User Manual Display and Firmware
Contents
1. v Latch a pulse switches the generator on a second pulse switches the generator back off gt Storage function 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 15 of 43 KN kka n ULTRASONICS TECHNOLOGY v Static the generator is on as long as the remote signal is active gt No storage function v Trigger this option is only recommended when at least one of the special operation modes Timer or Energy is used A short pulse starts the generator The device automatically switches off when the predetermined time or energy is reached generator j Static remote signal Predetermined time energy Generator Remote signal gt TRANSDUCER TEMPERATURE In this screen you can read out the current temperature Teme Transducer of the transducer Temp Transducer This feature is only active if a transducer with temperature sensor function is connected 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 16 of 43 AN kke ULTRASONICS TECHNOLOGY gt INFO Here you can see some information about the device 1 12 188 2268 v Engine Firmware revision of the i 1 12 43 228 t re 02 02 2012 001 04 40 0129 v Display Firmware revision of the i 0 00 00 front board v Datecode date of production v Serial Serial number of the device v Runtime total operating time h mm ss gt EXIT Pushing the rotary encoder leaves the setup menu a2. s SOniKKS ULTRASONICS TECHNOLOG User Manual Display and Firmware Generator model W with rotary encoder Puer E Sa a pa Sonc i 00 d l e ERROR TEST 80 9 8 lt gt NOMINAL 60 e Bea OVERTEMP 40 e o o yew MODE p 20 i OUTPUT amp GmbH ww sonikKKs LTRASONICS TECHNOLOGY 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 1 of 43 W kke ULTRASONICS TECHNOLOGY Table of contents Table Of contents ccccecseseececeececneeecnteeeneeeeaeseeaeeeeaeseeeeseeeaseeeaeaeeeeaeseeanseeaesaeeeseteasatsasatsesansegs 1 Parameters SECUN aa sateee tate teeta tattle en ea tide detect afer nea eden eee iene 4 Menu items and OPEratiOn cccccccececceceeeeeeeeeeeeeeeeeeseeeeeeeeeeeeeeeeeeeeeeeeseeeesereesereeseeeesaneesansesenness 4 SAUS LEDS cccccaccosstesvsaisicaciesciencicacecaveesccsssinaeieccicseicaveensaeadenisicaciercicscieaveesvensvcesvicieicacieretcnces 5 Navigation chart s ssssssssssnsrnrrrnsrnrrrnsrnrnrnsrnrnrnnrnrnrnsrnrnrnnrnrnrnnnnrnnnnnnrnnnnnnrnnnnnnnnnnnnnnnnnnnnnnnnn 6 Structure of the menu and functions cceeeeecceeee eee eeeeeeeeeeeeeeeeeeaeeeeaeaesesaeaeseeaeaesesaeaesesaeaesesaees 9 Me OVNEN e E E A EN E EE AEE Sa 9 De WING Ce ICTY E A E E E E vena etaueeeeans 9 3 PONO ES 9 i BCCI S E E E A eee ean E E ce veenieeekee sees seeauateeeneee 10 ie NA eater ate ates heeled T elena eet ea A ele
3. 1 Purpose of the feature The cycle mode has been designed to be used together with ultrasonic welding presses that do not feature a built in controller Controllers are commonly used in welding chains to make them more efficient and to improve their cadence In order to do this the controller makes sure that the ultrasonic energy is automatically delivered to the sonotrode at specific periods of the welding cycle during the welding time when the pieces are pressed against each other and optionally during an afterburst Therefore the welding cycles can be completed faster without any waste of time Thanks to this helpful feature the soniKKs Welding Generator can replace such a controller giving your ultrasonic presses the intelligence they are lacking 2 Status LEDs The behaviors and meaning of the status LEDs of the generator are globally the same as described on page 4 The only changes concern the Error LED and the Mode LED which will work as follows Welding Cycle mode disabled ON an error occurred e Welding Cycle mode enabled gt ON an error occured gt Blinking the weld time has expired whereas the energy threshold has not been reached see the Timing chart Error LED e Welding Cycle mode disabled gt ON the generator is set to a timer or energy mode Cole Wem Ml D e Welding Cycle mode enabled gt ON a welding cycle is ongoing 2015 01 29 soniKKs GmbH
4. Start command pending 2005 1 Bit Overtemp Status 0 Temperature OK 1 Temperature exceeded 2006 1 Bit Run Status 0 Generator is idle 1 Generator is running 2007 1 Bit reserved reserved Please note that the Run Status bit can be 1 even if the generator is not currently emitting power Example if a HoldTime and an Afterburst are set the ON OFF status will be 1 during the weld time and the afterburst and 0 during the hold time As for the Run Status it will be 1 during the whole run 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 32 of 43 sonikKKs ULTRASONICS TECHNOLOGY 3 3 3 3001 1 3002 1 3003 1 3004 1 3005 1 3006 1 3007 2 3009 2 3011 2 3013 1 3014 2 3101 1 3102 1 3110 2 3112 2 2015 01 29 Short Short Short Short Short Short Long Long Long Short Long Short Short Long Long Input Registers Read only Status code reserved Actual Power Peak Power Generator Temperature Transducer Temperature Actual Frequency Accumulated Energy Actual Timer reserved reserved Nominal Min Total Power reserved reserved soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a Current error code reserved Actual power level o Peak power from the previous run 0 Internal temperature C Transducer temperature C Working frequency Hz Accumulated energy J Elapsed time during the curren
5. Ultrasonics Technology Doc nr 3010 2399a page 23 of 43 KN kka a ULTRASONICS TECHNOLOGY 3 Testbutton function Please note that the testbutton s function remains the same whether the Welding Cycle feature is enabled or not The generator will emit ultrasonic power as long as the testbutton signal is active see the Testbutton and Remote sections page 15 It cannot be used to start a cycle for instance Of course the testbutton will be ignored during the welding cycles 4 Parameters of the welding cycle The welding cycle can include up to four steps whose durations can be tuned by the user The different times of the welding cycle are v Delay the delay between the moment the remote input is activated and the weld time starts v Weld Time Energy the generator emits ultrasonic power until the specified time energy threshold is reached If both thresholds are set the generator stops as soon as one of the two is reached v Hold Time a delay time after the generator has stopped emitting ultrasonic power This phase enables the press to hold the pieces while the weld cools down v Afterburst the time during which the generator will emit ultrasonic power at the end of the cycle The afterburst is used to remove the residues of material from the sonotrode In addition the user can also configure the Sonic output relay to act as a cycle status as explained on page 20 The output will then be active during the whol
6. 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 3 of 43 KN kka a ULTRASONICS TECHNOLOGY Parameters security The unit features a unique two level security concept based on numeric passwords gt User settings Password Level 1 gt Reseller settings Password Level 3 Please ask your retailer or your manufacturer for the passwords Menu items and operation The generator is operated by a rotary encoder which can be turned as well as pushed This makes the operation very easy and comfortable The menu is structured in several subitems see navigation chart You can change between the items by turning the SS Name of the subitem rotary encoder Uae FA ay The top bar of the screen indicates the name of the subitem while the bottom bar tells you if adjustments can be done in this screen see also color code of ate navigation chart If so the bottom bar will display PUSH asia LIY TO ADJUST see screenshot on the right or PUSH TO RESET Frequency A005 r kHz Amplitude Jro PUSH TO ADJUST A Possibility of adjustment To enter the adjustment mode push the rotary encoder as suggested A value will then be highlighted meaning that you can modify it by turning the encoder Once you have selected the value option of your choice push the encoder again to validate the change As you can see in the screenshot above some screens can contain several editable values In this ca
7. 3010 2399a page 34 of 43 K sonikKKs ULTRASONICS TECHNOLOGY 3 4 Practical examples Here are some actual examples that will help you start operating the soniKKs Welding Generator over Modbus TCP 3 4 1 Switching the generator ON and OFF This can be done by setting resetting the value contained in register 1001 using the Write single coil function 05 The actual address to be sent is then 10004 1001 1 which gives 03 E8h To set and reset a coil the values to send are respectively FF 00 and 00 O0h Therefore the message should look as follows Tran n Master 00 AAn 00 00h 00 06h 03 E8 FF 00h Slave O wm woa owo o os oses Fron The slave returns the same frame as for every write commands 3 4 2 Adjusting the Amplitude level The amplitude level is located in register 40014 and can be accessed using the Read Holding Register and Write Holding Register functions respectively 03 and 06n To read it the master should send the following packet Tran n Master 00 ABn 00 O00 00 06h OF AO 00 Oth Slave ee a O ce The master requests the slave number 5 to read in the holding register area function 03h starting at address OF AOn 40004 00 O1n 1a register The data returned by the slave contains the length of the holding register in bytes 02n followed by the content of the register 00 53 gt 834 of amplitude To tune it to 57 for example 39h the packet should
8. Afterburst In welding cycle mode the afterburst is the final step of the cycle After the hold time while the press releases the parts some material may stick to the sonotrode Setting an afterburst time will make the generator clean the sonotrode by emitting an additional burst of ultrasounds PUSH T ADJUST See the Welding Cycle mode section for further information 10 Counter The Counter works as a part counter and shows the amount of finished parts You can reset the counter by pushing the rotary encoder as suggested in the bottom bar A pop up window will invite you to confirm your request The option is selected when highlighted Select yes to confirm or no to cancel 11 Temperature This screen displays the internal temperature of the generator If your generator is not equipped with a temperature sensor the bottom bar will display the NOT AVAILABLE message 2015 01 29 soniKKs GmbH Ultrasonics Technology Counter no ees PUSH TO CONFIRM P Teme trature Temp Generator Doc nr 3010 2399a page 12 of 43 sonikKKs ULTRASONICS TECHNOLOGY 12 Display Here you can tune display related parameters such as the contrast and the backlight You can also activate de activate the beeper Lontrast racklight Push the rotary encoder to enter adjustment mode Select the desired contrast level by turning the enco
9. Doc nr 3010 2399a page 30 of 43 W kke ULTRASONICS TECHNOLOGY gt Connect your Modbus TCP master and wait until the left LED of the Ethernet port is steady green 3 2 Specifications and adjustments Modbus TCP connections to the generator should be established using TCP port 502 A 500ms connection timeout makes the connection restart if no poll has been performed in this time frame Thus please make sure that the poll rate respects this timeout otherwise the connection will restart indefinitely see Technical Support on page 35 The efficiency of the Modbus TCP protocol is well known However it requires an accurate adjustment of the master and slave settings Therefore you will have to give great attention to your master s tuning in order to optimize the link between your master and the generator If your knowledge about Modbus TCP is limited you can refer to the paragraph called Recommended poll rates of the Technical Support Regarding the slave the generator two parameters are adjustable The pipeline option in pipeline mode the slave processes every command present in its TCP stack one after the other When the option is deactivated the slave only responds to the newest command and ignores all other commands of the stack This way it allows the master to retry old requests without risking building up a stale queue of waiting requests The pipeline option is enabled by default You
10. and are indicated by the Mode LED If the energy function is activated the generator turns off automatically when the predetermined energy value is reached This makes sure that you have the same input energy in every welding process In case you use both operation modes simultaneously the value which is reached first turns the generator off E g if energy and timer are activated the timer works as a time limit If this time limit is reached before the predetermined energy value is reached the generator turns off automatically In this screen you can determine the desired energy value Please push the rotary encoder to activate the adjustment mode Turn it until your desired value is reached To close the adjustment mode please push the rotary encoder again W E nergy Valid interval O off 9999 J i 8 Hold time The hold time is available if your device is configured in welding cycle mode Once your welding press has squeezed the parts to solder together and applied the ultrasounds to them the press will keep squeezing them together for the specified hold time PUSH TO ADJUST It enables to maintain the parts still during the cooling down of the solder See the Welding Cycle mode section for further information 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 11 of 43 AN kke ULTRASONICS TECHNOLOGY 9
11. eee ate 10 ic L ii a AE teeter deere A A ce te E eee ae eee 10 Te OE act cetera ate ete etre ee teeta ete cle eat ee A 11 o WONG UN irs cr sees peste cen te es pant bee enc steepness ase 11 O PSUS see te ioa a ec ir ee ante dee ee a ea edn ee asec eee seen se ee 12 UO MC OMG T E E T eneneee ace eanraeueese ea E eee 12 e NS arte a cw se ee eee 12 iE E E occa eegn ua esastneses aan tac tease seanna E eeacwuasesesuiecdtase eecesasweacntessieansat 13 13 ND cca 13 13 1 Uoer SUAS seara ee see eee 14 13 2 ESE EE A E E E A 17 Waring Cyce MOO ae acta erect tree ee EEEE EEEE 23 1 Purpose of the feature sessssssenssnsrnnrsnsrnrrnnsrnrnrnnrnrrrnnrnrnnnernnnnnnrnrnnnnnnrnnnnnnrnnnnnnrnnnne 23 A OUS LED errer a e 23 3 T StDUTCON FUNCTION cccceccecseseesteeeeusnececeecesateeeateeeanseeeseeaeseeoeseesasatsasatsesatseeanseeansanes 24 4 Parameters of the welding CYCIC cccccsecseseceeeeeeeseeeeeeeeeeeeeeeeeeeeseseeseseraeseraesereesareesanees 24 Oi FMN CIN erine E E 25 Operation over MOCDUS TCP cscceccecseseceeseeeeeeeeeeeeeeseeeeeeenesseneeeeseeeeteeeesaeeeseenesaeseraesatensanees 26 1 Basic network information ssssssssssssnssnsrnrrrnsrnrnrnsrnrnrnnrnrnrnnrnrnnnnrnrnnnnrnrnennrnrnennrnrnnnne 26 1 1 IP Configuration MOG Gi ssesieeevieecrrsesaeevexesaeeis rises NTER PIETEI Err E R PATEAT TENERNE 26 1 2 IP address rn ee rere 26 1 3 ING GAS IS A A E E ee enseee assess 27 2 Modbus TCP protocol overview cccscce
12. fixes the problem flushes the bloated TCP queues full of stale requests The core problem is that the master client is using the old RS232 RS485 serial assumption that no answer means poll was lost However in the case of the Modbus TCP gateway in between it could also mean the gateway has not had time to answer because it is being overworked Also remember that TCP is reliable the gateway receives all polls sent without error The result is that the master client retries which makes it harder for the gateway to catch up Here is the scenario that is causing the problem Li 2 10 Master sends out MB TCP Poll A with a timeout of 1000 msec Gateway receives the poll but the serial link is busy so it waits possibly another MB TCP master is being serviced or timeouts waiting on off line stations are creating a backlog of new requests After approximately 850 msec the serial link is now free and the gateway forwards the MB RTU request to the controller The gateway receives the response from the generator and since the timeout on the gateway and master are not inherently synchronized the gateway sends the MB TCP response into the TCP socket In the best of times it may take 5 10 msec for this response to actually go down the gateway s TCP stack across the wire and up the master s TCP stack If a WAN or satellite is involved it could take 750 msec or longer Meanwhile before the master receives the Response A it gives
13. nr 3010 2399a page 29 of 43 ULTRASONICS TECHNOLOGY The exception response has the following pattern erection rt erata save 19 runcton oa Master 00 58h 00 O00 00 06h 3h 00 00 00 OAn In this example the master asks slave number 1 to read the content of the holding registers area 03n starting at address 40001 00 00n and including 104 registers 00 OA Slave The exception is recognizable thanks to the function field It is signaled by the slave by setting the first bit of the function code to 1 The nature of the exception is then indicated by the data field 02 corresponds to an Illegal Data Address for instance Please refer to the Modbus official documentation for the description of all possible exceptions 3 Operating a soniKKs Welding Generator over Modbus TCP 3 1 Configuring the generator s network settings To access your device over the network here is how to proceed gt Ask your administrator for this information v An available IP address v The netmask gt Start your generator gt Go to the Network Settings screen in the level 3 settings gt Set the configuration mode to Manual and enter your IP address and netmask gt Now configure the Modbus TCP parameters pipeline exceptions First try with the default settings gt Confirm the changes gt Power cycle your generator in order for the changes to be applied 2015 01 29 soniKKs GmbH Ultrasonics Technology
14. sonikKKs ULTRASONICS TECHNOLOGY 4 Frequency In this screen the current working frequency of the device is shown If there is no ultrasonic output the start frequency is displayed 5 Delay This screen makes it possible to use a start delay which is the time between the user s start request via the remote and the actual start of the device See the Welding Cycle mode section for further information 6 Timer The generator features two special operation modes iutss gt Welding on time Timer gt Welding on energy Energy Both operation modes can be used simultaneously and are indicated by the Mode LED If the Timer function is activated the generator automatically turns off when the predetermined time value is reached Thus it is possible to make welding processes on a specified time Push the rotary encoder to start the adjustment mode Turn it until the desired value is reached To close the adjustment mode please push the rotary encoder again Timer Timer Valid interval 0 off 99 999 s 7 A 000s 1 ms PUSH TO COMFIEM 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 10 of 43 sonikKKs ULTRASONICS TECHNOLOGY 7 Energy The generator features two special operation modes gt Welding on time Timer gt Welding on energy Energy Both operation modes can be used simultaneously
15. 1 Modbus TCP pattern A typical Modbus TCP frame is formatted as shown below It is composed of a 7 byte header that contains indications about the message followed by the actual data to be transmitted Example 00 58h 00 00h 00 06h Olh 04h OB BE 00 06n 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 27 of 43 W kke ULTRASONICS TECHNOLOGY The different packets have the following significations Transact ID 2 bytes Protocole 2 VLEs Length 2 bytes 1 byte el n N bytes On a network a master can send many requests in a short time and the answers to these requests may come in another order This identifier allows the master to link each response it receives to one command it has sent Thus each request has a unique identifier that the response also contains These 2 bytes indicate which protocol is used 00 00n corresponds to Modbus TCP The number of bytes contained in the rest of the message slave ID Function and Data The device address on the network Each slave present on the network has its own ID number from 1 to 247 allowing the master to indicate the recipient of the command i e to which device it is addressed Note that messages sent to slave 0 are processed by all the slaves The code for the function that the slave must perform The Modbus specification defines a set of functions see below and assigns a code to each of them Addi
16. 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 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 43 of 43
17. If you find stable results with these values when running the link over a longer period of time 2h you can try to lower the poll rate while keeping the response timeout untouched to allow for congestions to be gracefully resolved See below for a description of timeout factors to take into account How fast can I poll It is important to understand that the link to the generator s processor is realized through a gateway from Modbus TCP to a low speed serial link Therefore you cannot expect to poll any faster than you could by a direct serial link In fact since you are adding a number of queuing systems between your application and device you may even lose a bit of performance For example some download tests showed that remote download by Modbus TCP bridged to Modbus RTU ran about 20 percent Slower than direct download by Modbus RTU 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 37 of 43 KN kka a ULTRASONICS TECHNOLOGY G ee Above all remember that the serial speed or baud rate consumes the largest amount of time Suppose you issue a Modbus poll for 125 registers This requires a 255 byte response which at 115 2kbps the speed of the serial link requires over 22msec just to physically shift across the wire The overall time it takes to poll is the combined sum of these delays a Delay for master client to recognize need for poll b Delay to issue and get the poll onto the Eth
18. be the following 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 35 of 43 sonikKKs ULTRASONICS TECHNOLOGY eei n Master 00 ACh 00 00h 00 06h 6h OF AO 00 39h Slave er woe eee The slave returns the same packet as it is a write command NB The amplitude level can only be set between 50 and 100 3 4 3 Setting timers The Hold and Afterburst timers can be adjusted via the registers 40244 and 40264 Instead of setting them with two separate Write Holding Register commands you might want to adjust both with a single command In that case you can use the Write Multiple Registers function 10h as follows Trans Master OO AD 0000 000Fn Olin 10h OF B7 0003 06 00 00 03 E8 07 DOn Slave ODADy 00 00 00 06n Oly 10h OF B7 0003 When writing multiple coils or registers the length of the data to be written has to be specified Here the master asks slave 1 Oin to write to multiple holding registers 10n to the area starting at address 4023 OF B7n and involving 3 registers 00 03 the 6 following bytes 06n 00 00 03 E8 07 DO As the Hold Timer includes registers 40244 and 40254 it will receive the first 4 bytes each register is 2 byte wide The Hold Timer is then set to 00 00 03 E8 gt 10004ms The last 2 bytes will go to register 40264 which means that the Afterburst time will be 07 DOn gt 2000ums Note that this method is only applicable to consecuti
19. but the gateway can only process on average 290 of those per minute and some carry over After 10 minutes you may have up to 100 stale responses waiting in your master s TCP buffer This makes it appear as though there is now a 20 second lag in data reaching the master Here is the source of your data taking longer and longer to propagate to Master Client problem However if the master does implement Modbus TCP sequence numbers then the stale responses are rejected If the master is smart enough to resynchronize itself Response B does not kill poll C but master waits more then this resynchronization will manifest itself as the slave going off line and back on line intermittently If the master is not smart enough to resynchronize once this out of sync behavior occurs your slave goes permanently off line As you can see this Modbus TCP master is out of sync and the only cure may be to either restart the master or power cycle the soniKKs generator Both actions close the socket and purge the backlogged messages The use of a gateway brings out this shortcoming in master client Modbus TCP designs but even a pure MB TCP to MB TCP network would suffer from this problem if the poll cycle approached the average response time Any Modbus TCP network going through WAN will discover this Ideally the Modbus TCP master application used should implement the sequence number and gracefully handle receipt of stale responses with une
20. ck Modbus RTU raw in TCP this is not supported Make sure that you choose Modbus TCP as the protocol in your Modbus master application instead of Modbus RTU over TCP What to do if polls fail The soniKKs generator core probably cannot accept a new poll as fast as you are sending it over TCP TCP IP is a full duplex channel and since you can have up to 8 active sockets it is very easy to have a new request already waiting as your last poll s response is being returned The only solution to this is to slow down your Modbus TCP masters so that they never poll before the last poll s response has been seen This manually creates the time delay between polls your device expects 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 38 of 43 sonikKKs ULTRASONICS TECHNOLOGY My soniKKs generator runs fine for about 10 minutes and then my applications report it off line My soniKKs generator runs fine until it goes off line then it polls only intermittently Sometimes my soniKKs generator returns the wrong data After a while the sonikKKs generator seems to take longer and longer to answer After a few hours it takes 10 minutes or more for systems changes to propagate up to the master client All these relate to the same issue a mismatch in queuing behavior and expectation by the master client to the new realities of Ethernet it is not the generator behaving poorly Resetting the generator
21. cstsecstcecseseceeseeatseeceseecesuesesutsasatsesatseeatseesnseeansees 27 2 1 MOGDUS TCP Datler iD srrrerirrsriepirirsr terora r PEE RE R ETETE T REPEAT PETERET erie ees 27 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 2 of 43 sonikKKs ULTRASONICS TECHNOLOGY 2 2 Data ypes IN MOG DUS svisicesannesaccearesacieeesiseeiiserastinsessneiremasvieeeraseenrierie reat 28 2 3 Modbus memory Map and FUNCTIONS cceceeeeeeeeeeceeeeeeeeeeeeseeeeseraesesaesaees 29 2 4 MOGBDUS CX CCDE ONS ia gisecerneesecsaeesasiias teres EA ATA E 29 3 Operating a sonikKKs Welding Generator over MOCDUS TCP ecsesecseeeereesereeseeeeneeeenenes 30 3 1 Configuring the generator s network SettiINGS cccsceeceesecseseeeeseeeeeeeeesenees 30 3 2 Specifications and adjustments ccececseceeeeeeeeeeeeeeeeeeeeeeeeesersesereeseesesenees 31 513 soniKKs welding generator S Modbus map sccsceeceeeeceeeeceesereesereseeeesenens 31 3 4 Practical CXA MPlIES sieicncaneaccuavexesniisavaecvesareaneacaeisnmeearisduasaneeaveaswesnrasseeaness 35 A EO ara E EE EEEE EEE TE EE 37 S OCHINICA SUPPO ari irr sirine ri riCa enrarir EAEE EAEE EEEE ENEA NEEE EEEE Eri 37 TEOUDIGSOOUING E A A A A A E A eee 41 Mantenan ce and a O irae E E E 42 AEE A AEE E EE AE AA E A A A 42 AVM FUN siete cee cies te ce wie sie ee ee ea ee ee ca ee eee ee ee se ee ese se eee ce eee cece eee ceeesececesececececesesecesesececesesecee 43 2015
22. der and PUSH TO ADJUST push it to confirm the change Repeat the same operation for the backlight As you will notice you can choose between the three options below v On the backlight is switched on permanently v Auto the backlight switches automatically off after a while if the generator is not used v Dim the backlight is dimmed to a low level Push again to set the displayed option and go on to the beeper adjustment Choose between On and Off When ready push one last time to apply the change and quit the adjustment mode 13 Setup To change the settings you need a numeric password In the navigation chart you can see which settings require which password level gt User settings Password Level 1 gt Reseller settings Password Level 3 Upon entering adjustment mode the screen on the right appears The digits are set one by one by turning and pushing the encoder In order to reach the desired settings you will have to enter the corresponding password Please ask your reseller or manufacturer for the passwords 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 13 of 43 W kke ULTRASONICS TECHNOLOGY 13 1 User settings gt START FREQUENCY ATTENTION Start The adjustment of the start frequency should Generator f del requency only be done by experienced personnel The mo start frequency always has to b
23. e adjusted higher 20 5 kHz than the resonance frequency of the connected transducer system If the resonance frequency 30 5 kHz of the connected transducer system is unknown use the standard frequencies shown in the 35 5 kHz chart 40 5 kHz If the generator is started the displayed frequen 2 resonance frequency of the system 60 5 kHz Setting the start frequency too close to the resonance frequency of the system might cause the error amplitude protection active In this case please set the start frequency to a higher value See also Troubleshooting In this menu the start frequency can be adjusted by pushing and turning the rotary encoder ShOFt d ae LE C g LS Start Frequency Start frequency Valid interval Manufacturer setting gt NOMINAL SOURCE The amplitude can be controlled by an external voltage or tuned via the user interface the encoder and the O External voltage communication buses Front Comm bus Push the rotary encoder to activate the adjustment mode The currently set option is now highlighted By PUSH To ADJUST turning the encoder you can switch between the two options When the desired option is highlighted push the encoder again Herewith you confirm the setting and exit the adjustment mode v External voltage the amplitude can no longer be adjusted with the rotary encoder 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 14 of 43 k
24. e cycle i e from the start of the delay phase to the end of the afterburst phase interface 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 24 of 43 eee 5 Timing chart The graph below illustrates the welding cycle and its timings Delay Weld Hold J Afterburst oo gt AOH PS a Off Time On s i o a Ultrasonic Power Output Off Time Active 7 a HF Relay Output HF Status Inactive Time Active Inactive i i Time On l l l off Time On oh i i Error LED Off i 7 Time Start of Time Energy ene me the cycle threshold a reached This behavior only applies in the case when a Weld Time and a Weld Energy are both set and the Weld Time expires before the Weld Energy is reached 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 25 of 43 kke a ULTRASONICS TECHNOLOGY Operation over Modbus TCP The soniKKs welding generators can be equipped with an embedded server that enables them to be operated over TCP IP using the Modbus TCP protocol For these devices the user can configure the network settings as explained in this chapter 1 Basic network information 1 1 IP Configuration Mode The IP address of the device can be set manually in which case it is called a static address or automatically by an auto configuration server commonly a DHCP server it is then call
25. ed a dynamic address In manual addressing mode the user sets the IP address himself and can additionally set a netmask see explanations below This static configuration will remain the same as long as the user does not change it again The automatic addressing mode includes different modes that correspond to different auto configuration protocols v AutoIP the server automatically generates its own IP in the 169 254 x x range with a Class B subnet v Dynamic Host Configuration Protocol DHCP a DHCP configuration server will automatically provide the server with an IP address taken from its own pool of available addresses Y Bootstrap Protocol BOOTP a BOOTP configuration server will automatically provide the server with an IP address taken from its own pool of available addresses NB The user can enable either one of those modes or several modes at the same time 1 2 IP address The IP address is an identifier that allows a device to connect to an IP network Each device present on the network has a unique IP address in order to be reached easily The Modbus TCP servers integrated in soniKKs generators use an IPv4 address that consists of a 32 bit word that is usually given in the dotted decimal notation four decimal numbers ranging from 0 to 255 separated by dots ex 192 168 178 123 The IP address contains two pieces of information that are the network number and the host number which is the actual
26. er and Start Frequency In order to lock them you have to lock the corresponding screen amplitude Ome Pie tine O ME Exceptions the pipeline behavior of your Modbus TCP connection can be adjusted by turning the encoder When set the generator will queue the polls it receives and answer all of them in turn When disabled the generator only answers the last received poll and discards all stale polls This feature is enabled by defaut PUSH TO CONFIPM traditional Modbus uses silence to signal some errors e g unconfigured slave address timeout CRC error Setting this parameter will cause the generator to issue error messages instead specifying the cause of the error PUSH TO CONFIRM e g Overview for the When a screen is locked the bottom bar then shows LOCKED instead of PUSH TO ADJUST Trying to adjust parameters while the parameter locking is active will lead to an audio warning and of course the access will be refused gt EXIT Pushing the rotary encoder leaves the setup menu and leads back to the Overview screen PUSH TO COHFIEE 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 22 of 43 K sonikKKs ULTRASONICS TECHNOLOGY Welding Cycle mode If your generator is configured for cycle welding please take into consideration the following section in addition to the previous chapters
27. ernet c Delay for the poll to cross Ethernet and arrive error free at the device may include retries and contention Delay for Modbus TCP gateway to process and queue Modbus RTU poll Physical delay to shift poll bit by bit across the serial link Delay in the device to recognize process and start reply Physical delay to shift response out bit by bit across the serial link Delay for Modbus TCP gateway to process and queue Modbus TCP response Delay for the response to cross Ethernet and arrive error free at the master client may include retries and contention samo oO Delay a is defined by your OPC or DDE driver For example a driver that runs only once each 55 msec using the old DOS timer slice can have a variable delay here of between 0 to 110 msec Delays c and 1 are defined by the complexity load and link speed of your TCP IP network For example if you are going through radio or satellite links these delays routinely amount to 1000 msec 1 sec or more per poll and another 1000 msec for a response Delays e and g are defined by the baud rate and the amount of data you want to transfer per request Delay f is defined by the device The soniKKs implementation starts the reply within less than 5 msec Delays d e and h are defined by the load on the Modbus TCP gateway I cannot get a slave response The soniKKs generator only expects and processes genuine Modbus TCP from the network Some applications just pa
28. identifier of the device on the network 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 26 of 43 K soniKKs ULTRASONICS TECHNOLOGY The size of these numbers which means the number of bits dedicated respectively to the network and the host ID is defined by the first three bits of the address as follows Size of host number bit Leading Size of network number bit field field B 010 16 16 1 3 Netmask In IPv4 the netmask also called subnet mask is a 32 bit word used to divide a network into subnetworks As for the IP address it is commonly given in the dotted decimal notation This mask is used to indicate which part of the IP address corresponds to the network address and thus which part corresponds to the host identifier The ones delimit the bit field of the network whereas the zeros indicate the host s bit field 2 Modbus TCP protocol overview NB For more detailed information about the Modbus protocol you may want to refer to the official documentation available at http www modbus org Modbus is a Master Slave protocol used for supervisory control and data acquisition SCADA in which the master usually a PLC can obtain and modify parameters contained in the slave s memory via Read Write commands Only the master can send commands to the slave which executes it and systematically sends back a response even for Write commands 2
29. ke aam ULTRASONICS TECHNOLOGY Instead it is set by an external voltage 5 10V standard or rather 0 10V user specific adjustment that corresponds to 50 100 output power v Front Comm Bus the nominal power can directly be adjusted via the rotary encoder or the different communication buses gt TESTBUTTON In this screen you can adjust how the test button J a asand J Test works 4 options are available off Push Latch and Trigger Latch PUSH TO ADJUST Proceed as usual to activate the adjustment mode and change the settings v Off the test button has no function v Push as long as you push the test button the generator is on v Latch pushing the testbutton switches the generator on pushing again switches the generator off S Trigger this option is only recommended when at least one of the special operation modes Timer or Energy is used A short Trigger pulse starts the generator The device automatically switches off when the predetermined time or energy is reached gt see draft in item description Remote start mode gt REMOTE START MODE Here you can adjust how the remote signal works You can choose between the options Latch Static and Trigger O Latch O static Proceed as usual to activate the adjustment mode and Trigger change the settings sneuconnenenene SUS To BO GUST PTET TTT ET EERE
30. ly the relay will be opened upon stop if the relay polarity is set to normally closed gt HF RELAY MODE This screen is only available if the cycle timer option has HF Relay Mode been activated on your generator It can be done on HE Status request by the manufacturer O Cucle Le In this screen you can set the behavior of the HF DA internal relay to one of the two options below pusi To Boast v HF Status the relay behaves like in the Standard mode Welding Cycle mode disabled It indicates an active level high or low depending on its polarity if the generator is emitting ultrasonic power v Cycle the relay indicates an active level high or low depending on its polarity as long as the welding cycle is not complete gt OFFSETS ATTENTION firats It is only permitted to adjust the amplitude after Prinia having consulted the manufacturer Danger of damaging the transducer system A max offset 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 19 of 43 Brix _ ULTRASONICS TECHNOLOGY In this screen you can adjust the amplitude offsets A min offset and A max offset A min max offset Proceed as usual to activate the Valid interval 40 and 50 adjustment mode and change the v The value which you define for A min l offset changes the usually minimal 39 50 80 100 amplitude adjustment 50 Example If you choo
31. nd leads back to the Overview screen PUSH TO COHFIRH 13 2 Reseller settings gt SCREENS In this screen you can selectively disable or enable menu items If there is a cross in the check box this Delay menu item is shown in the menu If there is no cross Eis A Time the menu item is not shown in the menu A Timer Energy In the factory presets only the functions Timer and ee Energy are activated For more information about the functions please ask your reseller or manufacturer We recommend deactivating all the functions that you do not need Like this your item menu is more adapted to your requirements Proceed as usual to activate the adjustment mode and change the setting 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 17 of 43 AN kke ULTRASONICS TECHNOLOGY gt LANGUAGE 1 Here you can select the language in which the screens contents are displayed English Our generators are currently configurable to five Veutson different languages English German French Spanish 0O Fran ais and Polish PUSH TO ADJUST Proceed as usual to activate the adjustment mode and change the settings ATTENTION For your own safety do not choose a language you do not speak The language changes immediately by confirming your choice and the menu appears in the chosen language which could be foreign to you gt GREETINGS This screen allows you to select
32. queue up in the first place You can enable the use extended exception responses in the server configuration as well see page 22 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 40 of 43 sonikKKs ULTRASONICS TECHNOLOGY Troubleshooting ERR ce AMPLITUDE PROTECTION ACTIVE OVWERTEMPERA TURE JUC ERR ae PUSH To CONFIRM 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr Transducer broken Short circuit at RF cable Error on the generator Start frequency too close to resonance frequency Transducer broken Error on the generator Transducer not connected or broken Cable broken Fan broken Error on the generator Generator overloaded Replace transducer Replace RF cable Contact soniKKs Select higher value for start frequency Replace transducer Contact sonikKKs Connect or replace transducer Replace cable Check fan Check if air suctioning works Contact soniKKs Reduce compacting pressure Use generator with more power 3010 2399a page 41 of 43 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 device Keep the cooling slots clear all time Warranty The period and extent of the warranty is part of the commercial terms and conditions Special agreements are part of the confirmation of
33. ration of your device will Hetwork Settines be displayed and adjustable Beri fetwork Settings Please refer to the Modbus section page 27 for further ACFE information about this feature IP Address 132 169 172 122 Hetmask ZSS Z255 255 0 Depending on the configuration three or less parameters are displayed v Mode the IP configuration mode Manual AutoIP DHCP BOOTP Choosing a manual configuration mode will lead you to set an IP address and a netmask yourself Any other mode is an automatic mode for which the IP address and the netmask are provided automatically to the generator In manual mode the two parameters below are adjustable v IP address the IP address used by the device on the network It can only be set when the mode is set to Manual In automatic mode this line will not be displayed v Netmask the netmask used by the device on the network It can only be adjusted in manual mode In automatic mode this line will not be displayed 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 21 of 43 sonikKKs ULTRASONICS TECHNOLOGY Once you have set the parameters above two additional Modbus TCP related settings appear v Modbus Pipeline v Modbus Exceptions gt PARAMETER LOCKING The parameter locking enables the supervisor to Parameter Lockineas restrict access to the following parameters Amplitude Delay Timer Energy Hold Afterburst Count
34. ress Netmask MB Pipeline MB Exceptions Greetings Hello Logo Startup message Sonic relay polarity Normally open Normally closed Transducer limit Set limit for temperature of the connected transducer Parameter Locking Lock parameter adjustment in certain screens Doc nr 3010 2399a ie V V Q Q ja uhat Cc 9 dud V oS lt q Transition page 8 of 43 W kke ULTRASONICS TECHNOLOGY Structure of the menu and functions 1 Overview The overview displays the current working frequency of the device If there is no ultrasonic output the start frequency 2 is displayed Frequency 40 5 kHz Amplitude Here you can adjust the desired amplitude Push the rotary Esiz encoder to activate the adjustment mode The line where the amplitude value is displayed is now marked Turning the rotary encoder right decreases the value turning left increases the value To close the adjustment mode push the rotary encoder again DEF N Amplitude Frequency 40 5 kHz Amplitude Power Oy Valid interval 50 100 PUSH TO COHFIFH 2 Time amp Energy In this screen the accumulated energy is displayed as well as the duration of the last process elapsed time Accrued Energy Elapsed Time 3 Power Here you can read out the currently emitted power 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 9 of 43
35. se 40 for A min offset the absolute value 50 is downsized through 40 of his own value 40 of 50 gt 50 20 30 The amplitude value would be 30 40 of 50 20 of 100 30 50 80 100 v The value which you define for A max offset changes the usually maximal amplitude adjustment 100 Example If you choose 20 amp for A max offset the absolute value 100 is downsized through 20 of his own value 20 of 100 gt 100 20 80 The amplitude value would be 80 gt TRANSDUCER LIMIT In this screen you can determine a temperature value If the temperature of the transducer reaches this value the generator switches off automatically for reasons of Safety of the transducer This option is only available if a transducer with temperature sensor function is connected 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 20 of 43 sonikKKsS ULTRASONICS TECHNOLOGY FACTORY SETTINGS A confirmation dialog will appear if you push the encoder By choosing yes the factory settings will be restored HOT AVAILABLE gt NETWORK SETTINGS This screen deals with the generator s network Network Settings parameters It only concerns welding generators which feature an embedded server If your generator does not have any the message on the right will be displayed HOT gVOrlLGeELe Otherwise the current configu
36. se the values are edited in turn from the top to the bottom Validating the changes of the last editable value will then close the adjustment mode 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 4 of 43 ULTRASONICS TECHNOLOGY Status LEDs Sonic LED ON ultrasonic power is active Error LED ON there is a malfunction of the generator lt gt Nominal LED No function in this version ON the generator is overheating and the over temperature fuse has shut off the generator Overtemp LED Blinking the generator was shut down during the last welding process due to over temperature The LED turns off if you start the generator again gt ON the generator is set to stop after a predetermined condition is Mode LED reached These conditions are time or energy gt Blinking one or more welding cycle parameter is set Indicates the effective ultrasonic power in steps of 10 of the nominal ANS t t e LLA Output gauge PENS SONIC ERROR lt gt NOMINAL OVERTEMP MODE 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 5 of 43 W kke ULTRASONICS TECHNOLOGY Navigation chart Your logo Hello Overview Frequency Amplitude Power Frequency Shows current frequency Set an energy threshold upon which the device stops Counter Amount of finished parts User mu
37. should disable it only if you are having problems The exceptions option Traditional serial Modbus uses silence to signal some errors However Modbus TCP defines error codes to make the errors explicit The soniKKs generator can return two exceptions depending on the gravity of the error OxOA and Ox0B Ox0A indicates a hard error where a retry is not likely to succeed Conversely 0x0B stands for a soft error where a retry may succeed 3 3 soniKKs welding generator s Modbus map The parameters below are accessible at the specified addresses see also section Modbus memory map and functions To simplify the notations only the lower part of the address is shown in the tables e g 44018 gt 4018 Given the nature of the Modbus addressing scheme the address sent in the message should be register address 1 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 31 of 43 sonikKKs ULTRASONICS TECHNOLOGY 3 3 1 Coils Read Write 1001 1 Bit Start Stop command _ 0 Start the generator 1 Stop the generator 1002 1 Bit reserved reserved 1011 1 Bit reserved reserved 3 3 2 Discrete Inputs Read only 2001 1 Bit HF Status 0 No HF detected on output 1 HF detected on output 2002 1 Bit ON OFF Status 0 The generator is not emitting power 1 The generator is emitting power 2003 1 Bit Error Status 0 Status OK 1 Status Error 2004 1 Bit Start Command Status 0 No start command pending 1
38. st authenticate himself with a password 2015 01 29 soniKKs GmbH Ultrasonics Technology a Time amp Energy Accumulated energy Elapsed time Set the start delay Set the hold time Temperature Current internal temperature Shows current power Set the duration of ultrasonic power emission Afterburst Set the afterburst time Display Contrast Backlight Beeper User settings Reseller settings Doc nr 3010 2399a You can only adjust the amplitude Adjustment is possible p W at _ the other values are just displayed page 6 of 43 sonikKKs ULTRASONICS TECHNOLOGY User Settings Start frequ Nominal Testbutton Source ble Remote Transducer start mode Temperature is possi Adjustment V 4 le H 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 7 of 43 K SONIKKS ULTRASONICS TECHNOLOGY Reseller settings Screens de activate more functions Runtime Monitor operating time also resettable Sonic relay mode HF status Cycle Factory settings Restore factory settings Back to menu items 2015 01 29 soniKKs GmbH Ultrasonics Technology i _ Language English German French Spanish Polish Error relay polarity Normally open Normally closed Offsets A min offset A max offset Network Settings Config Mode IP add
39. t run ms reserved reserved Minimal amplitude Maximum total output power W reserved reserved page 33 of 43 Mike i a ULTRASONICS TECHNOLOGY 3 3 4 Holding registers Read Write Register Number of Type Description address registers 4001 1 Short Nominal Amplitude Nominal amplitude 4002 1 Short Weld Energy Welding energy threshold J 4004 1 Short reserved reserved 4005 1 Short reserved reserved 4006 2 Long Start Frequency Start frequency Hz 4008 2 Long reserved reserved 4010 2 Long reserved reserved 4012 2 Long ON Time Weld Time ON time Welding time ms 4014 2 Long reserved reserved 4016 2 Long reserved reserved 4018 2 Long reserved reserved 4020 2 Long reserved reserved 4022 1 Short reserved reserved 4023 1 Short Delay Time Delay time before welding ms 4024 2 Long Hold Time Delay time after welding ms 4026 1 Short Afterburst Time Additional US burst time ms 2 Make sure that the nominal source is set to Front Comm Bus see Nominal Source screen in the user settings 3 Please do not change this parameter unless you understand the implications 4 Used for the welding time if the Welding Cycle feature of your generator has been activated 5 Only available if the Welding Cycle feature of your generator has been activated See the Welding Cycle addendum for further information 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr
40. 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 non qualified staff Damage due to nonobservance of safety regulations or accident prevention regulations Damage due to modifications to the operating manual VV VV V V 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 42 of 43 ULTRASONICS TECHNOLOGY Imprint Purpose and use The operating manual explains the handling and operation of the display and the firmware in connection with standard accessories for use in laboratories and the industry Please read especially the safety instructions carefully and observe them all The operating manual should always be at hand to help you to solve any questions and problems that may arise All rights reserved This manual has been prepared with all due care nevertheless faults and omissions cannot be fully precluded sonikKKs 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 Ultrasonics Technology GmbH first edition August 2012 NeuenburgerstraBe 72 second edition March 2014 75335 Dobel
41. tional data accompanying the function code such as the address of the starting register the number of registers concerned and the data to be written for Write commands NB the values are in hexadecimal marked h that is to say that 2 digits represent 1 byte 2 2 Data types in Modbus Modbus differentiates 4 data types based on length and accessibility criteria e Coils Discrete Inputs e Input Registers e Holding Registers 2015 01 29 sonikKKs GmbH Ultrasonics Technology The coils are one bit values that can be modified as well as read e g on off command enable disable a mode The discrete inputs are one bit values that cannot be modified by the master They usually are status and thus can only be read e g run status error status The input registers are read only values that can occupy one or more registers depending on their length They are usually used for sensor measurements current temperature Current power The holding registers are read write values that can also occupy Doc nr 3010 2399a page 28 of 43 K sonikKKs ULTRASONICS TECHNOLOGY several registers They are usally used for configurable parameters such as nominal values thresholds 2 3 Modbus memory map and functions The parameters are stored in the slave s memory in 16 bit registers The Modbus protocol defines a memory map that separates the 4 data types depicted above Therefore the memory is s
42. ubdivided in 4 blocks of registers which contain our parameters In the array below you can see that each of these blocks can be accessed using its appropriate functions For instance the coils registers 1 to 9999 can be read thanks to function 01 only E Recos oO O Write Multiple cois Pc 024 02 10001 19999 CE 042 048 0000 30999 034 03 40001 49999 Write Single Holding Register E Write Multiple Holding Registers 16g 10 In the messages however the master always specifies an address between 0 and 9998 270E When processing the message the slave will then add an offset corresponding to the block implied by the function code 1 for the coils 10001 for the discrete inputs 30001 for the input registers and 40001 for the holding registers 2 4 Modbus exceptions The Modbus protocol also features some error recognition cases called exceptions When a command is sent there are 4 possible outcomes It does not reach the slave gt the master gets no response It reaches the slave with some glitches gt parity or CRC error gt the master gets no response It reaches the slave with no transmission error and is successfully processed by the slave gt the master gets a valid response It reaches the slave with no transmission error but the command cannot be processed gt the master gets an exception response indicating the cause of the failure 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc
43. up and makes the Modbus RTU assumption that the request must have been lost The master sends out a new MB TCP Poll B A few msec later there is a response that looks like a good Response B but actually is Response A If the master does not use a sequence number which many do not and has forgotten about pending poll A it wrongly assumes this is response B possibly with catastrophic results if Poll B was the same size but different register range Here is the source of the problem Generator returns the wrong data The master is idle and has no outstanding polls Yet the gateway has received Poll B by TCP IP It sends this out to Modbus RTU slave and gets an answer which means it s working normally and as expected The gateway then returns Response B to the master if the socket is still open and there it sits in its TCP IP buffer The master is not expecting more responses so it neither receives nor purges the extra response Master sends Poll C and magically finds a response waiting as soon as it looks in the receive buffer yet this is stale Response B received before poll C was even issued If the master does not implement Modbus TCP sequence numbers then it accepts the response B as satisfying poll C 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 39 of 43 sonikKKs ULTRASONICS TECHNOLOGY Imagine if the master is putting out 300 polls per minute 5 polls per second
44. ve registers The response from the device is the same frame without the written values 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 36 of 43 sonikKKs ULTRASONICS TECHNOLOGY 4 Errors In case an error occurs during the configuration on Network Settinas Startup an error message will be displayed in the Network Settings screen and the server configuration ERROR will remain unchanged CONFIGURATION FAILED You may want to power cycle your generator again If the problem persists please contact us HOT AVAILABLE 5 Technical Support Using the soniKKs generator with Modbus TCP is normally easy However if a problem occurs it is difficult to troubleshoot without an in depth knowledge of Modbus and the system dynamics of polling Some general guidelines for troubleshooting Start polling slowly and increase speed gradually Keep in mind that in many situations the host application declares No response when in fact the device did respond and the application did not understand the response Recommended poll rates We recommend using the following values to configure your Modbus TCP master assuming that your network load and latency times are within the range of a few msec response timeout 275ms poll rate for fast updating process values 300ms poll rate for slow updating process values e g temperature error code 1000ms commands etc on demand
45. what will be displayed on startup You can either choose to display the stored O Hella logo personal logo on request or a simple Hello Sis ae go message z PUSH TO ADJUST gt RUNTIME Here you can read out the total operating time of the generator Format h mm ss Reset of the runtime is possible Proceed as usual to activate the adjustment mode and change the settings ERROR RELAY POLARITY In this screen you can adjust the behavior of the internal error relay The current configuration is i Normally open indicated by a ticked check box 3 O Normally closed The relay can either behave as a normally open or a normally closed contactor BUSH To agair 2015 01 29 soniKKs GmbH Ultrasonics Technology Doc nr 3010 2399a page 18 of 43 kke am ULTRASONICS TECHNOLOGY Normally open means that the relay will be closed upon failure of the generator Conversely the relay will be opened upon failure if the relay polarity is set to normally closed gt SONIC RELAY POLARITY In this screen you can adjust the behavior of the HF Relow Polarity internal sonic relay The current configuration is Normally open indicated by a ticked check box O Normally close The relay can either behave as a normally open or a normally closed contactor BUSH To BOUST Normally open means that the relay will be closed upon start of the generator Converse
46. xpected sequence numbers Unfortunately the Modbus TCP specification says that this sequence number is optional and can be used by a master to match responses to requests however it can usually be just left as zero The Modbus TCP slave just echoes this back in the response Anyway most Modbus TCP OPC servers today do not implement the sequence number So what is your solution if your Modbus TCP master is first generation Slow down your poll rate You have to consider the worst case response time assume all polls timeout If you are only polling a single slave or poll one slave at a time then you can try to disable the MB Pipeline option in the server configuration see page 22 This will either help or make things hopelessly worse If your OPC server or host application relies on pipelining to send more than one outstanding poll at once then disabling the pipeline will essentially stop all data communication in which case you can just turn the pipeline back on The ideal solution is for your Modbus TCP master to not only support the Sequence Number but also support the receipt of the OxOA and 0x0B extended Modbus TCP exception response Then the master never needs to do retries for each poll it will receive either a value Modbus TCP response or a Modbus TCP exception that the slave is unreachable or timed out This prevents the master from sending more polls than the gateway can process and building the TCP buffer
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