Branson 2000 Series Manual
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Branson 2000 Series Manual

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BRANSON Automation Guide
EDP 100-214-273
Rev. 1
BRANSON Ultrasonics Corporation
41 Eagle Road
Danbury, Connecticut 06813-1961 U.S.A.
(203) 796-0400
http://www.bransonultrasonics.com

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  • Page 1 BRANSON Automation Guide EDP 100-214-273 Rev. 1 BRANSON Ultrasonics Corporation 41 Eagle Road Danbury, Connecticut 06813-1961 U.S.A. (203) 796-0400 http://www.bransonultrasonics.com...
  • Page 2 Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, cleaning and related technologies by continually improving our circuits and components in our equipment. These improvements are incorporated as soon as they are developed and thoroughly tested.

  • Page 3: Table Of Contents

    4.0- Special Features in V9.xx Firmware - - - - - - - - - - - - - - - - - - - - - - 2 5.0- 2000 Series Automation Logic Requirements - - - - - - - - - - - - - - - - - 5 5.1- To Start a Weld Cycle - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6...
  • Page 4 6.11.1-Wiring Table, Converter Stack, Standard Automation, Process Flow 11 - 6.11.2-2000 Series Automation, Process Flow 11 (Requires Jumper 100-246- 1178) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 38 6.12- Converter Stack, External Preset Select, Process Flow 12 - - - - - - - - - 39...

  • Page 5: Introduction

    This guide will help you to better understand the automation features available to you with the introduction of the version 9.x software to the Branson product line. The major feature of this software/firmware change is the user-configurable I/O. In the event you require additional assistance or information, please contact our Product Support depart- ment or your local Branson representative.

  • Page 6: Overview Of Automation Examples

    Audio-Video receivers: you can choose what output is present at the digitally optical jack, and which output is present at the digital hardware jacks, etc. in the 2000 Series welder it allows the user to configure certain connector J3 pin-outs (6 inputs and 3 outputs) to customer-desired features, optimizing the unit for specialized applications such as: switching up to 16 preset memories, switching con- verter/horn “stacks”, or for syncing several welders together.
  • Page 7 Automation Guide Special Features in V9.xx Firmware J3 Input Pins Default setting Selectable Setting (any pin) J3-1 Ext Signal Ext Sonics Delay J3-17 Select Preset #8 Display Lock Ext Signal J3-19 Select Preset #4 Sonics Disable Memory Reset J3-31 Display Lock Sync In Ext Start (input) J3-32...
  • Page 8 Special Features in V9.xx Firmware Ext Signal: Note: Not a new V9.xx feature but repeated here for clarity. Now the hardware pin and function is selectable in the User I/O menu. Used as input to allow external input to trigger amplitude or force change (model dependant). Optionally used as the start cycle input when in Hand Held mode.

  • Page 9: 2000 Series Automation Logic Requirements

    Cycle Abort to all the welders to make all retract simulta- neously.) 5.0 2000 Series Automation Logic Requirements NOTE Logic conditions shown are defaulted to factory shipped condition, with no configuration changes.This information applies to standard automation, such as a rotary index table appli-...

  • Page 10: To Start A Weld Cycle

    After the point of contact, force will develop against the workpiece. When the 2000 Series controls sense the trigger force set point the welder advances to the weld on state. Ultrasonics will start, and the start switches may now be released. We recommend monitoring the PB Release signal as the event to flag the release of the start signal.

  • Page 11: Weld (Ultrasonics) Finished, Hold Starts

    Automation Guide 2000 Series Automation Logic Requirements Then, on DB9 connector on rear of actuator, apply 0v to start pins 1 and 2 on the actuator connector before welder returns to home position, or Release contacts on pins 1 and 7, 2 and 6 on the actuator connector before the welder returns to home posi- tion.

  • Page 12: Process Flow And Wiring Tables

    Process Flow and Wiring Tables 6.0 Process Flow and Wiring Tables Each Process Flow diagram has a wiring table associated with setting up the connections to DB-9 on the rear of the actuator, and HD-44 which is the User I/O connector on the rear of the power supply. One excep- tion to this is “For Use with a Custom Actuator”...

  • Page 13: Actuator With Standard Automation, Process Flow 1

    Automation Guide Process Flow and Wiring Tables 6.1 Actuator with Standard Automation, Process Flow 1 100-214-273 Rev. 1...

  • Page 14: 1-Wiring Table, Actuator With Standard Automation, Process Flow 1

    Process Flow and Wiring Tables 6.1.1 Wiring Table, Actuator with Standard Automation, Process Flow 1 NOTE All voltages shown in this manual are direct current (DC) unless otherwise noted #1 Process Flowchart 1 Base/Start connector on actuator rear DB-9 Step Signal Name Colors Direction-...

  • Page 15: 2-2000 Series Automation Interface, Process Flow 1

    Automation Guide Process Flow and Wiring Tables 6.1.2 2000 Series Automation Interface, Process Flow 1 100-214-273 Rev. 1...

  • Page 16: Actuator, External Preset Select, Process Flow 2

    Process Flow and Wiring Tables 6.2 Actuator, External Preset Select, Process Flow 2 100-214-273 Rev. 1...

  • Page 17: 1-Wiring Table, Actuator, External Preset Select Process Flow 2

    Automation Guide Process Flow and Wiring Tables 6.2.1 Wiring Table, Actuator, External Preset Select Process Flow 2 NOTE All voltages shown in this manual are direct current (DC) unless otherwise noted #2 Process Flowchart 2 Base/Start connector on actuator rear DB-9 Step Signal Name Colors Direction-...

  • Page 18: Actuator, Delayed Sonics, Process Flow 3

    Process Flow and Wiring Tables 6.3 Actuator, Delayed Sonics, Process Flow 3 100-214-273 Rev. 1...

  • Page 19: 1-Wiring Table, Actuator, Delayed Sonics, Process Flow 3

    Automation Guide Process Flow and Wiring Tables 6.3.1 Wiring Table, Actuator, Delayed Sonics, Process Flow 3 NOTE All voltages shown in this manual are direct current (DC) unless otherwise noted #3 Process Flowchart 3 Base/Start connector on actuator rear DB-9 Step Signal Name Colors...

  • Page 20: 2-2000 Series Automation Interface, Process Flow 3

    Process Flow and Wiring Tables 6.3.2 2000 Series Automation Interface, Process Flow 3 100-214-273 Rev. 1...

  • Page 21: Actuator, Sonics Disabled, Process Flow 4

    Automation Guide Process Flow and Wiring Tables 6.4 Actuator, Sonics Disabled, Process Flow 4 100-214-273 Rev. 1...

  • Page 22: 1-Wiring Table, Actuator, Sonics Disabled, Process Flow 4

    Process Flow and Wiring Tables 6.4.1 Wiring Table, Actuator, Sonics Disabled, Process Flow 4 NOTE All voltages shown in this manual are direct current (DC) unless otherwise noted #4 Process Flowchart 4 Base/Start connector on actuator rear DB-9 Step Signal Name Colors Direction- Signal Type...

  • Page 23: Actuator, Sonics Disabled And Presets, Process Flow 5

    Automation Guide Process Flow and Wiring Tables 6.5 Actuator, Sonics Disabled and Presets, Process Flow 5 100-214-273 Rev. 1...

  • Page 24: 1-Wiring Table, Actuator, Sonics Disabled And Presets, Process Flow

    Process Flow and Wiring Tables 6.5.1 Wiring Table, Actuator, Sonics Disabled and Presets, Process Flow 5 NOTE All voltages shown in this manual are direct current (DC) unless otherwise noted #5 Process Flowchart 5 Base/Start connector on actuator rear DB-9 Step Signal Name Colors...

  • Page 25: Actuator, External Preset Select And Delayed Sonics, Process Flow 6

    Automation Guide Process Flow and Wiring Tables 6.6 Actuator, External Preset Select and Delayed Sonics, Process Flow 6 100-214-273 Rev. 1...

  • Page 26: 1-Wiring Table, Actuator External Preset Select And Delayed Sonics, Pro- Cess Flow 6

    Process Flow and Wiring Tables 6.6.1 Wiring Table, Actuator External Preset Select and Delayed Sonics, Process Flow 6 NOTE All voltages shown in this manual are direct current (DC) unless otherwise noted #6 Process Flowchart 6 Base/Start connector on actuator rear DB-9 Step Signal Name Colors...

  • Page 27: 2-Wiring Table, Process Flow 6, Required Functions: Logical Sequence

    Automation Guide Process Flow and Wiring Tables 6.6.2 Wiring Table, Process Flow 6, Required Functions: Logical Sequence NOTE All voltages shown in this manual are direct current (DC) unless otherwise noted 100-214-273 Rev. 1...

  • Page 28: 3-Wiring Table, Process Flow 6, Plc Connections

    Process Flow and Wiring Tables 6.6.3 Wiring Table, Process Flow 6, PLC Connections Definition, DB9, Actuator PB (actuator start) input PB (actuator start) input Source 24VDC (for hard contact) Source 24VDC (for hard contact) Source 24VDC (for hard contact) Source 24VDC (for hard contact) E-STOP input E-STOP input Definition, J3, Power Supply...

  • Page 29: 4-External Preset Select Binary Table

    Automation Guide Process Flow and Wiring Tables 6.6.4 External Preset Select Binary Table User I/O Input Pins When using External Preset Select User I/O Input Pin # PRESET PRESET (16) (16) 100-214-273 Rev. 1...

  • Page 30: 5-Preset Switching Diagrams, 1 Of 4

    Process Flow and Wiring Tables 6.6.5 Preset Switching Diagrams, 1 of 4 100-214-273 Rev. 1...
  • Page 31 Automation Guide Process Flow and Wiring Tables Preset Switching Diagram, 2 of 4 continued 100-214-273 Rev. 1...
  • Page 32 Process Flow and Wiring Tables Preset Switching Diagrams, 3 of 4 continued 100-214-273 Rev. 1...
  • Page 33 Automation Guide Process Flow and Wiring Tables Preset Switching Diagrams, 4 of 4 continued 100-214-273 Rev. 1...

  • Page 34: Actuator, Delayed Horn Travel, Process Flow 7

    Process Flow and Wiring Tables 6.7 Actuator, Delayed Horn Travel, Process Flow 7 100-214-273 Rev. 1...

  • Page 35: 1-Wiring Table, Actuator Delayed Horn Travel, Process Flow 7

    Automation Guide Process Flow and Wiring Tables 6.7.1 Wiring Table, Actuator Delayed Horn Travel, Process Flow 7 NOTE All voltages shown in this manual are direct current (DC) unless otherwise noted #7 Process Flowchart 7 Base/Start connector on actuator rear DB-9 Step Signal Name Colors...

  • Page 36: Actuators, Multi-Syncro (Simultaneous Sonic Start), Process Flow 8

    Process Flow and Wiring Tables 6.8 Actuators, Multi-Syncro (simultaneous sonic start), Process Flow 8 All welders get start signal from external control. 2. All welders move down to the part to be welded. 3. All welders reach trigger. 4. On all welders sonics is not activated because at this point, Sync In and Ext U/S Delay is missing. 5.

  • Page 37: Interrupting Cycle For Device Position (Hold Off On Horn Travel) Externally By Plc Device, Process Flow 9

    Automation Guide Process Flow and Wiring Tables 6.9 Interrupting Cycle for Device Position (Hold off on Horn Travel) Externally by PLC Device, Process Flow 9 100-214-273 Rev. 1...

  • Page 38: 1-Wiring Table, Interrupting Cycle For Device Position, Process Flow 9

    Process Flow and Wiring Tables 6.9.1 Wiring Table, Interrupting Cycle for Device Position, Process Flow 9 NOTE All voltages shown in this manual are direct current (DC) unless otherwise noted #9 Process Flowchart 9 Base/Start connector on actuator rear DB-9 Step Signal Name Colors...

  • Page 39: Custom Actuator, Process Flow 10

    Automation Guide Process Flow and Wiring Tables 6.10 Custom Actuator, Process Flow 10 100-214-273 Rev. 1...

  • Page 40: Converter Stack, Standard Automation, Process Flow 11

    Process Flow and Wiring Tables 6.11 Converter Stack, Standard Automation, Process Flow 11 100-214-273 Rev. 1...

  • Page 41: 1-Wiring Table, Converter Stack, Standard Automation, Process Flow

    Automation Guide Process Flow and Wiring Tables 6.11.1 Wiring Table, Converter Stack, Standard Automation, Process Flow 11 NOTE All voltages shown in this manual are direct current (DC) unless otherwise noted #10 Process Flowchart 11 Install 100-246-1178 jumper box into J7 User I/O connector on power supply rear HD-44 Signal Name...

  • Page 42: 2-2000 Series Automation, Process Flow 11 (Requires Jumper 100-246- 1178)

    Process Flow and Wiring Tables 6.11.2 2000 Series Automation, Process Flow 11 (Requires Jumper 100-246-1178) 100-214-273 Rev. 1...

  • Page 43: Converter Stack, External Preset Select, Process Flow 12

    Automation Guide Process Flow and Wiring Tables 6.12 Converter Stack, External Preset Select, Process Flow 12 100-214-273 Rev. 1...
  • Page 44 Process Flow and Wiring Tables 6.12.1 Wiring Table, Converter Stack, External Preset Select, Process Flow 12 NOTE All voltages shown in this manual are direct current (DC) unless otherwise noted #11 Process Flowchart 12 Install 100-246-1178 jumper box into J7 User I/O connector on power supply rear HD-44 Signal Name...

  • Page 45: Frequently Asked Questions (Faq)

    Automation Guide Frequently Asked Questions (FAQ) 7.0 Frequently Asked Questions (FAQ) 100-214-273 Rev. 1...
  • Page 46 Frequently Asked Questions (FAQ) 100-214-273 Rev. 1...
  • Page 47 Automation Guide Frequently Asked Questions (FAQ) 100-214-273 Rev. 1...
  • Page 48 Frequently Asked Questions (FAQ) 100-214-273 Rev. 1...
  • Page 49 Automation Guide Frequently Asked Questions (FAQ) the pneumatics are used as differential mode of operation, I would suggest to always use the 100 psi values from the above table to be on the conservative side for sizing airflow, rather than on the actual force values. Still add the same converter cooling values (0.034) as in the prior example.

  • Page 50: Glossary V9.Xx

    This refers to the feature set of the device that delivers the horn to the workpiece. It may be just a convertor/ horn “stack”, or a Branson furnished basic actuator, or a Branson furnished actuator with distance and force sensors.
  • Page 51 Automation Guide Glossary V9.xx This is a cycle when the welder would normally be in full control (as in a standard cycle) BUT and external device is performing an operation that interrupts the cycle. A typical example would be to perform a “test” on the workpiece to determine its merit before the weld (ultrasonics) cycle begins.
  • Page 52 Glossary V9.xx Missing Part A user output signal that indicates trigger occurred above the minimum or below the maximum user-set allowable distance settings. Modified Alarm A user output signal that indicates a user-set compensating condition occurred, (Only energy at this time). Multi head Multi head uses more than 1 horn, each horn has its own respective ultrasonic power supply.
  • Page 53 Automation Guide Glossary V9.xx Switching preset memories This is when different weld setups are stored in memory. They can be recalled from memory by the user from the front panel, or remotely from the User I/O input pins if properly selected settings are chosen in the System Configuration menu.
  • Page 54 Glossary V9.xx 100-214-273 Rev. 1...

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