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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.
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.
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.
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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...
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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.
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-...
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.
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.
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”...
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-...
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-...
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...
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...
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...
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...
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...
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...
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.
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...
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...
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...
Automation Guide Process Flow and Wiring Tables 6.12 Converter Stack, External Preset Select, Process Flow 12 100-214-273 Rev. 1...
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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...
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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.
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.
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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.
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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.
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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.
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