King Ultrasonic CO KWL3215 User manual

KWL3215
KWL4215
King Ultrasonic CO., LTD.
Ultrasonic Plastic Welder
User’s Manual

1
Safety Notes
1. The machine should be installed on a firm, flat surface.
2. The earth wires of the machine should be securely connected.
3. Do not modify any parts or lines of the machine without the
consent of King Supersonic Co., Ltd.
4. Do not use accessories that are not supplied by King
Supersonic Co., Ltd.
5. Do not push any button that should be pressed by both hands
with a toothpick or sharp-edged object for convenience.
6. Do not install footswitches without the consent of King
Supersonic Co., Ltd. to avoid danger.
7. Operating the machine by more than two people is strictly
forbidden.
8. Check screws in each section of the machine each month for
tightness.
9. Air-pressure hoses should be checked every three months. If
any brittleness or abnormality is founded, the hoses should be
replaced immediately to avoid danger. (It is recommended to
place all pipes once per year.)
10. During operation, do not lift the covers of the electronics box
or control box and cylinder to prevent high-voltage injury.
11. During operation, both hands should be placed around the
button and kept away from mold to avoid injury.

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Table of Contents
I. Specifications
II. Component Description
(1) Component Position
(2) Name and Function of Body Components:
(3) Air Circuit Diagram
III. Operation Guidelines:
(1) Notes:
(2) Operating Principles:
(3) Mechanism Principles:
(4) Installation Procedures:
(5) Mold Adjustment Procedure
(6) Ultrasonic Welding Steps
Basic Steps for Using Ultrasonic Plastic Welder of King Ultrasonic CO., LTD.
IV. Circuit Diagram
V. Welding Problems and Solutions

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I. Specifications
Model Frequency Power Welding
Capability
Compressed
Air
Dimension Power Source Weight
KWL-3215 15KHz 3200W
ψ220m/m 9KG/cm2750*990*2060 220V/15A3P 300KG
KWL-4215 15KHz 4200W
ψ250m/m 9KG/cm2750*990*2060 220V/20A3P 300KG
II. Component Description
(1) Component Position
(A) Position of Body Components
1. Triplet Set 2. Fixed Handle 3. Rise Buffer Adjusting
Screw
4. Drop Buffer Adjusting
Screw 5. Vibrating Cylinder 6. Stopper Screw
7. Spacer 8. Welding Head 9. Large Column
10. Base Plate 11. Pressure Gauge 12. Pressure Governor
13. Delay-on Timer 14. Welding Timer 15. Curing timer
16. Selector Switch 17. Counter 18. Rise Governor
19. Drop Governor 20. Hand Wheel For Height
Adjustment 21. Fixed Screw
22. Operator Push Buttons 23. Emergency Rise Button 32. Iron Male Connector
(B) Position of Electric Components
24. Power Switch 25. Amplitude Gauge 26. Overload Indicator
27. Power Indicator 28. Amplitude Adjusting
Button 29. Electrical Box
30. Earth Wire Socket 31. Power Cord
(2) Name and Function of Body Components:
1. Triplet Set:
A 5/16” air pressure hose is connected to a dry and clean air source to provide the
machine with compressed air.
Note: When the inside of the hose is half full of water, rotate the button
anti-clockwise on the bottom of the cup to drain the water. The operation and life of
the air pressure parts will be adversely affected by bad compressed air. For example,
the governor may produce noise, or the solenoid valve may be blocked and therefore
can’t work…etc.
2. Fixed handle:
Secure the body onto the large column.
3. Rise BufferAdjusting Screw:
Adjust the rise buffer rate of the welding head (at the point 14mm from the end of
the rise stroke). Rotate it clockwise to increase the buffer rate or rotate it
anti-clockwise to decrease the buffer rate.

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4. Drop BufferAdjusting Screw:
Adjust the drop buffer rate of the welding head (at the point 24mm from the end of
the drop stroke). Rotate it clockwise to increase the buffer rate or rotate it
anti-clockwise to decrease the buffer rate.
5. Vibrating Cylinder:
Accommodate and secure the oscillator and spacer to connect the welding head. The
vibrating cylinder is driven by an air cylinder. After the fixed screws are loosened,
the direction of the spacer and welding head can be changed.
6. Stopper Screw:
When welding, it is used to fine tune the drop of the welding head and adjust the
welding depth of the work-piece. When there is no work-piece on the base, it can
prevent the welding head from touching the base and causing damage.
7. Spacer:
Connect and secure the oscillator and welding head. The magnified amplitude of the
oscillator is delivered to the top of the welding head via the spacer.
8. Welding Head:
Ultrasonic wave energy is delivered to the work-piece via the welding head. In
general, the welding head has approx. 1/2 wavelength and the material has good
acoustic property and tensile strength. Residual oxides are easily left on the
work-piece when using the welding head made of aluminum alloy. However, this
problem can be solved with hard chromium or heatproof plastic film.
Note: The welding head should not be modified without prior consent. The spacer or
electrical component could be damaged if the resonance frequency is changed
inappropriately.
9. Large Column:
Located behind the base plate to support the body.
10. Base Plate:
A workbench with 17 screw holes (M8P1.25) for securing.
11. Pressure Gauge:
Indicate the pressure of the air source.
12. Pressure Governor:
Adjust the air-source pressure entering the air cylinder.
Note: Before adjusting, pull the red collar out. After the adjustment is completed,
push it in to lock.
13. Delay-on Timer:
The time from the drop of the vibrating cylinder to transmission of the ultrasonic
wave. The ultrasonic transmission is usually set to start at the time when the welding
head touches the work-piece to match with the drop rate of the vibrating cylinder and
meet the buffer requirement.

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14. Welding timer:
The time during which the ultrasonic wave is transmitting.
15. Curing Timer:
The time from stopping the ultrasonic transmission to when the vibrating cylinder
rises. During this time, the plastic is curing from its molten state with the pressure
being exerted on the work-piece.
16. Selector Switch:
a. Manual Operation:
When the operator presses two push buttons simultaneously with two hands, the
welding head drops together with the vibrating cylinder and remains at the drop
position. The welding head will rise together with the vibrating cylinder when
the emergency rise button is pushed.
b. Automatic Timing Operation:
When the operator presses two push buttons simultaneously with two hands, the
delay-on, melting, and curing timing operations will be carried out automatically.
c. Sonic Wave Inspection: Check if the ultrasonic wave is transmitted appropriately.
Note: Remember that the knob should not be set to the ultrasonic wave
inspection position when the power cord is unplugged.
17. Counter:
Record the operating times of the work-piece. Press the black button to zero the
counter.
18. Rise Governor:
Rotate it anti-clockwise to increase the rise speed or rotate it clockwise to decrease
the rise speed of the vibrating cylinder.
Note: The nut between knobs is used to lock the governor and should be tightened
after adjustment.
19. Drop Governor:
Rotate it anti-clockwise to increase the drop speed or rotate it clockwise to decrease
the drop speed of the vibrating cylinder.
Note: Refer to 18.
20. Hand Wheel:
After loosening two fixed handles and rotating the hand wheel, the body will rise or
drop alongside the large column to adjust the height of the welding head.
21. Fixed Screw:
After the four fixed screws are loosened, the welding head can be rotated and
tightened after being aligned with the direction of the work-piece.
22. Operator Push Buttons:
When two operator push buttons are pressed with both hands, the system operates in
accordance with the setting of the selector switch.
Note: Do not push one button with a toothpick or sharp-edged object for

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convenience.
23. Emergency Rise Button:
Upon pushing this button at any time, the ultrasonic transmission stops and the
vibrating cylinder returns to its original position immediately.
24. Power Switch:
Upon turning on this switch, the machine will be energized, indicators will light up,
and fans will run.
25. Amplitude Gauge:
It indicates the resonance level of the welding head when no load is exerted
(depending on the welding head and output level, the resonance is usually between
2.0~2.5) and indicates the level of the input power when the load is exerted
(depending on the work).
26. Overload Indicator:
It lights up and the operation stops when the ultrasonic oscillator of the machine
operates abnormally.
27. Power Indicator:
Indicate whether power is on or off.
28. AmplitudeAdjusting Button:
Select the appropriate output amplitude for the welding head to meet the
requirements of the work-piece.
29. Electrical Box:
Accommodate the air pressure, electrical control, and oscillating parts.
30. Earth Wire Socket: Refer to the “Correct Grounding Method” section.
Grounding is required to prevent leakage of current caused by electrostatic charge.
Correct grounding of the equipment and system is the prerequisite to ensure normal
operation of the production equipment. Always carry out the grounding in
accordance with (3).

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(1) Wrong Grounding
(2) Wrong Grounding
31. Power Cord:
AC220V three phase (3P).
32. Iron Male Connector:
Air pressure is delivered to the connector.
Ground Equipment A Equipment B
Ultrasonic Equipment C
Equipment A Equipment B Ultrasonic Equipment C
Ground
Ground
Equipment A
Equipment B
Ultrasonic Equipment C

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Position of Components
3
4
5
1
8
1
9
7
8
2
5
1
6
1
5
14
1
3
2
0
11
12
2
6
2
7
24
1
7
3
1
22
2
3
22
Position of Components
1
0
Position of Components

9
2
9
2
1
22
2
3
22
6
Position of Components