I. Operational Environment and Safety Preparations
1. Clear the worktable; remove debris, metal filings, and flammable solvents. Ensure adequate space around the equipment for heat dissipation and keep it away from water sources, corrosive gases, and strong electromagnetic interference.
2. Verify that the ambient temperature is between 0°C and 40°C with no condensation; for high-power models, ensure ventilation and heat dissipation channels are unobstructed.
3. Check that the emergency stop button and safety guards/light curtains are functioning correctly; do not bypass safety interlocks.
4. Operators must wear safety goggles and earplugs; avoid wearing loose clothing or jewelry near the moving welding head.

II. Electrical System Inspection (Before Powering On)
1. Confirm that the power supply voltage (AC 220V/380V) matches the equipment nameplate; if voltage fluctuations are significant, installing a voltage stabilizer is recommended.
2. Inspect power cables and transducer signal cables for damage or crushing; ensure the equipment is reliably grounded.
3. Ensure the generator switch is in the "OFF" position before connecting the power; do not plug or unplug the transducer connector while the power is on.
4. For high-power water-cooled models: Check that the cooling water circuit is unobstructed and free of leaks; verify that the cooling water level and flow rate are normal.

III. Pneumatic System Inspection (Required for Pneumatic Models)
1. Connect a supply of dry, clean, oil-free compressed air; activate the air service unit (FRL) and drain any accumulated water from the filter.
2. Adjust the air pressure to the equipment's operating range (typically 0.2–0.6 MPa) and check air hose connections for leaks.
3. Manually raise and lower the welding head to ensure smooth movement without sticking or abnormal noise.

IV. Installation and Inspection of Vibration Components (Welding Head / Booster / Transducer) [Critical]
Must be performed fully after replacing the welding head or following a prolonged shutdown.
1. Separate the mating surfaces of the welding head and the booster; thoroughly clean the contact surfaces with anhydrous ethanol to eliminate dust, oil, and metal filings. 
Even minute impurities can cause overheating, high-pitched noise, or component burnout. 2. Apply a thin, even layer of ultrasonic coupling grease (if required). Use a torque wrench to tighten the welding tip screws to the specified torque; avoid under-tightening (which causes vibration loss) or over-tightening (which can snap threads).
3. Visual inspection: Ensure the welding tip (sonotrode) and bottom die are free from cracks, chipped edges, or severe wear; ensure welding teeth are intact. Do not install deformed tooling.
4. Check the transducer housing for damage and ensure mounting bracket screws are secure.

V. Power-up and No-load Ultrasonic Test (without workpiece)
1. Turn on the generator power and allow it to warm up for 2–3 minutes to stabilize the circuitry.
2. Briefly activate the ultrasonic test function (duration < 1 second; prolonged no-load oscillation is prohibited).
Normal: Sound is crisp and steady, without harsh screeching or raspiness; no-load current is within the standard range; the overload indicator light remains off.
Abnormal screeching/overload alarm: Stop the machine immediately, check tooling tightness and contact surface cleanliness, and re-tune the frequency.
3. Complete automatic frequency tracking or manual tuning to ensure the system is in a resonant state.

VI. Tooling and Workpiece Preparation
1. Install and securely fasten the bottom die/positioning fixture; adjust the machine head stroke to ensure the welding tip aligns with the welding area.
2. Use a level to calibrate: Ensure the welding tip face is parallel to the bottom die to prevent uneven pressure, localized weak welds, or workpiece damage.
3. Workpiece pre-treatment:
Remove oil, fingerprints, and heavy oxide layers from the welding area (this is especially critical for dissimilar copper-aluminum welding);
Verify that the number of material layers and thickness are within the machine's welding capacity; 
ensure materials are stacked flat and free from warping.

VII. Process Parameter Setting
Select process parameters based on material type (copper, aluminum, nickel, busbars, tabs, etc.) and thickness:
Welding pressure, hold time, welding time/energy mode, and amplitude setting;
Use conservative parameters for the initial setup; do not start with maximum limit parameters. 

VIII. Trial Welding Verification (Final step before full-scale mass production)

1. Conduct trial welding using raw materials from the same batch.
2. Post-welding inspection: Ensure there are no severe extrusion cracks or extensive scorching; perform tensile/peel tests to confirm consistent weld strength.

3. In the event of welding defects, make minor parameter adjustments to eliminate issues such as cold welds (incomplete fusion), over-welding, or workpiece slippage; proceed to continuous production only after parameters have been stabilized.