Operations Manual for ultrasonic generators ... - Weber Ultrasonics

SONIC DIGITAL ULC - Ultrasonic generators 

Operations Manual 

for ultrasonic generators from the series 

SONIC DIGITAL ULC MD 

Version Premium & Basic 

Art.Nr: 9000.3001 GB 

WELDING 

www.weber-ultrasonics.com


Contents 

Introduction 3 

Safety instructions 3 

Assembly 5 

Operation 10 

Functions in the Settings menu 14 

Error messages and troubleshooting 19 

Maintenance 20 

Specifications 20 

Warranty 21 

Declaration of CE conformance 21 

Index 22 

Service hotline 22 

Spare parts 22 

Production, Sale and Service: 

Weber Ultrasonics GmbH Phone: +49 (0) 7 48 / 9 07-0 

Im Hinteracker 7 Fax: +49 (0) 7 48 / 9 07-11 

76307 Karlsbad-Ittersbach mail@weber-ultrasonics.de 

Germany www.weber-ultrasonics.de 



Introduction 

Dear Customer, 

Thank you for purchasing this Weber Ultrasonics product. 

You have chosen a first-class product that was developed using the latest technology. 

It is vital that you read these operating instructions and follow them carefully before installing 

or commissioning your product. Failure to observe these instructions can present a risk to life. 

Units may be operated by trained personnel only. Failure to comply with this will result in a loss 

of warranty rights. 

The device may only be operated and maintained by personnel who have read and understood 

this operating manual and are familiar with the applicable legal regulations for accident prevention 

and workplace safety. 

Safety instructions 

Before starting up your device, please read through the following instructions carefully, both for your own 

safety and for the safety of the device. 

Keep this manual where it can be readily accessed by all systems users. 

Installation is to be carried out by qualified technical personnel only! 

The ultrasonic generator is to be operated by properly trained personnel only! 

Due to the way it operates, additional safety measures must be taken if the device is to be used in areas 

posing an explosion risk. 

The electromagnetic compatibility corresponds to the standards and regulations listed in the specifications. 

All necessary settings were either made in the factory or are described in this handbook. 

However, should problems occur on start-up, please do not make any prohibited adjustments to the device, 

as this would endanger your warranty rights. If in doubt, please contact our technical service staff. 

Please contact our technical service if at all in doubt. 

Work inside the device may only be carried out to the extent described and, as with the electrical connection, 

should only be performed by skilled personnel. When performing such work, the ultrasonic generator must be 

completely disconnected from the mains (unplug the mains connection). 

Inputs or outputs that are used for controlling or monitoring purposes should be twisted and shielded. 

The device must not be in close proximity to electrically charged components or cables. 

The shielding should be connected to the generator‘s earth on one side of the generator. 

Attention: All connections for the signal or control lines are galvanically connected to the generator. 

Always observe any warnings or instructions given on the device itself. 

The device must always be disconnected from the mains before cleaning or when installing/uninstalling an option. 

Do not use liquid cleaners or sprays. Only use a damp cloth. 

Never operate the device in areas where moisture could penetrate the device. 

3 



The platform for the device must be sufficiently stable, as the device being jolted or falling could cause severe damage. 

Ensure that the power supply specifications given on the device are met. 

Only those transducers which have the correct frequency, power output and dimensions may be used with this generator. 

HF cables from the generator to the transducer as well as mains cables to the generator may not be rolled up 

if they are too long. Instead, they must be shortened to the required length due to the risk of overheating. 

With the exception of the permitted tasks listed in the handbook, you should never attempt to repair or modify the device 

yourself. 

In the following cases you should disconnect the device from the mains and contact a qualified service engineer: 

4 

· If the mains cable or plug is damaged 

· If liquid has penetrated into the device 

· If the device has fallen over or the housing is damaged 

· If the device displays noticeably different behaviour than standard operation 

ATTENTION: Repairs and modifications may only be carried out by competent, skilled personnel. 



Assembly 

Notes on the installation location 6 

Power supply 6 

Connections on the back of the generator 7 

Assignment of the 15-pole DSUB interface socket 8 

Interface Description 8 



Notes on the installation location 

During operation the generator will get very hot. 

If the generator cannot dissipate this heat sufficiently, it will display an error message due 

to excess temperature (see also the “OVER TEMPERATURE” error description). 

In addition, ambient temperatures of over 30°C should be avoided. 

Choose a suitable location that will protect the device from moisture, water, excessive sunlight and heat. 

ATTENTION: • Choose a location that will prevent steam or any other aggressive vapours 

from penetrating the device. 

Power supply 

6 

• Over a period of time, chemically contaminated ambient air can lead to 

the device being irreparably damaged. 

The ultrasonic generator draws its power ( 30 V and 0 / 60 Hz) via the connection cable. 

It has an internal main fuse (10 AF). 

If you need to change the fuses, unscrew the top of the housing. 

ATTENTION: • For safety reasons, always disconnect the unit from the mains before changing fuses. 

• Plug racks into earthed sockets only. 

• Always replace blown fuses with new fuses of the same type. 

• This should only be performed by qualified, skilled personnel. 



Connections on the back of the generator 

Converter negative connection: Shield of the BNC socket 

Converter positive connection: Inner conductor of the BNC socket 

ATTENTION: • When the converter is connected via a BNC cable, a safe PE conductor connection with a cable with 

a sufficient cross-section (min 1.5 mm 2 ) must also be established between the generator and the 

converter. There is a PE terminal on the back of the generator for connecting this PE conductor. 

7 

• Only use cables specified by the manufacturer. Use only shielded transducer connection cables. 

Connect the shielding to the PE conductor on the generator side. Only use cables with sufficient 

cross-section. Minimum cross-section: 1.5 mm 2 . 



Assignment of the 15-pole DSUB interface socket 

8 

8 1 

15 9 

PIN No. on DSUB SOCKET 

Interface X1 

Signal name Description 

1 +1 VOLT OUT 1 Volt for external use 

POUT Output 0 – 10 Volt = Power output 0 – 100 % 

3 P-EXT.-IN Input – 10 Volt for power control 

4 GND Shared reference point = Ground 

/9 HF-DA-ERROR Relay root (shared) for “HF-DA” and “ERROR” 

6 HF-DA Relay output “HF-DA” 

7 ERROR Relay output “ERROR” 

8 NC Not assigned! Do not connect! 

9/ HF-DA-ERROR Relay root (shared) for “HF-DA” and “ERROR” 

10 NC Not assigned! Do not connect! 

11 Nominal Output for nominal value 

1 FAN-ON Monitoring output = 1 Volt when the fan is running 

13 FS- 4 V Remote control input (with 1 – 4 Volt) 

14 FS-GND Remote control input (to GND) 

1 GND Shared reference point = Ground 

ATTENTION: A shielded control cable must always be used for the interface. 

Interface Description 

1.) Signal “+15 Volt Out” DSUB PIN 1 

A voltage of 1 V is available at this output. This voltage can be loaded with max. 100 mA and can, 

for example, be used to output a voltage for the function “HF-DA” and/or “Error”. 

This voltage can also be used to switch on the generator on the input “FS- 4 V”. 

2.) Signal “POUT” DSUB PIN 2 

At this output a voltage proportional to the power output of between 0 and 10 V 

(= 0 – 100 % power output) is available. 

Reference point = “GND”. 

3.) Signal “P-EXT.-IN” DSUB PIN 3 

By connecting a voltage between V and 10 V, the output of the generator can be set to 

between 0 % and 100 % of its nominal amplitude or power. To activate this function, 

go to the Settings menu (password 63 4) and select the “external voltage” setting under “Pwr.src”. 

Reference point = “GND”. 



4.) Signal “HF-DA ERROR” DSUB PIN 5/9 

Shared in/output for the internal relays “HF-DA” and “ERROR” (these PINs are connected internally). 

5.) Signal “HF-DA” DSUB PIN 6 

If the ultrasonic generator has been switched on via either of the signals “FS- 4 V”, “FS-GND” 

or with the test button on the front panel and is emitting HF voltage (i.e. there is no malfunction), 

an internal floating relay contact is closed. (between PIN 6 und PIN /9) 

The “root” of this relay contact leads through to a PIN /9 (these pins are connected internally) 

in the DSUB socket. This relay contact can now be queried by an external control system. 

A voltage connected to Pin /9 can, of course, also be switched through (max. 4 VDC / 100 mA). 

It is useful to query this contact when a timer operation is being carried out and the generator switches 

off automatically when the time is up (normally closed contact default setting). The contact can also be 

switched over to reverse polarity in the Settings menu. 

Standard factory setting: Contact closed when the generator outputs HF voltage. 

6.) Signal “Error” DSUB PIN 7 

This is the output of an internal relay (root to PIN /9). 

This relay reports generator malfunctions. This means that if the generator is switched on and, 

for some reason, the power output does not correspond to the set level, this relay is activated. 

Factory default settings: Closed in the event of a malfunction. It is possible to change the polarity 

in the Settings menu under the heading I/O Polarities (“Error detect”). 

An external voltage connected to “HF-DA-Error” can, of course, also be 

switched through here (max. 4 VDC / 100 mA). 

7.) Signal “FAN-ON” DSUB PIN 12 

At this output, there is a control voltage (1 Volt) for monitoring the fan function when the internal fan is running. 

8.) Signal “FS-24 Volt” DSUB PIN 13 

Switching on the generator (Ultrasound On) by connecting a voltage between 1 – 4 Volt 

between PIN 13 and GND (PIN 4/1 ). 

9.) Signal “FS-GND” DSUB PIN 14 

Switching on the generator (ultrasound ON) with a relay contact or switch by connecting 

PIN 14 on the DSUB socket to GND (PIN 4 /1 ). 

10.) Signal “ Nominal” DSUB PIN 11 

Open Collector output: high signal if a window function is active and the generator 

is operated outside the window set; low signal if a window function is active and 

the generator is operated within the window set. 

11.) Signal “GND” DSUB PIN 4, 15 

The GND signal is available on multiple pins of the DSUB socket. 

It is the common reference point for all input and output signals. 

9 



Operation 

Operator elements and display on the front panel 11 

Operating and display elements of the external controller 12 

The LCD display 13 

Functions in the Settings menu 14 

Factory default settings in the menu 17 

10 



Operator elements and display on the front panel 

Version Premium: 

LED-Sonic: Lights up when the generator emits HF voltage 

LED-Nominal: Lights up when a window function is active and the generator 

is operated outside the window set. 

LED-Mode: Displays selected special functions. 

In this version the timer function is signalised. 

LED-Error: Lights up in the event of an error 

LED-Power output display 

10 – 100 %: Displays the power output in 10 % steps 

Encoder / Select: For setting and entering values 

Test button: The generator can be switched on by pressing this button 

(see “Functions in the Settings menu” to configure the test button). 

11 



Version Basic: 

LED-Power: Lights up when the device is being supplied with mains voltage correctly 

and the power switch is on 

LED-HF: Lights up when the generator emits HF voltage. 

LED-Error: Lights up in the event of an error. 

Test button: This button is used to turn on the generator for testing purposes. 

Front socket: Connection for external control console. Available as an option. 

Operating and display elements of the external controller 

LED-HF: Lights up when the generator emits HF voltage. 

LED-Aux1: Lights up when the function “Window” is activated 

and the generator is operated off the adjusted 

Windows. 

LED-Aux2: Displays selected special functions. 

In this version the timer function is signalised. 

LED-Error: Lights up in the event of an error. 

LED-Power output display 

10 – 100 %: Displays the power output in 10 % steps. 

Encoder / Select: For setting and entering values. 

Test button: The generator can be switched on by pressing 

this button 

1 



The LCD display 

Various screens and functions are available in the LCD display: 

1. Start screen 

On the top left is the frequency in Hertz, in the centre the amplitude set 

in percent (adjustable between 0 % and 100 %), and on the right the last 

power output in watts. In the bar graph, the last power output in percent 

is also shown in diagram form. 

2. Starting frequency 

The display shows the starting frequency of the generator, in this example 

of a 40 kHz generator. 

3. Power output indicator in “Watts” 

The current power output is displayed. After switching off the device, 

the maximum power output reached is saved until the next time the 

device is switched on. 

4. Amplitude setting 

Here, the “Select” encoder can be used to set the desired power output 

to between 0 % and 100 % of the nominal generator amplitude. 

The desired amplitude is set by pressing and then turning the encoder. 

Pressing the encoder again applies the selected amplitude. 

5. P-Window function 

Here, the “Select” encoder can be used to set a window. 

If the power output is shown within this window, there is a low signal at 

the Nominal output (DSUB PIN 11) on the interface (see also interface description). 

If the power output is outside this window, there is a high signal at the Nominal 

output (DSUB PIN 11) on the interface (see also interface description). 

If the power output is outside the window, the Nominal LED lights up on 

the control panel, or the AUX1 LED lights up on the hand-held operating device. 

The desired window is set by pressing the encoder. The minimum and maximum values 

of the window can be set by turning the encoder. 

Pressing the encoder again applies the selected values. 

6. Timer function 

A time of up to 10 seconds can be set by pressing the encoder. This time starts running 

when the generator is switched on, either via the interface or the test button. No error 

message is displayed when the time expires. When the generator is switched on using 

the test button and the time expires, the generator switches off and remains in this state 

until it is switched on again. The end of the expired time can be determined via the interface 

by requesting the “HF-DA” signal. If an “OFF” time is also set, the generator switches on 

and off continuously. 

7. T-Window function 

Here, the “Select” encoder can be used to set a window. If the operating time is shown 

within this window, there is a low signal at the Nominal output (DSUB PIN 11) on 

the interface (see also interface description). If the operating time is shown outside 

this window, there is a high signal at the Nominal output (DSUB PIN 11) on the interface 

(see also interface description). If the operating time is outside the window, 

the Nominal LED lights up on the operating panel or the AUX1 LED lights up on 

the hand-held operating device. 

The desired window is set by pressing the encoder. The minimum and maximum 

values of the window can be set by turning the encoder. 

Pressing the encoder again applies the selected values. 

13 



8. Power welding function 

Here, the “Select” encoder can be used to set a value in watt-seconds. 

When the power set is reached, the welding procedure ends. 

Attention: the welding procedure ends after a maximum of 10 seconds, 

even if the power set has not been reached. 

9. Counter 

This counts how often the welding procedure has been started. 

This counter can be reset by the operator. 

10. Adjusting the starting frequency 

Here, the “Select” encoder can be used to adjust the starting frequency. 

Depending on the generator‘s basic starting frequency, the starting 

frequency can be adjusted by approximately 1. kHz to kHz. 

11. Contrast setting 

The contrast of the LCD display can be adjusted by pressing and turning the encoder. 

Pressing the encoder again applies the set value. Set the contrast in such a way that 

the LCD display can be easily read. 

12. Display backlight 

The display‘s backlight can be turned on and off by pressing and turning the encoder. 

For optimum readability, we recommend turning the backlight on. 

13. Settings 

You can access the Settings menu by entering the password “63 4”.This is also done 

by turning the encoder. After selecting the correct number each time, confirm by pressing 

the encoder. 

Functions in the Settings menu 

1. Adjusting the starting frequency 

The generator has an automatic “frequency tuning”. This means that it fully automatically 

sets itself to the resonant frequency of the connected transducer system. The capture 

range is 1 kHz. The resonant frequency of the connected system must be known. 

Generally, a starting frequency which is approximately 00 Hz above the resonant frequency of the connected 

system leads to good results. In special cases, however, it can also 

be necessary to set the starting frequency closer to the resonance of the transducer system. 

Under no circumstances should the starting frequency be set so that it is below the resonant 

frequency of the connected transducer system! The starting frequency can be changed 

by pressing and then turning the encoder. 

The area which is covered depends on the device type. 

2. Control Assignment 

Here you can set how the generator is to be controlled. Internal Front means control 

via the front control panel, Front & ext. Voltage means that the generator can also be 

operated via an external voltage (see pin assignment of the interface) and RS 3 means 

that the generator can be controlled via the RS 3 interface (available as an option). 

14 



I/O Polarities 

Remote IN: The polarity of the remote control input can be altered by changing 

this value. 

Factory default settings: 

A closed contact switches the generator on. 

Symbol “H”: When the contact is closed, the generator is switched on. 

Symbol “L”: When the contact is open, the generator is switched on. 

Error out: The polarity of the internal error relay can be switched over 

by altering this value. 

Factory default settings: 

Opened contact is an error, thereby safe of cable break. 

The polarity of the internal error relay can be switched over by 

altering this value. 

Symbol “L”: Closed contact is an error. 

Symbol “H”: Opened contact is an error. 

If the polarity is altered in such a way that a closed contact reports an error, you should 

be aware that the contact is open when there is no mains voltage at the generator or 

if the generator displays complete failure. 

Recommendation: Do not change the factory settings so that the errors described above 

can be detected properly. 

RF detect: The status signal HF-DA (generator is emitting HF voltage) 

can be altered by changing this value. 

Symbol “H”: Closed contact – generator emits HF voltage. 

Symbol “L”: Open contact – generator emits HF voltage. 

Please note that when the generator is not connected to the mains or there is a complete 

failure, this contact is open. 

Recommendation: Do not change the factory settings. 

1 



Pre/Post function 

Here a maximum time lag of 1,000 ms can be set before welding. Power is only output after 

this time has expired. An afterburst can be set, which means that there is a fixed waiting 

time of 100 ms after the actual welding procedure. Power is then output to the transducer 

system again for a maximum of 00 ms to remove residue from the transducer system. 

Example: 

Delay before weld 

00 ms 

Time after burst 

1 0 ms 

Energy 

1,000 Ws 

Pause set before 

welding 

16 

Power set by operator Fixed waiting 

time 

Afterburst 

00 ms 1,000 Ws 100 ms 1 0 ms 

Parameter Lock 

The basic setting for the Parameter Lock is “Off”. If you set Parameter Lock to “On”, all 

functions in the basic menu other than the LCD contrast settings and the backlight are 

disabled for the user. They then cannot be changed until Parameter Lock is set back to 

“Off” in the Settings menu. 

Operating hours indicator 

This displays the time during which the generator emitted HF. 

Display format: Days, hours, minutes. 

Display of the serial number and date of production 

In the Info menu item you can view the serial number and date of production 

of the generator. 

Sensorics 

By connecting a voltage between V and 10 V to PIN 3 of the interface, the output of the 

generator can be set to between 0 % and 100 % of the nominal amplitude or power. 

The voltage connected can be displayed in percent here. 10 V corresponds to 100 %, 

so in this example we can see that the voltage is 6. V. To activate this function, go to the 

Settings menu (password 63 4) and select the “external voltage” setting under “Pwr.src”. 

Reference point = “GND” 

EXIT – Exiting the Settings menu 

Total run time 

00d 0h 0m 

6 % 

Exit 



Factory default settings in the menu 

The framed settings are the basic settings 

17 

Depends on the frequency of the generator 





18 

P-Limiter 

not available 

Cntrol & Params 

are accepted from 

internal front 

Total run time 00d 0h 0m 

module n/a 


(off) 

6 % 



front & ext. voltage 


(on) 



RS232 



Error messages and troubleshooting 

The following error messages may appear in the display: 

A – PROTECTION ACTIVE 

The electronic overcurrent fuse has detected an error 

Possible causes: · Transducer is defective 

· Power supply or plug is defective 

Remedy: · Unscrew the transducer connection on the housing 

· Switch on the generator without the transducer connected 

19 

a.) Error message still displayed: 

Generator is defective 

b.) Error message no longer displayed: 

Check the transducer and power supply 

NO RF – DETECTED 

The electronic overload/short-circuit fuse has detected an error. 

Causes and remedy: see “A-PROTECTION ACTIVE” 

E-SEARCH 

The generator cannot find the working frequency 

Possible causes: · No transducer system connected 

· Transducer system defective 

· Supply cable or plug connector defective 

Remedy: · Replace transducer system 

· Check supply cable and plug-in connections 

OVER TEMPERATURE 

The generator is too hot 

Possible causes: · The generator‘s ventilation slits are blocked 

· Unsuitable assembly area for the generator 

· The transducer is defective 

· The fan is defective 

Remedy: · Check the fan! When the mains power is switched on, 

the fan should briefly start running 

· Check the air flow to and from the generator 

(The fan should not be assembled upwards) 

· Check the transducers 

E 

E 

E 

A protection 

active 

No RF 

detected! 

Search 

Temperature 

E 

limit reached 



Maintenance 

The ultrasonic generator does not need special maintenance. 

Dust and dirt should be removed regularly using a damp cloth. 

ATTENTION: • Do not use aggressive cleaners! 

Specifications 

0 

• Not suitable for ultrasonic cleaning! 

SONIC DIGITAL ULC MD 

Device specifications of all generators 

Frequency ULC 200 

MD 

BASIC 

PREMIUM 

20 kHz 

30 kHz 

35 kHz 

40 kHz 

ULC 400 

MD 

BASIC 

PREMIUM 

Operating voltage 30 V +/- 1 % 

Power consumption 1.0 A 1.9 A 

Effective power 

output 

00 W 

0 VA 

400 W 

440 VA 

Maximum output 400 W 800 W 

Fuse protection 10 A 

Mains connection 

on Schuko casing 

30 V 

Dimension casing W x H x D 

Weight 

0 x 7 x 180 mm 

.8 kg 

Temperature range -10 to +40°C Protection class 

generator module 

Remote control 

Analogue inputfor 

controlling the 

output 5 – 10 V 

IP 0, IEC 60 

Interface functions 

9, EN 60 

Floating error relays These functions are standard on every generator. 

Analog power 

indicator 5 – 10 V 

See also assignment of the 1 -pole DSUB socket generator back panel. 

20 kHz 

30 kHz 

35 kHz 

40 kHz 



Warranty 

The length and coverage of the warranty can be found in the terms of delivery as part of the general terms 

and conditions (valid at the time of purchase) or in the sales contract / order confirmation, should any 

special agreements have been made. 

The following cases are not covered by warranty: 

1 

· Damage caused by inappropriate operation 

· The device not being used for its intended purpose 

· Inappropriate alterations or modifications made without prior authorisation from 

the manufacturer 

· Damage caused by extreme circumstances, such as knocks, falling over, moisture and dirt 

· Insufficiently qualified operating staff 

· Non-compliance with current safety and accident-prevention regulations 

· Damage resulting from modifications made to the operating instructions 

Declaration of CE conformance 

We: Weber Ultrasonics GmbH 

Im Hinteracker 7 

D-76307 Karlsbad 

Germany 

hereby declare under our sole responsibility that the product: 

Designation: Ultrasonic generator “ULC xxxx MD” 

(xxxx is for different power output) 

Conforms to the requirements of the following EMV standards: 

EN 0081-1 

EN 008 - 

EN 0 

EN 014 

EN 60 

EN 61000 

and meets the requirements of the Low Voltage Directive. 

Karlsbad, 10.11. 004 

Markus Weber 

Managing Director 



Index 

A/B 

Assembly 

Assignment of the interface 

socket 8 

Assignment of the mains 

connection 6 

Installation 3, 6 

C 

CE conformance 1 

Connections 7, 8 

Connection of the external 

controller 1 

Contrast setting 14 

D 

Dimension generator 0 

Display backlight 14 

E 

Error messages 

and troubleshooting 19 

Power welding 14 

Service hotline 

F/G/H 

Fuse 6, 0, 1 

I/J/K 

Interface 8 

Introduction 3 

L 

LCD display 13 

Location 3, 6 

Output setting 13 

M/N/O 

Maintenance 0 

Operation 10 

Operating hours 16 

Operating and display elements 1 

Operating and display elements 

of the generator 11, 1 

P/Q/R 

Polarities 1 

Power output indicator 13 

Power supply 6, 0 

P-Window 13 

Should you still have questions after reading through the operating instructions thoroughly, 

please feel free to call our service hotline. 

Please have the following information to hand to help us answer your questions quickly. 

Device type, serial number (the serial number is on the backside of the generator) 

Spare parts 

Our service hotline number: 

+49 (0) 72 48 / 92 07-0 

We can only deliver spare parts and accessories if you quote the serial number of your device. 

S 

Settings 14–16 

Safety instructions 3 

Spare parts 

Specifications 0 

T/U 

Test button 11, 1 

Timer function 13 

T-Window 13 

V 

Voltage 6, 0 

W/X/Y/Z 

Warranty 1

Operations Manual for ultrasonic generators ... - Weber Ultrasonics

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