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6.4 Setting up the tools

IN THE SETUP OR TEST MODES, SOME PROTECTIVE DEVICES AT THE

MODULE COULD BE PARTIALLY DISABLED. THE NOISE PROTECTION
OR FINGER GUARD OR THE PROTECTIVE DEVICES COULD HAVE
BEEN REMOVED.

Therefore, when setting up or testing, the following must be kept in mind:

• Switch the key switch of the controller to setup mode (key position
1).

• With the <F4> key, select setup mode

• If the setting up or testing can only be carried out with driving

energy owing to the technological process, there is a significant
risk

• The machine may only be operated by a particularly well-trained

and authorised person

• Do not touch live electrical parts. Work on the electrical system,

such as connecting to the electrical supply or changes and repairs
to electrical wiring and connections, may only be carried out by
persons who are qualified and authorised to do so.

• Do not touch moving and vibrating parts

• Exercise particular care

The Ultrasonic Welding System must be set up for the application to be

processed.

The possible consequences of a setting that is not correctly done are serious
damage to the machine or tools.

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Therefore:

• Only tools compliant with and suitable for the application should be
used

• The tools must be set correctly

• Only original spare parts should be used to ensure operational

safety

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6.4.1 Changing the sonotrode / Replacing the welding surfaces of the

sonotrode

- Remove the front and rear panels of the soundproofing and finger guard
- Separate the HF-cable from the converter
- Remove the lateral slider, right-hand side (Pos. 1)
and cutting unit (Pos. 2) (Fig. 1)

Fig. 2

Pos. 2 Pos. 1

Fig. 1

- Loosen the two screws of the Sonotrode support (Fig. 3) as well as the
screws of the oscillation system clamp (Fig. 4)
- Pull the oscillator system one piece backwards and remove the
sonotrode support

Sonotrode support Bit stop

Fig. 3 Fig .4

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- Rotate the oscillator system through 90° and pull it backwards out of the
housing.
- Replace the welding surface of the sonotrode or replace the sonotrode
- Dismantle the oscillator system (Fig. 5) with the help of the sickle
spanner.
- Clean the booster and sonotrode coupling surface and apply a thin film
of silicone paste.
- Screw on a new Sonotrode
- Tighten with a sickle spanner and torque wrench
(tightening torque = 100 Nm)!

Fig. 5

- Insert the oscillator system in the bearing and turn it to the desired
welding surface
- Mount the sonotrode support and push the oscillator system into the
housing till it comes to rest

Fig. 6

- Align the sonotrode with a bevelled steel square (Fig. 6)

- Tighten the screws of the sonotrode support (Fig. 3)
- Tighten the screws of the oscillator system clamp (Fig. 4)
- Check sonotrode setting by means of a bevelled steel square

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- Set the bit stop to a safety distance of 0.3 to 0.5 mm between the anvil
and the sonotrode.
The safety distance is set by rotating the bit stop.
For this purpose, the sonotrode must be in its upper end position.

The movement between upper and lower end position takes place by
means of the function key F2.

CAUTION: DANGER OF CRUSHING!

- By tightening the screw (Fig. 2), tighten the bit stop

- Mount the lateral slide unit, right-hand side and set it up
(see Chapter 6.4.3)
- The gap size between sonotrode and conductor stop must be 0.3 mm -
0.5 mm. Check! The sonotrode and conductor stop must not touch each
other under any circumstances
- If required, once again loosen the oscillator system clamp and set the
gap size. Check sonotrode setting by means of a bevelled steel square
- Set up the lateral slide, left-hand side (see Chapter 6.4.3)
- Mount the cutting unit (see Chapter 6.4.4)
- After checking the settings, fasten the front and rear panel of the
soundproofing and the finger guard

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6.4.2 Change the anvil inset stake

- Remove the front panel of the soundproofing and finger guard

- Completely remove the lateral slide unit, right-hand side.
- Remove the cutting unit
- Loosen the sonotrode and pull it backwards
- Loosen the locking screws of the anvil insert stake (Fig. 7) and change
the anvil inset stake.

Fig. 7

- Align the anvil inset stake centrally and screw it tight.

- Align the sonotrode
- Mount the hold-down device, right-hand side, and the cutting unit
- Mount the front panel of the guard.

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6.4.3 Setting the pusher, left-hand side / Hold-down device right-hand side

- With the adjusting screw, the pusher, left-hand side is set.

Fig. 8

Adjusting screw

- Machine in setup mode, F4 key (manual functions)

- Set the pusher, left-hand side by means of the adjusting screw and foil at
0.02 mm (Fig. 8)

Fig. 9

Setting
aid

- Mount the setting aid on the connecting link

- Lower the hold-down device right-hand side with the F4 key.
- Pre-set the hold-down device, right-hand side (Fig. 9)

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- Fine setting of the hold-down device, right-hand side, by means of a

connecting link (Fig. 9). Loosen the two screws M6, position the 0.02 mm
foil between the sonotrode and the hold-down device, right-hand side
(Fig. 10)
- Press the hold-down device, right-hand side against the sonotrode till the
setting 0.02 mm is in order.
- Upon completion of the settings, check the tightening torque of all the
screws.
- With the manual functions (setup mode F4), close the tools, lower the
sonotrode (Fig. 10), check the gap sizes and heights.
- Lower the sonotrode by manual function into the welding position, and
set the bit stop (Fig. 2) to an intermediate space of 0.3 to 0.5 mm.
- Insert the pneumatic pipe and the HF-cable in the converter.
- Mount the housing cover and sonotrode support.
- Mount the front panel of the protection.

Fig. 10

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6.4.4 Setup of knife

• Key switch in Setup mode

• Press the button F4 (manual functions)
• Detach the worn knife and replace it (Fig. 20). When replacing the knife,
ensure ease of movement and lightly oil the coupling surfaces
• Loosen the screws (A, B, C, Fig. 21) and release the new knife
somewhat from the cutting edges. Turn in the stop screw (D) about one
revolution.
• Place the spacer around the threaded rod (Fig. 22), bring the knife into
cutting position with the F7 and F6 keys
• With the F6 and F7 keys, bring the knife to the cutting position
• The knife is now moved up to the spacer (Fig. 23)
• Now, using the fastening screw and the adjusting foil 0.1 mm, (feeler
gauge) the cutting gap can be adjusted (Fig. 21).
• Position the adjusting foil between the anvil and the knife, press the knife
lightly against the anvil and tighten the screws (B). It must be possible to
easily move the adjustment foil between the anvil and the knife.
• Then, set the second cutting edge with the adjustment foil 0.1 mm and
the stop screw (D).
• Now, with the function keys F6 and F7, move the knife upwards and
remove the spacer
• In the base position, tighten the screws (A)
• Now, simulate the complete cutting cycle with the manual functions
(Setup mode, F4 key; Manual functions, keys F7 and F6)
For this purpose, the lateral slide must be at the bottom right

Fig. 20

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A C B

Fig. 21

Fig. 22

Fig. 23

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6.4.5 Setting the cyclical feed

• Machine in setup mode, key F4, Manual functions

• The end positions of the transport latch can be adjusted using the 2
screws SW 13 (Fig. 30).
• Caution, the screws are secured against getting loosened
unintentionally.
• The upper screw is used for setting the position of the MAK 12 contact in
the welding room.
• The lower screw is used for setting the base position or the loading
position.
• When setting the base position, care must be taken that the transport
latch dovetails neatly into the tappet hole of the transporting belt (large
hole).
• The loading process can be simulated and checked using the manual
functions (Set up Mode, F4, F5).
• When the setting of the cyclical feed is complete, check whether the
sensors for querying the end positions are still OK. If not, these should
be corrected (Fig. 30).

• The transport latch is spring-loaded; set the spring pressure in such a

way that the latch cleanly dovetails into the tappet hole provided for the
purpose.

Fig. 30
Proximity switch

Adjusting screw SW13

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6.4.6 Cooling the welding system

The feed quantity for cooling the oscillator system is set at the factory. It is
imperative to ensure that both the converter as well as the sonotrode are
sufficiently cooled by the air blast.

Cooling pipe
for Sonotrodes-
cooling

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