Connections - soniKKs Ultrasonics Technology GmbH
Contents
1. 14 Dud Example Of Application cccccccceeeeseeeeeeeeeeeeeeeeeeaeeesesaeeeeeeaeeeeeeaeeeeeeaneegags 16 4 Profibus socket OPtional cccscsecseseceeeeeeeeeeeeeeeeeeeeeeeeeeeeesesseseraesereesetsesateetensesenness 17 Controls and display elements seseseeeeeeenenneene nennen nennen nenne nnne nnne nnn nnns 18 1 LED Stats IMGICAOUS 15v Dr RFEEYEREREEEEERE REX SARERIR PERI PASERTUPERPFREREREE TERME FELIPE FUEKEX MR FA RUPES 18 2 Control ana conrectlofis sssmaeexua i enki FE Fr T NENET TER Vea R E Cr rREFE ER PH Ft ra 19 TOUDE IO ONG TOT T TUM 20 Maintenance and CdfessdisivisurE peri gu TERRE RTITE SEP EQETI EP ATETI SMS I EPIRaS ERIT REI RERO E quREPEPEYETORET E PATE PUER EXE REF 22 VG C 22 Biene CONTO tiia OT 23 RIM MUU 24 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 2 of 24 W kke ULTRASONICS TECHNOLOGY Introduction Dear customer we would like to thank you for buying this product You have purchased a high quality product developed based on the latest technology standards developed and produced exclusively in Germany General information The ultrasonic generator soniKKs digital K3 DR W can be used for ultrasonic plastic and metal welding applications as well as for other speci2. soniKKe ULTRASONICS TECHNOLOGY d i Ep Ospe Profibus Ge i d Ose Qs Data exchange 9 Com M GmbH XSsoniIKKS ULTRASONICS TECHNOLOGY 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 1 of 24 sonis ULTRASONICS TECHNOLOGY Table of contents PARIS OF COMPS sra 2 Il gie CCIE OVEN RTT t eem 3 euis IRORI zie PTT OO TUTTI 3 ccc are r E 4 L Conventional USE eseina E 4 s SCCUHUY IMSMUCHONS rererere eae EEEE t cte Re cei Cen rr Y do eee oa 5 WO VIC SPC SINS Mes carina seu UE EPREDOTSHUEMDREEEMERUGEINNPSHUUIRNVARECIENUUEE IINE SMASH EOUER NI CUN 7 ien cERTTET TITOLI I E AEE EEE E E 8 Back panel variants ccsccccscsecessenecesnenecesnenseeseenseeseeneeeseenseeseenseeseeeseeseenseeseennenseeunenseeunensagues 9 BoE AU A eiui ea iati eta s in ain in ar Le a ELT LL La LT LL LT a 10 1 Electrical connection assesessvstes idu ias sctesassscucaanaiatcaacssinensnseetesenciieesencacteaeacsctesanaieteiaecesce 10 2 M12 type Interface connector eseeseeeeeeeeenee nennen nenne nnne nnn nnne nnn nnns 11 2l ligo de 11 2 2 Example of application eese nnns 12 2 3 Interface signals description eeeeeeeeeeennnn mener 13 3 Phoenix type Interface CONNECCOS ccccceccseceeceeceeceeseeeceeueeueeueeeeeueneesaeneesaesaetaeseeseesass 14 3 1 ullo
3. that the product Type Ultrasonic generator soniKKs digital K3 DR W xxxx where xxxx indicates the power ratings Corresponds to the following EEC directives EN 50081 1 EN 50082 2 EN 55022 EN 55014 EN 6055 EN 61000 The requirements of the low voltage directive are observed ATTENTION The device is not designed to be connected to the public utility AC power line Unauthorized modification of the device makes this declaration void Dobel 01 11 2008 Klaus Kern Managing Director 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 23 of 24 oo ULTRASONICS TECHNOLOGY Imprint Purpose and use The operating instructions explain the construction and operation of the ultrasonic generator soniKKs K3 DR W in connection with standard accessories for use in laboratories and the industry Please read especially the safety instructions carefully and observe them all time The operating instructions should always be at hand to help you to solve any questions and problems that may arise All rights reserved The manual has been prepared with all due care nevertheless faults and omissions cannot be fully precluded soniKKs GmbH reserves the right to make changes to the technical data and specifications during the curse of further development of the product Without given prior notice Address Editing soniKKs amp Ultrasonics Technology GmbH first edition August 201
4. 2 Neuenb rgerstraDe 72 second edition January 2015 75335 Dobel Germany Phone 49 0 7083 92 48 360 Fax 49 0 7083 92 48 370 Mail info sonikks de www sonikks de www sonikks com 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 24 of 24
5. ND only on the generator side gt All I O signals have a galvanic contact to the generator Please pay attention at all warnings and hints in this manual and on the generator Do not use the generator in wet and damp environment Danger of damage on the generator Always place the generator on a stable and flat surface Great attention should be given to the mains supply voltage Over or undervoltage can cause malfunctions or destroy the generator 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 5 of 24 sonikKKsS ULTRASONICS TECHNOLOGY gt EN Correct operations can only be guaranteed if the generator is used along with the recommended ultrasonic transducers Use only the recommended interface cables Do not coil up the RF cable or the line cord Coiling up these cables can cause overheating of the cables Do not touch the horn sonotrode while the generator is active Caution could be very hot Never point the connected transducer at people If you work with sonotrodes please wear an adequate ear protection or just operate in an acoustic noise protection box Avoid all operation of the generator in presence of animals They have a more extended frequency range of audible sound than people and are thus highly sensitive to ultrasounds In the following cases immediately disconnect the unit from mains and call a qualified service technician VN NV V WV If cabl
6. al applications like sieving atomizing etc The main features are Auto tuning circuit to tune automatically to the resonant frequency of the connected horn Fully digital frequency generation High speed microcontroller to control all functions of the generator Y VV WV LCD display with rotary encoder or touchscreen operation except device in Profibus version Constant adjustable amplitude 50 100 Y Protected against o Short circuit o Idle run o Overtemperature o Overload 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 3 of 24 KN kks ULTRASONICS TECHNOLOGY Safety Below you can see all the warning and security symbols used in this manual Symbols in manual Immediate imminent danger health and life bad injuries or death Attention hot surface Do not Touch Possible damage without danger for people Electrical voltage Symbols on device CE Conformity Symbol 1 Conventional use The generator was designed to be used for following applications Ultrasonic welding of plastic and metal Ultrasonic cutting Ultrasonic sieving 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 4 of 24 C kka ULTRASONICS TECHNOLOGY This generator can only be used with soniKKs components i e transducers sonotrodes and other accessories We cannot guarantee the compatibility and the good functioning of t
7. blem 1 Disconnect the cable to the transducer 2 Switch on the generator with the test button Then what a The error still comes up generator faulty b The error does not come up again transducer or cable faulty The Error LED comes up with some delay after the generator is started with the test button or a remote control signal Possible reasons There is no ultrasonic converter connected The tool has a malfunction The ultrasonic converter is broken Malfunction of the connection cable or plug V NW ON V How to fix the problem 1 Check the transducer converter and sonotrode exchange them if necessary 2 Check cabling and connectors exchange them if necessary 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 20 of 24 W kke ULTRASONICS TECHNOLOGY Overtemp LED lights up or flashes If the generator gets overheated during sonification the Overtemp LED will light up and the generator switches off automatically When cooling down below the trip point the generator restarts automatically The Overtemp LED will flash to signalize this error until the generator is switched off with the test button or the remote control Possible reasons The cooling slots are obstructed Device is placed too close to another heat source Malfunction in the converter Malfunction of the fan VV ON WV How to fix the problem Check the fan Check the cooling slots on the backside
8. es or connectors are damaged If the housing is damaged If fluid came into the generator If the unit fell to the ground If the unit shows significant differences from normal operation 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 6 of 24 sonikKKs Device Placement A running generator can heat up noticeably If the generator cannot dissipate the heat there is a possibility of an overheat condition An error message Overtemperature will appear if a display is connected and the OVERTEMP LED will light up See the error description Overtemperature for details If possible avoid operating the unit at ambient temperatures above 30 C 86 F Make sure that sufficient cool air can reach the generator for proper cooling Air conditioning helps in high temperature environment Always keep the cooling slots on the rear of the generator clear Do not place anything in front of the cooling slots Keep the generator away from heat sources to avoid overheating Also avoid direct sunlight exposure Place the unit so that no humidity or fluid can come into the generator Lay the cables in a way that no one can stand on them or stumble over them Never lift the device or carry it by its cables ATTENTION Place the unit in a way that no vapor water or other can get into the device 1 Dusty or chemically contaminated air may cause long term corrosion of the device Avoid heat sources cl
9. hird party manufacturers components For other applications please obtain explicit written approval from the manufacturer 2 Security instructions For your own Safety please read this manual carefully before using this product and keep this manual in a place where it is accessible for all users The electrical connection may only be done by qualified personnel Operations of all ultrasonic equipment by trained staff only gt Do not use this unit in explosive environments without taking all necessary security measures gt Check the unit any time before operating The electromagnetic compatibility must be conform to international standards For more details consult the Technical data section of this manual gt All necessary adjustments are either made by the manufacturer or are described in this manual In case of any trouble with the generator do contact our technical service gt Never open the unit or in any way tamper with it This will void your warranty and may cause an electric shock gt All maintenance should be done by trained staff only For any cleaning or maintenance of the device do disconnect the mains supply The cable connected to the interface socket must be shielded Please make sure that this cable is not in close contact to other cables that are conducting high currents Also avoid close contact of this cable to transformers and relays Please connect the shield to protective earth G
10. nstance 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 9 of 24 WW soniKKs ULTRASONICS TECHNOLOGY Connections Connections of the back panel gt Mains supply gt Interface connector gt Transducer connector ATTENTION When connecting a converter an additional protective earth connection must be provided This cable must provide a sufficient cross section of at least 1 5mm Max 2000Watt 2800 VA tung p Li Electrical connection The generator may only be connected to a proper mains supply The allowed voltage is 230 Volt AC 50 0 Hz Netzspanung 210 250 V AC N PE Linevoltage 50 80 Hz Max 2000Watt 2800 VA Dauerleistung continuous power The Mains supply must have a protective earth connection Care must be taken that the supply connection carries neither over nor undervoltage this may cause malfunctions or even damage the unit Pin assignment of the mains socket see on the right PE 1 PE N 2 N A 3 L 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 10 of 24 sonikKKs ULTRASONICS TECHNOLOGY 2 M12 type Interface connector 2 1 Pin out 8 0 INTERFACE L2 U 7 6 NY 5 Pin Color LINIEN RF DA amp Error 1 white Common relay root for RF DA and ERROR relays Vm na GND Common ground Remote input active low link to ground to t
11. of the generator 3 Check device placement pay attention at the placement advice N e The generator starts and stops on its own How to fix the problem 1 Set the Timer value to zero 2 Verify that the MODE LED is off 3 Restart the generator 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 21 of 24 W kke ULTRASONICS TECHNOLOGY Maintenance and care There is no need for special maintenance Please remove any dust and dirt with a damp woven fabric Do not use any chemicals to clean the generator Keep the cooling slots clear at all times Warranty The period and extent of the warranty is part of the commercial terms and conditions Special agreements are part of the confirmation of the order The warranty does not cover any malfunctions injuries and damages that result from such use or improper operation in use Warranty exclusion applies in the following cases Damage due to wrong handling or tampering Damage due to wrong application Damage due to shock dirt or moisture Damage due to operation by nonqualified staff Damage due to nonobservance of safety regulations or accident prevention regulations Vv Vv V V V WV Damage due to modifications to the operating manual 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 22 of 24 K sonikKKs a Declaration of Conformity We soniKKs Ultrasonics Technology GmbH declare in sole responsibility
12. ose to the generator to prevent overheating 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 7 of 24 sonikKKsS ULTRASONICS TECHNOLOGY Technical Data 175 x 70 x 362 mm approx 2 5 kg IP 20 IEC60529 EN 60 525 Depending on generator type 20 100 kHz 210 250 VAC L N PE 50 60Hz Depending on model up to maximum 10 A Maximum 2000 W 10 C through 40 C not condensing RS232 socket Profibus socket External graphic display with touchscreen operation or operation with a rotary encoder 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 8 of 24 soniKKs ULTRASONICS TECHNOLOGY Back panel variants Our K2 generators are available with different back panels which offer different connectors see below LEMO connector transducer plug Phoenix connector mains supply plug penno Phoenix connectors Interface and RS232 plugs ouvrir appareil ae lg e INTERFACE M12 connector eom Interface plug f T ces Phoenix connector BNC connector mains supply plug transducer plug NB the BNC and LEMO sockets are interchangeable which means that the right panel is also available with a BNC connector However the other connectors power supply sockets included cannot be interchanged In other words you cannot combine the M12 interface connector with the right Phoenix mains connector for i
13. ower level 0 100 Analog voltage corresponding to the current transducer temperature 15V supply voltage for external use max 100mA Remote input active low Generator ON if connected to GND Common ground 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 15 of 24 soniKKs 3 2 Example of application Generator 11 pole interface Error HF DA Relay Relay Error L HF RF a TEMP i GND Please note The HF DA relay connected to pin 1 and 9 can also be configured as a driver relay for a pneumatic cylinder Pls refer to the manual section Cycle mode Temp sensor Example of external connections 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 16 of 24 sonikKKsS ULTRASONICS TECHNOLOGY 4 Profibus socket optional Hexadecimal Low byte High byte 11 gt Address decimal 17 22 gt Address decimal 34 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 17 of 24 K sonikKKs i ULTRASONICS TECHNOLOGY Controls and display elements 1 LED Status indicators Indicates that the generator is connected to the mains supply and the mains switch is switched on 2 n Hag Sio gm Sonic Indicates that ultrasonic power is emitted Indicates that there is a malfunction Indicates that a monitoring function has been set and the requested condition was not met
14. reference to GND 2 GND Common reference point for input output signals except for the relay outputs 3 FS GND To switch the generator on connect this signal to GND pin 2 4 RF DA relay As soon as ultrasonic voltage is available on the RF output socket a relay contact closes and this pin 4 is linked via the relay to Pin 1 RF DA amp ERROR Normally open by default user configurable To use this function connect for instance 24V to pin 1 RF DA amp ERROR This voltage will then appear on this pin 4 as soon as the generator is turned on and an ultrasonic signal is available on the output socket 5 Error relay This pin is internally connected to the error relay contact root of the relay contact is pin 1 Normally open by default user configurable If there is any malfunction of the generator this relay contact will be closed 6 A extern The generator s amplitude can be controlled with an external voltage applied to this pin This function can be enabled on the external display Applying a voOltage between 5 and 10V the amplitude can be adjusted in a range of 50 100 of the nominal generator amplitude Any voltage below 5V will clip the amplitude to 50 7 P Out On this pin there is a voltage proportional to the emitted ultrasonic power in the range of 0 10 volts This voltage corresponds to the nominal ultrasonic output power OV 0 10V 100 8 15 V This output provides an a
15. urn on the generator Optionally also remote with 24 V is available Relay output RF DA closed when ultrasonic voltage is emitted normally open by default CEA FS ND WAJIONE RF DA relay 5 grey Error relay Relay output Error closes upon error normally open by default 6 pink A extern Input 5 10 Volt for external adjustment of amplitude 7 blue P out Output 0 10 Volt corresponds to the output power 0 100 8 red 15V 15 Volt supply voltage for external use max 100mA A ATTENTION The specified core colors relate to the cables supplied by the device manufacturer Cables from third party manufacturers might have a different color coding 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 11 of 24 WW soniKKs i 2 2 Example of application Generator 8 pole Interface HF Error DA Relay Relay A Ext P Out PS 5 10V 0 10V GND AN RF Example of external connections 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 12 of 24 C kks ULTRASONICS TECHNOLOGY 2 3 Interface signals description 1 RF DA amp Error Common input output root of the internal relays RF DA and ERROR Relay input output signals have no
16. uxiliary voltage of 15V for external use The maximum output current is 100mA 75mA permanent load and can be used as a supply voltage of the relay root RF DA amp Error on pin 1 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 13 of 24 sonikKKs ULTRASONICS TECHNOLOGY 3 Phoenix type Interface connector 3 1 Pin out Modbus interface P Sa RS232RXD T WM RS232 TXD lee RS232 GND T c ae NA GND REM GND HF RF v 15V OUT Swa TEMP P 0 10V E Status and Control I O ike A5 10V A ERROR 9 ERROR REM 24V HF RF soniKKs GmbH Ultrasonics Technology 2015 02 25 Doc nr 3000 2302 A page 14 of 24 sonikKKs ULTRASONICS TECHNOLOGY REM 24V ERROR A 5 10V P 0 10V TEMP 15V OUT REM GND GND Input I O Input Output Input Output Input Output Up to 24V 24V Up to 24V 5 10V 0 10V Option 15V Up to 24V Status and Control I O HF RF RF DA relay input and output Relay closed when ultrasonic voltage is emitted Normally open by default user configurable Relay also works as control relay in cycle welding mode Remote input active high Reference is GND Error relay input and output Normally open by default user configurable Input for amplitude control 5V 50 amplitude 10V 100 amplitude Output corresponding to the current output p
17. ye during the last run Cleared automatically upon next start Monitoring functions can be set using a LCD display extern integrated When lit the generator is overheating and cannot be started When flashing the generator was shut down during the last process due to overtemperature If you start sonic again the LED disappears Indicates that the generator s set to stop after a predetermined condition has been reached The setting of these conditions can be done with the LCD display extern integrated 33 veces Shows the effective ultrasonic power output gauge in steps of 10 of the nominal power 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 18 of 24 Jee PG LAE ha EL EEA X ANNAM if 4 i l D 131118 Z q X X LY X y X VAR Y ULTRASONICS TECHNOLOGY SANS WS WE b 2 Controls and connections Test Button Possibility to connect an external display and also an interface can be connected with a special adapter cable 2015 02 25 soniKKs GmbH Ultrasonics Technology Doc nr 3000 2302 A page 19 of 24 C kks ULTRASONICS TECHNOLOGY Troubleshooting The Error LED comes up right after the generator is started with the test button or a remote control signal Possible reasons gt Malfunction of the ultrasonic converter gt Malfunction of the cable to the transducer short circuit How to fix the pro
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