K&M DS400 User manual

K&M Technologies LTD
User’s Manual

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Contents：
1. Preface..................................................................................................................................................2
2. Precautions:.........................................................................................................................................2
3. Installation Place................................................................................................................................3
4. Power Supply......................................................................................................................................3
5. Ultrasonic Welding Principle......................................................................................................... 3
6. Pictures Of Machine.........................................................................................................................5
7. Power supply/connection ports................................................................................................... 7
8. Port Connections.................................................................................................................................12
8.1 Control Input port ........................................................................................................................12
8.2 Working Status Output Port.....................................................................................................13
8.3 Analog Quantity Input/Output Port.......................................................................................14
8.4 Communication Port...................................................................................................................14
8.5 Communications Ports for Human-Machine Interface................................................... 16
9. MODBUS PROTOCOL................................................................................................................... 17
10. Power Supply
11. Operation Panel ................................................................................................................................ 17
11.1 Password Keyboard, Parameter Keyboard........................................................................17
11.2 Version Information Page.......................................................................................................18
11.3 Main Page.................................................................................................................................... 19
11.3.1. Welding record page...................................................................................................... 19
10.3.2 Trigger preparation page................................................................................................20
11.3.3 Parameter Setting Page....................................................................................................... 21
11.3.4 QA Management Page.........................................................................................................23
11.3.5 Protection Function Page.................................................................................................... 23
11.3.6 Factory Setting........................................................................................................................ 24
11.3.7 Amplitude calibration........................................................................................................... 25
12. Trouble Shooting..............................................................................................................................26
13. Quality Guarantee............................................................................................................................ 29
14. Additional Information....................................................................................................................30
15. Contact us ........................................................................................................................................... 30

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1. Preface
Dear users,
Thank you for using KnMTech ultrasonic systems, a smart, digital control ultrasonic
power supply developed by our company.
Before using this product, please read this manual carefully and be familiar with the
operation regulations and parameter scopes.
Only Professional technicians or trained personnel can commission or maintain this
product.
2. Precautions:
Please read this manual in details before operation to guarantee a smooth operation
and self-safety.
Only professional personnel is allowed to install this system. Operators must be
trained before work.
Protection measures have to be taken for operation in hazardous environment. As
some energy will be transformed into heat during the operation, be cautious that the
accumulation of heat will lead to explosion or burning without any protection.
Peripheral electric device electromagnetic compatibility must meet the requirement
of the related country. All the operation parameters can be set by user, but the
parameters protected by passwords shall be kept at factory default parameters. For
any support, please contact our technical personnel. It is strictly prohibited to turn
on the machine with a loose welding horn.
When moving or maintaining the device, it has to be handled by professional
personnel under condition when power is off.
For repairing or maintaining the generators dust has to be removed by compressed
air blower or brush. Please don’t use cleansing reagent to clean the case or LCM
interface. Cloth with slight water can be used for rubbing the dirt.
High-load driving cables can control or signal monitoring cables shall be screened
stranded conductors. Please don’t install it close to high-current devices. The
screened cables shall be connected to power supply grounded line. All the driving
cables can control cables shall be grounded, and the generator’s ground line shall be
connected to the ground line of power supply.
Pay more attention to the malfunction codes on the generator to facilitate early
action to prevent expansion of the malfunction.

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The generator shall be installed in correct direction to assure firmness without
loosening. Power supply specs must meet the demand of the generator.
Professional personnel shall be in charge of the repair or maintenance if any of
following happens:
After turning off the power:
When any liquid or metal or conductive material goes into the generator;
When cable connection is loose or damaged;
When the power supply is installed loose;
When the displayed contents is obviously different from normal conditions.
Attention: Please do the maintenance with prior agreement of chief technician.
3. Installation Place
The generator will produce heat during work, over-heat will lead to over-heat
protection (see details in “Over-heat malfunction”, so we used strong cooling
system.
The distance between generator vent port and other obstacles shall be kept in 10cm.
The temperature shall not exceed 40℃and moisture shall be exceed 75%.
4. Power Supply
Input: AC 220V, 50/60Hz.
Grounded 3-core cables shall be used to connect with generator.
Power supply fuse is inside the generator. When it is needed to replace the fuse,
the generator case has to be opened.
5. Ultrasonic Welding Principle
The ultrasonic generator converts 50/60hz electric current into 15khz,20khz, 30khz
or 40khz or higher frequency energy, and output to the piezoelectric ceramics inside
the converter, to make same frequency vibrations by the converter, and the
mechanical movement will be transmitted to the booster that can change the
vibration amplitude, and to the welding horn. The horn will transmit the received
vibration energy to the bonding surface of two parts.
In this bonding area, the vibration energy is converted into heat energy by way of
friction, then plastic parts melts and joined with a certain pressure.

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Actuator
Pressure Sensor
Converter
Booster
Welding horn
Product Upper Part
Product Lower Part

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6. Pictures Of Machine
v
Fixation handle
Fixation handle
Pressure gauge
Human-machine
interface
One-way throttle valve
Machine Column
Working table
Pressure adjuster
Converter installation flange

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Leveling screw
Limitation screw
Filter cup
Signal plug

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7. Power supply/connection ports
7.1 Power supply
Power supply: AC 220V 50/60HZ
Grounded 3-core cables shall be used to connect with generator.
Power supply fuse is inside the generator. When it is needed to replace the fuse,
the generator case has to be opened.
Note: The input power must be disconnected before replacing the fuse. Please
replace the damaged fuse with one of the same specifications. For details, please
refer to "Power Specification Table" (page P8).
7.2 Power connection port/external control input/output interface
7.2.1 Power supply input interface (A)
A: L 220VAC power live wire
B: N 220VAC power null wire
C: PE Power supply grounded line
Note: Grounded 3-core cables shall be used to connect with generator with the
diameter no less than 1.5mm2
7.2.2 High frequency output interface (B)
A: HF+: connect to transducer “+” port

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B: RF-: connect to transducer “-” port
Note: Please use shielded wire to connect, withstand voltage≥2000V
7.3 Input/Output control interface (C1, C2, C3)
7.3.1 C1 port
1: COM_24V: 24V power output common port 7: AUX_3: Auxiliary port 3 input
2: READY: Ready to output 8: AUX_2: Auxiliary port 2 input
3: Mvt: Cooling or Cylinder movement output 9: AUX_1: Auxiliary port 1 input
4: H.F: Ultrasound output 10: START:Work start input
5: OVL: Operation overload output 11: COM_0V: 0V power input common port
6: Error: Malfunction alarm output
7.3.2 C2 port
1: A_0-10V: External analog amplitude input 4: GND: Internal power grounding
2: P_0-10V: Real-time Power output 5: RS485_A: RS485 communication port A
3: FREQ: Frequency pulse output 6: RS485_B: RS485 communication port B
7.3.3 C3 port
1 2: EXT_24V: 24V power supply
3 4: EXT_0V: 0V power supply
Note: If the input/output common port is not enough, it can be connected to Port C3.
The 24V power supply of Port C3 and the public power supply of port C1 are
connected internally.

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7.3.4 Input/output control interface (DB25)
7.4 Power Supply Connection Ports/Outer Control Input/Output Ports
Pin
Name
Status
Function description
C1_10
Start
Input ports
US start up (Note 1)
C1_9
AUX_1
In Standard mode: US searching; in Auto
mode, US trigger (Note2)
C1_8
AUX_2
In Standard mode: amplitude
segmentation; in Auto mode: Emergency
stop (Note3)
C1-7
AUX_3
In Standard mode: Shake-off control; in
Auto mode: grounding detection (Note4)
C1_11
COM_OV
Common port for output
C1_2
READY
Output ports
“READY” status output.
C1_3
Mvt
“Hold” status output (Note5)
C1_4
H.F
“US work” status output (Note6)
C1_5
OVL
“Overload” status output (press RESET or
US search to remove it.
C1_6
ERROR
“Error” status output (Note7)
GND
14 15 16 17 18 19 20 21 22 23 24 25
RS485_A
RS485_B
COM_0V
COM_0V
COM_0V
COM_0V
COM_0V
COM_24V
COM_24 V
COM_24V
COM_24V
1 2 3 4 5 6 7 8 9 10 11 12 13
GND
FREQ
P_10V
A_10V
START
AUX_1
AUX_2
AUX_3
Mvt
READY
H.F
OVL
ERROR

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C1_1
COM_24V
Common port of output ports
C3_1,
C3_2
24V
External control
power supply
24V output positive pole (24V/1A) (Note 8)
C3_3,
C3_4
0V
24V output negative pole (Note8)
C2_1
A0_10V
Amplitude control
Amplitude control input 0-10V (10-100%)
C2_2
P0_10V
Power output
Power output 0-10V(10-100% rated)
C2_3
FREQ
Frequency output
Frequency pulse output (3.3V/10mA)
C2_5
RS485_A
Communication
ports
RS485 (MODBUS_RTU)communication
ports
C2_6
RS485_B
C2_4
GND
Internal power
grounding
Internal power common grounding (C2
port common grounding)
Note 1: Select “Key ” in the IO type, the port response time will be delayed 30mS to
remove the trembling, and in the continuous mode, the port will be self-locked,
other ports will be inching type. Select “PLC” in the IO type, the port will respond
quickly and the port will be inching type.
Note2: In the Mode type of STANDARD, and select PLC as the IO type, this port is
used to external trigger for ultrasonic frequency search; in case there is any
malfunction, this port can be used as external RESET port.
In the Mode type of AUTO, and select KEY as the IO type, and External Trigger,
this port will start the Ultrasound as Ext trigger (such as Pressure trigger).
In the Mode type of AUTO, and select SAFE as the IO type, this port will be used
together with the START port, in order to make two-button simultaneous start, to
ensure a safe start way.
Note3: In the Mode type of AUTO, and select Key or Safe as the IO type,this port
will be used as Emergency Stop input, or it can be used for Amplitude segmentation
(Segment B) input.

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Note4: In the Mode of STANDARD, and select PLC as the IO type, before start, this
port amplitude will be switched to Shake-off amplitude (Amplitude Segment C) .
Select “Key” as the IO type, and select “Grounding” as the work mode, this port is
used as Grounding Input.
（when Grounding hold time is off, the ultrasonic stops, and when Amplitude
Segmentation is enabled, the amplitude will be switched to amplitude Segment B.
In the Mode of AUTO，select “PLC” as the IO type, this port will trigger ultrasonic
immediately. Select other IO types, “Grounding” work mode, this port is used as
grounding input.
Note 5: In the Mode of STANDARD, The port can drive the Solenoid (24V/5W)
directly, and control blowing for cooling , and in the Mode of AUTO, this port can
drive cylinder movement. This port can be used to drive the solenoid (24V/3W)
directly.
Note 6: In the Mode of AUTO, when select ‘Ready A’ function, Ready A output is
enabled(such as control of protection film roller motors) .
Note7: It means malfunctions, such as wrong parameter setting, abnormal
communications or overheated. In this case, the machine has to be reset.
In the Mode of AUTO, when select ‘Ready B’ function, Ready B output is enabled
(such as control of the clamping action by the solenoid).
In the Mode of AUTO, when select ‘end action’ function, it is enabled to end the
action such as mould retreating controlled by solenoid. The port will automatically
switch to ‘H.F’ or ‘ERROR’.
Note 8: When it is not convenient to connect to the common port for input or
output, this port can be used for connection, as this port is connected internally with
the common port.

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8. Port Connections
8.1 Control Input port
external control
Generator inside circuits
PLC output port
Relay
Press
Control mode

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8.2 Working Status Output Port
Attention: The maximum driving current for 24V power supply input is 1A.
Signal cables shall be screened type with diameter ≥0.3mm2, length shall not
exceed 6 meters.

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8.3 Analog Quantity Input/Output Port
Attention: analog input and output ports shall be equipped with insulated
switching circuit, and the frequency port is 3.3V/10mA electrical level output.
8.4 Communication Port
Attention: RS485 communication port shall be insulated and the twisted-pair wire
shall be screened in strong interference place.

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9.MODBUS PROTOCOL（MODBUS_RTU,8/N/1,）
9.1 01H function code：Reading coil status
IP type：0x，IP scope 0x0--0x5.
9.2 02H Function code：Reading input status
IP type: 1x, scope:1xX1000-1xX1015
1x0: Run status 1x8: data error
1x1: trigger cycle data reading 1x9: suspected bad quality
1x2: Emergency stop 1x10: over-heated
1x3: Ready 1x11: abnormal load
1x4: cooling or cylinder action 1x12: Exceed the protection limit
1x5: ultrasonic work status 1x13: welding horn resistance too big
1x6: exceed work limit 1x14: exceed frequency limit
1x7: alarm for malfunction 1x15: exceed power limit
9.3 03H function code: Reading save register
IP type: 4x, Scope:4x0-4x33
4x0: amplitude mode 4x11: shake off delay
4x1: amplitude segment A 4x12：shake off time
4x2: amplitude segment B 4x13: work time of amplitude
segment A
4x3: shake-off amplitude 4x14: work energy of amplitude
segment A
4x4: run mode 4x15: quality mode
4x5: trigger mode 4x16: lower limit of time
for quality calibration
0x0：US working
0x1：Frequency search
0x2：US test
0x3：Horn Adjustment
0x4：Trigger calibration
0x5：Clear count to zero

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4x6: Delay time 4x17: upper limit of
time for quality calibration
4x7: US time 4x18: lower limit of
energy for quality calibration
4x8: US energy 4x19: upper limit of
energy for quality check
4x9: grounding hold time 4x20: protection sensitivity
4x10: cooling or holding time
4x21: slow start speed
4x22: Energy stop speed
4x23: frequency auto-tuning mode
4x24: frequency search direction
4x25: lower limit for frequency search bandwidth
4x26: upper limit for frequency search bandwidth
4x27: Idle resistance limit
4x28: Peak voltage limit
4x29: factory debug
4x30 lower limit for constant amplitude comparison
4x31:upper limit for constant amplitude comparison
4x32: introduce compensation frequency
4x33: start method
9.4 04H function code: reading input register
IP type: 3x, scope: 3x0-3x11
3x0: external control amplitude 3x5: real-time frequency
3x1:internal PWM value 3x6:ultrasonic energy(double-bit)
3x2:load resistance value 3x8: ultrasonic period
3x3:amplitude strength value 3x9: quality result
3x4:real-time power 3x10: work times(double-bit)
9.5 05H function code: compulsory single coil

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IP type: 0x, scope: 0x0-0x15
See details for 01H function code.
9.6 06H function code: pre-written single register (support 10H function code)
IP type: 4x, scope: 4x0-4x33.
See details for 03H function code.
10 Power supply
Model
DS400
Power
4200W
3000W
2200W
1200W
1000W
Frequency
15KHz
15KHz
20KHz
15KHz
20KHz
20KHz
35KHz
Voltage
220VAC±10% 50-60Hz
Rated current
12.9A
9.6A
6.5A
4.8A
3.2A
Rated power
4000W
3000W
2200W
1200W
1000W
Peak power
5600W
4200W
2400W
1800W
1500W
Fuse protection
current
25A
25A
20A
15A
10A
Environment
Temperature
-10 to +55°C
Protection
grade
IP 20, IEC 60 529, EN 60 525
Air source
6-8kg/cm²，clean air
11. Operation Panel
11.1 Password Keyboard, Parameter Keyboard

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Password keyboard： the password input keyboard has blue backboard with numbers,
backspace, clear, ESC and ENT keys.
Parameter keyboard: Parameter keyboard has a green backplate with numbers,
backspace, CLR (or+/-),ESC and ENT keys.
11.2 Version Information Page
This page is a default display page when you start the machine. Click any area on
this page or just wait for 6s without any action, it will go to weld record page.
This page will display the rated power, rated frequency, version information and
date.

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11.3 Main Menu
Main Menu is the Menu page-click the corresponding button to enter the
corresponding page. Password to each page is:
Protection function: 1962
Amplitude calibration: 8080
Factory setting: 2005
11.4 Welding record page
This page displays the welding record, welding power and data management.
Note: Shut down the machine 40s later after the welding done to prevent the loss of
the welding data.
Click “Welding record” button to enter Data Management menu. Click any button as
per your demand.