Lukasiewicz Sonic Blaster Plus User manual

Document ver.: 4.00
Revision: 24/01/2019
Software ver.: 0.6.1
Sonic Blaster Plus ultrasonic generator operating
manual
types: SBP520, SBP320, SBP220, SBP230, SBP240

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Safety
The device meets the general conditions for safe operation and bears the CE marking.
National and industry safety regulations must be observed during installation and operation.
Risk of voltage on accessible structural components.
Danger of fire hazard due to malfunction of the electrical system.
All electrical system connections are made inside the insulated housing, which does not contain
any flammable components. All routed conductors are insulated with fire-retardant materials.
If the device is improperly used or used not for its intended purpose, the user shall be fully
responsible for any possible risks to safety and resulting damage to the device.
Correct and trouble-free operation of the device requires proper transport, storage, assembly,
installation and commissioning, as well as proper operation, maintenance and service.
The installation and operation of the device should only be carried out by appropriately trained
personnel.
Comments
We reserve the right to introduce changes to the device.
The device is intended for operation in industrial conditions.
Other documents about the device can be downloaded from przemysl.itr.org.pl

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Table of Contents
1. Introduction........................................................................................................................................................... 4
2. General .................................................................................................................................................................. 5
3. Installation instructions ......................................................................................................................................... 6
3.1. Connection to the mains ....................................................................................................................... 6
3.2. Connection to the vibration system ...................................................................................................... 6
3.3. Connection of SBE1 I/O card control lines............................................................................................. 7
3.4. RS-485 MODBUS RTU communication interface................................................................................... 9
4. Operating instructions ......................................................................................................................................... 11
4.1 Generator functions control panel ...................................................................................................... 11
4.1.1 WELDING window............................................................................................................................... 13
4.1.2 PROGRAMME parameter setting window.......................................................................................... 14
4.1.3 MODE welding mode selection window ............................................................................................. 16
4.1.4 Numerical value editing window ........................................................................................................ 16
4.1.5 Measurement, protection and scanning results window ................................................................... 17
4.1.6 Login window ...................................................................................................................................... 20
4.1.7 Recorder window ................................................................................................................................ 22
4.1.8 Date and time setting window............................................................................................................ 23
4.2 Generator start ................................................................................................................................... 24
6. Maintenance, periodic inspections and repairs.......................................................................................................... 24
7. List of spare parts delivered on request...................................................................................................................... 25
8. Storage and transport ................................................................................................................................................. 25
9. OHS instructions.......................................................................................................................................................... 25
10. Technical data ........................................................................................................................................................... 25
11. Disposal ..................................................................................................................................................................... 27

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1. Introduction
In order to become familiar with the generator, please read this operating manual before use. This will ensure its safe
and proper operation.
Symbols:
Electrical warning sign indicating important information regarding the presence of a hazard
that could cause an electrical shock.
Warning sign indicating important information about a hazard
that may cause damage to the device or its malfunction.
Information sign highlights important device features and parameters.
This device cannot be disposed of with household waste.

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2. General
SONIC BLASTER Plus generators, types: SBP520, SBP320, SBP220, SBP230 and SBP240 are intended for
use in industrial environment as components of a machine performing ultrasonic processes.
Sonic Blaster Plus generators have the following features:
•User interface with graphical display;
•User access control for: operator, administrator and service;
•Editing values of process parameters, such as: welding active power, welding time, output signal
amplitude;
•Measurement and visualisation of process parameters during the welding cycle;
•20 independent welding programmes;
•Performance of power level protection functions;
•Performance of vibrating unit protection functions;
•Editing setpoints of protection functions;
•Synchronisation with external process controller using a binary interface;
•
Possible communication with a PLC controller using MODBUS RTU.
Rys.1. Sonic Blaster Plus generator view
Before using the generator in an ultrasonic machine, it is recommended to consult with the machine
manufacturer.
The SONIC BLASTER Plus generator presented in Fig. 1 is equipped with a digitally-controlled power converter,
consisting of a rectifier and an inverter, which generates an output voltage signal with controlled amplitude and
frequency. To stabilise the active power consumed by the load, an output signal amplitude and frequency control
tracking system were used.
The SONIC BLASTER Plus generator offers extended setup capacity on the basis of a system of welding programmes.
The device is equipped with 20 welding programmes with setpoints that determine the course of the welding
process.
It complies with the requirements of the Directives of the European Parliament and of the Council:

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Directive Description
2014/35/UE
on the harmonisation of the laws of the Member States relating to the making
available on the market of electrical equipment designed for use within certain
voltage limits
2014/30/UE on the harmonisation of the laws of the Member States relating to
electromagnetic compatibility
2011/65/UE on the restriction of the use of certain hazardous substances in electrical and
electronic equipment
Standard Description
IEC 61010-1:2010
Safety requirements for electrical equipment for measurement, control and
laboratory use – Part 1: General requirements
IEC 61000-6-2:2016 Electromagnetic compatibility (EMC) – Part 6-2: Generic standards – Immunity
standard for industrial environments
EN 55011:2016 Industrial, scientific and medical equipment – Radio-frequency disturbance
characteristics – Limits and methods of measurement
EN 50581:2012 Technical documentation for the assessment of electrical and electronic products
with respect to the restriction of hazardous substances
CE The device meets the general conditions for safe operation and bears the CE
marking.
3. Installation instructions
The SONIC BLASTER Plus generator can be installed in enclosed areas which meet the corresponding general
conditions related to buildings and can be operated under normal working environment conditions (effective
temperature range 0-45ºC, relative humidity ≤ 75% at 20 ºC).
The device cannot be installed in rooms with an aggressive atmosphere, a high dust content or in hazardous areas. It
should be installed in a room with a properly working ventilation system.
The ultrasonic generator should be positioned so that air can flow into the ventilation openings.
3.1. Connection to the mains
The SONIC BLASTER Plus generator should be connected to the mains using the power cable attached to the
generator. If the cable is to be replaced, brand new cables with IEC C19 connector and a core cross-section of at least
1.5 mm2should be used. It is possible to deliver 2 m, 3 m or 5 m power cables on special request.
The correct cabling of the generator power outlet as shown in Fig. 2 must be ensured.
Fig. 2 Recommended power outlet cabling.
If the power supply connection needs to be extended, a three-core cable with a core cross-section not less
than 1.5 mm2(2.5 mm2for SBP520) and mains sockets and plugs with a ground pin, adopted to currents
equal to or higher than 16 A (32 A for SBP520) should be used.
3.2. Connection to the vibration system
The SONIC BLASTER Plus generator should only be connected to the vibration system using the brand-new high-
voltage connection cable (HV cable) supplied with the device. Any modifications to the HV cable or its connectors are

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not permitted. The HV cable length should be specified when ordering. If the HV cable provided with the generator is
damaged or its length is inappropriate for a given application, a new HV cable should be delivered by the
manufacturer for an extra charge.
The HV cable that connects the generator and the vibration system is terminated with a high-voltage
FFB.1S.405.CTAC47 connector by LEMO, compatible with a ERA.1S.405.CTL outlet by LEMO. The vibration
system must be factory-equipped with this outlet. Any modifications to the outlet and use of any adapter
cables are prohibited.
3.3. Connection of SBE1 I/O card control lines
The SONIC BLASTER Plus generator is equipped with an SBE1 I/O card. The card is a unit that expands the Sonic
Blaster Plus generator’s capabilities. It has a binary I/O interface (DB15F), an analogue I/O interface (DB9F), a RJ-45
RS-485 MODBUS RTU connector and a LAN/ETHERNET RJ-45 connector.
3.3.1. Analogue inputs/outputs
Fig. 3 DB9F interface diagram
Table 1 Description of signals at the analogue I/O interface
Signal
name
DB9
interface
pin
number
Signal type
Current
efficiency/consumption
Signal significance
A_IN1
1
0-10 V line input
< 0.5 mA
Set amplitude setpoint
A_IN2
2
0-10 V line input
< 0.5 mA
-
A_IN3
3
0-10 V line input
< 0.5 mA
-
A_IN3
4
0-10 V line input
< 0.5 mA
-
GND
5
Ground
-
-
12 V
6
12 V / 50 mA auxiliary
power supply
50 mA
-
A_OUT1
7
0-10 V line output
max. 5 mA
Power output level
A_OUT2
8
0-10 V line output
max. 5 mA
-
A_OUT3
9
0-10 V line output
max. 5 mA
-
In standard setup, only 2 signals are used: A_IN1 and A_OUT1.
A_IN1 – input signal for setting the generator’s output amplitude. The value of the input voltage applied to this input
determines in a linear manner the generator’s output amplitude within a range of amplitude from 10% to 100%. If
the signal level at the input is lower than 10% of the range, a value defined in the welding programme is set.
AO= UA_IN1 / 10 * 100%
where: AO– set generator output amplitude (in %),
UA_IN1 – voltage (in volts) at A_IN1 line input.
Example: if 5 V is applied to A_IN1, the generator’s output amplitude will be set to 50%.

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A_OUT1 – output signal providing the value of current power supplied by the generator to the load. The value of the
output voltage corresponds linearly to the value of the power output (in watts) within a range from 0 to the
maximum power output of a given type of generator (3000 W for SBP320, 5000 W for SBP520 etc.). Example: 1 V in
SBP320 means that the current power output is 300 W.
12 V / 50 mA auxiliary power supply – the unit is equipped in an internal insulated power supply unit with a voltage
of 12 V ±5%. This voltage is available at the DB9 interface and may be used to supply additional circuits, whereas the
total current consumption of the circuits connected cannot exceed 50 mA.
3.3.2. Digital inputs/outputs
Fig. 4 DB15F interface diagram
Table 2 Description of signals at digital I/O interface
Signal
name
B15
interface
pin
number
Signal type
Current
efficiency/consumption
Signal significance
24 V
1
24 V power supply output
1.5A
D_IN1
2
0-24 V binary output
< 0.5 mA
Scanning start
D_IN2
3
0-24 V binary output
< 0.5 mA
Welding start
D_IN3
4
0-24 V binary output
< 0.5 mA
Welding stop
D_IN4A
5
0-24 V floating binary output
< 0.5 mA
Welding start/stop
D_IN4B
6
D_OUT5A
7
Floating relay output
1A/48VAC
-
D_OUT5B
8
GND24
9
24 V power supply ground
-
-
D_IN_GND
10
Ground of inputs 1...3
-
-
D_OUT_COM
11
Common contact of outputs
1...4
D_OUT1
12
NO relay output
1A/48VAC
Standby
D_OUT2
13
NO relay output
1A/48VAC
Welding
D_OUT3
14
NO relay output
1A/48VAC
Scanning
D_OUT4
15
NO relay output
1A/48VAC
Error
D_IN1 – the application of a positive impulse with a duration of > 100 ms triggers the activation of the
generator scanning process, exactly as it is after switching on the power supply. This occurs only when
the generator on standby and the welding process is not in progress.
D_IN2 – the application of a positive impulse with a duration of > 100 ms triggers the activation of the welding
process according to the preset programme (start at impulse).
D_IN3 – the application of a positive impulse with a duration of > 100 ms triggers the deactivation of the
welding process, if in progress (stop at impulse).

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D_IN4 – the application of a high state triggers the activation of the welding process according to the preset
programme, whereas the application of low state, if a high state was previously applied at this input,
triggers the deactivation of the welding process (start/stop at level). NOTE Floating output – state
should be applied between D_IN4A and D_IN4B pins with any polarity.
D_OUT1 – a closed contact indicates generator standby (power supply on, scanning completed).
D_OUT2 – a closed contact indicates that the welding process is in progress.
D_OUT3 – a closed contact indicates that the scanning process is in progress.
D_OUT4 – a closed contact indicates that an error occurred.
24 V – 24 V DC / 1.5 A auxiliary power supply output which can be used to supply an external automation
system.
3.4. RS-485 MODBUS RTU communication interface
The generator is equipped with an RS-485 communication interface that supports MODBUS RTU transmission.
The I/O card has a RJ-45 connector, designated as RS-485. It is compatible with a UTP twisted pair. A connection
diagram is presented in Fig. 5.
Fig. 5 RJ-45 interface diagram and RS-485 interface cable and plug diagram
Transmission and reception lines are separated at this interface. To operate using RS-485, the appropriate
lines should be interconnected (as indicated with the broken line on the diagram). 5 V auxiliary output
voltage with a current efficiency of 100 mA is available at this interface.
To activate the MODBUS RTU communication unit, set the activity switch in the RS-485 position in the
SETTINGS menu to active (green) by clicking it.
MODBUS RTU:
RS-485/RS-422 transmission
Setup: 8 data bits, no parity, 1 stop bit
Bitrate: 9600 bps (to change, go to SETTINGS -> RS-485)
Generator address: 0xAA (to change, go to SETTINGS -> RS-485)
Available commands:
FC 03 – Read n setup registers
FC 04 – Read n input registers
FC 06 – Store one setup register
FC 16 – Store n setup registers
Register map:
Input registers (read-only, FC 04 command), numbers from 30001:
30001: uint16 status; status bit field: (adr:0)
GEN_IDLE 0x00 – Generator on standby, not welding
GEN_SCANNING 0x01 – Generator scanning
GEN_WELDING 0x02 – Generator welding
GEN_ERROR 0x03 – (Protection) error occurred

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GEN_MAINS 0x04 – Mains supply on (in parallel with others)
GEN_SCAN_OK 0x08 – Scanning completed and correct (in parallel with
others)
E.g. 0x12 =0x00+0x04+0x08 – Generator on standby, power supply on, scanning
correct
E.g. 0x14 =0x02+0x04+0x08 – Generator welding, power supply on, scanning
correct
30002: uint16 power; Power in watts (0–3000)
30003: uint16 amplitude; Amplitude with a resolution of 0.1% (range 0-1000)
30004: uint16 Uout; Output voltage in volts
30005: uint16 Iout; Current in mA (0.001 A)
30006: uint16 Zout; Instantaneous impedance of the vibration system in Ω
30007: uint16 Zph; Instantaneous impedance phase in degrees
Protections:
30008: uint16 protection; Protection activation code
error code: 0 – none, 1 – voltage protection, 2 – current protection
30009: uint16 Uprot; RMS voltage value at protection activation
30010: uint16 I_prot; RMS current value at protection activation
Scanning results (32-bit registers treated as 2 MODBUS registers):
30011: uint32 f_ser; Scanned frequency of series resonance
30013: uint32 z_ser; Scanned impedance in series resonance
30015: uint32 f_par; Scanned frequency of parallel resonance
30017: uint32 z_par; Scanned impedance in parallel resonance
30019: uint32 f; Current operating frequency
Setup registers (read-only, FC 04, FC 06, FC 16 commands), numbers from 40001:
40001: uint16 start_stop; 0 – welding or scanning stopped, if previously activated using MODBUS
1 – scanning start
2 – scanning stop
4 – welding or scanning totally stopped, even if previously activated without using
MODBUS
40002: uint16 set_power; Set power in watts (0-3000)
(in amplitude mode, it acts as power limiter)
40003: uint16 set_amplitude; Set amplitude in 0.1% (range 0-1000, that is 0.0%-100.0%) (in power mode, it acts
as amplitude limiter)