K&M KM-QD-G User manual

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
User’s Manual
Model: KM-QD-G

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
Contents
1.Preface...................................................................................................................................................... 3
2.Precautions: .............................................................................................................................................. 3
3.Installation Place .......................................................................................................................................5
4.Power Supply ............................................................................................................................................ 5
5.Port connections ....................................................................................................................................... 9
6.MODBUS communication protocol(MODBUS_RTU, 8/N/1, Slaver) ...................................................... 11
7.How to Set Parameters for Continuous Welding? ..................................................................................14
8.Display interface..................................................................................................................................... 17
8.1 LCM (12864)LCD display interface ...............................................................................................17
8.11 Start Page ...........................................................................................................................17
8.12 Work Page .......................................................................................................................... 18
9.Function menu ........................................................................................................................................19
10.Parameter setting ................................................................................................................................. 20
10.1 Amplitude setting: ..................................................................................................................... 20
10.2 Parameter setting: ..................................................................................................................... 21
11.Protection function ...............................................................................................................................22
12.Factory default setting .......................................................................................................................... 24
12.1 User’s parameter management menu .............................................................................. 24
12.2 Factory setting menu .........................................................................................................25
12.3 Operation parameter verification menu ........................................................................... 26
13.Malfunction protection displays and solutions ....................................................................................26
13.1 Abnormal communication .................................................................................................26
13.2 Function restrictions ..........................................................................................................26
13.3 Grid voltage is abnormal ................................................................................................... 27
14.Power supply Specifications ................................................................................................................. 29
15.Principle for coding: ..............................................................................................................................30
16.Installation size ..................................................................................................................................... 30
17.Application example pictures and setting ............................................................................................ 31
17.1 Hand-held welding (standard) ...................................................................................................31
17.2 Non-standard machine-External PLC control (standard) .......................................................... 32
17.3 Plastic welding (programmed machine) ...................................................................................32
18.Interface of generator with built-in PLC ............................................................................................... 34
19.Quality Assurance ................................................................................................................................. 36

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
1.Preface
Dear users,
Thank you for using SONIC 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.

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
The generator shall be installed in correct direction to assure firmness without loosening.
Power supply specs must meet the demand of the generator.
Select generators as per the load specs (such as frequency, power, etc. ). On-load high
frequency driving cables and the temperature sensor cables shall not be too long, and
shall not be rolled up, otherwise the temperature will go up to affect the accuracy.
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.

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
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%.
Please do not make metal or vapor go into the generator case. Long time exposure to the
chemicals will damage the electronic elements in the generator.
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.
Attention: Input power has to be cut off when replace fuse. Please use the fuse with same specs
to replace the damaged one. See “Power Supply Specs”.

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
Note 1: Select “Press ” start mode, 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” start mode, the port will respond quickly and the port will be inching type.
Note2: For programmed machine with “Press Button” start mode, when the delayed time is Zero,
the port will start the Ultrasound as Ext trigger (such as Pressure trigger).
For standard machine, the port will work as frequency searching input, and when malfunction
happens, the port can be used for Ext Reset input.
Note3: For standard machine with “PLC” start mode, the port will control the amplitude in stages.
For programmed machine, the port will be used as Emergency Stop input.
Note4: For standard machine with “Press Button” start mode, the port is used as grounding test
input, while with “PLC” start mode, the port will control the Shake off mode to start.
For programmed machines with Depth Mode, the port will trigger ultrasonic stop, with other
modes, the port will be grounding test input.
Note 5: The port can drive the Solenoid (24V/5W) directly, and control blowing for cooling or
cylinder movement.
Note 6: In case of error setting, abnormal communication or over-heating, it is in “Malfunction”
status, only automatic reset or re-setting can be done.
Note7: 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.

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
5.Port connections
Input port
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 6meters.
Analogue quantity Input/output port
Control mode
Relay
Press button
PLC output port
Generator Internal circuit
External control
Control mode
Relay
PLC input port
Generator Internal circuit
External control

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
Attention: For the Analogue quantity input/output port, an insulation/convert circuit must be
added externally.
Communication port
Attention: RS485 communication port shall be insulated and the twisted-pair wire shall be
screened in strong interference place.
Amplitude control
Power
Frequency
Generator Internal circuit
Insulation/convert circuit
External control
Generator Internal circuit
External control

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
6.MODBUS communication protocol(MODBUS_RTU,
8/N/1, Slaver)
01H function code: read the coil status
IP type 0X, scope:0x0-0x15
0x0: ultrasonic working 0x3: welding horn adjustment
0x1: frequency search 0x4:trigger calibration
0x2: ultrasonic check 0x5: clear count to zero
02H function code: reading input status
IP type: 1x, scope:1xX1000-1xX1015
1x0: Operation 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
03H function code: Reading save register
IP type: 4x, Scope:4x0-4x33
4x0: amplitude mode 4x11: shake off delay
4x1: amplitude stage A 4x12：shake off time
4x2:amplitude stage B 4x13: work time of amplitude stage A
4x3: shake off amplitude 4x14: work energy of amplitude stage A
4x4:work mode 4x15: quality mode
4x5:trigger mode 4x16: lower limit of time for quality check
4x6: Delay time 4x17: upper limit of time for quality check
4x7: ultrasonic time 4x18:lower limit of energy for quality check
4x8: ultrasonic 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

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4x29:factory commissioning
4x30 lower limit for constant amplitude comparison
4x31:upper limit for constant amplitude comparison
4x32: introduce compensation frequency
4x33: start method
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)
05H function code: compulsory single coil
IP type: 0x, scope: 0x0-0x15
See details for 01H function code.
06H function code: pre-written single register (support 10H function code)
IP type: 4x, scope: 4x0-4x33.
See details for 03H function code.
Attention:
For detailed applications, please ask our company for <Digital ultrasonic
power supply communication examples>.
It can only support MODBUS_RTU slave machine, data format: 8/N/1.
Double-bit, high and low bit upside down.
Interface:

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [e-mail] • Tel: +86 0512 - 57403727
Indicators:
READY: ready to use
Mvt: Hold status
H.F.: Ultrasonic working status
OVL: overload
ERROR: malfunction of the system
Power Switch in Ultrasonic Generator
Increase (Note1), number increase or go left or go up
decrease (Note1), number decrease or go right or go
down
Enter (Note2), to confirm parameter settings or hold
longer to exit
Reset (Note3), to reset the frequency searching, or
return with one press
Test button, to check ultrasound

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
Note1: press this key to move the cursor to select the function icon or parameters needed,then
confirm for adjustment. Press this key can also adjust the values. Hold longer to speed up the
adjustment. For programmed model, hold this key longer on the main page,“clear count to
zero”menu will appear.
Note2: Select the parameter to be adjusted, shortly press the Enter key to start the adjustment,
press it again to exit the adjustment; long press on this key will return to previous page. For
programmed model, long press on the Enter key on the main page, welding horn adjustment
page will appear.
Note3: on the main page, press this key to start the frequency searching and reset the over-limit
alarm status, and press this key, the function menu or parameter setting will return to main page.
7.How to Set Parameters for Continuous Welding?

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Step 1: Press Enter key to enter into Factory Setting, Press + key to input password: 2005.
Step2: Press downward key to select Mode Type: Press the Upward or Downward key again to
choose [Standard] (change Auto to Standard).

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K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
Step3: Press downward key to select IO type: Press the Upward or Downward key again to
choose [PLC) (change[ Key] to [PLC]), press Enter again to confirm, and then Search key.
Step 4: Press the Upward or Downward key to select Setting icon on the display, and press
Enter to confirm. Press Downward key again to select Cooltime, and select Runmode, change
[Time] to [Sailed]. It is continuous welding mode.

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
8.Display interface
8.1 LCM (12864)LCD display interface
8.11 Start Page
After turning on the power, machine model, rated power, rated frequency, software version
and manufacture date,etc will be displayed.
Attention: Some functions may be forbidden in a different mode. For changing application
functions, please consult our company.

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
8.12 Work Page
Ultrasonic work or test shall be started after “Ready” displays.
It will display work frequency, amplitude, ultrasonic time, ultrasonic energy, power, work
status and over-limit alarm in real time.
a. Press and hold ENTER key to check ultrasound and assess the welding horn resistance. The
smaller the resistance value is, the better for ultrasonic weld result.
b. For verification in factory, please press and hold the TEST key to start checking the
ultrasound and record value of “B”, the first 2 seconds data and the two groups of data
before release will be used as the upper and lower limit base for “fixed amplitude
scope”(amplitude setting is 100%).
Welding horn adjustment menu
Press and Hold the ENTER key on the main page to go into Welding Horn Adjustment menu,
select “trigger to calibrate” to quickly judge the ultrasonic start position through the cylinder
action; Long press the ENTER key or RESET key to return to main page.

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
Clear count to Zero
On the Main Page, concurrently pressing the Plus/Minus key to go into the menu for clearing
the count to zero; press ENTER key to clear the count to zero, and press RESET key to cancel
the clearing.
9.Function menu
Function menu in pictures: amplitude adjustment, parameter setting, protection function, factory
setting (password) etc.
Press the ，enter the next page：”Fctory setting”.

上海标星科技发展有限公司
K&M Technologies Ltd.
• Website：www.knmsonic.com • Email: [email protected] • Tel: +86 0512 - 57403727
Attention: After enter into Function Menu or Parameter Setting Menu, the ultrasonic system
cannot be started by pressing the start button, but external port can be started normally for
easy parameter adjustment.
10.Parameter setting
10.1 Amplitude setting:
The ultrasonic work amplitude can be adjusted between 10-100%, with variation of 1%. For fixed
amplitude mode, only Amplitude Stage A can be adjusted; For multiple-stage amplitude mode,
amplitude Stage A and Stage B can be adjusted.