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MS Spaichingen GmbH
Karlstrasse 8 - 20
78549 Spaichingen
Germany
Supplementary Operating Instructions
Table of contents
These operating instructions are only intended for the operator and the operator’s personnel who are
involved with the machine.
The copyright to these operating instructions is owned by MS Spaichingen GmbH.
The content (text, images, drawings, graphics, plans, etc.) must not be reproduced, or disseminated in full or
in part, in printed or electronic form without our written consent.
This also applies for unauthorized use for competitive purposes or disclosure to third parties.
All drawings, sketches and illustrations are the property of MS Spaichingen GmbH.
Table of contents
Table of contents ......................................................................................... 3
1 Introduction ............................................................................................. 4
1 Introduction
These supplemental instructions describe the communication of the generator with the PLC.
Applicable documents
• Operating manual of the ultrasonic generator.
Profibus
Installation of the BMP file is recommended for visual presentation.
Generator GSD file BMP file
35 / 1000 _MS_05F2.GSD PS1000DP.bmp
30 / 2000 _MS_07ED.GSD PS2000DP.bmp
20 / 4000 _MS_0B09.GSD PS4000DP.bmpllung
recommended.
DeviceNet
ProfiNet IO
EtherNet / IP
35 / 1000 EDS_soniGEN_EIP_35_1000.EDS
30 / 2000 EDS_soniGEN_EIP_30_2000.EDS
20 / 4000 EDS_soniGEN_EIP_20_4000.EDS
Modbus / TCP
Parameterization
• Byte 22: Identifier = 2
• Word 20: Identifier variant = 0 (no variant)
Depending on the application, it is possible that parameters must be assigned for the ultrasonic
generator. A possible parameterization is not remanent. After every interruption of the processor's
power supply the parameterization must be re-executed.
For the precise procedure for parameterization, and for the interpretation of the input data, see
Chapter 3.3 "Identifier 2 = parameterization", page 11.
If one of the above turn-off options is parameterized, the ultrasonic generator must remain
switched on via the "start bit" until the appropriate feedback value is signaled by the slave in the
function code. Thereafter the "start bit" must be taken back in order to be able to restart another
welding procedure.
If one of the above shut-off options are parameterized, and the "start bit" is reset during the
welding process, the running welding process will be immediately interrupted.
Byte 0 Byte For the ultrasonic function code, see "Overview - function codes"
Byte 1 uint8 Actual welding power
Word 20 uint16 Identifier variant (is reflected back from the slave)
Byte 20 (MSB) .. 21 (LSB)
Byte 22 uint8 Identifier (is reflected back from the slave)
Byte 23 uint8 Checksum = sum byte 0 .. Byte 22
Bytes 2-19 are reserve for “identifier 0”.
Word 20 uint16 Identifier variant (is reflected back from the slave)
Byte 20 (MSB) .. 21 (LSB)
Byte 22 uint8 Identifier (is reflected back from the slave)
Byte 23 uint8 Checksum = sum byte 0 .. Byte 22
Bytes 6-19 are reserve for “identifier 1”.
Word 20 uint16 Identifier variant (is reflected back from the slave)
Byte 20 (MSB) .. 21 (LSB)
Byte 22 uint8 Identifier (is reflected back from the slave)
Byte 23 uint8 Checksum = sum byte 0 .. Byte 22
Bytes 0-19 are reserve for “identifier 2”.
In this regard, energy and time welding are mutually exclusive. Only one of these option can be
activated.
1. So that the slave can be parameterized, it must be in cyclic communication (byte 22: Identifier
= 0).
2. In the master output range the appropriate option bits are set.
3. The output double word 2 (byte 2..5) must be written with the appropriate values for energy
welding or time welding.
4. For the option, start frequency offset, the output bit 6 must be written with the appropriate
values.
5. For the option, control factors, the output byte 7 and byte 8 must be written with the
appropriate values.
6. The identifier byte 22 must be written with the value 2.
7. Verification of the input range:
Checksum, identifier, and identifier variant must be identical (see general communication
guideline). If the conditions are satisfied, then the slave has applied the parameterization.
8. The identifier byte 22 must be written with the value 0. The communication switches back to
the cyclic operation.
1. So that the teaching-in function can be started, the slave must be in cyclic communication
(byte 22: Identifier = 0).
2. In the master output range bit 1.0 is set.
3. The output double word 2 (byte 2..5) can be written with the appropriate load frequency offset.
Otherwise the value must be filled with 0. The value of the load frequency offset depends on
the resonant unit and must be determined appropriately for the application.
4. In master output byte 6, a start frequency can be transferred if needed. Through this measure,
the entire teaching-in frequency window can be moved.
5. The identifier byte 22 must be written with the value 2.
6. Verification of the input range:
Checksum, identifier, and identifier variant must be identical (see general communication
guideline). If the conditions are satisfied, then the slave has applied the parameterization.
7. The identifier byte 22 must be written with the value 0. The communication switches back to
the cyclic operation. Only after this has been done, will the ultrasonic generator start the
teaching-in procedure. This can be identified via the flashing "Start LED" on the front of the
ultrasonic generator.
8. The teaching-in procedure must be monitored by the master. The slave signals in function
code (input byte 0) as soon as the teaching-in procedure has ended.
Function code 90 = teaching-in ended with no errors
Function code 91 = teaching-in ended with errors
Report back must be monitored by the master. After a maximum of 15 seconds, the function
must be ended by the ultrasonic generator. An abort by the master is not possible.
9. If the slave signals the function as ended, (function code 90 or 91) the "teaching-in bit" must
be reset.
10. For this, the bit 1.0 is reset in the master output range.
11. The output double word 2 (byte 2..5) must be written with the value 0.
12. The identifier byte 22 must be written with the value 2.
13. Verification of the input range:
Checksum, identifier, and identifier variant must be identical (see general communication
guideline). If the conditions are satisfied, then the slave has applied the parameterization.
14. The identifier byte 22 must be written with the value 0. The communication again switches
back to cyclic operation.
After the teaching-in procedure, the possible parameterization, such as energy welding, time
welding, continuous sonic, ultrasonic stop - external, or control factors, must be reassigned. These
parameters are deleted through the start of the teaching-in function.
A parameterization of start frequency offset is not necessary after the teaching-in procedure,
because the ultrasonic generator ignores this specification. The ultrasonic generator starts with the
starting frequency determined during the teaching-in procedure.
Byte 9 uint8 For the ultrasonic function code, see "Overview - function
codes"
Byte 10 uint8 Feed current resonance circuit [x.xx A]
Byte 11 uint8 Ultrasonic peak power [x.x W]
Byte 12 uint8 Ultrasonic voltage [x.x V]
Byte 13 uint8 35 / 1000: Ultrasonic line voltage [x.x V]
30 / 2000, and 20 / 4000: Ultrasonic intermediate circuit voltage
[x.x V]
Byte 14 uint8 Ultrasonic temperature sensor [x.x °C]
Word 20 uint16 Identifier variant (is reflected back from the slave)
Byte 20 (MSB) .. 21 (LSB)
Byte 22 uint8 Identifier (is reflected back from the slave)
Byte 23 uint8 Checksum = sum byte 0 .. Byte 22
Bytes 15-19 are reserve for “identifier 3”.
See the soniGEN operating instructions for the calculation guideline of the protocol data
Double word 0 uint32 Counter - ultrasonic start from PLC via AnyBus
Byte 0 (MSB) .. 3 (LSB)
Double word 4 uint32 Counter - ultrasonic start from PLC via DC 24 V
Byte 4 (MSB) .. 7 (LSB)
Double word 8 uint32 Counter - ultrasonic start from hand welding gun
Byte 8 (MSB) .. 11 (LSB)
Double word 12 uint32 Counter - ultrasonic start from test button
Byte 12 (MSB) .. 15 (LSB)
Double word 16 uint32 Counter - ultrasonic start from V24 interface
Byte 16 (MSB) .. 19 (LSB)
Word 20 uint16 Identifier variant (is reflected back from the slave)
Byte 20 (MSB) .. 21 (LSB)
Byte 22 uint8 Identifier (is reflected back from the slave)
Byte 23 uint8 Checksum = sum byte 0 .. Byte 22
Word 20 uint16 Identifier variant (is reflected back from the slave)
Byte 20 (MSB) .. 21 (LSB)
Byte 22 uint8 Identifier (is reflected back from the slave)
Byte 23 uint8 Checksum = sum byte 0 .. Byte 22
4 Start Info
0 Ultrasonic start aborted
1 Ultrasonic start of PLC (AnyBus, amplitude of PS4000)
2 Ultrasonic start of PLC (24 V DC)
3 Ultrasonic start of hand welding gun
4 Ultrasonic start of test button
5 Ultrasonic start of V24