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Operating Manual

ROTOSONIC V4E

www.nucleus-gmbh.com
 i This operating manual is valid for all machine versions,
models, and subclasses listed in section 2.02.

Reprinting, duplication, as well as translation of NUCLEUS operating manuals

Is only permitted with prior consent of NUCLEUS and citation of proper reference.

–­ Gesellschaft für nucleare Verfahrenstechnik mbH

Gerresheimer Str. 99
40233 Düsseldorf

Duisburger Str. 111

40479 Düsseldorf

2
 Table of Contents

1 Comments about the Manual

2 Safety
2.1 Guidelines...............................................................................................................................................2  -  1
2.2 General safety instructions ..................................................................................................................2  -  1
2.3 Safety symbols.......................................................................................................................................2  -  2
2.4 Owner’s obligations...............................................................................................................................2  -  2
2.5 Operating personnel and specialized personnel.................................................................................2  -  2
2.5.1 Operating personnel..............................................................................................................................2  -  2
2.5.2 Specialized personnel. ...........................................................................................................................2  -  3
2.6 Warnings. ...............................................................................................................................................2  -  3

3 Proper use
3.1 General. ..................................................................................................................................................3  -  1
3.2 Machine versions ..................................................................................................................................3  -  1
3.2.1 Free-arm version.....................................................................................................................................3  -  1
3.2.2 Column versions ....................................................................................................................................3  -  1
3.2.3 Downward-arm version ........................................................................................................................3  -  2
3.2.4 Flatbed version ......................................................................................................................................3  -  2

4 Technical data
4.1 Technical data.........................................................................................................................................4  -  1

5 Disposal of the machine

5.1 Disposal of the machine........................................................................................................................5  -  1

6 Transport, packaging, and storage

6.1 Transport to the customer’s facility......................................................................................................6  -  1
6.2 Transport within the customer’s facilities............................................................................................6  -  1
6.3 Disposal of the packaging.....................................................................................................................6  -  1
6.4 Storage. ..................................................................................................................................................6  -  1

7 Work symbols
7.1 Work symbols.........................................................................................................................................7  -  1

8 Hardware
8.1 Model-dependent components . ..........................................................................................................8  -  1
8.2 Connection / replacing the pedal. ........................................................................................................8  -  1

9 Adjustment
9.2.1 Adjustment instructions.........................................................................................................................9  -  1
9.2.2 Tools, gauges, and other resources.......................................................................................................9  -  1
9.2.3 Replacing the transport roller for the free-arm version and flatbed version ...................................9  -  2
9.1 Replacing the transport roller for the downward-arm version and column version . .....................9  -  3

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Table of Contents

9.2 Relative position of the transport rollers.............................................................................................9  -  4

9.3 Servo eccentric basic position...............................................................................................................9  -  5

10 Maintenance and care

10.1 Daily or weekly inspection: .................................................................................................................10  -  1
10.2 Monthly to quarterly inspection:..........................................................................................................10  -  1
10.3 Cleaning the stainless steel cladding:. .................................................................................................10  -  1

11 Set-up and first start-up

11.1 Set-up......................................................................................................................................................11  -  1
11.2 Initial startup..........................................................................................................................................11  -  2
11.3 Switching the machine on/off. .............................................................................................................11  -  2

12 Software
12.1 Software operation. ..............................................................................................................................12  -  1
12.1.1 Buttons....................................................................................................................................................12  -  1
12.1.2 Text boxes...............................................................................................................................................12  -  1
12.1.3 Numeric entry text boxes.......................................................................................................................12  -  1
12.1.4 Alpha-numeric text boxes......................................................................................................................12  -  1
12.2 The main view........................................................................................................................................12  -  2
12.2.1 The main menu. .....................................................................................................................................12  -  2
12.2.2 Runtime data .........................................................................................................................................12  -  2
12.2.3 Motor control of the transport wheel .................................................................................................12  -  3
12.3 The configuration menu .......................................................................................................................12  -  3
12.3.1 Analyser..................................................................................................................................................12  -  3
12.3.1.1 Recording length. .....................................................................................................................................12  -  3
12.3.1.2 The display length.....................................................................................................................................12  -  4
12.3.1.3 Drive ........................................................................................................................................................12  -  4
12.3.1.4 Return speed/afterrun speed.....................................................................................................................12  -  4
12.3.1.5 Return speed/afterrun speed.....................................................................................................................12  -  4
12.3.1.6 Differential ...............................................................................................................................................12  -  4
12.3.1.7 Minimum speed .......................................................................................................................................12  -  4
12.3.1.8 Acceleration .............................................................................................................................................12  -  5
12.3.1.9 Brake .......................................................................................................................................................12  -  5
12.3.2 Extra functions. ......................................................................................................................................12  -  5
12.3.2.1 Layer detection ........................................................................................................................................12  -  5
12.3.2.2 Runout detection .....................................................................................................................................12  -  5
12.3.2.3 Pressure correction ...................................................................................................................................12  -  6
12.3.2.4 Programmed welding (optional) ...............................................................................................................12  -  6
12.3.2.5 System settings.........................................................................................................................................12  -  6
12.3.2.5.1 Network (optional) ...................................................................................................................................12  -  6
12.3.2.5.2 Remote maintenance (optional) . ..............................................................................................................12  -  7
12.3.2.5.3 Pedal configuration and respective function .............................................................................................12  -  8
12.3.2.5.4 Server (optional) .......................................................................................................................................12  -  9
12.4 The MaterialEditor ................................................................................................................................12  -  9
12.4.1 Loading material templates. .................................................................................................................12  -  9
12.4.2 Editing material templates ...................................................................................................................12  -  10
12.4.2.1 Weld parameters. .....................................................................................................................................12  -  10
12.4.2.1.1 Use the Profile-Editor to set ......................................................................................................................12  -  10
12.4.2.1.2 Drive.........................................................................................................................................................12  -  12
12.4.2.1.2.1 Speed.......................................................................................................................................................12  -  12
12.4.2.1.2.2 Drive-delay ...............................................................................................................................................12  -  12
12.4.2.1.3 Layer detection.........................................................................................................................................12  -  12
12.4.2.1.3.1 Sensitivity .................................................................................................................................................12  -  12
12.4.2.1.3.2 Startup delay. ...........................................................................................................................................12  -  13
12.4.2.1.4 Saving changes of a material profile..........................................................................................................12  -  13
12.4.2.1.4.1 Save as new material profile .....................................................................................................................12  -  13
12.4.2.1.4.2 Saving by overwriting the edited template . ..............................................................................................12  -  13

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 Table of Contents

12.4.3 Creating a new material profile using the material wizard................................................................12  -  14

12.4.4 Close the MaterialEditor........................................................................................................................12  -  15
12.4.5 Transferring material profiles ...............................................................................................................12  -  15
12.5 The Analyser ..........................................................................................................................................12  -  16
12.5.1 Operation. ..............................................................................................................................................12  -  16
12.5.2 Closing the Analyser. .............................................................................................................................12  -  16
12.5.3 Adapting the view. ................................................................................................................................12  -  17
12.6 The QuickMenu .....................................................................................................................................12  -  18
12.7 Tools........................................................................................................................................................12  -  19
12.7.1 Zero-Calibration.....................................................................................................................................12  -  19
12.7.2 Safety-Calibration. .................................................................................................................................12  -  19
12.8 Programmed welding ...........................................................................................................................12  -  20
12.8.1 Open the program editor......................................................................................................................12  -  20
12.8.2 Loading welding programs. ..................................................................................................................12  -  20
12.8.3 Saving welding programs......................................................................................................................12  -  21
12.8.4 Transferring welding programs.............................................................................................................12  -  21
12.8.5 Creating new programs.........................................................................................................................12  -  22
12.8.5.1 Programmed.............................................................................................................................................12  -  22
12.8.5.2 Self-learning/teaching ..............................................................................................................................12  -  22

13 Welding
13.1 Welding principle...................................................................................................................................13  -  1
13.2 Determining welding parameters. .......................................................................................................13  -  1
13.2.1 Welding. .................................................................................................................................................13  -  1
13.2.2 Separation welding................................................................................................................................13  -  3

14 Flow diagram
14.1 Circuit diagrams.....................................................................................................................................14  -  1

5
Comments about the Manual

1. Comments about the Manual

Unless expressly indicated otherwise, the descriptions in this manual refer to the software of your Rotosonic V4E,
and thus can be selected via the touch-sensitive monitor.

Figures showing screenshots of the software are provided frequently in this manual to present the function as
efficiently as possible. These figures contain numbered markings in the format [x/y] that are referred to in the
description. The first number indicates the number of the figure, the second number refers to a marker in this
figure.

Please note that the graphic illustrations in this manual can vary in whole or in part to your machine software,
due to updates for example.
In this case you will always find current manuals on our website (http://www.nucleus-gmbh.com/service/manuals.
html). However in this regard, note that due to the modular design and thus the wide range of customization
possibilities of our machines, deviations can occur between the illustrations of the machine provided in the manual
as examples, and your configuration.
Consequently the version number of the installed software is the deciding criterion for selecting the optimally
suited manual. Section 12 describes how to read the version numbers.

1  -  1
Comments about the Manual

1  -  2
Safety

2. Safety

2.1 Guidelines
The machine has been built in accordance with the European Directives specified in the declaration of conformity or
manufacturer’s declaration.
In addition to this operating manual also into consideration, legal regulations, other regulations and statu-
tory regulations – including those of the owner’s country – and valid environmental protection regulations into
­consideration!
The locally valid regulations issued by the employer’s liability association or other supervisory authorities must
always be taken into consideration.

2.2 General safety ins tructions

• The machine should only be operated by appropriately instructed operating personnel after they have read the
­associated operating manual.

• Warnings and safety instructions affixed to the machine must be complied with!
• Do not operate the machine for any purpose other than its intended purpose, and do not operate the machine
without the associated protective devices; in this regard comply with all applicable safety regulations.
• When changing the anvil wheel, when leaving the workstation, and when performing maintenance work, the
­machine must be disconnected from the power supply by activating the main switch or by unplugging the power
plug.
• Daily maintenance work should only be performed by appropriately instructed personnel.
• Always disconnect the machine from mains supply when performing maintenance or repair work on devices
powered by servo motors! Exceptions are only permitted for adjustment work and function tests performed by
appropriately trained specialized personnel.
• Repair tasks, as well as special maintenance tasks should only be performed by specialized personnel or
appropriately instructed persons.
• Work on electrical systems should only be performed by qualified electricians.
• Do not work on live parts and devices. The EN 50110 regulations govern the exceptions.

• Conversions or modifications of the machine should only be undertaken in compliance with all applicable safety
regulations!

• Only use the spare parts approved by NUCLEUS for repairs! We explicitly state that original spare parts and
accessories not delivered by NUCLEUS have not been tested and approved by NUCLEUS. Consequently
installation / and or use of such products can negatively change design-specified characteristics of the machine.
We assume no liability whatsoever for damage that occurs due to the use of non-original spare parts.

2  -  1
 Safety

2.3 Safety symbols

Danger point!
Points that require special attention.

Danger of crushing hand injuries!

Danger of burn injuries due to hot surface!

Life-threatening danger due to electrical shock.

2.4 Owner’s obligations

• This manual is a component of the machine and must be available to operating personnel at all times.
The operating manual must be read prior to commissioning.
• Operating personnel and specialized personnel must be instructed concerning the protective devices of the machine
as well as in safe work methods.
• The owner is obligated to operate the device only in problem-free condition.
• The owner must ensure that safety devices are not removed or rendered inoperable.
• The owner must ensure that only authorized personnel work on the machine.

2.5 Operating personnel and specialized personnel

2.5.1 Operating personnel

Operating personnel are personnel who are responsible for charging, operating, and cleaning the machine, as well
as for fault correction in the welding area.
Operating personnel are under obligation to comply with the following points:

• The safety instructions specified in the operating manual must be complied with for all tasks!
• Refrain from any manner of work that impairs the safety on the machine!
• Wear tight-fitting clothing. Do not wear jewelry, such as chains and rings!

• Ensure that only authorized persons are in the danger zone of the machine.

• Changes that occur on the machine that impair safety must be reported to the owner immediately!

2  -  2
Safety

2.5.2 Specialized personnel

Specialized personnel are personnel with technical training in the areas of electronics and mechanical engineering.
They are responsible for lubricating, maintaining, repairing, and adjusting the machine.
Specialized personnel are under obligation to comply with the following points:

• The safety instructions specified in the operating manual must be complied with for all tasks!
• The main switch must be switched off and safeguarded against being switched on again prior to starting adjust-
ment tasks and repair tasks.

• Work on live parts and devices is not permitted!

• The EN 50110 regulations govern the exceptions.
• The protective covers must be re-attached after performing repair and maintenance tasks!

2.6 Warnings

A work area of 1m in front of and behind the machine must be kept free so that unobstructed access
is possible at anytime.

Do not operate the free-arm, column, and downward arm versions of the machine without finger
guard 1! Danger of crushing injuries if fingers are caught between transport roller 3 and 4!

Do not operate the flatbed versions of the machine without finger guard 5!
Danger of crushing if fingers are drawn in!

Do not operate the free-arm versions of the machine without cover 2!

Danger of crushing injuries if fingers are caught between transport roller 3 and 4!

Do not grasp transport roller 3 during machine travel!

There is a danger of burn injuries due to the heat generating surface!

When operating ensure that your head is more than 30 cm away from transport roller 3! Danger of
hearing damage due to ultrasonic radiation!

2  -  3
Safety

2  -  4
Proper Use

3. Proper use

3.1 General
All NUCLEUS Rotosonic V4E machines are used to continuously weld thin, thermoplastic materials such as fleece,
felt, fabric, or knitted fabrics via ultrasound. The special application areas of the specific versions are described
below [see section 3.2. Machine versions].

Any use that is not approved by the manufacturer is considered to be improper use!
The manufacturer is not liable for damage due to improper use! Proper use also includes compliance
with the operating, maintenance, adjustment, and repair measures prescribed by the manufacturer!

i All descriptions in this operating manual refer to the free-arm version of the welding machine.
If necessary, reference is made to deviating work steps for the other versions.

3.2 Machine versions

3.2.1 Free-arm version

The free-arm version is used to weld a seam or hem at the

end of sleeves or tubes. In addition, it is particularly suited
for welding bottoms in tubes and containers, as well as for
welding annular seams on hoses.
For the free-arm version the upper transport wheel is the
sonotrode.

3.2.2 Column versions

The column version is particularly well suited for weld-

ing three-dimensional shapes, such as hoods, caps, bags,
etc. With the aid of the column two parts can be joined
together flat, or a part can be welded to a shorter tube.
In this process the part is placed around the column and
then welded from the column out (e.g. the longitudinal
seal of a sleeve or of a filtering bag.
For the column version the upper transport wheel is the
sonotrode.

3  -  1
 Proper Use

3.2.3 Downward-arm version

The downward-arm version is ideal for welding the

longitudinal seam of a sleeve or tube of any length.
For the downward-arm version the upper transport wheel is
the sonotrode.

3.2.4 Flatbed version

The flatbed version is used particularly for welding two flat

parts. This can involve overlap seams, peel seams, topstitch
seams, or hems. The processing possibilities correspond
to the processing possibilities of a typical “rapid-action”
sewing machine.
For the flatbed version the upper transport wheel is the
sonotrode.

3  -  2
Technical Data

4. Technical data

4.1 Technical data

Dimensions and weights:

Depth [mm] Free-arm Flatbed Downward-arm Column

Width [mm] approx. 460 approx. 600 approx. 760 approx. 460

Breite [mm] approx. 740 approx. 925 approx. 740 approx. 740

Height [mm] approx. 1180 approx. 1180 approx. 1180 approx. 1180

Weight [kg] approx. 100 approx. 120 approx. 115 approx. 100

Passage width: 400 mm

Passage under the drive rollers: 25 mm

Line voltage: 230 V ± 10%, 50/60 Hz, phase

Power consumption: 800 VA
Fusing: 1 x 16 A, time lag

Weld pressure: 750 N

Welding power: 400 W
Welding speed (drive dependent):
Standard motor: max. 12 m/min

Seam width: max. 10 mm

Noise specification: LpA < 70 dB(A)1

Emission sound pressure level at the workplace
(Noise measurement in accordance with DIN 45 635-48-A-1, ISO 11204, ISO 3744, ISO 4871)

1 KpA = 2,5 dB

4  -  1
 Disposal of the Machine

5. Disposal of the machine

5.1 Disposal of the machine

• It is the customer’s obligation to properly dispose of the machine.
• The materials used to construct the machine are steel, aluminum, brass, and various plastics.
The electrical equipment is made of plastic and copper.

• The machine must be disposed of in accordance with local applicable environmental protection regulations; it may
be necessary to commission a special company in this regard.

Ensure that parts on which lubricants adhere are disposed of separately in accordance with local
environmental regulations!

5  -  1
Transport, Packaging and Storage

6. Transport, packaging and storage

6.1 Transport to the customer’s facility

The machines are delivered completely packed.

6.2 Transport within the customer’s facilities

The manufacturer assumes no liability for transport within the customer’s facilities or to the specific installation
sites. Ensure that the machines are only transported in vertical position.

6.3 Disposal of the packaging

The packaging of this machine consists of paper, cardboard, and VCE fleece.
It is the customer’s obligation to properly dispose of packaging.

6.4 Storage
If the machine will not be used it can be stored for up to 6 months. After 6 months it should be protected from dirt
and moisture.
For a longer period of machine storage the individual parts, particularly the sliding surfaces, must be safeguarded
against corrosion, e.g. with a film of oil.

6  -  1
 Work symbols

7. Work symbols

7.1 Work symbols

In this manual activities to be executed or important information is emphasized with symbols. The symbols used
have the following meaning:

Note, information

Cleaning & care

Lubrication

Service, repair, adjustment, maintenance (activity that should only be executed

by specialized personnel)

7  -  1
Hardware

8. Hardware

8.1 Model-dependent components

1. Touch screen
????????????
2. On/off switch
??????????? ????????????????? 3. Generator on/off
4. Lever puller left/right

?????????????????????????

Fig: Control elements

3 1. LAN
1 2. Power (cold devices)
3. USB
4 4. Main switch
5. Pedal

5
2

Fig.: Connections (rear of the machine)

8.2 Connection / replacing the pedal

If necessary unplug the mounting of the pedal cable [see Fig. Connections], remove the connected pedal and
­connect the desired pedal. To conclude re-attach the cable with the fixture provided for this purpose.
Note: You must explicitly set the pedal type; see point [12.3.2.5.3] for instructions on how to do this.

8  -  1
 Adjustment

9. Adjustment

9.2.1 Adjustment instructions

All the tasks described below presuppose a completely assembled machine and should only be executed by
­appropriately trained specialized personnel. Machine covers that must be unscrewed and screwed on again for
control and adjustment work are not mentioned in the text.
The sequence of the following sections follows the practical work sequence of a machine that must be completely
adjusted. If only individual work steps are specifically executed then the instructions in the preceding and following
sections must also be complied with.
The screws and nuts cited in parentheses (example: screws (2)) are fastenings of machine parts that must be
­loosened prior to adjustment and re-tightened after adjustment.

If not otherwise specified the machine must be disconnected from the power supply by switching
off on the main switch or by pulling out the power plug. Hazard posed by unintentional machine
startup!

9.2.2 Tools, gauges, and other resources

• 1 set of screwdrivers with blade widths from 2 to 10 mm
• 1 set of screwdrivers with blade widths from 7 to 17 mm
• 1 set of Allen keys from 1.3 mm to 10 mm
• 1 pin wrench for 2-hole nuts for the transport wheel

9  -  1
Adjustment

9.2.3 Replacing the transport roller for the free-arm version and flatbed version

Transport roller 2 must be stored carefully after dismantling!

Any minor damage to the roller will have a negative effect on the welding result!










• Pull off cover 1, (screws (2))

• Hold transport roller 2, loosen transport wheel 3 using the pin wrench for the 2-hole nut, and un-
screw it. With the flatbed version the transport wheel 5 can be arrested in place with the Allen key
(SW 4). To do this, guide the Allen key through the bore of the column from the right and turn the
transport wheel 5, until the Allen key engages.

• Pull off transport roller 2, and put it in a safe place.

• Slide a new transport roller onto the shaft, hold it in place and firmly tighten transport wheel 3.

• Remove the Allen Key and mount cover 1.

• Adjust the position of the transport rollers relative to each other.

•
• Perform the zero calibration / safety calibration as specified in sections 12.7.1 and 12.7.2

9  -  2
 Adjustment

9.1 Replacing the transport roller for the downward-arm version and column version

Transport roller 7 must be stored carefully after dismantling!

Any minor damage to the roller will have a negative effect on the welding result!


  






• Remove screws (2), then take off cover 1. For the “front downward“ version, also remove cover 8.

• Arrest the transport wheel 5 in place using the Allen key (SW 4). To do this, guide the Allen key
through the bore of the arm from the right and turn the transport wheel 5 until the Allen key
engages.

• Loosen the transport wheel 6 via the pin wrench for two-hole nuts, and unscrew it.

• Pull off transport roller 7, and put it in a safe place.

• If necessary vacuum off contamination (lint) in the area around the transport roller.

• Slide a new transport roller onto the shaft, hold it in place and firmly tighten transport wheel 6.

• Remove the Allen key and mount cover 1 (screws (2)).

• Adjust the position of sonotrode 4 relative to transport roller 2 as specified in section 7.4 Adjusting
the relative position of the transport rollers.

9  -  3
Adjustment

9.2 Relative position of the transport rollers



 

The anvil wheel should always be positioned centered and parallel to the sonotrode.
The parallelism adjustment should be executed if possible with a wide anvil wheel (12 mm) and thin welding
deposit (30-40 g/mm²).

• De-energize the machine.

• Slightly loosen both screws (10).

• Use the two set screws (12) to align the incline of the complete anvil wheel arm in such a manner that the anvil
wheel contacts the sonotrode over the full width.

• Then adjust the center position of the anvil wheel with the set screw (6) (turning the screw clockwise = shift to
the right).

• To conclude re-tighten the two screws (10).

• Execute several sample weld seams, if necessary repeat the adjustment.

9  -  4
 Adjustment

9.3 Servo eccentric basic position

 




A readjustment is always necessary if anvil wheels with different diameters are used (standard d=65 mm).

• De-energize the machine

• Dismount the front housing lid

• The anvil wheel (7) must sit on the sonotrode (8).

• Loosen the Allen bolt (4) in the eccentric block

• Turn the servo eccentric shaft (6) into horizontal position, so that the axes of the eccentric shaft (6) and the moun-
ting bore of the eccentric arm (3)
• are horizontally flush.

• Slightly loosen the two screws (5) of the slotted holes and likewise adjust the flattening of the small eccentric (6) in
horizontal position. The eccentric arm (3) should now be vertical.

• In this basic position (as shown in the diagram) first tighten the screw (4) and then the screws (5).

9  -  5
Maintenance and Care

10. Maintenance and care

All moving parts of the Rotosonic V4E are maintenance-free or of low maintenance.
However certain cleaning and maintenance tasks may be necessary depending on the type of implementation,
installation site, and exterior temperature:

10.1 Daily or weekly inspection:

Remove welding residues on the sonotrode and anvil wheel unit with a dry cloth.
Particularly in the lower boom arm of the machine (flatbed version), or in the housings of the free-arm variants,
material remnants, fine fibers, or dust residues can collect that can block the gear motor and drive elements. These
residues must be removed. Vacuuming is better than blowing out, as in this case the contaminants do not settle at
other points.

• Switch off the ultrasound; move sonotrode or anvil column into the upper position.

• Unscrew the cover caps and covers of the free arms (it may be necessary to remove puller wheels and anvil wheels)

• Allow the drive to slowly run forward incrementally and intermittently vacuum off the residual contamination
(attention: Do not pinch the suction nozzle).

• Listen for grinding and blocking noises

10.2 Monthly to quarterly inspection:

• Switch off the main switch or unplug the power supply plug.

• Unscrew the front housing cover (4 small M4 screws), unplug the monitor, and buttons “PC on”, US on” plug-in
connectors.

• Carefully place the housing part with monitor to the side.

• Vacuum out the upper boom, remove any residual contamination, check the eccentric for ease of movement.

• Clean and lightly grease anvil wheel shaft as well as side surfaces of the anvil wheels and puller wheels.

• Open the control cabinet, carefully vacuum off the contaminant residues, check all plug-in connections for
firm seat.

• Clean the filter mats of the cabinet fans.

• Re-mount the housing lid, check the plug-in connections for firm seat.

10.3 Cleaning the stainless steel cladding:

• Clean the housing parts with a soft cloth, do not scratch or abrade.

• If necessary use an off-the-shelf cleaning fluid for stainless steel sheets.

Exercise extreme caution when cleaning the touch screen; only use a soft cleaning cloth, do not use
any scratching or abrasive agents.

10  -  1
 Set-up and first Start up

11. Set-up and first start-up

After unpacking, check the machine for transport damage. If there is damage, notify the transport company and
the responsible NUCLEUS representative.

Only qualified personnel should set-up and commission the machine! Strictly comply with all
­applicable safety guidelines in this regard.

11.1 Set-up
Suitable power supply connections must be available at the set-up site (see section 3 Technical data).

• Slide the machine off of the transport pallet.

• Place the machine at a slight diagonal angle and screw in the feet 1 that are included in the accessories, so that the
machine stands horizontally.

Do not tilt the machine at too much of a diagonal incline!

There is danger of tipping due to the machine’s high center of gravity!

• Connect the plug-in connection 2 of the pedal 3.

5 5. Pedal connection

11  -  1
Set-up and first Start up

11.2 Initial startup

• Check the machine, particularly the electrical lines, for possible damage.
• Thoroughly clean the machine, see section 8, maintenance.
• Connect the machine to the electrical power, in this process have specialists check whether the machine should be
operated with the existing supply voltage and that the machine is properly connected.

If the supply voltage does not agree with the machine specifications do not place the machine in
service under any circumstances.

The machine should only be connected to a grounded socket!

11.3 Switching the machine on/off

• Establish the power supply to the device.
• Switch the device on by briefly pressing the power switch one time.
• The device will start. Wait until the following view is displayed:

• The software is operated exclusively via the touch-sensitive monitor, there are no additional control elements such
as mouse or keyboard.

For a quick introduction to the basic functions of the software, initially the accompanying “Getting Started”
document suffices.

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12. Software

12.1 Software operation

The software is controlled exclusively with the touch-sensitive screen. Therefore you will find the following control
elements:

12.1.1 Buttons

Trigger the button function by simply tapping on the button.

12.1.2 Text boxes

Usually you will find an EDIT button directly next to the text boxes for changing the value of the text boxes.

. Alternatively you can simply tap the text box.

In this case an appropriate screen keyboard will be displayed depending on the type of text box.

12.1.3 Numeric entry text boxes

Use this keypad to enter numeric values. Confirm your selection by pressing [OK]. The keypad will be hidden and
the value will be transferred to the box.

12.1.4 Alpha-numeric text boxes

In this case you will see the name and the description of the text box, as well as the text that you have typed, above

the keyboard. After you have concluded your entry, simply close the keyboard with

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12.2 The main view

After the machine starts you will see the following view:

Fig. 1: The main view

12.2.1 The main menu

Is shown on the lower edge of the screen [see Fig.1]:

Fig. 2: The main menu

This menu is visible if you are not in the MaterialEditor or the configuration.

12.2.2 Runtime data

Starting point: Main view

In the center, large area of the main view, the runtime data is displayed analog so that it can be more quickly
understood. In addition you will also find the exact value below each representation. The following values are
displayed:

• Power [Fig.1, 1 ]
The power displayed here corresponds to the thermal output given off to the material in watt.

• Amplitude [Fig.1, 2 ]
Amplitude of the sonotrode in percent; insufficient amplitude and excessive amplitude have negative effects on
fusion, as in these cases the power can no longer be adequately controlled. [ --> autom. pressure control]

• Pressure [Fig.1, 3 ]
Shows the pressure exerted by the machine on the processed material, in percent. Values that are too low can have
a negative effect on the welding result.

• Speed [Fig.1, 4 ]
Indicates the speed in meters/minute with which the material is directed past the sonotrode.

• Position [Fig.1, 5 ]
The position of the arm in micrometers, where 0 µm corresponds to the highest possible position.

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12.2.3 Motor control of the transport wheel

Starting point: Main view

Here you can quickly intervene in the running behavior of the transport wheel:

• With switch [Fig. 1, 6 ] you switch the running speed over to a constant / uniform speed, so that it
makes no difference how far the pedal is depressed. In this process the speed corresponds to the maximum speed
set in the MaterialEditor.

• The switch [Fig.1, 7 ] reverses the direction of transport wheel travel.

The same applies for both switches: If the respective function is activated, the system indicates that the function is
activated by displaying the button as depressed.
Both functions can be used independently of each other.

12.3 The configuration menu

Starting point: Main view

In the main menu [Fig.1, 8 ] click on [Fig.2, 5 ], to go to the configuration menu:

Fig. 7: Configuration menu

The specific menu items are explained below.

12.3.1 Analyser

Starting point: Main view >

Fig. 8: Analyser configuration

This is where you set the times for recording length [Fig. 8, 1 ] and display length [Fig. 8, 2 ] of the Analyser:

12.3.1.1 Recording length

[Fig.8, 1 ] is the period (in seconds) that can be considered in the Analyser after the event. The default setting is

120 seconds. To change this setting press . See also: [The Analyser].

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12.3.1.2 The display length

[Fig.8, 2 ] is the period that is provided in the Analyser for direct view, i.e. on a screen width. Increasing this value
increases clarity, reducing the display length

Increases the resolution, and thus the precision (of the view). To make changes touch .
See also: [The Analyser].

12.3.1.3 Drive

Starting point: Main view > (Fig.2, 5 )

Fig. 9: Drive settings

Basic settings can be made for the drive here, these settings are described in more detail below:

12.3.1.4 Return speed/afterrun speed

[Fig.9, 1 ] Use this parameter to determine the speed with which the system will reset to avoid gaps between
interrupted welding processes.

12.3.1.5 Return speed/afterrun speed

[Fig.9, 2 ] Determines the length that the system runs back (negative value) or overtravel (positive value) after
­stopping.

12.3.1.6 Differential

[Fig.9, 3 ] Use this parameter to set the running speed of the transport wheel relative to the speed of the
sonotrode. You can enter values ranging from –100­ % to +100 % for this setting. 0 % corresponds to the identical
speed; negative values cause a slower running speed, positive values cause a faster running speed of the transport
wheel (the faster speed always corresponds to the set maximum value [of the MaterialEditor].

12.3.1.7 Minimum speed

[Fig.9, 4 ] This is where you specify the minimum speed with which the transport wheel will run in each case
(naturally only if the pedal is activated). This setting also overwrites the settings made in the MaterialEditor (except
the maximum speed).

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12.3.1.8 Acceleration

[Fig.9, 5 ] The lower this value the slower the machine moves, and vice versa.

12.3.1.9 Brake

[Fig.9, 6 ] The lower this value the slower the machine brakes, and vice versa.

12.3.2 Extra functions

Starting point: Main view > [Fig.2 5 ]

Fig. 11: Extra functions

Here additional functions that are not mandatory for operation can be activated or deactivated as needed.
Switched off functions are indicated by the lettering „Off“ and by the absence of a check mark.

12.3.2.1 Layer detection

[Abb.11, 1 ] The ROTOSONIC V4E series has an automatic layer detection feature.
This means that the machine automatically detects whether an additional layer of material has been added or
whether one material layer less must be welded. To implement a change in power or force after a layer jump,
the appropriate dependency must be set up in the Profile Editor (section 11.4.2.1.1).

12.3.2.2 Runout detection

[Fig.11, 2 ] Automatically detects that there is no material between sonotrode and anvil wheel, and switches off
the ultrasound.

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12.3.2.3 Pressure correction

[Fig.11, 3 ] To ensure constant power the amplitude must be in a range that can be controlled. If there is exces-
sive amplitude this is regulated by more pressure, if there is insufficient amplitude this is regulated by less pressure
with this function. This readjustment is executed in temporal increments. Thus it may take several seconds until the
correct value is reached. If you are working with a welding profile this function can have a negative effect, and it
should not be used because it changes the profile.

12.3.2.4 Programmed welding (optional)

[Fig.11, 4 ] Switch on this function to make the appropriate functionality available in the main menu.

12.3.2.5 System settings

Fig. 12: System settings

In the upper right you will first see the version information [Fig. 12, 1 ] that is important for support and service.
Now we will discuss the sub-items of the system configuration that are displayed in the left area, in more detail
below:

12.3.2.5.1 Network (optional)

[Fig.12, 2 ]
Starting point:

Main view > > [Fig.7, 4 ]

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Fig. 13: Network settings

Unfortunately at this point the manual cannot provide any detailed information because we are not aware of your
specific network configuration. We recommend that you make these settings in consultation with your
network administrator.

12.3.2.5.2 Remote maintenance (optional)

[Fig.12, 3 ]

Main view > > [Fig.7, 4 ]

Fig. 14: Remote maintenance

After consultation, simply click on to establish a support connection. The online status displayed in

[Fig. 14, 1 ] should change to “online”. After concluding the maintenance session simply click on .

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Note: Remote maintenance is only possible if you have made the necessary settings (as described under point
[Network]), if these settings are valid, and if an Internet connection exists through the network (gateway, DNS). In
addition the following ports must be released in your firewall:
• TPC port: 1723
• IP port: 47

12.3.2.5.3 Pedal configuration and respective function

[Fig.12, 4 ] Here you specify the pedal you have connected so that the software can appropriately regulate the
functions. To do this simply click on the appropriate switch:

Right: Lift/lower – upper, lower position,

(no contact)

Left: Press/lift – pressing position, lower position

Center: Drive

Left (long): Lift/lower – upper, lower position,

(no contact)

Left (short): Press/lift – pressing position,

lower position

Right: Drive

Comb (short) Press/lift – pressing position,

lower position

Comb (long): Lift/lower – upper, lower position,

(no contact)

Press upward: Drive

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12.3.2.5.4 Server (optional)

[Fig.12, 5 ]

These settings serve as the basis for the network-based distribution of material profiles and welding programs
described in the section [Transfer]. We recommend that you make these settings in consultation with your
administrator.

12.4 The MaterialEditor

[Fig. 2, 1 ] Use this dialog to adjust the processing profiles of the material. To do this,

touch the switch and the system will display the following view:

Fig. 3: MaterialEditor

Since for the most part these values are based on customer experience we recommend using one of the material
templates to begin with, and then adapting it to your needs. The manual will now follow the sequence Load, Edit,
Save, (which is opposite of the arrangement of the switches in the menu) and will then explain how you (using the
wizard) can create a new (empty) profile.

12.4.1 Loading material templates

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Starting point: Main view > [Fig.2, 1 ] Press the switch [Fig.3, 1 ]. The system
will then ask you to select the template that will be loaded:

Fig. 4: Loading a profile

In the upper area [Fig. 4, 1 ] select the desired template by simply tapping on it so that it has a blue background.

Then confirm your selection with , or you can cancel the process with at any time.

12.4.2 Editing material templates

Starting point: Main view > [Fig.2, 1 ]

As you can see in Fig. 3 the adaptations of your Rotosonic V4E to the material used are divided into the three areas
“Weld parameters”, “Drive”, and “Layer detection”, as these parameters can vary with each material.

12.4.2.1 Weld parameters

Starting point: Main view > [Fig.2, 1 ]

You can specify the weld parameters on the basis of power or pressure.
To do this, you have the possibility of defining power depending on pressure, position, and/or speed. In a similar
manner pressure is defined depending on position, power, and/or speed.

In this regard the procedure is quite similar in each case, and it is now explained for the dependence of power on
speed, as an example:

12.4.2.1.1 Use the Profile-Editor to set

for the example “Dependence of power on speed”

Starting point: Main view > [Fig.2, 1 ]

Tap the switch [Fig.3, 3 ]. This opens the Profile Editor:

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Fig. 6: The Profile Editor

To the left you will see the reference points [Fig. 6, 1 ] contained in the profile, In the middle you will see the
function graphs that the Rotosonic calculates from these reference points [Fig. 6, 2 ]. In between there is a button
for adding a new reference point [Fig.6, 3 ] and for deleting [Fig.6, 4 ] an existing reference point.

The dependent force (in this case power) is transferred to the Y-axis, the determining force is transferred to the
X-axis.

First select the value on which power will be dependent, by tapping on the right side. In this case this is speed

[Fig.6, 5 ].
Then specify the base value for power.

To do this, tap on [Fig.6, 6 ]. Now a screen keyboard will be displayed with which you can make the

entry. Conclude the entry in this screen with .

Add a new reference point by tapping on [Fig.6, 3 ]. This reference point is now automatically marked for
modification. The software inserts initial values for this point, which are directly next to the previous point, or if

this is the first point, at (0/0). Change the values of the point by entering the desired values in the fields

[Fig.6, 7 ] and [Fig.6, 8 ].

Important: After entering the values, they will not be transferred until after you have confirmed your entries by

tapping on [Fig.6, 9 ].

Now follow the same procedure to add additional points in the profile. Because the program automatically
­interpolates the free space between the reference points you have entered, it usually suffices to limit yourself to
a start point, an intermediate point, and an end point. However any number of intermediate values can be entered,
should it be necessary.

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When you have achieved the desired result check whether an “x” is displayed next to the speed icon .
If this is the case, then although you have defined a dependence, it is not active. To activate the dependence tap on

in the lower right. The speed icon should now have a green check mark .
To conclude save your settings on the profile by activating [Fig.6, 10 ].

12.4.2.1.2 Drive

Starting point: Main view > [Fig.2, 1 ]

12.4.2.1.2.1 Speed
This is where you define the appropriate maximum speed for this material

• For dynamic transport: Max. speed with pedal pressed all the way down
• For constant transport: Max. speed regardless of pedal position

12.4.2.1.2.2 Drive-delay

Press the appropriate button [Fig. 3, 5 ] to enter the drive speed in 1/100th of a second increments.
This makes it possible to prevent the welding deposit from not being strongly enough connected when approach-
ing, as the US starts immediately, drive however starts with delay.

12.4.2.1.3 Layer detection

The ROTOSONIC V4E series has an automatic layer jump detection feature. This means that the machine automati-
cally detects whether an additional layer of material has been added or whether one material layer less must be
welded. To implement a change in power or force after a layer jump, the appropriate dependence must be set up
in the Profile Editor (section 12.4.2.1.1).

12.4.2.1.3.1 Sensitivity
This factor depends on the density and thickness of the material and must be determined empirically. In this regard
the smaller the value, the more sensitive the layer detection reaction (the prerequisite is that this additional function
must be activated [Configuration -> Layer Detection])

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12.4.2.1.3.2 Startup delay

Regulates the time in 1/100th of a second increments from weld begin after which layer detection is activated.
(In this case an appropriate value is 10) The reasons for this are provided below:

• Start without material between sonotrode and anvil wheel:

When introducing the material, layer 1 was already detected as layer 2.

• Start with material between sonotrode and anvil wheel:

Reduction of material thickness at welding begin would cause the system to detect a jump from 2 layers to one
layer, for example.

12.4.2.1.4 Saving changes of a material profile

Starting point: Main view > [Fig.2, 1 ]

You have two possibilities for saving your changes:

12.4.2.1.4.1 Save as new material profile

Press the switch [Fig.3, 2 ]. The system will ask you for the name of the new profile, and
a description (optional) of the new profile. You can now conveniently enter the information via the screen keyboard
that will be displayed.

For subsequent activation tap on . You will now see on the header of the dialog [3/0] that the settings
have been saved under the new name. You are now processing a new material profile and can thus exit the
MaterialEditor without danger as described in the following paragraph.

12.4.2.1.4.2 Saving by overwriting the edited template

You can only close the MaterialEditor with the switch. When doing so all changes will be
transferred into this material profile.

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12.4.3 Creating a new material profile using the material wizard

Starting point: Main view > [Fig.2, 1 ]

Tap on to start the wizard.

The wizard is comprised of 3 recurring steps, each of which is used to set a reference point:

Please place material that is at least 40 cm long be-

tween the anvil wheel and sonotrode.

Use the „Lower button“ to lower the pressing unit,

if you then subsequently activate the „Press“ button
then the arm will move into welding position. (Alter-
natively you can also use the pedal)

Then press on „Next“.

Now enter the lowest speed at which you want to

weld. If you only want to traverse with a constant
speed then enter this speed. In addition you must
specify the power with which your material will be
welded. In this regard we recommend starting with
the default values and then slowly approaching the
desired welding result. At any time you can start the
welding process with the pedal. During this proc-
ess the system will display the actual amplitude and
actual power. Ensure that the amplitude is in a range
that can be regulated [>50 % & <100 %] (see section
10 Welding). You can switch on the automatic pres-
sure correction feature for support. As soon as you
have found the correct parameters for the set speed,
tap on “Next”.

Now enter the next speed at which you want to weld.

In addition, determine the other required welding

parameters empirically.

Press on „Next“ if you want to add parameters for an

additional speed.

Press on „Finish“ if you want to save your settings in

a new material and exit the wizard.

Repeat steps 1-3 any number of times to generate your new material profile; close with .

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12.4.4 Close the MaterialEditor

Closes the MaterialEditor. All parameters will be saved automatically in the actual material (old values will be
overwritten).

12.4.5 Transferring material profiles

Starting point: Main view > [Fig.2, 1 ]

To do this tap on [Fig.3, 9 ]. Now you will see different methods for transferring material profiles:

Please note in this regard that the two server-supported methods, described below, are only available if you have
made the appropriate settings in the configuration. In this regard see: [12.3.1].

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12.5 The Analyser

Starting point: Main view > [Fig.2, 2 ]

The Analyser enables you to display the runtime data that is also visible in the main view, and to adapt it to your
requirements. This means that you do not need to display all the data; you can select the data to suit your needs.
The data is shown live in graph form, and you can specify a different color for each graph, line thickness, as well as
the value range that will be displayed. We will now explain this in more detail.
Note: You can change the displayed time interval and the recording length in the configuration - [11.3.1]

12.5.1 Operation
The recording length can be greater than then the displayed interval. Move the view to the left to display data that
is no longer visible. To do this, simply move your finger from left to right over the view. Or from right to left if you
want to return to the actual range.

12.5.2 Closing the Analyser

The Analyser covers the main view. To return to the main view, tap again on the Analyser button.

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12.5.3 Adapting the view

In the top of the Analyser press the button and the following setting possibilities will be displayed:

Now you see the available graphs, the current line color, and whether they are visible.

To activate a graph simply place a check mark for , as shown in the Fig. above for Pressure, for example.

As previously mentioned you also still have the possibility of changing the line display of each graph. To do this,

click on the respective Edit button .

A dialog will be displayed where you can make settings for the respective graph:

If this has a green/yellow background you can specify the value range of the graph via minimum and maximum,
the line thickness (in pixels), and the line color by tapping on A selection window will be displayed:

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Simply press on the desired color. The selection is indicated by a marker in the color field (in this case green,

for example). Confirm the color selection with .

After completing the graph settings, confirm, as in the preceding dialog, also with , which will return
you to the Graph Editor.
Note: Changing the settings of a graph will not make it automatically visible if it was previously hidden. You must

first set it to as shown above.

12.6 The QuickMenu

Starting point: Main view > [Fig.2, 2 ]

Press the switch. The following window will be displayed:

Press the respective text box to quickly adjust the power (basic value), the pressure (basic value), and the speed
during the work. Your changes will be transferred directly into the material profile. Thus explicit save is not
necessary. This function is quite useful if you want to quickly trial-weld materials at constant speed. A complete
profile is recommended for production.

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12.7 Tools
Starting point: Main view see Fig.1

Press the switch [Fig.2, 4 ]. The following window will be displayed:

12.7.1 Zero-Calibration
The zero point is the position at which the anvil wheel barely touches the
sonotrode. In order for the machine to work properly, after each change
of the anvil wheel, or after each adjustment the zero point needs to be
re-calibrated. To do this the lowering unit is de-energized and thus can be
placed on the sonotrode, (note the warnings on the monitor).
You can then confirm the zero position with „OK“.

12.7.2 Safety-Calibration
The Rotosonic V4E has a safety mechanism that monitors the lowering of
the anvil wheel from the upper position.
If an obstacle, such as a hand, is in between then the arm will move
upward immediately (please note that danger of injury is still present).

In order for this mechanism to function faultlessly after each “zero-

calibration”, a „safety-calibration“ must be executed.

In this regard a lowering is analyzed one time, and there should be no

obstacle under the anvil wheel (please note the safety instructions on the
monitor). To execute the calibration follow the instructions in the menu
provided for this purpose.

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12.8 Programmed welding

If you have not already done so, first activate the additional function “Programmed welding” in the settings. In the
main view as well as in the Analyser note in the lower area the toolbar for programmed welding:

12.8.1 Open the program editor

Starting point: Start view, see Fig. 1

To change the program, to create a new program, to load or transfer an existing program, first tap on

, to start it.

12.8.2 Loading welding programs

Starting point: Start view, see Fig. 1,

Tap on , to open a dialog in which you will be requested to select an existing program:

The list shows the program names as well as the assigned description. Tap on the desired program so that it is

displayed with a blue background. Then confirm your selection with .

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12.8.3 Saving welding programs.

Starting point: Start view, see Fig. 1,

Tap on . The system will now ask you to enter the name and description of the program:

The description is optional in this case. For activation tap .

12.8.4 Transferring welding programs

Starting point: Start view, see Fig. 1,

Tap on . The system will ask you to select the transfer method:

Select the method; you will then see a list of programs on the respective source:

Using the same procedure used when opening programs, select the desired program and confirm your selection

with .

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If there is already a program with the same name on the destination, then the system will ask you to decide
whether this program should be overwritten:

If you do not want to overwrite the file, you can now do the following:
Open the appropriate program on the machine and save it under a different name that is not yet in use, to avoid
conflicts.

12.8.5 Creating new programs

Starting point: Start view, see Fig. 1,

Save the current program under a new name, and then remove any existing program steps with the
button. You will then have the possibility to add individual steps to the program or teach the machine.

12.8.5.1 Programmed

Recurring welding sequences (path length, speed) can be programmed to ensure faster, more effective work.
All welding parameters are based on the stored material profiles. You have the possibility of inserting new steps
into an existing program, or deleting existing steps.
To selectively delete a specific step, select the step, by tapping the associated select button (far right)

And then tap below on .

Add new steps to the end of the list with .

In this process this step will be selected automatically.

As shown above, you can now set the length, the speed, the pressure, and the force with which the system will

work. In addition you can specify whether the arm will be raised after concluding the step or not: .

After concluding the entries, save the profile or exit the Program-Editor with the switch; the
changes will be saved under the current program.

12.8.5.2 Self-learning/teaching
In order to program welding sequences that are even more dynamic, manual welding can be recorded at variable
speed. Thus even with complicated welding processes 100% repeat accuracy is guaranteed.

Starting point: Start view, see Fig. 1,

To start the teaching process tap below on the button.

The Program-Editor will be closed and you will return to the main view. The flashing text in the upper right

­indicates active recording .

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Here it is also possible to end the recording by tapping on “Stop”.

Now teach the program and then stop the recording. The Program-Editor will now open, and you will see program

that you have taught. Save this program, or exit the Program-Editor with the switch and the
changes will be saved under the current program.

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13. Welding

Only appropriately trained personnel should operate the machine. Operating

personnel should also ensure that only authorized persons are positioned in the
danger zone of the machine.

13.1 Welding principle

With the ultrasonic process the electrical vibrations generated by the ultrasonic generator are transformed into
mechanical vibrations of the sonotrode.

Under the influence of pressure and temperature the material to be welded is heated. It is heated up to reaches the
elastic-plastic threshold and is simultaneously transported.

To obtain an optimal welding result, certain prerequisites must be in place for the materials that will be processed.

The material that will be processed must

• Be weldable (thermoplast),
• Thickness and condition must be suitable for processing on the NUCLEUS Rotosonic V4E,
• Should not have any contamination in the seam area.

The basic requirement on the machine side is

• Proper selection of the anvil wheel,

as well as the
• Proper setting of: contact pressure,
welding energy,
welding speed.

INFO:
All settings of the welding machine are dependent on the specific characteristics of the welding deposit.
Optimal values must be determined by experimental-welds.

13.2 Determining welding parameters

To determine the correct welding parameters you must first decide between separation welding and pure overlap
welding (for overlap welding go to section 13.2.2).

13.2.1 Welding

When welding there are basically three adjustable parameters - power (watt), contact pressure (display in % of
maximum), and speed (m/min).

The greater the speed, the more power is required.

Power, in turn, is determined by 2 values – the set pressure and the amplitude, which is automatically regulated.

Automatic power control:

The NUCLEUS Rotosonic V4E series is factory-equipped with a real-time power control. This regulation makes it
possible to compensate for mechanically and physically occasioned fluctuations in the application of welding energy
between sonotrode and anvil wheel. In this process, constant power is realized by increasing or decreasing the
amplitude. The prerequisite in this regard is that the amplitude must be in the control range of >50 % and <100 %,
and not on minimum or maximum.

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Example (fictive parameters):

Set values:
Power: 40 watt
Pressure: 2%
Speed: 3 m/min

If you now start the welding process you will note that actual power of only 20 watt is shown as an example (link
main menu and Analyser) and the amplitude constant is on 100 % [see Fig. 15].

Explanation:
The machine attempts to reach the set power of 40 watt (by increasing amplitude), however it does not reach this
level because it is not possible to reach the desired welding power with the set pressure.

Solution:
Increase the pressure to a value at which the desired power can be achieved and the amplitude reaches the control
range (optimally: amplitude between 60 % and 90 %) [see Fig. 16].

Fig. 15

Fig. 16
Tip:
If you operate with a constant speed and do not use profiles, you can switch on automatic pressure correction,
under Configuration->Additional Functions (section 12.3.2.3), which automatically adapts the pressure as soon as it
drops out of the control range.

If you want to work dynamically with different speeds, then you must create a profile in the MaterialEditor. This can
be done manually (link to Profile Editor) or via the standard installed “wizard” (here link to wizard). In this regard
through a function suitable power will then be set for each speed.

Depending on the material it may be the case that other welding results occur at the same power setting but
different contact pressure (i.e. with more or less amplitude). This is primarily possible with extremely solid and
strong materials, and the setting must be determined empirically.

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Welding

13.2.2 Separation welding

The prerequisite in this case is that your Rotosonic V4E must be fitted with a hard-
ened cutting sonotrode or with the C|W package. If this is not the case then the
sonotrode will be damaged and guarantee claim is void.

Only use NUCLEUS C|W anvil wheels. If you use other anvil wheels the guarantee
claim is void because damage to the sonotrode cannot be excluded.

With separation welding constant power is not necessary because power is only applied on a very thin stay.

Basically – depending on material thickness – you need relatively high contact pressure (>35 %) to separate the
material.

Always start with low values and increase pressure and power step-by-step until you have reached your desired
welding result. To protect the running surface of the cutting electrode, you should only use the minimum necessary
contact pressure.

13  -  3
 Flow Diagram

14. Flow diagram

14.1 Circuit diagrams

14  -  1
Flow Diagram

14  -  2
Flow Diagram

14  -  3