Test of all inputs and outputs

Testing inputs and of the controller. Caution! The
outputs machine can get into dangerous
states.
Shut down the

Safe shutdown of the computer
computer
Exit programme Exit the program

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Operation
Switching on
The device must be switched on in the following order:
¬ Turn main switch MAIN SWITCH (2) to I position

¬ PC is booting: Wait until the time for the purging air warning has expired
¬ Switching on control voltage: ON button (5)
The button lights up in switched on state.
¬ The screen of the program selected using the key switch appears, e.g. setup
mode, production mode, teach mode
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Switch-off
The device must be switched off in the following order, otherwise the hard drive
may be damaged:
¬ Before switching off, the device must be taken into a safe place without an
explosive atmosphere
¬ Press the OFF button (4) (controller Off).
¬ If the control voltage is switched off, the screen „5.4 Switching the device on
or off“ appears.
¬ Shut down the PC using the key

¬ After shutting down the PC, set the MAIN SWITCH (2) to 0 position
ATTENTION
Switch off the machine using the main switch
Damage to the hard drive
→ Do not switch the machine off directly via the main switch, keep to the
sequence described under „Switch-off“
i Please wait 10 seconds before switching it on again!

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Operation
5.5 Welding
WARNING
Heat and welding fumes occurring during the welding procedure
Injuries and burns, irritation of the respiratory through residues of draw-oil, or

similar substance
→ Always use the personal protective equipment assigned to you!

Do not touch the welding tools or the workpiece!
Avoid inhaling welding fumes!
i
The welding gun is equipped with an electrical safety monitor, which widely
prevents an inadvertent triggering of the welding process if about to be welded
is not inserted.
1. Bring the system in welding position

The welding gun is guided to the part to be welded.
2. Insert the part to be welded.
Position machine in such a way the tube in the welding gun is perpendicular
to the machine. When the tube touches either the sonotrode or the anvil
and at the same time a limit stop, a green LED lights up to enable welding.
3. Until the start button is pressed, the contact between the tool, workpiece
and limit stop must be maintained.
4. Press the start button → The pliers close
The weld is triggered (duration approx. 1.2 seconds).
5. After welding, the tools open automatically. The machine can be moved to
the next welding position.
6. The welding parameters as shown on the monitor or a message appears that
the weld is defective.
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5.5.1 Correct insertion of the tube
90 °
Fig. 61: Correct insertion of the tube Fig. 62: Welding gun with inserted tube
Fig. 63: Incorrect insertion of the tube Fig. 64: Incorrect insertion of the tube

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5.5.2 LED enabling and start button
1 2
Fig. 65: Start button and LED enabling
Pos. Designation
1 LED enabling of the welding process

2 Start button 'Initiate the welding process'
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5.5.3 Welding strategy
For optimal use of welding tools and good welding results, the following welding
strategy is recommended.
These values are only guide values the tubes with an outer diameter of 6 mm
and a wall thickness of 0.75 mm and shall be adapted according to the respective
requirements.
1
7´
2 7
Fig. 66: Welding positions
Pos. Designation
1 Position 'Sonotrode turned'

2 Sonotrode position
i Position 1 is only used to calibrate the welding module and is disabled for
welding.

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Operation
Step Operation Position Number of welds

1 Welding 7 4000
2 Turn the sonotrode
3 Welding 7‘ 4000
4 Adjust limit stop 6
5 Welding 6‘ 4000
7 Welding 6 4000
9 Welding 4 4000
11 Welding 4‘ 4000
13 Welding 2‘ 4000
15 Welding 2 4000
16 if necessary repeat the se-
quence from 1 to 15
If the sonotrode wear has been determined, e.g. based on different welding
results, it must be exchanged.
The above-specified number of welds per position is only an initial guide value
and must always be adapted to the desired result.
The service life of the tools depends on the material to be welded and the wel-
ding parameters selected and may significantly differ from the specified values.
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5.6 Production mode
The values entered here are used for illustrative purposes and do not guaran-
i tee accuracy.
5.6.1 Production mode overview
Welding can be carried out in production mode and the welding results are dis-
played with the respective messages.
New welding parameters can also be loaded.
The current welding parameters of the weld to be made next are displayed on
the left side (1). Another view can be selected with a click on this area.
The results of the last welding are shown on the right side (2). Another view
can be selected with a click on this area. After a double-click, the height curve is
zoomed in.
Warning and alarm messages are displayed above (3). If a sequence has been
loaded, its current state is also displayed.

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Operation
View 1:
Fig. 67: Production mode menu view 1
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Operation
5
View 2:

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Operation
View 3:
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5
Current welding
Performance and height curve
parameters
Change the display by clicking
Right side (2) display
Current welding
parameters Change the display by clicking
Right side (2) display
Current welding
Tube diameter and wall
parameters
thickness
Left side (1) display
¬ Switching time t1
Current welding ¬ Welding duration t2
parameters
Left side (1) display ¬ Working pressure
¬ Amplitude in μm

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Operation
Export logbook files

Export logbook files to arbitrary
(see „5.6.1.1 Export
directories
of logbook files“)
Loading welding
parameters (see
Loading welding parameters or
„5.6.1.2 Loa-
sequences
ding welding
parameters“)
Operator counter This counter can be set by the

(see „5.6.1.3 Opera- user. It increases its value by 1
tor counter“) with every successful weld.
Exit the program or shut down

Exit programme
the computer.
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5
5.6.1.1 Export of logbook files
Fig. 70: Export of logbook files

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Operation
All selected logbook files are

Export the logbook
copied to the selected directory.
Selects all logbook files of

Selecting all logbook
the Kobra III and the selected
files
directory.
Deleting log fi- All selected logbook files in

les from external the selected directory will be
memory deleted.
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5.6.1.2 Loading welding parameters
The loading sequence function is only available with the sequence dongle.
i If the function is deactivated, directly open the menu loading welding
parameters.
Fig. 71: Loading welding parameters

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Operation
Loading welding
parameters (see Selection of welding parameter
„Loading welding sets to be loaded
parameters“)
Loading sequen- Selection of sequences to be
ce (see „Loading loaded (only available with se-
sequence“) quence dongle)
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Loading welding parameters
A parameter set to be loaded can be selected on the left side from existing para-
meter sets.
The parameters are displayed on the right side. The view can be changed by
clicking on it.
Fig. 72: Select welding parameters view 1

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5
Loading sequence
Here you can select which sequence of welding parameter sets (sequence) to be
loaded. By clicking on the welding parameter sets of the above sequence you can
view its parameters.
Fig. 75: Loading sequence view 1

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Fig. 76: Loading sequence view 2
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Operation
5
Sequence display Display of the current sequence
Sequence name Name of the selected sequence

Tube parameters parameters

Tube parameters parameters
Selection of the required

Sequence selection
sequence

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5.6.1.3 Operator counter
Fig. 77: Operator counter
This counter can be set by the

user. It increases its value by 1
Quantity counter
with each successful weld from
the set value.
Forward counter Sets higher value
Reverse counter Sets lower value
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6
6. Changing tools
6.1 Safety information on changing tools
The ultrasonic welding system has been designed and built in accordance with
the basic safety requirements of the EC Machinery Directive.
Dangers can emanate from the ultrasonic welding system, if the ultrasonic wel-
ding system is improperly used by untrained persons, or if it is not used as in-
tended, or if safety instructions are not followed.
Only trained and authorised persons may carry out the activities described
below!

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Changing tools
WARNING
DANGER
Protective equipment and covers are not in use when tools are changed.
Before working on the welding module and each time before changing the tool:
→ The control system must always be depressurised!

→ The welding module must always be disconnected from the system cable!
→ The plug should never be disconnected when energised!
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Preparation for changing the oscillator unit
1 2
max. 3 Nm
Fig. 78: Changing tools
Pos. Designation
1 Cover
2 Oscillator unit with sonotrode
3 System cable connector
4 Threaded pin
5 Cylinder screws
6 Anvil

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Changing tools
For type name, order numbers of the oscillator unit, sonotrode and anvil see
tool kit.
Required tools:
- Allen key (WAF 4)

- Torque wrench (5 Nm and 10 Nm)
ATTENTION
Improper tool change
Material damage on the welding module or workpiece
→ Sonotrode, threaded pin and anvil should always be changed in a set.
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6.2 Disconnect the system cable from the welding module
¬ Switch off the system via the controller

¬ Unlock the connector with the key at the two yellow locking buttons by tur-
ning them 90° counterclockwise. The unlocked locking button is in a vertical
position (Fig. 79)
90 °
Fig. 79: Open the lock
¬ Press the two yellow locking buttons to disconnect the system cable connec-
tor from the module.
Fig. 80: Remove the plug from the module

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6.3 Open housing
¬ Loosen the fixing screw with an Allen key (WAF 4) and slightly lift the upper
cover so that you can reach the connector of the emergency-stop cable.
Fig. 81: Release clamping screw
Variant: handle on the side

When the handle for horizontal securing to the balancer is installed on the
side, make sure that the screw that secures the balancer is also loosened when
opening the housing.
Fig. 82: Variant: handle on the side
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¬ Disconnect the plug connection from the emergency stop and deposit the
top cover.
Fig. 83: Open housing
Fig. 84: Disconnect plug connection from emergency stop

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¬ Disconnect the converter plug (red and black cable) from the connector
socket in the module and connect it directly to each other
Fig. 85: Connect the plug
DANGER
Piezoceramics can generate voltages
→ Always connect the red and black cables immediately!
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Fig. 86: Connected plugs

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6.4 Dismantling the oscillator unit
¬ Loosen and remove the set screw of the oscillator unit (1000, sonotrode tool
kit) with an Alen key (WAF 4) so that the oscillator unit can be removed.
¬ When replacing a sonotrode, change the threaded pin (1000, sonotrode tool
kit).
¬ If only one revolution of the sonotrode is necessary, loosen the screw with 2
turns.
Fig. 87: Loosen and remove the clamping screw of the sonotrode
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¬ The oscillator unit can be carefully pulled out to the rear out of the main
body of the welding module.
Fig. 88: Pull out the oscillator unit
ATTENTION
Cable
Damage to the welding module, breaking of the cables
→ Avoid squeezing and catching of the cables

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6.4.1 Sonotrode replacement
6.4.1.1 Dismantling the sonotrode
¬ Clamp the oscillator unit to the sonotrode (use vice for this purpose)
¬ Place 2 hook spanners on the booster (Fig. 89 and Fig. 90, 1)
Loosen the converter and booster with hook spanners from the sonotrode
by rotating counterclockwise
Once the screw connection between the booster and the sonotrode is loosened,
remove the converter and booster by hand out of the sonotrode by turning.
Fig. 89: Disassembling oscillator unit - sonotrode change
1 2
Fig. 90: Oscillator unit disassembled on sonotrode
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6.4.1.2 Installing new sonotrode
¬ Clean the coupling surfaces between the new sonotrode and the booster
and coat thinly with silicone paste
¬ Clamp the new sonotrode (use vice for this purpose)
ATTENTION
Damage to the threaded bolt
→ The threaded bolt must always be checked for damage and replaced if
necessary!
¬ Turn the converter and booster with threaded bolts by hand to the new
sonotrode
¬ Screw the oscillator unit together using the torque wrench of 100 Nm on the
converter (Fig. 90, 2)
6.4.2 Converter change
The converter should only be replaced in exceptional cases, e.g. if damaged.
¬ Clamp the oscillator unit to the sonotrode (use vice for this purpose)
¬ Place a hook spanner on the converter, place the other one on the booster,
loosen the converter with hook spanners and remove from the booster and
sonotrode by counterclockwise rotation

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Fig. 91: Disassembling oscillator unit - converter change
¬ If the threaded connection between the booster and the sonotrode is

loosened before the connection between the converter and the booster, the
converter and booster shall be detached from the sonotrode by hand.
¬ Then place the converter and booster a work surface and apply a hook
spanner at each part. Then undo the screw connection by turning it coun-
terclockwise with a key and turning the other key counterclockwise.
Fig. 92: Dismantling converter - Booster
¬ Finally, the converter and booster are to be twisted apart by hand.
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Fig. 93: Dismantled vibrator unit

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6.4.3 Mounting the vibrator unit
¬ Clean and lightly coat with silicone paste the coupling surfaces between the
sonotrode and the booster and between the booster and the converter.
¬ Screw individual components together
ATTENTION
Damage to the threaded bolts
→ The threaded bolts must always be checked for damage and replaced if
necessary!
¬ Place the torque wrench on the converter

¬ Screw with a torque of 100 Nm
Fig. 94: Assembly - Tighten the oscillator system with torque
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6
6.5 Installation of the oscillator unit
i
Before installing the oscillator unit, the marked areas must be thoroughly
cleaned and rubbed thinly with silicone grease.
max. 3 Nm
Fig. 95: Areas to be cleaned and greased
¬ Now push the new oscillator unit forward from the back of the welding
module through the main body so as to ensure that the zero point mark of
the sonotrode is in the position of the zero point bearing. Press slightly and
a move the ocillator unit slightly back and forth to reach exactly the final
position.

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Fig. 96: Inserting the oscillator unit
¬ The correct position of the oscillator unit is achieved when the front side
of the sonotrode is congruent with the front edge of the anvil support, i.e.
when the two edges are aligned (see „Fig. 97: Correct position of the oscilla-
tor unit“, 1)
Fig. 97: Correct position of the oscillator unit
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¬ Push the sonotrode slightly upwards
¬ Slightly tighten the threaded pin (1000, sonotrode tool kit).
Fig. 98: Tighten the clamping screw
¬ Now you can easily screw the threaded pin (1000, sonotrode tool kit) back to
the limit stop on the sonotrode and fix it with a tightening torque of 5 Nm.
ATTENTION
Position of the threaded pin
→ The position of the threaded pin (1000, sonotrode tool kit) depends on
whether the anvil is left- or right-hand cutting. The screw must always be on
the side of the anvil cutting edge!

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Fig. 99: Left-hand cutting, threaded pin, left Fig. 100: Right-hand cutting, threaded pin, right
Pos. Designation
1 Threaded pin
2 Cutting edge
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Check the safety depth stop after every sonotrode change!
¬ Set key switch to set-up mode
i ¬ Move tools together

¬ Check depth stop with feeler gauge
¬ The set dimension should be 0.1 mm ±0.05 mm
Fig. 101: Check depth stop with feeler gauge

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DANGER
Safety depth stop is not correct
Risk of injury! Material damage on the machine!

In extreme cases sparking can cause an explosion!
→ The machine must not be operated!

→ Check the correct assembly of the anvil and the sonotrode!
→ If the safety stop is still not correct, replace the tools and contact Schunk
Sonosystems Service.
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6.6 Anvil changing
¬ Remove the cylinder screws on the anvil support with an Allen key (WAF 4).
The anvil can be removed.
¬ After cleaning the coupling surfaces, insert a new anvil into the centring
groove on the anvil support and fasten with a tightening torque of 10 Nm via
the two cylinder screws (WAF 4).
¬ For setting the individual tools, see „4.4.1 Setting the tools“
1 2
Fig. 102: Cylinder screws on the anvil support Fig. 103: Anvil changing
Pos. Designation
1 Anvil
2 Centring groove
3 Cylinder screws (anvil tool kit, 1000)

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ATTENTION
Incorrect assembly of the anvil
Serious faults that can destroy the welding module
→ When mounting the anvil, pay attention to the cutting side of the sonotrode!
→ Before mounting the anvil, insert the sonotrode to know the position of the
cutting edge and to install the anvil accordingly!
→ Wrong installation may cause serious malfunctions with lead to malfunction
that can destroy the welding module.
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6
6.7 Setting the limit stop welding position
¬ To set the limit stop slightly loosen the clamping screw.

¬ The limit stop will be moved to the next position.
¬ The clamping screw is tightened again with max. 3 Nm using the torque
wrench (order no. 10774222).
2
1
Fig. 104: Setting the limit stop
Pos. Designation
1 Clamping screw
2 Stop positions
i The stop must be in the stop position 1 during calibration!

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6.8 Assembling welding module
¬ Disconnect the converter plug (red and black) and plug it into the connector
socket
¬ Ensure a correct fit
Fig. 105: Disconnect converter plug
Fig. 106: Insert converter plug into the connector socket
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6
¬ Hold the upper cover (180.10) close to the mounting position and insert the
plug of the emergency cable again.
Fig. 107: Plug in the emergency stop cable again
¬ Now place the, cover the final position and tighten again with the tightening
screw (WAF 4) to max. 3 Nm.
Fig. 108: Fix the clamping screw

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6.9 Connect welding module with system cable
¬ The connector into the welding module

When plugging the connector, the two yellow locking buttons must be in
vertical position (Fig. 110).
The connection is established correctly if a click is heard on each of the two
locking sides when plugging in the system cable connector.
Fig. 109: Plug the connector onto the welding module
¬ The two yellow locking buttons must be rotated 90° in the direction of the
arrow (Fig. 111) so as to ensure that they are in a horizontal position.
90 °
Fig. 110: Vertical position of the locking button Fig. 111: Locking the connector
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6.10 Replacing the sealing of the anvil support (10.40, 60.1000 and 60.1010)
Fig. 112: Replacing the sealing of the anvil support
¬ Remove screws (2020) with (WAF 2.5)

¬ Remove the sonotrode cover (200)
¬ Remove screws (10.2030) with (WAF 2.5)
¬ Replace seal (10.40) and retighten
¬ Replace seal (60.1000 and 60.1010) and retighten
¬ Replace sonotrode cover (200) and secure

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Changing tools
6.11 Changing left limit stop (70.10) and limit right stop (70.20)
Fig. 113: Change limit stops

¬ Align the left liit stop (70.10) and secure the guide shaft against rotation with
a 5 mm open-end wrench when screwing in place.
Remove screws from the limit stop on the right (70.2030) with (WAF 2.5)
¬ Align the limit stop on the right (70.20) and secure the guide shaft against
rotating with a 5 mm open-end wrench when screwing in place.
¬ Replace sonotrode cover (200) and secure.
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Changing tools
6
i The distance between anvil support and limit stop must be min. 1 mm!
Fig. 114: Distance between anvil support and limit stop

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Changing tools
6.12 Support spring, zero-point bearing (20.20)
Fig. 115: Support spring zero point bearing

¬ Remove screws (20.2020) with (WAF 2.5)
¬ Replace the support spring (20.20) and secure it again
¬ Replace sonotrode cover (200) and secure
i Before mounting the support spring, the assembly area in the zero point bea-
ring must be completely cleaned of dirt and deposits.
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Changing tools
6
i Each time after tool change, the welding module must be calibrated
(see „4.4 Setup mode“, Calibrating and setting the machine)

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Maintenance
7. Maintenance
i Maintenance work shall be carried out each time after tool change or at least
every 3 months!
WARNING
→ Maintenance and repair tasks must only be performed by persons who have
been qualified in this regard
→ Troubleshooting may only be performed by qualified personnel
DANGER
Protective equipment and covers are removed when tools are changed.
Touching energised parts is possible
Danger of fatal electric shock if energised surfaces up touched
Before working on the welding module and each time before changing the tool:
→ the control system must always be switched-off!

→ The welding module must always be disconnected from the system cable!
→ The plug should never be disconnected when energised!
Remount and check all protective cladding elements and safety devices for cor-
rect functioning after conclusion of maintenance and repair tasks!
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Maintenance
7
WARNING
Damaged housing parts
→ Each time before opening the cover / housing parts, check them for damage
and replace if necessary.
→ After assembly, check the front section (sonotrode cover) for escaping pur-
ging air. If there is no purging air, the machine must not be used in
Ex-Zone II.

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Maintenance
7.1 After each tool change
7.1.1 Calibration
Each time after tool change, the welding module must be calibrated, see „4.4.1.5
Calibration“
The limit stop must always be in position 1.
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Maintenance
7
7.2 During each sonotrode change
→ Clean the zero point bearing

(vacuum and clean with a lint-free cloth)
→ Before installation of the oscillator, grease
the contact points with silicone paste no.
10354243
→ Check the function of the seals (1)

→ If damaged, replace the seals and vacuum
the area behind. Remove impurities if
necessary, dismantle the lower cover (2) so
as to be able to access the lower section of
the machine.

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Maintenance
7.3 Annual examination
7.3.1 Emergency stop button
Checking the function of the emergency stop

switch / button
7.3.2 Purging air monitoring
Check the function of the purging air switch
→ Call up the purging air monitoring

(„4.4 Setup mode“)
→ Proper function of the purging air
DANGER
Purging air monitoring does not work
Danger to life, danger of injury and material damage
→ If the purging air monitoring does not work, do not use the machine in Ex
zone II and notify Schunk Sonosystems Service!
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Maintenance
7
7.3.3 Pressure test - proportional valve
→ Depressurise the pneumatic system

→ Install the pressure gauge at the pneumatic
connection P1
→ Call up the pressure test display

(see „4.5 Teach mode“)
→ Input of test pressure

Is used to check the outlet pressure at the
proportional valve
→ Set pressure between 1.00 bar and 6.00 bar
(test values are 1.50 bar, 4.00 bar and 6.00
bar)
→ 3 confirm with the green checkbox
→ The selected pressure is set by the valve and
can be read out at the pressure gauge.
Setpoint is ± 0.1 bar to set value.
In case of higher deviations, notify the
Schunk Sonosystems Service!
→ Exit the pressure test display

→ Remove pressure gauge, restore pneumatic
connection.

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Maintenance
7.3.4 Amplitude measurement
Checking the amplitude of the sonotrode
→ Remove the anvil and screw in place dial

gauge holder (Order no. 10843157 for
7,3 mm / 10862780 for 12,3 mm) on the
front side of the sonotrode.
→ Press test sound check button (see „4.5

Teach mode“
→ The amplitude values can be modified and

applied here.
→ activation of the oscillation system with the

specified amplitude value
→ The sonotrode will sound for about 1 second
with the set value.
→ The amplitude to be used for the test sound

can be set here.
If there is a deviation of more than 10% from the set amplitude value, the
i system must be checked by Schunk Sonosystems!
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Maintenance
7
7.3.5 Cleaning the electronics and pneumatic section of the machine
→ The electronics and pneumatic section of

the machine must be cleaned of dirt and
vacuumed at regular intervals.
7.3.6 Large maintenance
After 1 million of welding operations or after 2 years, a major maintenance must

be performed by Schunk Sonosystems (see „Contact Information“) or by a person
commissioned by Schunk Sonosystems.

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Maintenance
7.4 Electronic controller
Damage to the electrical supply lines, RF connections, connectors for the welding
module or ultrasound control can lead to fatal electric shocks.
DANGER
Touching damaged electric supply lines / RF connector of ultrasonic control /

welding module.
Fatal electrical shock when touching damaged electrical cables of ultrasonic

control / welding module
→ De-energise ultrasonic control, disconnect from the mains and secure

against reconnecting to mains voltage
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Maintenance
7
The control system (with the electrical and pneumatic supply points / control of
the machine) must not be open or opened when mains voltage is applied!
After shutting off the electric power supply, it takes at least 2 minutes for the
internal voltage to drop sufficiently, so that this is no longer hazardous!
DANGER
If the housing of the ultrasonic control is opened
There is risk of electrocution if the housing of the ultrasound controller is open

and contact is made with live parts inside the unit.
Ramp-down duration of internal electrical voltage of controller: 2 minutes.
→ De-energise ultrasonic control, disconnect from the mains and secure

against reconnecting to mains voltage
→ Do not open the slide-in housing until at least 2 minutes after shutting off
the mains power supply

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Maintenance
7.4.1 Error analysis in the control system
Disconnect the generator to ensure more safety for the personnel when trou-
bleshooting in the controller.
¬ First the main switch must be switched off (pos. "O") (see „Fig. 12: Front
view ‒ ultrasonic controller“).
¬ The waiting time to discharge the residual voltage is at least 1 minute.
¬ Then remove the cover from the ultrasonic controller.
¬ The J10 supply plug has to be disconnected from the main generator circuit,
the generator is now de-energised.
Fig. 116: J10 supply plug
¬ Controller supply: Switch on main switch again (pos. "I")

¬ Perform fault analysis in energised condition in the controller.
¬ After the repair has been completed, switch off the control unit once again
(procedure as described above) and plug in the J10 connector.
¬ Close the cover
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Maintenance
7
7.4.1.1 Maintenance tasks
Filter mat at the fan

The filter mat must be checked every three months for fouling and replaced if
necessary.
The fleece surface with the smaller thickness must face the outside.
Condensate in the filter of the maintenance unit

Drain at regular intervals after visual inspection

1234567-89 Rev 4.0 Rev 4.0 219
8 Kobra-III Operating Manual - Translation -
Decommissioning and disposal
8. Decommissioning and disposal
8.1 Decommissioning
Switch off the machine to decommission it („5.4 Switching the device on or off“).
Then disconnect the system cable from the machine.
The system cable lines must be disconnected from the ultrasonic controller.
Disconnect the ultrasonic controller from the electrical and pneumatic supply
used for operation.
8.2 Shutdown
After the welding machine has been shut down, the machine components should
be stored in their original packaging to the extent possible and at ambient condi-
tions that are dry and free of dust.
8.3 Dismantling and disposal
The welding machine should be dismantled and properly disposed of at the end
of its service life according to the national regulations.
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Annex
9
9. Annex
9.1 Versions
Top handle
Fig. 117: Top handle

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Annex
Side handle (left)
Fig. 118: Side handle left
Side handle (right)
Fig. 119: Side handle right
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Annex
9
Support handle (order no. 10881226)
Fig. 120: Support handle
¬ for mounting left or right
i The support handle cannot be used together with the suspension.

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Annex
Twin handle (order no. 10881482)
Fig. 121: Twin handle
¬ Trigger and LED for mounting left and right

¬ Transport strap (red) can be ordered separately
Bezeichnung Bestell-Nr.
Transport strap 10880748
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Annex
9
Twin top handle (order no. 10875492)
Fig. 122: Twin top handle

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Annex
Single handle (left with suspension) (order no. 10891436)
Fig. 123: Single handle (left with suspension)
Single handle (right with suspension) (order no. 10903047)
Fig. 124: Single handle (right with suspension)
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Annex
9
Top handle with side trigger (order no. 10913810)
Fig. 125: Top handle with side trigger

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Annex
9.1.1 Suspension, vertical
Fig. 126: Suspension, vertical
Suspension, vertical 10858476
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Annex
9
9.1.2 Suspension, horizontal
Fig. 127: Suspension horizontal, handle on the left
Fig. 128: Suspension horizontal, handle on the right

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Annex
Suspension horizontal
Opening dimension 7 mm 10860232
(see „Fig. 129: Opening dimension“, item 1)
Suspension horizontal
Opening dimension 12 mm 10860229
(see „Fig. 129: Opening dimension“, item 1)
Fig. 129: Opening dimension
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Annex
9
9.2 ASSY 360° Rotation device (order no. 10914363)
Fig. 130: 360° rotation device front view
Fig. 131: 360° rotation device rear view

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Annex
9.2.1 Assembly of the rotation device
If the turning gear is mounted to the welding machine, it must be fixed via the
adapters on the device using the screws listed below.
Fig. 132: Assembly of the rotation device, screws and adapter
Designation Quan- Order no.

tity
Kobra III without
Screw kit M6x25 ASSY 4 10927719
plate:
Kobra III with plate: Screw kit M6x30 ASSY 4 10927709
Adapter 2 10914143
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Annex
9
9.2.2 Disassembly of the rotation device
If the rotation device is disassembled from the welding machine, all threaded
holes on the device must be closed
¬ with screws (4x) DIN7380 M6x8 (order no. 10690146)

for Kobra-III without plate or
¬ with screws (4x) DIN 7380 M6x12 (order no. 10758138)
for Kobra with plate
Fig. 133: Position of the screws without plate Fig. 134: Position of the screws with plate
DANGER
Danger of explosion
Death or severe injury!
→ Closing all holes to ensure explosion protection

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Annex
9.2.3 Stops for the rotation
Depending on whether left or right cutting tools are used, the stop can be moved
in order to change the rotation in the opposite direction.
Fig. 135: Stops and holder
The holder can be mounted on the right or on the left side.
Pos. Designation
1 Position stop screw clockwise
2 Position stop screw counterclockwise
3 Holder side
4 Stop bolt
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Annex
9
9.3 Overview Drawings

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Annex
Fig. 136: Overview drawing Kobra-III opening 7 mm
236 1234567-89
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Annex
9
Fig. 137: Overview drawing Kobra-III opening 12 mm

1234567-89 Rev 4.0 Rev 4.0 237
Options
10. Options
10.1 Barcode Scanner (Order no. 10878736)
including extension cable 10 m.
10.1.1 Functions
The Kobra-III welding machine allows to use barcode scanner supporting RS232
interfaces. The barcode scanner can be used for the following actions:
¬ Load already taught welding parameters

¬ Load a sequence of welding parameters (sequence function must be
enabled)
¬ Log product information together with a welding
238 1234567-89
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Options
10
10.1.2 Activating the barcode scanner function
Fig. 138: Activating the barcode scanner function
¬ After activating the barcode scanner function the machine can load welding
parameters and welding parameter sequences (sequence function must be
enabled) and log product information.
¬ The machine disables the welding function in the production mode until a
valid barcode is scanned.
• If the name of a single welding parameter has been scanned, the machi-
ne performs one welding and will be disabled again.
• If no welding parameter matching the scanned barcode string is found,
the machine will search for a sequence with the specified name. If a se-
quence with the specified name exists, the sequence will be loaded and
the first welding parameter will be loaded. After finishing the welding
parameter sequence the machine will be disabled again.
• To add product information to the weld results, a substring in the bar-
code can be identified using a specific prefix. By default the prefix is ‘+‘.

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Options
10.1.3 Definition of barcode scan functions
¬ In case a barcode label is illegible, the operator can manually enter the
barcode in production mode or in teach mode. Therefore, the operator must
double click on the welding parameter preview with activated barcode scan
function.
Fig. 139: Barcode scan function
240 1234567-89
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Options
10
10.1.4 Example 1
Example using default settings
¬ If a valid welding parameter called „weldParam12“ has been saved and the
sequence function is disabled, following actions can be performed:
• If the Barcode string „weldParam12“ has been received, the „weld-
Param12“ welding parameter will be loaded and the machine will be
enabled.
• If the Barcode string „weldParam12+57439“ has been received, the
„weldParam12“ welding parameter will be loaded, the machine will
be enabled and after the next welding the weld results will contain
„57439“.
• If the Barcode string „+57439“ or „57439“ has been received, the ma-
chine will remain disabled because a welding parameter with the name
„ 57439“ does not exist and cannot be loaded.

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Options
10.1.5 Further settings
¬ If the barcode scanner should only be used for loading welding parameters
or for logging information, the other function can be disabled in the confi-
guration file. To achieve this, the operator must leave the Sutwin program
by entering the standard password and change the respective entry in the
configuration file. The file is located at C:\Sut\sut.ini.
¬ Set „LoadWeldingParameterWithoutDialogActive=Off“ to disable the load

function
¬ Set „LogSerialNumberWithoutDialogActive=Off“ to disable the logging
function
¬ Change the prefix behind the „LogSerialNumberUsingFollowingPrefix=„ entry
to use a different prefix for identifying a substring which contains product
information
242 1234567-89
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Options
10
10.1.6 Example 2
Example using LoadWeldingParameterWithoutDialogActive=Off:
¬ If a valid welding parameter called „weldParam12“ has been saved, following

actions can be performed:
• If the Barcode string „+57439“ or „57439“ has been received, the text
„57439“ will be logged and the machine will be enabled.
• If the Barcode string „weldParam12“ has been received, the „weldPa-
ram12“ string will be logged and the machine will be enabled. The wel-
ding parameter „weldParam12“ will not be loaded even though it exists.
• If the Barcode string „weldParam12+57439“ has been received, the text
„57439“ will be logged and the machine will be enabled. The welding
parameter „weldParam12“ will not be loaded even though it exists.

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Options
10.2 Dongle versions
3 Kobra-III software licenses with USB dongle are available:
The respective dongle is plugged internally into the controller in the box PC.
Fig. 140: Inserting the dongle
10.2.1 Dongle no. 134 - Set Kobra-III Sequences (order no. 10877431)
(cannot be used together with Dongle no. 135)
¬ APR (auto parameter recommendation)

¬ Barcode scanner (with extension cable 10 m)
¬ Parameter adjustment to welding position and servomotor stop
The barcode scanner can also be ordered separately, see „10.1 Barcode Scanner
(Order no. 10878736)“.
DANGER
Danger of explosion
→ Do not use barcode scanner in potentially explosive areas.
244 1234567-89
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Options
10
10.2.2 Dongle no. 135 - Set Kobra-III Start Parameters - APR (order no. 10877432)
(cannot be used together with Dongle no. 134)
¬ Pipe measurement and automatic selection of start parameters (auto para-

meter recommendation)
10.2.3 Dongle no. 136 - Set Kobra-III PLIS-Interface - order no.: 108 774 33
¬ Software activation for PLIS connection

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Options
10.3 Set monitor 17“ (2nd parallel monitor) (Order No. 10877568)
incl. 10 m cable and delock splitter 2 port
The monitor is only used for display (no touch function) and can be operated
additionally to the touch monitor.
DANGER
Danger of explosion
→ Do not use monitors in potentially explosive areas.
10.4 External emergency stop box (order no. 10589624)
Emergency stop and reset
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Options
10
10.5 Uninterruptible Power Supply (optional)
Back-UPSTM BK500EI 500VA (APC)
10.5.1 Function/general points
The uninterruptible power supply (UPS) protects the electronic control unit/PC
from fluctuations and interruptions in mains voltage.
If the interruption in mains voltage lasts for a longer period, the PC is shut down
in a controlled way. This avoids damage to the hard drive and loss of data in the
event of mains interference.
All settings for operating the UPS are made using the UPS-specific software
“PowerChute Personal Edition” which is already installed on the PC system of
machines with UPS option.
10.5.2 Hardware installation
The UPS can be supplied completely by the control unit via socket no. 8, feed-in
of the uninterruptible power supply (UPS) takes place via connector no. 9. The
external electrical connections listed below must be set up. In addition, a plug-
type connection X7 within the electronic control unit must be plugged to another
socket, see „10.5.2.2 Plugging X7.1/X7.1 UPS into another socket“

1234567-89 Rev 4.0 Rev 4.0 247
Options
10.5.2.1 Electrical connections
C13-C14
3
1 C13-C14
5
DVI
4
C13-C14
X7.1
X7.1 USV
6
DVI
Fig. 141: UPS installation
i The UPS is only charged in operation when the main switch is switched on!
248 1234567-89
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Options
10
Item Function Rear, Designation
labeling
UPS Electronic control unit
Power supply connection

1 Mains feeder 8
(monitor)
2 RJ-45 socket USB USB interface
Battery-powered connec-
3 9 UPS feeder
tion sockets
UPS Additional device
Additional socket
4 only with overvoltage Monitor
protection
Additional device Electronic control unit
5 Monitor PC-DVI DVI interface for monitor
Electronic control unit Power line
Power supply connection

6 Mains feeder 230 V
(socket)
1. Connect the mains feeder 230 V (UPS) via an inlet connector for non-heating
appliances C13-C14 to the power supply connection monitor (8) on the rear of
the electronic control unit.
2. Connect the USB cable (RJ-45 socket, data port) with one of the USB inter-
faces of the electronic control unit.
3. Use one of the 3 battery-powered connection sockets (3) and connect to the
connector UPS feed-in (9) on the electronic control unit. Cable type: C13-C14
4. Connect the additional socket (with overvoltage protection) of the UPS to
the external monitor via an inlet connector for non-heating appliances C13-C14.
The monitor is not supplied with mains voltage in the event of power outage.
5. Connect the DVI input monitor with the DVI interface (PC-DVI) on the rear of
the electronic control unit.
Cable type: DVI cable.
6. The mains feeder 3x400V (electronic control unit) is supplied via the external
power supply connection (CEE socket).

1234567-89 Rev 4.0 Rev 4.0 249
Options
10.5.2.2 Plugging X7.1/X7.1 UPS into another socket
Terminal block X7 contains connector X7.1 by default, which is supplied with

3x400V via the feeder of the control unit.
Connector X7.1 must be removed and the dummy plug X7.1 UPS must be plugged
into terminal block X7. Supply is now via the UPS feeder (9) on the rear of the
electronic control unit.
Fig. 142: Standard connection without UPS Fig. 143: Connection with UPS
250 1234567-89
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Options
10
10.5.3 Software installation
The software “PowerChute Personal Edition” is already installed on the PC when

machines are delivered with UPS. In this case you do not need to take the follow-
ing software installation instructions into consideration.
10.5.3.1 Before installing PowerChute Personal Edition
¬ The APC UPS cable must be connected to the USB port of your computer.
¬ .NET Framework 4.0 must be installed on the computer before installation
can be continued.
¬ PowerChute v3.1.0 supports upgrades from PowerChute Personal Edition
v3.0.x. If a version of PowerChute other than v3.0.x is installed, this version
must be uninstalled using the Windows option “Add or remove program”.
Then PowerChute v3.1.0 can be installed.
10.5.3.2 Installation steps
¬ Double-click the file “PCPE Installer.exe” downloaded from the APC website
¬ Follow the on-screen instructions given by the installation program
¬ Activate the control box “Register your product online” on the last screen
and click “Finish”
10.5.4 Further information
You can find further information on the enclosed USB flash drive under „13.2 APC
UPS“ .

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Options
10.6 Calibrating and measuring device case Kobra III (order no. 10884834)
Pos. Pcs. Designation Order no.

10 1 Aluminum multi-purpose case 10603015
20 1 Digital manual manometer 10387479
30 1 Compact thermal anemometer 10884817
40 1 Purging air hood ASSY 10884868
50 1 Dial bench gage 10354718
60 1 Gage insert, pointed, 0.5mm 10824578
70 1 Holder 7.3mm for dial gage 10843157
80 1 Holder 12.3mm for dial gage 10862780
90 1 Thickness gage 0.05-1.0 13 sheet 10356680
100 1 Gage t=0.4mm 10355859
110 1 Gage t=0.3mm 10912545
10.7 Recommended tools

Torque wrench 1/4" 2.5 - 25 Nm 10774222
1/4" insert for hexagon socket 4 mm 10430628
Torque wrench 110 Nm 10445534
Hook wrench insert D38 - 18x14 mm 10377641
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Pneumatic circuit diagram
11
11. Pneumatic circuit diagram

1234567-89 Rev 4.0 Rev 4.0 253
254
Spülluft Sicherheitsfreigabe "AUF" / "ZU"
11
purge air Safetyrelease "Open" / "close"
QSM-M5-4-I
ZU Auf
10355209
1080 QSM-M5-4-I Zu
UC-QS-4-H 10355209
AUF
140 L 10449897
QS-4
10641882 1070
YP2.1-90
SF
rot
ø6
1060 1050
ø4 rot
QS-PK-3
YP2.1-63
YP1-75
SPAE-P10R-Q4-
10841989
10809772
1040
SF-110 ø4 ø4 SF.2-120 QST-6-4
P
1060 schwarz rot 10582494
ø6
blau
SPAE-P10R-Q4-
ø4
P
10809772
schwarz
ø6 YP2-90
ø4
rot
rot
ø4
schwarz
YP1.1-135
YP1-110
VUVG-L10-B52-ZT-M7-1P3
566483
10352866
1020
10352866
QSMLL-M7-6
QSMLL-M7-6
10920039
10355092
10355092
VAVE-L1-1H3 VAVE-L1-1H3
QSML-M5-4
2x3/2 Wegeventil kpl
QSML-M5-4
VAVE-L1-1H3
10810682 10574510
Pneumatic circuit diagram
VAVE-L1-1H3 14 12 10574510
SF.1-185
10830114 1030
10810682
14 12 5/2 Wegeventil kpl
VUVG-L10-T32C
1234567-89
10842474
10830113 YP2 YP2.1
YP1 YP1.1
10924009
10924009
10845574
U-M7 725445
U-M7 725445
QSM-M3-4-I-R
AMTE-M
10352864
10797659
AMTE-M
QSML-M7-6
10797659
P2 - 120 P1 - 120
10352834
QSML-M5-6
blau ø6 ø6 rot
1234567-89Rev Rev
P2 P1
Druck, pressure Druck geregelt
4.0 4.0
6 bar pressure controled
ø6 ø6 Schlauchkupplung
hose connector
In Steuerung verbaut !
12
In Controller installed ! ø6
P
1010 P2
QS-8H-6
10380622
E
10354052 P
Wartungseinheit P1 ø6
Maintenance unit QS-8H-6
10380622
1000 10354014 1010

3-Wege Proportionalventil Änderungsindex -A
3-Way proportional valve
Zeichnungs-u.EDV-Nr.
Kunde/Projekt: Fluiddraw
87638 M-Typ: Gez. 23.03.2018 R.Wagenbach

Kobra-III Blatt:
Gepr. Schunk
Freig
SAP 10845813 Fert.-Nr. gesamt:
Geän.
Sonosystems GmbH
18.09.2019 D. Günther
© Schunk Sonosystems GmbH

Electric circuit diagram
12
12. Electric circuit diagram

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256
0 1 2 3 4 5 6 7 8 9
12
Schunk Sonosystems GmbH

Hauptstraße 95
D-35435 Wettenberg
Tel. +49 (0)641-803-0
Company / customer Serie

1234567-89
Project name USC-5 Kobra-III Ex
Machine-No.
1234567-89Rev Rev
4.0 4.0
Circuit diagram
+INH/2
Date 11.02.2020 project: Document type: customer: Schunk Sonosystems GmbH Machine-No.: -
= TDI USC-5 - Kobra-III
User fg Hauptstraße 95 + TDB - Title page / cover sheet
USC-5 Kobra-III Ex Titel- / Deckblatt Serie
Check Rev.: 1, 08.05.01.2018 D-35435 Wettenberg designation: Page 1

title sheet
Change Date Name Original +49 (0)641-803-0 Page 25
0 1 2 3 4 5 6 7 8 9
table of contents
machine Mounting location Page Page description supplementary page field Date editor X
Title page / cover sheet 1 title sheet 11.02.2020 fg X
table of contents 2 Table of contents 11.02.2020 fg
Revision overview 3 Revision overview 11.02.2020 fg X
4 power suply 30.07.2019 fg
5 Power supply 24V/DC SPS/PC 28.11.2018 fg

6 HF Output / Converter 14.05.2018 fg
7 Emergency stop Relais 11.02.2020 fg
8 Power supply Compact Power 09.11.2018 fg
9 control generator 06.11.2018 fg
10 release start Kobra-Ex 12.12.2019 fg
10.1 release start Kobra-Ex 16.12.2019 fg
11 PLC digital - input E0 - E7 12.12.2019 fg
15 PLC digital - output A0 - A7 14.05.2018 fg
1234567-89
1234567-89
Rev 4.0
19 motor control - ENCODER 09.11.2018 fg
20 Inkremental Measuring system 28.11.2018 fg
21 PLC analog - in- / Output 06.11.2018 fg
22 Interface RS 232 Compact Power - PC 08.05.2018 fg
Rev 4.0
25 Interface XS12 20.03.2018 fg
version USV 4a power suply 08.05.2018 fg

+TDB/1 +REV/3
User fg Hauptstraße 95 + INH - table of contents
USC-5 Kobra-III Ex Inhaltsverzeichnis Serie
Check D-35435 Wettenberg designation: Page 2
257
12
Table of contents
258
0 1 2 3 4 5 6 7 8 9
12
Revisionsübersicht F17_001
Revisionsname Revisionskommentar Revisionsänderungsgrund Seitenname Revisionsbeschreibung Ersteller Datum
10.01.2018 D-Modul deleted measuring line voltage in the generator 5, 6, 20 Gas 10.01.2018
09.11.2018 Change cable color Motor revision div. Gas 09.11.2018
11.02.2020 Change SRB-400SNA response time improvement 7 Gas 11.02.2020

1234567-89
1234567-89Rev Rev
4.0 4.0
+INH/2 =ANL USC-5 - Kobra-III+USC-5/4

User fg Hauptstraße 95 + REV - Revision overview
USC-5 Kobra-III Ex Revisionsübersicht Serie
Check D-35435 Wettenberg designation: Page 3

Revision overview
0 1 2 3 4 5 6 7 8 9 10 11 12 13
L1 / 5.1
N / 5.1
L+2 / 5.4
-X7.1 1
Option
ML / 5.4
USV
L1 N terminal strip
Power supply 1 2 3 4
PE

T1 T2 T3 10 12 10 12
-Q2 -Q2
/4.9 L1 L2 L3 9 11 /4.2 9 11
main switch
control unit
-X1 1
PE
Cover
-X1 2
L1.1 N1 PE Floor
2 -X1 3
-V3 3
Corcom
16FC10 L1 N PE
front
-X1 4
1234567-89
fan
-X1 5
L1 N PE PE PE
sidelockl
-X1 6
1234567-89
Rev 4.0
-WX1
H05RR-F
3x1,5 mm²
2,5 m BN BK GNYE 205V-255V
Rev 4.0
-XJ10 L1 N -XJ11 PE L1 N
7 8 /6.3 5
-A1 1
/6.1
/9.5 F1
/21.1 1 2
/22.8 F16A
250V 2
230V
16A L1 N PE
M
PMH8/20KHz
-M1
24V 1~
3000W
0,12A
fan 3
generator modul
L1 N PE L1 N PE
3KW / 230V
-XS9 -XS10
IEC connector IEC connector
USV USV
power suply control Generator Supply monitor fan

unit 230V,N,PE 50/60 Hz USG-3000 Generator
230V /16A
=TDI USC-5 - Kobra-III+REV/3 5
Date 30.07.2019 Date Document type: customer: Schunk Sonosystems GmbH Date -
= ANL USC-5 - Kobra-III
Ed. fg Hauptstraße 95 + USC-5 -
USC-5 Kobra-III Ex Schaltplan allpolig Serie
Appr Rev.: 1, 30.11.2016 D-35435 Wettenberg Date Page 4
259
12
power suply
Modification Date Name Original +49 (0)641-803-0 Page 25
260
0 1 2 3 4 5 6 7 8 9 10 11 12 13
12
4.12 / N
1
4.12 / L1 -F1
2A
Fuse power 2
supply
-X7 1 -A8
1 2 3 4 PC
terminal strip
Power supply
Box-PC - Supply
12V GND
2 3 -X1
1 2 3 4 1 2 3 4
1 2
PE PE
T1 T2
1234567-89
PE 24V/3,8A 12V/4,5A
L1 N PE L1 N PE
T1A T1A
1234567-89Rev Rev
24V power supply 12V power supply
4.0 4.0
H1 H1
- - + + - - + +
ML
BU
2x0,25 mm²
PE
4.12 / ML
4.12 / L+2
M1 L+TP L+12
BU 1 2
0,5 mm²
M
-M2
L1 N PE 24V, 1,3W
Papst type 614NGH
-XS8
IEC socket
M1
L+1
L+12
L+TP
6.8 /
6.6 /
6.8 /
6.8 /
Supply monitor voltage Supply fan 24V power supply Supply monitor
24V/DC / control unit / Touch
3,8A Box - PC Screen 12V/DC /
4 4,5A 6

Power supply 24V/DC SPS/PC
0 1 2 3 4 5 6 7 8 9 10 11 12 13
-X5
1
5.5 / L+1 L+1 / 7.1
-X5
2
5.5 / M1 M1 / 7.1
-X5
3
5.6 / L+TP L+TP / 8.1
-A1 -X5
/4.4 4
230V 5.9 / L+12 L+12 / 8.6 -C18 470nF ESB / 7.5
16A
generator modul
-X5 PE
PMH8/20KHz 3KW / 230V 5
3000W L+ / 7.1
-X5
6
PE / 7.1 Res / 10.12

PE
P 0VL HF GND PE
PE
-X8 5 3 4
-A3
/7.0
-XJ7 16 15 -XJ11 1 3 4
/21.1 /4.7
PE with option
Ext. emergency
stop
PE remove jumper XS7:1+2
PE
2,5 mm²
jumper
-XS01 -XS7
2 B (4) A (5) 1 3 1 2 3 4
1234567-89
1234567-89
-W7
Rev 4.0
LIY-CY
PE GN YE WH BN
2,5 mm²
5x0,25 mm²
-HF
1,5 m
2x0,25 mm² Ext. NA
Rev 4.0
-AM -AM2 PE
HF SH
/11.0
Modul
Kobra-III
+ -A11
-AM2.1
Piezo
11 13
-S2.1 -S3
-
Emergency stop 12 Reset 14
Converter
emergency stop emergency
stop / Reset box
5 7
261
12

HF Output / Converter
262
0 1 2 3 4 5 6 7 8 9 10 11 12 13
12
-A3 6.12 /
/6.8
L+1 L+1 / 8.1
/8.1
/9.1 6.12 /
/10.1
M1 M1 / 8.1
/10.1.1
/11.0
/12.0
MP / 21.6
/13.0 6.12 / L+ L+ / 8.1
/14.0 x1 x1 x1
/14.0
/15.1 -C13 -C14 -C15 SF1 / 10.2
/16.1 470nF x2 470nF x2 470nF x2 SF2 / 10.2
/17.1
/18.1
/19.1 PE PE PE A7 / 15.11
/20.1
/21.1 6.9 / PE A7.1 / 10.2
6.12 / ESB
/22.3 SF / 10.2
-X4 1 2 3
PE -X7 1 2 3 4 5 8
-X6 7 6 5 -XS1 3 4 -X4 4
-WS1
GN
-XS15 3 1 2 SUPERTRONIC
25x0,25 mm²
15 m
-AM -XS1.1
/11.0 3
/15.7
Modul Harting
Kobra-III
-W15
-XM1 1
LIYY
1234567-89
GN WH BN
3x0,34 mm² RD
1,5 m -WM2
Maintenance unit
21
-S1
Emergency 22
stop module
-WM2
LIYY -RD
-X14 1 3
1234567-89Rev Rev
2x0,25 mm²
-XM1 3 21
4.0 4.0
-S3
stop 22
-XS1.1
/15.7 4
13
Harting
-S4
/14.3 14
-WS1 start
/9.1 YE
-X14 2 4
-K1
A1 X2 S12 S22 X1 S32 S42 13 33
A1
x1 x1
A1 A1 13 23 33 43
PE -R2 emergency stop
K1.2 -R3 K3.4 -R4 K1.2 K3.4 K1.2 K3.4
11R-100µF relais SRB-400SNA 22R-47µF 4K7 14 24 34 44
-Y1 A2 A2
x2 x2
Maintenance unit A2
A2 14 24 34 44
L+
BU
0,5 mm²
Main valve safety cover 1 + 2 safety cover 1 + 2 safety release release

Maintenance unit closed closed valve
6 8

Emergency stop Relais
0 1 2 3 4 5 6 7 8 9 10 11 12 13
-A3 7.12 /
/7.0
L+ L+ / 9.1
7.12 / M1 M1 / 9.1
6.12 / L+TP
5V / 10.2
7.12 / L+1 M2 / 20.6

6.9
L+1 L+12
18.1 K 1 1 1
1
-H5 -R2 -R3 -R4
L+12 A 2K4 2K4 2K4

-R1 2 2 2
2K4 1 A A A
2
A -R5 -H2 -H3 -H4
2K4 L+ K L+TP K 5V K
-H1 2
/18.3 K
L+1
S10.1 / 14.1 PWM-1A / 19.1
S10.2 / 14.2 PWM-1B / 19.1
PE PE PE PE PE PE PE PE PE
RxD3 / 22.3
x1 x1 x1 x1 x1 x1 x1 x1 x1 TxD3 / 22.3
-C2 -C3 -C4 -C5 -C11 -C12 -C1 -C10 -C9 GND3 / 22.4
1nF x2 1nF x2 1nF x2 1nF x2 1nF x2 1nF x2 1nF x2 1nF x2 1nF x2
2 3 4 5 11 12 1 10 9 13 14 15
-XS18
-X3.1 1 2 3 4 5 -X2.1 29 30 31 32
L+TP L+TP M1 M1 11 12 L+ S10.1 S10.2 RXD3 TXD3 GND3
1234567-89
-W18
JZ-500 GY RD BK Box-PC
2x0,5 mm² USB -W2
2,5 m /14.10
/15.1
/16.1
1234567-89
/17.1
/18.1
Rev 4.0
/19.5
/20.1
-XS18.1 - + /22.5
L+1 M1 L+ 5V M2 3WH 3BK 4BN 4RD
BU BU BU BU BU Flachband
0,5 mm² 0,5 mm² 0,5 mm² 0,5 mm² 0,5 mm² -TS -USB
Touch Touch
50x0,128 mm²
Screen Screen
GND 12V
Rev 4.0
10" - Touch Screen
-X3 1 2 3 4 5 -X2 29 30 31 32
-A2
/11.1
/12.1 +24V-VDC M1 +24V-Out UHall-5V M2 PWM-1A PWM-1B PWM-2A PWM-2B
/13.1
/15.1
/16.1
/17.1
/18.1 4A DCOK Status Evo Control
/19.5
/21.9
PE
/22.1
/14.1
/20.1
/21.1 24V/DC 24V/DC Supply Touch PWM signal PE
Power supply Digital Screen motor control

output
7 9
263
12

Power supply Compact Power
264
0 1 2 3 4 5 6 7 8 9 10 11 12 13
12
-AM -A1
/11.0 /4.4
Modul L+M / 10.1 230V
Kobra-III 16A
generator modul
MM / 10.1 PMH8/20KHz 3KW / 230V
3000W
NC NC NC NC A1 +24V ext. A2 A3 NC GND ext. E1 E2 E3 E4
-XJ6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
/22.8
-XS1.1
/15.7
Harting 1 2 24 25
-WS1
/7.5
/7.5
/10.5
/10.1.5
/11.2
/12.1
/15.7
/19.2
/20.1
/21.6 -WJ6
1234567-89
SUPERTRONIC-C-PVC GY /22.8
WH BN BN-RD WH-BK YE OG RD BN 2BK 2WH 2GY 2VT 2BU 2GN 2YE 2OG 2RD 2BN
25x0,25 mm² Flachband
20x0,072 mm²
1234567-89Rev Rev
-A3
/7.0
4.0 4.0
-XS1 1 2 24 25 -XJ61 7 8 9 10 11 12 13 14 15 16 17 18 19 20
/22.8
20 polig
G-A1 G-A2 G-E1 G-E2

11.10 11.11 17.2 17.4
8.12 / L+ L+ / 10.2
8.12 / M1 M1 / 10.2
module welding max. power Reserve Reserve

power supply active exceeded
8 10

control generator
0 1 2 3 4 5 6 7 8 9 10 11 12 13
-AM 9.4 /L+M

/11.0
L+M / 10.1.1
Modul 9.4 / MM MM / 10.1.1
Kobra-III
5VM / 10.1.12
-H10
LED
24V-20mA
-X10 2 4 K K
5V 5V 5V GND
-A15 1 2 3 5
/10.1.5
-X -H3 -H4
SF1-A SF1-B -U1 -F1 13
Z-SSO gn A rt A
/10.1.5 Logik 1 2 -S13
6,8V/50mA x1 x1
Logik
-X1 5V_S 14
1 3 CH1-CH2
-X10 63mA -R100 -R101
Option: UND /10.1.7
x2 SF2 2K4 2K4
RA1 Gabelabfrage SF1+2 x2 x2
max. 1mA -X6 Brücke entfernen

-V1
Siehe Bl. 23 /10.1.7 x1
-X7 RA2 Z6,2
-X4 SF1 MM
PE
Z-SSO
-XS1.1 Starttaster error
/15.7
Harting 14 11 12 13
PE PE PE-Modul PE
PE PE
-WS1
/9.1
2,5mm² SUPERTRONIC-C-PVC GY BN-GN GY-PK RD-BU WH-GN
25x0,25 mm²
module
-A3 PE PE-Steuerung
-XS1 14 11 12 13
/7.0
1234567-89
A21 / 10.1.12
6.12 / Res Res / 10.1.12
1234567-89
-A3.1 14 11 12 Starttaster Reset 23
/10.1.3 SF1 SF2 LED-gn
Rev 4.0
Gabel- Start- Röhrchen
Diagnose SF-E0 22 SF-E0 / 10.1.12
abfrage taster eingelegt
Spülung Timer 21 E5 / 10.1.12

10.1.2 / B1-Out 0 B1-Out Druckschalter SF
Diagnose D-B1 20 D-B1 / 10.1.12
10.1.2 / 1 B2-Out Spüldruck
Rev 4.0
B2-Out
Diagnose D-B2 19 D-B2 / 10.1.12
7.12 / SF 2 SF Sicherheitsfreigabe
SF SF 18 SF / 10.1.2
7.12 /A7.1 3 A7.1 Sonotrode ab
Sonotrode ab A7.1 17 A7.1 / 10.1.2
7.12 / SF1 4 SF1 Sicherheitsfreigabe CH-1
Diagnose D-SF1 16 D-SF1 / 10.1.12
7.12 / SF2 5 SF2 Sicherheitsfreigabe CH-2
Diagnose D-SF2 15 D-SF2 / 10.1.12
8.12 / 6 5V 5V 13
5V release logic 5V / 10.1.2
9.12 / L+ 7 L+ L+ 10 L+ / 10.1.2
9.12 / M1 8 M1 M1 9 M1 / 10.1.2
safety release safety release

SF1 SF2
9 10.1
265
12

release start Kobra-Ex
266
0 1 2 3 4 5 6 7 8 9 10 11 12 13
12
-AM 10.12 /L+M
/11.0
L+M / 11.1
Modul 10.12 / MM MM / 11.1
Kobra-III
5VM / 10.12
ws bk
13 bk bk
-X10 2 4 -S13b -H10a -H10b
5V 5V 5V GND
-A15 1 2 3 5 14 LED LED
/10.5
-X 24V-20mA 24V-20mA
SF1-A SF1-B -U1 -F1
Z-SSO K K K K
/10.5 Logik 1 2 SF2
6,8V/50mA ws
Logik -H3 -H4 -H3 -H4
-X1 5V_S
1 3 CH1-CH2
-X10 63mA gn A rt A gn A rt A
Option: UND /10.7
x2 SF2 x1 x1 x1 x1
RA1 Gabelabfrage SF1+2
max. 1mA -X6 Brücke entfernen -V1 ws
Siehe Bl. 23
-R100 -R101 -R100 -R101
/10.7 x1 2K4 2K4 2K4 2K4
-X7 RA2 Z6,2 13 x2 x2 x2 x2
-S13a
rd rd
-X4 SF1 MM 14
PE ws gn gn
Z-SSO
-XS1.1 double error
/15.7 gn rd
release start
Harting 14 11 12 13
PE PE PE-Modul PE
PE PE
-WS1
/9.1
2,5mm² SUPERTRONIC-C-PVC GY BN-GN GY-PK RD-BU WH-GN
25x0,25 mm²
1234567-89
module
-A3 PE PE-Steuerung
-XS1 14 11 12 13
/7.0
A21 / 10.12
10.12 / Res Res / 13.8
1234567-89Rev Rev
-A3.1 14 11 12 Starttaster Reset 23
/10.3 SF1 SF2 LED-gn
4.0 4.0
Gabel- Start- Röhrchen
Diagnose SF-E0 22 SF-E0 / 10.12
abfrage taster eingelegt
Spülung Timer 21 E5 / 10.12

10.2 / B1-Out 0 B1-Out Druckschalter SF
Diagnose D-B1 20 D-B1 / 10.12
10.2 / B2-Out 1 B2-Out Spüldruck
Diagnose D-B2 19 D-B2 / 10.12
10.12 / SF 2 SF Sicherheitsfreigabe
SF SF 18 SF / 15.7
10.12 /A7.1 3 A7.1 Sonotrode ab
Sonotrode ab A7.1 17 A7.1 / 15.11
/ SF1 4 SF1 Sicherheitsfreigabe CH-1
Diagnose D-SF1 16 D-SF1 / 10.12
/ SF2 5 SF2 Sicherheitsfreigabe CH-2
Diagnose D-SF2 15 D-SF2 / 10.12
10.12 / 5V 6 5V 5V 13 5V / 19.1
release logic
10.12 / L+ 7 L+ L+ 10 L+ / 14.1
10.12 / M1 8 M1 M1 9 M1 / 14.1
safety release safety release

SF1 SF2
10 11
Appr Rev.: 1, 30.11.2016 D-35435 Wettenberg Date Page 10.1

release start Kobra-Ex
0 1 2 3 4 5 6 7 8 9 10 11 12 13
-AM
/6.3 monitoring
/7.5 control air
/9.1 (safety release)
/10.1
/10.1.1
/12.0 -B1 -B2
/15.1 OUT = 1 11 OUT = 1 11
/19.1 P < 1bar -B P P = 2,6bar -B P
/20.0
/21.6 12 12
Modul 24V 0V Out 24V 0V Out
Kobra-III

BN BU BK
-WB1 -WB2
Without option
Ex: jumper
XS1.1:2 -> XS1.1:10
10.1.12 /L+M L+M / 12.1
10.1.12 / MM MM / 12.1
-XS1.1
/15.7
Harting 9 10
1234567-89
-WS1
BK VT
/9.1
1234567-89
Rev 4.0
-A3 9 10
/7.0
-XS1
/ B1-Out / B2-Out
SF-E0
/ D-B1 / D-B2 / D-SF1 / D-SF2 / E5 9.7 / G-A1 9.8 / G-A2
Rev 4.0
-X1.1 1 2 3 4 5 6 7 8
-W1
/21.9 1BN 1RD 1OR 1YE 1GN 1BU 1VT 1GY
Flachband
40x0,128 mm²
-X1 1 2 3 4 5 6 7 8
counter A counter B clk / R

-A2 E0 E1 E2 E3 E4 E5 E6 E7
/8.2
Digital Inputs E0-E7 Evo Control
safety cover close Pressure switch - 1 Pressure switch - 2 diagnose SF1 diagnose SF2 diagnose Output A1 Output A2
/ safety release release control air (SF) scavenging Pipe inserted start - button scavenging time 10 seconds generator generator
engaged
B1 = 1 (P<1bar) pressure B2 = 1 (P>2,5bar) welding active=0 max. power exceeded
10.1 welding End=1 12
267
12
PLC digital - input E0 - E7

268
0 1 2 3 4 5 6 7 8 9 10 11 12 13
12
11.12
-AM
/11.0 L+M
Modul L+M / 19.7
Kobra-III
MM / 15.1
MM
11.12
1 2
+ -
-SE8
3
-XS1.1
1234567-89
/15.7 23
Harting
-WS1
/9.1
WH-RD
SUPERTRONIC-C-PVC GY
25x0,25 mm²
1234567-89Rev Rev
module
4.0 4.0
-A3
-XS1 23
/7.0
Layoutänderung
-X1.1 9 10 11 12 13 14 15 16
-W1
/21.9 1WH 1BK 2BN 2RD 2OR 2YE 2GN 2BU
Flachband
40x0,128 mm²
-X1 9 10 11 12 13 14 15 16

-A2 E8 E9 E10 E11 E12 E13 E14 E15
/8.2
Digital Inputs E8 - E 15 Evo Control
Referenz- Punkt Reserve Reserve Reserve Reserve Reserve Reserve Reserve

verstellbarer
Anschlag
11 13

0 1 2 3 4 5 6 7 8 9 10 11 12 13

1234567-89
1234567-89
Rev 4.0
-A3 3 4 5
/7.0
-XS4
10.1.12 / Res
Res IST
Rev 4.0
17 18 19 20 21 22 18.9 23 21.6 24
-X1.1
-W1
/21.9 2VT 2GY 2WH 2BK 3BN 3RD 3OR 3YE
Flachband
40x0,128 mm²
-X1 17 18 19 20 21 22 23 24

-A2 E16 E17 E18 E19 E20 E21 E22 E23
/8.2
Reserve Reserve Reserve Reserve Reserve Reset pressure Reserve

Input Input Input alarm reached
12 14
269
12

270
0 1 2 3 4 5 6 7 8 9 10 11 12 13
12
-A3 10.1.12 /
/7.0
L+ L+ / 18.1
10.1.12 / M1 M1 / 18.1
-X7 6 7
-X14 5 7
11 13 X2
-S4
-S10
/7.9
12 14 X1 on
1234567-89
-X14 6 8
1234567-89Rev Rev
4.0 4.0
-A3 1 2
/7.0
-X8
8.9 / S10.2 14.4 / L+ L+ / 14.4
8.9 / S10.1
-X1.1 25 26 27 28 -X2.1 38 41
-W1 -W2
/21.9 3GN 3BU 3VT 3GY /8.11 4GY 5BN
Flachband Flachband
40x0,128 mm² 50x0,128 mm²
-X1 25 26 27 28 -X2 38 41

-A2 E24 E25 E26 E27 Count-R2 Count-R3
/8.2
receiver. send
setup tools setup emergency Reserve Reserve

welding stop monitoring
parameter
13 15

0 1 2 3 4 5 6 7 8 9 10 11 12 13
-A2
/8.2
Digital Outputs A0-A7 Evo Control
A0 A1 A2 A3 A4 A5 A6 A7
-X2
1 2 3 4 5 6 7 8
-W2
/8.11 1BN 1RD 1OR 1YE 1GN 1BU 1VT 1GY
Flachband

50x0,128 mm²
-A3 1 2 3 4 5 6 7 8
/7.0
-X2.1
7.12 / A7
10.1.12 / SF 10.1.12 / A7.1
-XS1 5 6 7 8
-WS1
/9.1
GY PK BU RD
SUPERTRONIC
25x0,25 mm²
6m
-AM -XS1.1 5 6 7 8
/11.0 /7.5
Modul /7.5
Kobra-III /9.1
1234567-89
/10.5
/10.1.5
/11.2
/12.1
/19.2
/20.1
/21.6
1234567-89
Harting
Rev 4.0 Rev 4.0

12 14 12 14
A1 A1 A1 A1
-YP1.1 -YP1 -YP2.1 -YP2

Typ: M Typ: M Typ: J Typ: J
A2 A2 A2 A2
12.12 19.3
MM MM
Reserve Reserve Reserve Reserve safety release cooling / cutting tool up cutting tool closed
scavenging home
position
14 16
271
12

PLC digital - output A0 - A7
272
0 1 2 3 4 5 6 7 8 9 10 11 12 13
12
-A2
/8.2
A8 A9 A10 A11 A12 A13 A14 A15
-X2
9 10 11 12 13 14 15 16
-W2
/8.11 1WH 1BK 2BN 2RD 2OR 2YE 2GN 2BU
Flachband
50x0,128 mm²
-A3 9 10 11 12 13 14 15 16
/7.0
-X2.1
1234567-89
1234567-89Rev Rev
4.0 4.0
Reserve Reserve Reserve Reserve Reserve Reserve Reserve Reserve
15 17

0 1 2 3 4 5 6 7 8 9 10 11 12 13
-A2
/8.2
A16 A17 A18 A19 A20 A21 A22 A23
-X2
17 18 19 20 21 22 23 24
-W2
/8.11 2VT 2GY 2WH 2BK 3BN 3RD 3OR 3YE
Flachband

50x0,128 mm²
-A3 17 18 19 20 21 22 23 24
/7.0
-X2.1
A23 / 18.7
9.10 / G-E1 9.10 / G-E2 A19 / 18.7 / A21
L+OFF / 18.2
-XS4 6 7 8 9
1234567-89
1234567-89
Rev 4.0 Rev 4.0
option Input E1 Input E2 welding ok Error signal lamp - 1 signal lamp - 2 signal lamp - 3 signal lamp - 4 A23 - machine
welding generator generator Bit 2 Operation error option tool setup machine Off ready
active option option option option option
16 18
273
12

274
0 1 2 3 4 5 6 7 8 9 10 11 12 13
12
-A2
/8.2
A24 A25 A26 A27
-X2
25 26 27 28
-W2
/8.11 3GN 3BU 3VT 3GY Attantion max. Voltage = 24VDC
Flachband
50x0,128 mm²
Interface XS12
-A3 25 26 27 28
-Kunde
/7.0
-X2.1
function Interface
-XS12
1 VCC
-BSS169 -X1:1
1 100mA
18.2 19.8 VCC/24V

-H1 G L+ L+
/8.2 2 max. 400mA
-XS12
6
1
1234567-89
welding Error -X1 6
-R169 13
33Ohm
2 -KS1
0,5W
Reset 14
external
-XS12 Option
7
13.9 / Res
-X1 7
17.12 -R23 -V23
1234567-89Rev Rev
A23
+
+
Funktion: 1 2 A K
14.12 18.8
Inverter L+ 2K4 -XS12
L+ L+ C E 2 Bereit
4.0 4.0
max. 200mA -X1:2
-
machine
ready
17.6 -R19 -V19
L+1 L+1 A19
+
+
8.2 19.8 1 2 A K
2K4 -XS12
C E 3 Schweißung
- -X1:3
-V28 1 welding ok Error
A1 11
24V
max 200mA -K1 -K2 -R26 - Bit 2
A2 12 2K4 -V26
+
+
2 A K
-XS12
C E 4 Error-1
- -X1:4
1 Error - Bit 1
-R27
2K4 -V27
2
+
A + K
L+OFF
17.12 -XS12
C E 5 Error-2
- -X1:5
Error - Bit 0
14.12
M1
M1 / 19.8
Reserve Alarm Error Bit 1 Error Bit 0 machine ready /

welding active
17 19

0 1 2 3 4 5 6 7 8 9 10 11 12 13
-A2
/8.2
A3 B3
-X2
39 40
-W2
/8.11 4WH 4BK

Flachband
50x0,128 mm²
-A3 39 40
/7.0
-X2.1
10.1.12 / 5V
5V 5V 5V 18.9 /L+ L+ / 20.3
19.6 19.5 20.2 18.9 / M1 M1 / 20.3
8.12 / 1 1 18.2 /
PWM-1B L+1 L+1 / 20.6
8.12 / PWM-1A -R12 -R13 RxD / 22.6
1K2 1K2
2 2 TxD / 22.6
-XS1 19 20 22 21 -XS3 1 8 9 4 5 2 3
GND
Option
Servomotor /
1234567-89
-WS1 Web IO RS232-0
/9.1 PE
SUPERTRONIC-C-PVC GY
WH-PK PK-BN BN-BU WH-BU
25x0,25 mm²
1234567-89
Rev 4.0
-AM -XS1.1 19 20 22 21
/11.0 /15.7
Modul Harting
Kobra-III
19.12 / 5VM 5VM / 19.3

15.12 / MM MM / 20.2
12.12 /
Rev 4.0
L+M
-WM3
BN RD OR YE GN BU
Flachband -WXH1
WH BN
10x0,072 mm² TRONIC (LiYY) GY
2x0,25 mm²
-XM3 1 2 3 4 5 6
x1 x1
-XH1 1 3
-C1 -C2
100nF x2 100nF x2
-WM3.1 -WH1
RD GY GY GY GY GY BN BU
Flachband TRONIC (LiYY) GY PE PE
GY0,072 mm² 2x0,25 mm²
A
-H1
-M3 1(-) 2(+) 5(B) 6(A) 24V/DC
3 4
K
M G
GND VCC 5V
chanel A B
motor control depth lighting tool noise

stop suppression EMV
18 20
275
12

motor control - ENCODER
276
0 1 2 3 4 5 6 7 8 9 10 11 12 13
12
-AM
/11.0
-A9
Modul
MR1
Kobra-III
module INC - Measuring system 1
cable disposal
down
A B 5V GND
-WA9
YE GN RD BU
LIY-CY
4x0,25 mm²
-XA5 2 1 3 4
-WA9.1
LIYCY BN WH BU BK
4x0,25 mm²
2m 20.3 20.2
5VM 5VM
19.12
MM
MM
-XS1.1 21.6
/15.7
17 18 15
Harting
-WS1 WH-GY GY-BN WH-YE

/9.1
1234567-89
PE
-A3 17 18 15 1 2 14 15 11 12 13
/7.0
-XS1 -XS4
19.6 20.6 20.2
1234567-89Rev Rev
5V 5V 5V
4.0 4.0
-R11 Bit2 Bit1 Bit0
a b
19.12 / L+1 0 0 0 Typ: Kobra-III
21.6
1K K 0 0 1
L+
19.12 / L+ -V5 0 1 0
5V1 A 0 1 1
19.12 / M1 8.12 / M2 M2 / 21.1 1 0 0
M1 1 0 1
33 34 35 22.4 36 37 42 35 36 1 1 0
-X2.1 -X1.1
1 1 1
-W2 -W1
/8.11 4OR 4YE 4GN 4BU 4VT 5RD /21.9 4GN 4BU
Flachband Flachband
50x0,128 mm² 40x0,128 mm²
-X2 33 34 35 36 37 42 -X1 35 36
-A2 A1 B1 R1 A2 B2 BIT-2 BIT-0 BIT-1

/8.2
200mA
function Option Reserve

module Minic II counter 2
19 21

Inkremental Measuring system
0 1 2 3 4 5 6 7 8 9 10 11 12 13
-A1 -AM -A2

/4.4 /11.0 /8.2
230V Modul
16A
generator modul Kobra-III 3
PMH8/20KHz 3KW / 230V
3000W -R1
5K
1 2
VOUT1 VOUT2 VOUT3
P 0VL UHF GND NC

-X1
32 33 34
5VM
-XJ7 16 15 -XJ8 13 12 11
/6.1
-W1

/11.1
MM /12.1
20.3 -XS1.1 /13.1
/15.7 /14.1
Harting 16 /20.8
/21.1
/22.10 4RD 4OR 4YE
Flachband
-WS1 YE-BN
40x0,128 mm²
/9.1
pneumatic
PE
-A3
/7.0 -X9 1 2 -XS1 16 -X1.1 32 33 34
20.9
M2
1234567-89
x1
x1 13.10 / IST x1
1234567-89
-C16 -L1 -C17
470nF x2 20.5 / 470nF x2
L+
x2
Rev 4.0
7.2 / MP PE
PE
-X1.1 29 30 31 -X6 1 2 3 4 -XS4 10
-W1
Rev 4.0
/21.9 3WH 3BK 4BN -WX6 WH BN GN YE
Flachband LIY-CY
40x0,128 mm² 5x0,34 mm²
-XS6.1
-X1 29 30 31 1 7 3 2
-YP1.2
proportional valve
-A2 U14BIT U12A U12B
/8.2 24V Ist Soll 0V
U P
generator Pipe stop Reserve proportional Analog output - 2 Analog output - 3
power 0 - 2V / position valve 0-10V 0-10V
Converter Voltage welding pressure
20 0 - 5V 22
277
12

PLC analog - in- / Output
278
0 1 2 3 4 5 6 7 8 9 10 11 12 13
12
A2
/8.2
RS232/1 RS232/1 RS232/0 RS232/2 RS485 RS232/2 RS485

RxD TxD GND RxD TxD
RxD TxD RxD+ RxD- TxD+ TxD- RxD+ RxD- TxD+ TxD-
-RS232/1 -X2 -X1

5 7 1 45 46 43 44 47 48 49 50 37 38 39 40
-W2 -W1
5GN 5BU 5OR 5YE 5VT 5GY 5WH 5BK /21.9 4VT 4GY 4WH 4BK
/8.11
COM3 Flachband Flachband
box - PC 50x0,128 mm² 40x0,128 mm²
0,3 m
-A3 45 46 43 44 47 48 49 50 37 38 39 40
/7.0
-X2.1 -X1.1
/ / 19.12
M1 M1
/ 20.5 22.10 RxD
GND3
/ 8.10
TxD3
1234567-89
8.10
M1
/ RxD3 22.5
8.10 PE PE PE
x1 x1 x1 TxD
19.12
-C6 -C7 -C8
1nF x2 1nF x2 1nF x2
-RS232/3 5 TxD 7 RxD 1 GND
10 pole. 5 7 1 -XS18 6 7 8 -XJ61 1 2 3 4 5 6

/9.5
1234567-89Rev Rev
GND
4.0 4.0
-COM-2 -COM-3 RS232/1 RS232/0 -WJ6
/9.5
0,35 m BN GN WH 0,35 m BN GN WH BK WH GY VT BU GN
LIY-CY LIY-CY Flachband
3x0,25 mm² 3x0,25 mm² 20x0,072 mm²
-XJ6 Y Z B A
-COM 2 -COM 3 /9.5 1 2 3 4 5 6
3 2 5 3 2 5
-A1 1
/4.4
230V
TxD+ TxD- RxD- RxD+ GND GND
16A
DOUT22 RIN32 GND DOUT22 RIN32 GND PMH8/20KHz
3000W
box - PC RS232 generator modul

3KW / 230V
Schnittstelle interface RS232/3 interface RS232/1 interface RS485/2 interface RS485/3

RS232/1 Box PC Touch Screen option Touch Panel option generator option
ID-Chip
21 25

Interface RS 232 Compact Power - PC
0 1 2 3 4 5 6 7 8 9
Interface XS 12
Interface
start Welding
machine ready (XS12 : 2)

Welding cycle OK
welding Error (XS12 : 3)
Reset (XS12 : 7)
VCC / +24V (XS12 : 1)
1234567-89
1234567-89
Rev 4.0
start Welding
machine ready (XS12 : 2)
Rev 4.0
Welding cycle Error
welding Error (XS12 : 4+5)

Reset (XS12 : 7)
22 +USV/4a
User fg Hauptstraße 95 + USC-5 -
USC-5 Kobra-III Ex Grafik Serie
Check Rev.: 1, 30.11.2016 D-35435 Wettenberg designation: Page 25
279
12
Interface XS12
Appendix
13. Appendix
You can find further information on the enclosed USB flash drive under “Appen-
dix” .
13.1 Wacker Safety data sheets
SILICON-PASTE P (Bestell-Nr. 10354243)
13.2 APC UPS
¬ Safety Information APC

¬ User Guide PowerChute Personal Edition v3.1.0
¬ Back-UPS CS User Manual
¬ Installation Guide & Release Notes Powerchute Personal Edition v3.1.0
280 1234567-89
1234567-89Rev Rev
List of Figures
Fig. 1: Usual operation of the machine with vertical suspension 17

Fig. 2: Scope of delivery (assembly stand is not included) 21
Fig. 3: Emergency stop button 27
Fig. 4: Schematic structure of the vibration-relevant elements 31
Fig. 5: Dimensions ‒ welding gun (one-hand guidance without system cable) 34
Fig. 6: Dimensions ultrasonic controller 35
Fig. 7: Dimensions of ultrasonic controller basic version 36
Fig. 8: Dimensions of ultrasonic controller with calibration unit (explosion-proof
version) 36
Fig. 9: Welding gun with inserted tube 38
Fig. 10: Welding gun with inserted tube - top view 38
Fig. 11: Safety area - explosion protection 39
Fig. 12: Front view ‒ ultrasonic controller 43
Fig. 13: Front view of ultrasonic controller with calibration unit 43
Fig. 14: Electronic controller - rear 45
Fig. 15: Schematic representation of the welding tools 47
Fig. 16: Cooling device with filler tube (A) for welding with right-hand cutting tools 47
Fig. 17: Cooling device with filler tube (A) for welding with left-hand cutting tools 47
Fig. 18: Welding room and anvil support 50
Fig. 19: Overview of basic mechanical parts, opening dimension 7 mm 53
Fig. 20: Overview of basic mechanical parts, opening dimension 12 mm 56
Fig. 21: Overview of basic mechanical parts, motorized depth stop, opening
dimension 7 mm 59
Fig. 22: Overview of basic mechanical parts, motorized depth stop, opening
dimension 12 mm 62
Fig. 23: Support spring zero point bearing 65
Fig. 24: Sealing of anvil support, stroke 7 mm 66
Fig. 25: Sealing of anvil support, stroke 12 mm 67
Fig. 26: Stop left and right 68
Fig. 27: Replacement snap fastener with slot 69
Fig. 28: Flat cage guidance system ASSY 70
Fig. 29: ASSY pneumatic valve 2x3/2 way valve 71
Fig. 30: ASSY pneumatic valve 2x3/2 way valve 71
Fig. 31: Pressure switch 72
Fig. 32: Maintenance unit 79
Fig. 33: Rear panel of the ultrasonic controller 81
Fig. 34: Welding position 87
Fig. 35: Gap width between tools (mm) (closed) 88
Fig. 36: Welded tube (target height) 88
Fig. 37: Setup mode overview 90

1234567-89 Rev 4.0 Rev 4.0 281
Fig. 38: Tool selection 92

Fig. 39: Teach mode overview 106
Fig. 40: Options menu 115
Fig. 41: Setting counter menu - Stop 117
Fig. 42: Setting counter menu - Warning 118
Fig. 43: Keyboard input alarm thresholds 120
Fig. 44: Parameterise further counters 122
Fig. 45: Machine setup 125
Fig. 46: Edit sequences 126
Fig. 47: Enter the sequence name 128
Fig. 48: Editing sequence 129
Fig. 49: Delete sequence 131
Fig. 50: Import or export of welding parameter sets 132
Fig. 51: Export of logbook files 136
Fig. 52: Create new parameter set 138
Fig. 53: Entering the tube name 140
Fig. 54: Entering the comment 140
Fig. 55: Enter the tube diameter 141
Fig. 56: Entering the wall thickness 141
Fig. 57: Automatic tube detection, right cutting 142
Fig. 58: Loading or deleting a parameter set 144
Fig. 59: Control elements on the ultrasonic controller 148
Fig. 60: Switching the device on or off 151
Fig. 61: Correct insertion of the tube 155
Fig. 62: Welding gun with inserted tube 155
Fig. 63: Incorrect insertion of the tube 155
Fig. 64: Incorrect insertion of the tube 155
Fig. 65: Start button and LED enabling 156
Fig. 66: Welding positions 157
Fig. 67: Production mode menu view 1 160
Fig. 70: Export of logbook files 165
Fig. 71: Loading welding parameters 167
Fig. 72: Select welding parameters view 1 169
Fig. 75: Loading sequence view 1 171
Fig. 76: Loading sequence view 2 172
Fig. 77: Operator counter 174
Fig. 78: Changing tools 177
Fig. 79: Open the lock 179
282 1234567-89
1234567-89Rev Rev
Fig. 80: Remove the plug from the module 179

Fig. 81: Release clamping screw 180
Fig. 82: Variant: handle on the side 180
Fig. 83: Open housing 181
Fig. 84: Disconnect plug connection from emergency stop 181
Fig. 85: Connect the plug 182
Fig. 86: Connected plugs 183
Fig. 87: Loosen and remove the clamping screw of the sonotrode 184
Fig. 88: Pull out the oscillator unit 185
Fig. 89: Disassembling oscillator unit - sonotrode change 186
Fig. 90: Oscillator unit disassembled on sonotrode 186
Fig. 91: Disassembling oscillator unit - converter change 188
Fig. 92: Dismantling converter - Booster 188
Fig. 93: Dismantled vibrator unit 189
Fig. 94: Assembly - Tighten the oscillator system with torque 190
Fig. 95: Areas to be cleaned and greased 191
Fig. 96: Inserting the oscillator unit 192
Fig. 97: Correct position of the oscillator unit 192
Fig. 98: Tighten the clamping screw 193
Fig. 99: Left-hand cutting, threaded pin, left 194
Fig. 100: Right-hand cutting, threaded pin, right 194
Fig. 101: Check depth stop with feeler gauge 195
Fig. 102: Cylinder screws on the anvil support 197
Fig. 103: Anvil changing 197
Fig. 104: Setting the limit stop 199
Fig. 105: Disconnect converter plug 200
Fig. 106: Insert converter plug into the connector socket 200
Fig. 107: Plug in the emergency stop cable again 201
Fig. 108: Fix the clamping screw 201
Fig. 109: Plug the connector onto the welding module 202
Fig. 110: Vertical position of the locking button 202
Fig. 111: Locking the connector 202
Fig. 112: Replacing the sealing of the anvil support 203
Fig. 113: Change limit stops 204
Fig. 114: Distance between anvil support and limit stop 205
Fig. 115: Support spring zero point bearing 206
Fig. 116: J10 supply plug 218
Fig. 117: Top handle 221
Fig. 118: Side handle left 222
Fig. 119: Side handle right 222
Fig. 120: Support handle 223
Fig. 121: Twin handle 224

1234567-89 Rev 4.0 Rev 4.0 283
Fig. 122: Twin top handle 225

Fig. 123: Single handle (left with suspension) 226
Fig. 124: Single handle (right with suspension) 226
Fig. 125: Top handle with side trigger 227
Fig. 126: Suspension, vertical 228
Fig. 127: Suspension horizontal, handle on the left 229
Fig. 128: Suspension horizontal, handle on the right 229
Fig. 129: Opening dimension 230
Fig. 130: 360° rotation device front view 231
Fig. 131: 360° rotation device rear view 231
Fig. 132: Assembly of the rotation device, screws and adapter 232
Fig. 133: Position of the screws without plate 233
Fig. 134: Position of the screws with plate 233
Fig. 135: Stops and holder 234
Fig. 136: Overview drawing Kobra-III opening 7 mm 236
Fig. 137: Overview drawing Kobra-III opening 12 mm 237
Fig. 138: Activating the barcode scanner function 239
Fig. 139: Barcode scan function 240
Fig. 140: Inserting the dongle 244
Fig. 141: UPS installation 248
Fig. 142: Standard connection without UPS 250
Fig. 143: Connection with UPS 250
284 1234567-89
1234567-89Rev Rev

Kobra-III Operating Manual Rev 4.0 en COMPRESSED

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Kobra-III Operating Manual Rev 4.0 en COMPRESSED

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Operating Manual

Machine No. 1234567-89

Schunk Sonosystems GmbH  +49 (0) 641 8 03 - 0

THIS GUIDE APPLIES TO BOTH KOBRA-III AND KOBRA-III EX IN THE

PRIOR TO STARTUP CAREFULLY READ THE OPERATING MANUAL OF THE

THE OPERATING MANUAL MUST BE ACCESSIBLE FOR THE OPERATORS AT

KEEP THE OPERATING MANUAL IN A SAFE PLACE FOR FUTURE USE

THE OPERATING MANUAL CONTAINS ALL AVAILABLE OPTIONS.

YOU WILL FIND THE COMPLETE VERSION OF THE OPERATING MANUAL ON

© Schunk Sonosystems GmbH 1234567-89

3. Transport and installation 73

© Schunk Sonosystems GmbH 1234567-89

5.1 Daily start-up 145

6. Changing tools 175

8. Decommissioning and disposal 220

© Schunk Sonosystems GmbH 1234567-89

10. Options 238

11. Pneumatic circuit diagram 253

12. Electric circuit diagram 255

13. Appendix 280

Schunk Sonosystems GmbH

© Schunk Sonosystems GmbH 1234567-89

1.1 Presentation of hazard-related information

Type and source of the hazard

Possible consequences if not complied with

→ Measures for hazard avoidance

Symbol, signal word and type of hazard

This symbol is used for an application recommendation.

i optimized operating procedures.

The possible consequences of failure to comply can be material damage, e.g.

→ Handling instruction or precautionary measure to avert the hazard.

© Schunk Sonosystems GmbH 1234567-89

1.2 Types of hazards

Warning signs indicating the type of hazard

General warning sign

Attention symbol in conjunction with signal words DANGER,

Also used as general warning sign.

Warning ‒ high voltage

Warning ‒ dangerous voltage on electrical components.

Possible consequences may include death or serious injury (personal injury).

Warning of hot surfaces

Risk of burns on hot surfaces.

Possible consequences may include minor or serious injuries (personal injury).

Warning ‒ hand injuries

Possible consequences can be minor or severe injuries (personal injury)

Warning ‒ pointed objects

Observe the manual

→ Adhere to the operating steps

Disconnect the mains plug

© Schunk Sonosystems GmbH 1234567-89

1.3 Personal protective equipment

Use of the following personal protective equipment is mandatory when operating

Use ear protection

Possible consequences of non-compliance may include irreversible damage to

Use eye protection

Use suitable eye protection: for protection against mechanical,

Possible consequences of non-compliance may include irreversible damage to

Use hand protection

Use suitable hand protection:

Possible consequences of non-compliance may include irreversible damage to

Use protective footwear

Use suitable safety shoes:

Possible consequences of non-compliance may include irreversible irreversible

Untrained persons at the the ultrasonic welding system.