Interface Manual

Supplementary Operating Instructions

PLC Communication
(Translation of the original operating instructions)
MS Spaichingen GmbH
Karlstrasse 8 - 20
78549 Spaichingen
Germany
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.
All rights reserved. Subject to change without notice.
2014 MS Spaichingen GmbH

Karlstrasse 8 - 20
78549 Spaichingen
Tel.: +49 7424 701 0
Fax: +49 7424 701 63
E-mail: info@ms-spaichingen.de
www.ms-spaichingen.de
Page 2 / 22 03 / 2015 Version: 1.0

Table of contents
Table of contents
Table of contents ......................................................................................... 3
1 Introduction ............................................................................................. 4
2 Overview of the device description files ............................................... 5
3 Protocol DeviceNet, ProfiNet, EtherNet / IP, Modbus TCP ................... 6

3.1 Identifier 0 = cyclical I/O data .......................................................................... 8
3.1.1 Ultrasound on / off: ........................................................................................................ 8
3.1.2 Calculation guideline of the amplitude: .......................................................................... 9
3.1.3 Calculation guideline of the max - min level specification: ............................................. 9
3.1.4 Calculation guideline of welding power ........................................................................ 10
3.2 Identifier 1 = read version states .................................................................. 10
3.3 Identifier 2 = parameterization ....................................................................... 11
3.3.1 Parameterization procedure ........................................................................................ 13
3.3.2 Sequence of the teaching-in function .......................................................................... 14
3.4 Identifier 3 = read weld protocol .................................................................... 17
3.5 Identifier 4 = read start counter ..................................................................... 18
3.6 Identifier 5 = read error counter .................................................................... 19
4 Start Info ................................................................................................ 21
5 Overview function codes ...................................................................... 22
Version: 1.0 03 / 2015 Page 3 / 22

1 Introduction
1 Introduction
These supplemental instructions describe the communication of the generator with the PLC.
Applicable documents
• Operating manual of the ultrasonic generator.
Page 4 / 22 03 / 2015 Version: 1.0

2 Overview of the device description files
2 Overview of the device description files
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
Generator EDS file

35 / 1000 EDS_soniGEN_DEV_35_1000.EDS
ProfiNet IO
Generator GSDML BMP file

35 / 1000 GSDML-V2.25-MS-soniGEN-35-1000- GSDML-soniGEN-35-1000.bmp
20120502.xml
20120927.xml
20111214.xml
EtherNet / IP
Generator EDS file
35 / 1000 EDS_soniGEN_EIP_35_1000.EDS
Modbus / TCP
Addressing Modbus Register:

Input Register: 000H to 000BH
Holding Register: 000H to 000BH
Version: 1.0 03 / 2015 Page 5 / 22

3 Protocol DeviceNet, ProfiNet, EtherNet / IP, Modbus TCP

For the communication between master (PLC) and slave (ultrasonic generator MS soniGEN) 24-
byte output data and 24-byte input data are used.
Via the identifier in byte 22, the function of the telegram is switched over between master and
slave. The word 20 (identifier variant) must be described depending on the preselected identifier.
The following functions are available:
Cyclic communication
• Byte 22: Identifier = 0
• Word 20: Identifier variant = 0 (no variant)
The cyclic communication is used to start and stop the ultrasonic generator.
The welding amplitude and the min/max level can be prescribed via the Fieldbus. If an error is
queued, the ultrasonic generator will signal the error as a function code in the cyclic
communication. Moreover, the actual welding power will be transmitted.
Function code, see Chapter 5 "Overview ", page 22
Calculation guidelines, see Chapter 3.1 "Identifier 0 = cyclical I/O data", page 8
Read version states

If the version states are read, the ultrasonic generator, reports back the software and hardware
versions.
See Chapter 3.2 “Identifier 1 = read version states”, page 10 for the interpretation of the input
data.
Parameterization
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.
Read weld protocols

• Word 20: Identifier variant = 1 .. 2000 (weld protocol number)
When reading the weld protocols, the appropriate protocol number must be transferred in word 22.
For the calculation guidelines of the individual values, see 3.4 "Identifier 3 = read weld protocol",
page 17 and in the generator operating manual.
Page 6 / 22 03 / 2015 Version: 1.0

Read start counter

When the start counters are read, the ultrasonic generator reports back various counter states.
See Chapter 3.5 “Identifier 4 = read start counter”, page 18 for the interpretation of the input data.
Read error counters
• Word 20: Identifier variant = 1 .. 2
When the error counters are read, the ultrasonic generator reports back various counter states.
See Chapter 3.6 “Identifier 5 = read error counter”, page 19 for the interpretation of the input data.
General communication guideline

To check the consistency of the data and to exclude the possibility of transmission errors, the
master as well as the slave forms a checksum via byte 0 to byte 22 by addition of the individual
bytes. The checksum must be calculated for the input data and for the output data. In this regard,
the entire input - output range must be interpreted by the data type "Byte".
The following operations apply:
• The checksum of the input byte 0 .. 22 must be compared with the checksum reported by the
slave in byte 23. If the calculated checksum and the value in the input byte 23 are identical,
the input data is free of transmission errors.
• Input value 20 must be identical to output data 20.
• Input value 22 must be identical to output data 22.
If all three conditions are fulfilled, the input data is valid and the slave has taken over the protocol
of the master.
The checksum of the output byte 0 .. 22 must be written into the output byte 23. Only if the
checksum has been correctly calculated and transmitted, will the slave react to the protocol and
execute the appropriate function.
Version: 1.0 03 / 2015 Page 7 / 22

3.1 Identifier 0 = cyclical I/O data

Address Data type Description
Master output range
Byte 0, bit 0: Bool Ultrasonic on / off

Ultrasonic is active as long as the bit is controlled on "1"
Byte 0, bit 1: Bool Amplitude specification via master / via display
If this bit is controlled on "1", then the amplitude is specified via the
master. Welding amplitude is specified via the data bits 3 .. 7
If this bit is controlled on "0", then the amplitude is specified via the
master.
Byte 0, bit 2: Bool Min - max level specification via master / via front panel
If this bit is controlled on "1" then the max - min level is specified via the
master in byte 2 and byte 3.
If this bit is controlled on "0" then the max - min level is specified via
potentiometer on the front panel of the ultrasonic generator.
3.1.1 Ultrasound on / off:

Ultrasound is active as long as bit 0 is controlled on "1".
This function will be overlaid through any parameter-assigned turn-off functions. If the generator is
parameterized to the turn-off option energy welding, time welding or "Ultrasound stop external",
then the ultrasonic switches off after reaching the appropriate turn-off option. This can be detected
through the generator feedback in the function code (input byte 0).
• 80 Welding stopped through turn-off option - energy

• 81 Welding stopped through turn-off option - external stop
• 82 Welding stopped through turn-off option - welding time
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.
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3.1.2 Calculation guideline of the amplitude:

The amplitude can be set in the range from 38% to 100% in 2% increments.
The transfer occurs dual coded. In this regard 38% = 0 (2) and 100% = 11111 (2)
For example, Amplitude specification = 68%

 the value (68 – 38) = 30 must be transferred to the slave
30(10) = 0 * 32 (10) + 1 * 16 (10) + 1 * 8 (10) + 1 * 4 (10) + 1 * 2 (10) = 01111 (2)

Master output range
Byte 0, bit 3: Bool Amplitude specification bit 1 = 2 (10) = 1 * 2 (10)

3.1.3 Calculation guideline of the max - min level specification:

The level can be set in the range from 0% to 100%. Transfer occurs as unsigned byte value. In this
regard 0% = 0 (10) and 100% = 255 (10)
For example, Level specification = 55%

 the value (55 * 255 / 100) = 140 must be transferred to the slave
(in this regard there are slight rounding errors)
Master output range
Byte 2 Byte Max level specification 0% = 0 (10) ; 100% = 255 (10)

Byte 3 Byte Min level specification 0% = 0 (10) ; 100% = 255 (10)
Word 20 uint16 Identifier variant = 0

Byte 22 uint8 Identifier = 0
Byte 23 uint8 Checksum = sum byte 0 .. Byte 22
With "identifier 0" byte 1 4-19 are not relevant and must be allocated with "0".
Master input range
Byte 0 Byte For the ultrasonic function code, see "Overview - function codes"
Byte 1 uint8 Actual welding power
Version: 1.0 03 / 2015 Page 9 / 22

3.1.4 Calculation guideline of welding power

The welding power is transferred to the master as a percentage value for the maximum power of
the ultrasonic generator. This means: 0 (10) = 0 W and 255 (10) = Pmax
• Ultrasonic generator 35 / 1000: Pmax = 1000 W
Address Data Description

type
Master input range
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)
Bytes 2-19 are reserve for “identifier 0”.
3.2 Identifier 1 = read version states

type
Master output range

With "identifier 1" bytes 0-19 are not relevant and must be allocated with "0".
Master input range

Byte 0 Byte Hardware version
Byte 1 uint8 Generator type: 0 = 35 / 1000; 2 = 20 / 4000; 3= 30 / 2000
Byte 2 uint8 Software version (day)
Byte 3 uint8 Software version (month)
Byte 4 uint8 Software version (year)
Page 10 / 22 03 / 2015 Version: 1.0

3.3 Identifier 2 = parameterization

type
Master output range
Byte 0, bit 0: Bool Reserved

Byte 0, bit 1: Bool Energy welding
If this bit is set to "1", then the ultrasonic generator will be
switched over to the "energy welding" mode. The welding energy
is specified via the double value 2 (byte 2..5)
If the ultrasonic generator is not switched over to the "energy
welding" mode, then this bit must be set to "0".
Byte 0, bit 2: Bool Continuous sonic
If this bit is set to "0", then after 30 seconds, a safety switch-off of
the ultrasonic occurs.
If this bit is set to "1", then the ultrasonic is not switched off.
Byte 0, bit 3: Bool Start frequency offset
If this bit is set to "1", then the function "start frequency offset" is
activated. Transfer of the offset value occurs via byte 6.
If this bit is set to "0", then the function "start frequency offset" is
deactivated.
Byte 0, bit 4: Bool Control factors
If this bit is set to "1", then the function "control factors" is
activated. Transfer of the control factors occurs via byte 7 and
byte 8.
If this bit is set to "0", then the function "control factors" is
deactivated.
Byte 0, bit 5: Bool Ultrasonic stop - external
If this bit is set to "1" then the ultrasonic generator can be
stopped by activating a digital input on the I/O interface.
If this bit is set to "0", then this function is deactivated.
Byte 0, bit 6: Bool Time welding
switched over to the "time welding" mode. The welding energy is
specified via the double word 2
(byte 2..5)
If the ultrasonic generator is not switched over to the "time
welding" mode, then this bit must be set to "0".
Version: 1.0 03 / 2015 Page 11 / 22


type
Byte 1, bit 0: Bool Teaching-in

switched over to the "teaching-in" function.
By resetting the bit to "0" the function will be aborted or stopped.
Mode "energy welding" (byte 0 bit 1 = "1")

Double word 2 uint32 Welding energy
Byte 2 (MSB)..5 (LSB) 35 / 1000: 1 Ws = 510, 100 Ws = 51000
30 / 2000: 2 Ws = 510, 200 Ws = 51000
20 / 4000: 4 WS = 510, 400 Ws = 51000
Mode "energy welding" (byte 0 bit 6 = "1")
Double word 2 uint32 Welding time

Byte 2 (MSB)..5 (LSB) Time setpoint: 10 ms .. 10s ≙ 20..20000
Mode "teaching-in" (byte 1 bit 0 = "1")

Double word 2 uint32 Load frequency offset
Byte 2 (MSB)..5 (LSB) Value range -500 .. +500
Byte 6 sint8 Start frequency offset

Byte 7 uint8 Control factor 1
Byte 8 uint8 Control factor 2
Master input range
Page 12 / 22 03 / 2015 Version: 1.0

3.3.1 Parameterization procedure

The following options can be parameterized:
• Energy welding
• Time welding
• Continuous sonic
• Ultrasonic stop - external
• Start frequency offset
• Control factors
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.
Parameterization is concluded. The generator can now be started.
Version: 1.0 03 / 2015 Page 13 / 22

3.3.2 Sequence of the teaching-in function

The teaching-in function is a procedure in which the ultrasonic generator measures the entire
oscillating unit relative to frequency. In this process the optimal start frequency is determined and
thus a shortened transient oscillation is achieved.
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.
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.
14. The identifier byte 22 must be written with the value 0. The communication again switches
back to cyclic operation.
Page 14 / 22 03 / 2015 Version: 1.0


Function code must go to "0"
checksum, identifier, and identifier variant must be identical (see general communication
The teaching-in procedure is concluded. The generator can now be started.
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.
Fig. 1: Graphic presentation - teaching-in function procedure
Version: 1.0 03 / 2015 Page 15 / 22

Fig. 2: Evaluate function code
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3.4 Identifier 3 = read weld protocol

 See the generator instructions for the calculation guidelines.
Master output range
Word 20 uint16 Identifier variant = 1 .. 2000 = protocol number

Master input range
Double word 0 uint32 Frequency control [x.xxx kHz]

Word 4 uint16 Ultrasonic power [x.x W]
Word 6 uint16 Ultrasonic welding time [x.xxx s]
Byte 8, bit 0: Bool Start info bit 1 = 2 (10)

Byte 8, bit 3: Bool Amplitude specification bit 1 = 2 (10)

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]
See the soniGEN operating instructions for the calculation guideline of the protocol data
Version: 1.0 03 / 2015 Page 17 / 22

3.5 Identifier 4 = read start counter

type
Master output range

Master input range
Double word 0 uint32 Counter - ultrasonic start from PLC via AnyBus
Double word 4 uint32 Counter - ultrasonic start from PLC via DC 24 V
Double word 8 uint32 Counter - ultrasonic start from hand welding gun
Double word 12 uint32 Counter - ultrasonic start from test button
Double word 16 uint32 Counter - ultrasonic start from V24 interface
Page 18 / 22 03 / 2015 Version: 1.0

3.6 Identifier 5 = read error counter

Master output range
Word 20 uint16 Identifier variant

Byte 20 (MSB) .. 21 (LSB) 1 = error counters 1 .. 5 read from slave
2 = error counters 6 .. 9 read from slave
Master input range
Identifier variant 1 = (error counters 1 .. 5)

Double word 0 uint32 Overload, amplitude > 125% or ultrasonic watchdog
Byte 0 (MSB) .. 3 (LSB) overflow
Double word 4 uint32 Overload, frequency too high

Double word 8 uint32 Overload, frequency too low
Double word 12 uint32 Analog supply +/- 15 V
Double word 16 uint32 Intermediate circuit too small;
Byte 16 (MSB) .. 19 (LSB) at 35 / 1000: Ultrasonic power supply too low
Identifier variant 2 = (error counters 6 .. 9)

Double word 0 uint32 Overload, amplitude > 125% or ultrasonic watchdog
Byte 0 (MSB) .. 3 (LSB) overflow
Double word 4 uint32 Overload, frequency too high

Double word 8 uint32 Overload, frequency too low
Double word 12 uint32 Analog supply +/- 15 V
Double word 16 uint32 Intermediate circuit voltage too low;
Byte 16 (MSB) .. 19 (LSB) at 35 / 1000: Ultrasonic power supply too low
Double word 0 uint32 Intermediate circuit voltage too high;

Byte 0 (MSB) .. 3 (LSB) at 35 / 1000: Ultrasonic power supply too high
Double word 4 uint32 Heat sink temperature > 75° C

Double word 8 uint32 Window error, US_SP > US_MAX
Version: 1.0 03 / 2015 Page 19 / 22

Double word 12 uint32 Window error, US_SP < US_MIN

Double word 16 uint32 Reserve
Page 20 / 22 03 / 2015 Version: 1.0

4 Start Info
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
Version: 1.0 03 / 2015 Page 21 / 22

5 Overview function codes
5 Overview function codes

0 Welding stopped without generator error. No turn-off options occurred
1 Overload, amplitude > 125% or ultrasonic watchdog overflow
2 Overload, frequency too high
3 Overload, frequency too low
4 Analog supply ±15V
5 Intermediate circuit voltage (30 / 2000 or 20 / 4000)
or ultrasonic power (35 / 1000) too low
6 Intermediate circuit voltage (30 / 2000 or 20 / 4000)
or ultrasonic power (35 / 1000) too high
7 Heat sink temperature > 75° C
8 Window error, US_SP > US_MAX
9 Window error, US_SP < US_MIN
10 Max. welding time exceeded
50 Ultrasonic watchdog self test t < 9ms
51 Ultrasonic watchdog self test t > 11.5ms
80 Welding stopped through turn-off option - energy

81 Welding stopped through turn-off option - external stop
82 Welding stopped through turn-off option - welding time
90 Teaching-in ended without errors

91 Teaching-in ended with errors
92 It is necessary to repeat the teaching-in.
93 After teaching-in, 80% of the target amplitude was not reached in the welding process.
Page 22 / 22 03 / 2015 Version: 1.0

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Supplementary Operating Instructions

Supplementary Operating Instructions

All rights reserved. Subject to change without notice.

2014 MS Spaichingen GmbH

Page 2 / 22 03 / 2015 Version: 1.0

2 Overview of the device description files ............................................... 5

3 Protocol DeviceNet, ProfiNet, EtherNet / IP, Modbus TCP ................... 6

4 Start Info ................................................................................................ 21

5 Overview function codes ...................................................................... 22

Version: 1.0 03 / 2015 Page 3 / 22

Page 4 / 22 03 / 2015 Version: 1.0

2 Overview of the device description files

Generator EDS file

Generator GSDML BMP file

Generator EDS file

Addressing Modbus Register:

Version: 1.0 03 / 2015 Page 5 / 22

3 Protocol DeviceNet, ProfiNet, EtherNet / IP, Modbus TCP

Read version states

Read weld protocols

Page 6 / 22 03 / 2015 Version: 1.0

Read start counter

General communication guideline

Version: 1.0 03 / 2015 Page 7 / 22

3.1 Identifier 0 = cyclical I/O data

Master output range

Byte 0, bit 0: Bool Ultrasonic on / off

3.1.1 Ultrasound on / off:

• 80 Welding stopped through turn-off option - energy

Page 8 / 22 03 / 2015 Version: 1.0

3.1.2 Calculation guideline of the amplitude:

For example, Amplitude specification = 68%

30(10) = 0 * 32 (10) + 1 * 16 (10) + 1 * 8 (10) + 1 * 4 (10) + 1 * 2 (10) = 01111 (2)

Master output range

Byte 0, bit 3: Bool Amplitude specification bit 1 = 2 (10) = 1 * 2 (10)

3.1.3 Calculation guideline of the max - min level specification:

For example, Level specification = 55%

Address Data type Description

Master output range

Byte 2 Byte Max level specification 0% = 0 (10) ; 100% = 255 (10)

Word 20 uint16 Identifier variant = 0

Version: 1.0 03 / 2015 Page 9 / 22

3.1.4 Calculation guideline of welding power

Address Data Description

Master input range

3.2 Identifier 1 = read version states

Master output range

Master input range

Page 10 / 22 03 / 2015 Version: 1.0

3.3 Identifier 2 = parameterization

Address Data Description

Master output range

Byte 0, bit 0: Bool Reserved

Version: 1.0 03 / 2015 Page 11 / 22

Address Data Description

Byte 1, bit 0: Bool Teaching-in

Mode "energy welding" (byte 0 bit 1 = "1")

Double word 2 uint32 Welding time

Mode "teaching-in" (byte 1 bit 0 = "1")

Byte 6 sint8 Start frequency offset

Page 12 / 22 03 / 2015 Version: 1.0

3.3.1 Parameterization procedure

Parameterization is concluded. The generator can now be started.

Version: 1.0 03 / 2015 Page 13 / 22