Kaer KCH Series User manual
KCH Series Hand-type Ultrasonic Plastic Welding Machine
Instruction
Weihai Kaer Sonic Power Co., Ltd.
Read the users manual carefully before use.
KCH Series Hand-type Ultrasonic Plastic Welding Machine
Special Statement
1. Our company provides warranty of free warranty and technical
services for 12 months since it leaves the factory.
2. Our company charges for any maintenance beyond the warranty
period and services.
3. The following conditions are not within the warranty:
●Damage caused by using device in abnormal circumstances.
●Equipment failure caused by the working environment that is not meet
the device requirements.
●Equipment damages caused by private reparation or transformation.
●Fuse tube and other easy to wear and tear parts
●Spare parts
●Appearance and package of equipment
●Incidents or damages caused by natural disasters
4. The contents of this manual is only for reference, any questions
please contact the service hotline: 86-631-5690111.
5. This manual and the equipment technical data belongs to Weihai kaer
Sonic Co., Ltd., No permit for any change and copy.
KCH Series Hand-type Ultrasonic Plastic Welding Machine
I. General Information
KCH series hand-type ultrasonic plastic welding machine is mainly used for
secondary joining of thermoplastics. Compared with other traditional processes (such
as gluing, electric heat-joining, or screw tightening), it has remarkable advantages like
high productivity, sound welding quality, environmental protection and energy saving,
among others.
II. Structure features and working principle
Working principle of KCH series hand-type ultrasonic plastic welder: the welder
converts the electric energy into ultrasonic energy through the ultrasonic transducer
(i.e. high-frequency mechanical vibration energy with the frequency exceeding the
threshold of human’s auditory sense). To conduct ultrasonic energy to the plastic work
piece through the welding head, such ultrasonic energy melts down the joint face of
the plastic work piece after rubbing the joint face violently with ultrasonic frequency at
the speed of tens of thousands of times per second and with certain amplitude. The
transient pressure maintained at the work piece after stopping vibration makes two
pieces of weldment solidify together in the form of molecular interlinkage. And the
weld strength compares favorably with that of a weldment itself.
KCH series hand-type ultrasonic plastic welder has such features as high automation,
easy and safe operation, stable and reliable running, etc.
KCH series hand-type ultrasonic plastic welder is applicable for butt welding of
thermoplastics. With its welding head replaceable according to the customers’
requirements, the welder can also be used for processing such as rivet welding, spot
welding, embedding, cutting, etc.
1. Equipment structure instruction
Overall outline and parts’ structure name shown in picture as following:
KCH Series Hand-type Ultrasonic Plastic Welding Machine
KCH Series Hand-type Ultrasonic Plastic Welding Machine
2. Equipment normal operating instruction
When the equipment has installed and commissioning, operator holds the hand-type
welding head with one hand, after adjusting the welding head relative to workpiece
position, force’s strength and direction, to press the control handle ，and the
equipment will send ultrasonic as pre-setting welding time to complete welding
process.
III. Main Technical Parameters
1. Operating Power supply: single-phase AC220V±5%
2. Operating current: less than 1A
3. Apparent power of transducer: □500W □800W □1000W
4. Ultrasonic frequency: 28KHz
5. Power supply noise: do not exceed 100Vp_p
6. Allowed momentary interruption: less than 10ms
7. Operating temperature: 0～50℃
8. Equipment storage temperature: -10～60℃
9. Ambient humidity: 20～70%(non-condensation)
10. Around no vibration existing
11. Around no dust and no corrosive gas
12. Equipment overall dimension:
400mm（L）×450mm（W）×150mm（H）
KCH Series Hand-type Ultrasonic Plastic Welding Machine
IV. Installation and Commissioning
1. Installation of the equipment
1) The equipment should be installed on the solid table board, with a space of 150mm
in the rear.
2) Power supply should meet the requirements of equipment operating technical
parameters, unstable voltage will exert direct influence on the welding effect, or in an
even more serious case, result in shortening service life of power generator or burning
it! Areas with unstable voltage require a voltage stabilizer with fluctuation of output
voltage below 2% and the output power double the nominal power of the welder.
3) There is no fire source, well-ventilated, stable installing.
4) Before operating the welder, make sure to connect the ground wire properly, with
ground resistance less than 0.5ohm.
Never operate the welder without proper grounding!
5) Before switching on, please make sure that proper power supply and air supply are
used, the cable wires have been connected correctly, the limit of welding head has
been well set, and the hands and other parts are at safe operation position.
2. Commissioning the operational parameters
1) Parameters of working frequency
The power generator of KCH series hand-type ultrasonic welding machine can track
the working frequency of the transducer automatically within certain range of working
frequency (i.e. working frequency band). However, influenced by external factors,
changes of the transducer’s natural frequency may exceed the generator’s working
frequency band, which may lead to the fault of frequency deviation. Operating the
welder under the status of frequency deviation will cause poor welding quality, or more
seriously damage the ultrasonic power generator or transducer system. Therefore, in
the event of frequency deviation, make sure to calibrate it.
zPhenomena of faults of frequency deviation:
a. The degree of frequency deviation is too high, and frequency deviation
protection occurs.
b. No load output current is very high, or even overload protection occurs.
c. The welding head squeals, with serious heating up.
zMethod of commissioning:
KCH Series Hand-type Ultrasonic Plastic Welding Machine
Click the ultrasonic testing button for short time, observe the indicated value of the
degree of frequency deviation (frequency deviation protection will occur when the
degree of frequency deviation exceeds 20%); adjust the frequency-adjusting knob
finely to raise or lower the working frequency band, and then click the ultrasonic
testing button, observe if the indicated value of the degree of frequency deviation
is lower than the previous value; if lower, continue to adjust the
frequency-adjusting knob in the previous direction, and simultaneously, click the
ultrasonic testing button in short time, observe the indicated value of the degree of
frequency deviation until the degree of frequency deviation is adjusted to the
minimum (less than 10%). If higher than the previous value, adjust the
frequency-adjusting knob in reverse direction, and simultaneously, click the
ultrasonic testing button in short time, observe the changes in the degree of
frequency deviation until the degree of frequency deviation is adjusted to the
minimum.
zNotes for the adjustment:
a. The minimum degree of frequency deviation (less than 10%) and the
minimum no load (less than 0.5A) are the standards for frequency control.
b. In case of errors with transducer system or serious frequency deviation for
connection failure or misconnection of transducer, it will not work to correct
frequency now. The transducer and connecting wires will have to be adjusted
or replaced.
c. In special unexpected cases such as replacing or repairing the components of
transducer (like acoustic welding head), the occurrence of frequency deviation
protection during operation, and the first time of switching on and operation, it
requires calibrating the working frequency band of the generator.
2) Load parameters
KCH series hand-type ultrasonic welding machine can adjust load parameters
automatically according to the load. Under normal status, the load under no load is the
lowest (less than 0.5A), and the load is related to the factors like the welded work
piece and the welding pressure in the process of welding. Over high load may result in
overload protection. Some models can limit the load automatically.
KCH Series Hand-type Ultrasonic Plastic Welding Machine
3) Pressure parameters
Selection and adoption of pressure parameters often relates to such factors as the
welding area and the material of the weldment, and the amplitude of welding head, etc.
The pressure parameters exert direct influence on the output load of the welder.
Generally, the higher for the pressure, the higher output load. However, over-high
pressure will cause overload protection or reduction of effective output. Therefore,
pressure parameters shall be selected as appropriate. For common small work pieces
or non-crystallized materials such as ABS, start adjustment from 0.2MPa; for larger
work piece or semi-crystallized materials such as polypropylene, polyethylene, or the
weldment with higher requirements for sealing, start adjustment from 0.4MPa.
4) Parameters for weld time
Weld time is the time for outputting the ultrasonic welding power, which influences the
quality of welding directly. Just like the pressure parameters, its selection relates to
such factors as the welding area and the material of the weldment, and the amplitude
of welding head, etc. Generally, too short weld time will lead to insufficient weld
strength, while too long weld time will exert negative effect on the appearance of the
weldment. Actual selection shall be determined by means of testing.
In practical application, the influences of the pressure parameters and the parameters
for weld time on the weldment are a couple of correlative factors. Moderately higher
pressure will shorten the weld time; vice versa, to achieve longer weld time, lower the
pressure appropriately.
V. Precautions for Application
1. User shall not alter welding head at option, or it may change frequency
parameters of transducer system, which will result in damages to transducer
system and ultrasonic power generating system.
2. Never leave both hands under the welding head when the machine is in operation
or is testing ultrasonic sound, to guarantee operating safety for operators!
3. No direct contact is allowed between the welding head and the machine base or
other metal fixtures during operation or test, to ensure safe operation of the
equipment;
4. No start-up or operation of this equipment is allowed before reliable connection to
earth!
5. Start-up or operation is prohibited where high temperature and high dust
environment exist!
6. Stable operational power supply is required while operation beyond the rated
voltage is prohibited!
7. Earplugs are recommended for a long-term operator to avoid injury by noise
KCH Series Hand-type Ultrasonic Plastic Welding Machine
pollution;
8. Proper ventilation facilities should be made available when processing noxious
plastic parts or those with peculiar smell,
9. Stop and check the machine immediately in case any abnormal noise occurs or
transducer system heats to over 50 during operation. Only after returning to℃
normal can the production be continued; If temperature of transducer system is
still on the high side, continuous operation shall only be allowed after cooling it
down. In special situation, forced heat-elimination measures should be taken.
10.If fuse of the machine is blown, a fuse with regulated nominal value should be
adopted. If fuse is blown for several times, the machine should be stopped
immediately for inspection. Only after an error (errors) is located and proper
repairing is conducted can it be put into application;
11.Remove dust from electric cabinet regularly after a long time operation; if
equipment is not used, proper dust cover should be chosen to cover them;
12.If heat emission fan gets blocked from running, stop immediately for inspection.
Continuous use will not be allowed until normal condition is resumed;
13.Special staffs shall be designed for debugging and maintaining the equipment;
14.Please feel free to contact us should any error occurs. No continuous use or
optional alteration is allowed.
15.Press the operational button with both hands for operation. Foot operated switch is
not available for this machine. Any consequences resulting from self-modification
or self-setting shall not be our responsibility.
VI. Troubleshooting for Frequently Asked Questions and
Equipment Maintenance
1. When turning on power switch, power indicator doesn’t light and fan doesn’t run,
and no response is seen to operation, then possible causes are as follows:
a. No electricity for power source, please check to confirm;
b. Bad contact between power line and outlet, please make due repairing;
c. If fuse of equipment power supply is blown, please change fuse with regulated
nominal value.
2. If non-logic action is found, please make inspection as suggested below. Contact
our service staff if it still can’t be solved.
a. Check if connection of logic cable conductor is normal;
b. If control handle is well connected;
3. In the event of unstable logic control, check and handle it as follows. If not
successful, please contact our service department in case of failure.
d. Caused by the interference due to too close distance between the logic wire
and the power output wire.
KCH Series Hand-type Ultrasonic Plastic Welding Machine
e. The logic wire or logic board is in contact with the ground wire, or too close to
the ground wire.
f. The connecting plug-in units of the logic wire are in bad contact.
g. Power supply is impure, with interference factors.
h. Supply voltage fluctuates greatly.
4. Unstable welding quality.
a. Nonuniform shape, dimensions or material quality of the weldment; improper
design of fusion face; improper selection of welder power and amplitude of
welding head.
b. Unstable supply voltage; unstable air pressure of air supply.
c. Occurrence of frequency deviation protection or overload protection during
welding.
d. Unstable outputting of ultrasonic.
e. Because the power output of this welder is adjusted automatically according to
the load, improper adjustment of the limit screw or the moving stroke of the
welding head exceeding allowable stroke of the welder may result in the
reduction of power output.
5. Occurrence of frequency deviation protection during welding.
a. Improper adjustment of frequency. Raise the frequency slightly, to surmount
the influence of frequency rising on the transducer system under the action of
pressure. Ensure stable degree of frequency deviation with slight changes
during welding.
b. Parameters of the components of transducer system are matchless, which is
generally caused by too high natural frequency of the acoustic welding head.
c. Serious heating up of the transducer system.
d. Too high welding pressure.
6. The occurrence of overload protection during welding is mainly caused by higher
load. Generally, lowering the working pressure appropriately can manage. Untight
fixing of acoustic welding head or its rupture from vibration may cause overload
protection as well.
7. Unstable output of ultrasonic, and indication of high load but very faint sense of
ultrasonic vibration are mainly caused by the automatic tracking system falling out
of synchronism, with the following causes:
a. The working frequency deviates seriously, which causes the failure of
frequency tracking.
b. The transducer system is damaged seriously, or the parameters deviate
KCH Series Hand-type Ultrasonic Plastic Welding Machine
seriously.
c. Over high load while starting ultrasonic causes the failure of starting. At this
moment, shorten the delay time to bring the triggering mode under the mode of
advance triggering, or reduce the pressure to lower the starting load.
8. The following cases may be caused by the faults of the transducer system,
especially the acoustic welding head.
a. High no-load current and unstable ultrasonic.
b. Particularly serious heating up of the welding head, and squealing of the
welding head while testing ultrasonic.
c. Constant frequency deviation protection or overload protection; invalid
frequency adjusting.
VII. Special Statement
1. This manual is presented based on Model KCH-800W/28KHz hand-type ultrasonic
welding machine. Part of its framework may not comply with the model you choose.
Therefore, this manual is only for your reference, with your concrete model subject to
the real machine.
2. Weihai Kaer Sonic Power Co., Ltd. reserves the right for interpretation and revision
for this manual. This manual is subject to change without notice.
2010-10-9 Version
Weihai Kaer Sonic Power Co.,Ltd.
Address: No.54, Dalian Road, Torch Hi-Tech Science Park, Weihai city, China
Hotline: 86-631-5690111 Aftersales: 86-631-5623298
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