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Emerson GSX-E1 V2 Quick Start Manual
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Emerson GSX-E1 V2 Quick Start Manual

Emerson GSX-E1 V2 Quick Start Manual

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Q u i c k S t a r t G u i d e
Branson Ultrasonics Corporation
120 Park Ridge Road
Brookfield, CT 06804
(203) 796-0400
http://www.bransonultrasonics.com
Original Instructions
1032610 - REV. 02
GSX-E1 V2
Automation Models

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  • Page 1 Original Instructions 1032610 - REV. 02 GSX-E1 V2 Automation Models Q u i c k S t a r t G u i d e Branson Ultrasonics Corporation 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400 http://www.bransonultrasonics.com...
  • Page 2 [This page intentionally left blank] 1032610 REV. 02...
  • Page 3 Manual Change Information At Branson, we strive to maintain our position as the leader in ultrasonics plastics joining, metal welding, cleaning and related technologies by continually improving our products. These improvements are incorporated as soon as they are developed and thoroughly tested.
  • Page 4 [This page intentionally left blank] 1032610 REV. 02...

  • Page 5: Table Of Contents

    Chapter 1: Introduction Configuration Options ..........4 All-in-One Automation Assembly.

  • Page 6: Configuration Options

    Configuration Options Figure 1.1 All-in-One Automation Assembly ACTUATOR POWER AUXILIARY SUPPLY COLUMN Column Mount No Mount Non-Assembled Non-Assembled ACTUATOR ACTUATOR POWER AUXILIARY POWER AUXILIARY SUPPLY SUPPLY COLUMN 1032610 REV. 02...

  • Page 7: All-In-One Automation Assembly

    All-in-One Automation Assembly Figure 1.2 Table 1.1 Item Description Quantity HMI Monitor Monitor Arm GSX All-In-One System Actuator I/O Cable Power Supply I/O Cable Power Supply Line Cord Start Cable Ground Detect Cable (optional) 1032610 REV. 02...

  • Page 8: Column & Hub Mount (Non-Assembled)

    Column & Hub Mount (Non-Assembled) Figure 1.3 Table 1.2 Item Description Quantity HMI Monitor Monitor Arm (optional) Actuator* Column Power Supply* Power Supply Mounting Bracket Auxiliary Box* Auxiliary Box Mounting Brackets Cables (see Table 2.1 for more information) Ground Detect Cable (optional) NOTICE *There are two different configurations for the actuator, power supply, and auxiliary box.

  • Page 9: No Mount (Non-Assembled)

    No Mount (Non-Assembled) Figure 1.4 Table 1.3 Item Description Quantity HMI Monitor Monitor Arm (optional) Actuator* Power Supply* Power Supply Mounting Bracket Auxiliary Box* Auxiliary Box Mounting Brackets Cables (see Table 2.1 for more information) Ground Detect Cable (optional) NOTICE *There are two different configurations for the actuator, power supply, and auxiliary box.

  • Page 10: Actuator, Power Supply, Auxiliary Box Configurations

    Actuator, Power Supply, Auxiliary Box Configurations 1.5.1 Actuator Configurations 1.5.1.1 Top Exit Actuator with connections on top of the unit. Figure 1.5 1.5.1.2 Rear Exit Actuator with connections on the back of the unit. Figure 1.6 1032610 REV. 02...
  • Page 11 1.5.2 Power Supply Configurations 1.5.2.1 Bottom Exit Power supply with connections on the bottom of the unit. Figure 1.7 1.5.2.2 Rear Exit Power supply with connections on the back of the unit. Figure 1.8 1032610 REV. 02...
  • Page 12 1.5.3 Auxiliary Box Configurations 1.5.3.1 Bottom Exit Auxiliary box with connections on the bottom of the unit. Figure 1.9 1.5.3.2 Rear Exit Auxiliary box with connections on the back of the unit. Figure 1.10 1032610 REV. 02...
  • Page 13 Chapter 2: Interconnection Interconnection Diagram & Cables ....... . . 12 Cable Interface Points .
  • Page 14 Interconnection Diagram & Cables Figure 2.1 Interconnection Diagram - 01 1032610 REV. 02...
  • Page 15 Figure 2.2 Interconnection Diagram - 02 NOTICE For detailed pin-out information, please refer to the GSX-E1 User Manual. 1032610 REV. 02...
  • Page 16 Table 2.1 Interconnection Cables Connection Item Length Description Reference Points 1018644 2.5 m Actuator J56 - 1018645 7.5 m EtherCAT Cable Power Supply J15 1018646 15 m 100-240-383 2.5 m Actuator J1 - Power 100-240-385 7.5 m SHV RF J1 Cable Supply J1 100-240-386 15 m...
  • Page 17 Table 2.1 Interconnection Cables Connection Item Length Description Reference Points 1018648 2.5 m Power Supply J23 - 1018649 7.5 m Ethernet Cable HMI LAN Port 1018650 15 m 1029730 2.5 m Power Supply J16 - 1029731 7.5 m 12 V HMI Cable HMI DC Input 1029732 15 m...
  • Page 18 Table 2.1 Interconnection Cables Connection Item Length Description Reference Points 1018437 2.5 m 1018438 7.5 m Actuator I/O Cable Actuator J58 1018439 15 m 1017955 2.5 m 1017956 7.5 m Remote Start Cable Actuator J60 1017957 15 m 1019375 2.5 m Power Supply I/O 100-240-392 7.5 m...
  • Page 19 Cable Interface Points 2.2.1 Actuator Figure 2.3 GSX Actuator Cable Interface Points Table 2.2 GSX Actuator Cable Interface Points Connection Point Description Cable Required/Notes RF In SHV RF J1 Cable Servo Control Servo-Control Cable Servo Power In Servo-Power Cable Sonics Status In/24 VDC Actuator In Sonics Off/24 V Actuator Cable Ground Detect Ground Detect Cable...
  • Page 20 2.2.2 Power Supply Figure 2.4 GSX Power Supply Cable Interface Points Table 2.3 GSX Power Supply Cable Interface Points Connection Point Description Cable Required/Notes RF Out SHV RF J1 Cable Main Supply Voltage Input Power Supply Line Cord 24 VDC Power Supply In 24 V Power Supply Cable Auxiliary Box AC Supply Auxiliary Box to Power Supply...
  • Page 21 2.2.3 Auxiliary Box Figure 2.5 GSX Auxiliary Box Cable Interface Points Table 2.4 GSX Auxiliary Box Cable Interface Points Connection Point Description Cable Required/Notes Main Supply Voltage Input Auxiliary Box to Power Supply 24 VDC Power Supply Out 24 V Power Supply Cable Servo Control Servo-Control Cable Servo Power Out...
  • Page 22 2.2.4 Figure 2.6 HMI Interface Points Table 2.5 Touchscreen Connections Item Description LAN Port USB 2.0/USB 3.0 Ports DC Input NOTICE USB ports on the HMI are for keyboards and mice only. Do not use any other kind of device into these ports.
  • Page 23 Chapter 3: I/O Specifications Start Switch and E-Stop Connections ....... 22 Actuator I/O Specifications .

  • Page 24: Start Switch And E-Stop Connections

    Start Switch and E-Stop Connections The system requires two start switches and one emergency stop connection. The start switches and E-Stop switches need to be electrically isolated from each other to complete their circuit closure. Solid state switches may be used if the leakage current is less than 0.1mA.
  • Page 25 3.1.1 Specifications Table 3.1 E-Stop Specifications Description Value Outputs 2 Source: SRC1 & SRC2 Output Voltage 24 VDC Inputs 2 Sink: E-Stop NO & E-Stop NC Input Impedance 2 kΩ Input Current 12 mA Protection Ext. Switch Type 1 NO & 1 NC Isolated Ext.

  • Page 26: Actuator I/O Specifications

    Actuator I/O Specifications Figure 3.3 Actuator I/O Pin Number and Equivalent Circuit GSX ACTUATOR Figure 3.4 Typical Connection to PLC/Controller GSX ACTUATOR 1032610 REV. 02...
  • Page 27 Table 3.4 Digital I/O Specifications Inputs Outputs Description Value Description Value Number of Inputs 5 (Sink) Number of Outputs 5 (Source/Sink) Wiring Wiring PNP/NPN Input Voltage Range 15-30 VDC ON Output Voltage 24 VDC Input Impedance 16 kΩ OFF Output Voltage 0 VDC Source Output 1.5 mA @ 24 VDC...

  • Page 28: Power Supply I/O Specifications

    Power Supply I/O Specifications Figure 3.5 Power Supply I/O Pin Number and Equivalent Circuit GSX POWER SUPPLY Figure 3.6 Typical Connection to PLC/Controller GSX POWER SUPPLY 1032610 REV. 02...
  • Page 29 Table 3.6 Digital I/O Specifications Inputs Outputs Description Value Description Value Number of Inputs 9 (Sink) Number of Outputs 8 (Source/Sink) Wiring Wiring PNP/NPN Input Voltage Range 15-30 VDC ON Output Voltage 24 VDC Input Impedance 16 kΩ OFF Output Voltage 0 VDC Source Output 1.5 mA @ 24 VDC...

  • Page 30: Gsx Default I/O Configurations

    GSX Default I/O Configurations Inputs and outputs can be reconfigured to specific pin numbers. The I/O configuration is in the system configuration setup. 3.4.1 Default Actuator I/O Configurations Table 3.8 Default Actuator I/O Configurations Input/Output Default Function Cable Color (IEC) Digital Input Digital Input Part Present...
  • Page 31 Default Power Supply I/O Configurations Table 3.9 Default Power Supply I/O Configurations Input/Output Default Function Cable Color (IEC) Digital Input Cycle Abort Digital Input U/S Disable Digital Input Reset Digital Input +24VDC SRC Supplied from GSX System +24VDC SRC Digital Output Ready WHT/BLK Digital Output...

  • Page 32: I/O Descriptions

    I/O Descriptions Inputs and outputs are configurable to specific pin numbers. The configuration is in the system configuration setup. All discrete or digital inputs are 0 or 24VDC. 3.5.1 Available Actuator I/O Table 3.10 GSX Actuator I/O Descriptions - Inputs Input Level Range Definition...
  • Page 33 3.5.2 Available Power Supply I/O Table 3.12 GSX Power Supply I/O Descriptions - Inputs Input Level Range Definition Default Value & Logic Terminates a running cycle and Cycle Abort 0/24VDC returns the actuator to home 24VDC - Terminates a cycle. position.
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  • Page 35 Chapter 4: Mounting & Dimensions Enclosure Mounting Considerations ....... . 34 Column.

  • Page 36: Enclosure Mounting Considerations

    Enclosure Mounting Considerations Depending on the weld cycle rate and total weld power used, the ultrasonic Power Supply and Auxiliary Box can generate a large amount of internal heat. Cooling and heat management need to be considered when selecting and designing an enclosure to house the Power Supply and Auxiliary Box.
  • Page 37 Heat loss generated by the Auxiliary Box and Power Supply Dynamic Loss - For the Power Supply, it is the internal heat generated in Watts during the ultrasonic on phase of a cycle. For the Auxiliary Box, the Dynamic Loss is the internal heat generated by the servo amplifier during the weld and hold phases of a cycle Static Loss - The quiescent power loss in Watts due to the normal operation of the system controller and other related circuits.

  • Page 38: Column

    Column Remove the M4 screws from the front cover and backplate and remove them. Mount the column to a work surface using the four M12x1.75 bolts inside. Reinstall the front cover and backplate. NOTICE Torque bolts to 135 N·m (100 f-lb) in an X pattern. Figure 4.2 Figure 4.3 1032610 REV.
  • Page 39 Figure 4.4 1032610 REV. 02...

  • Page 40: Actuator

    Actuator Mount the actuator to an I-Beam or other rigid structure using four M10x1.5 bolts. Use dowel pins to aid with insertion and alignment (customer providzed hardware). NOTICE Mounting bolts must not extend more than 10 mm into the actuator Figure 4.5 Table 4.3 Item...
  • Page 41 Figure 4.6 1032610 REV. 02...

  • Page 42: Power Supply

    Power Supply 4.4.1 Rear Mounting Attach the mounting brackets to the power supply using four M6 bolts and washers. Figure 4.7 Mount the power supply to an electrical cabinet using four M6 bolts, with flat washers against its metal plate (customer provided hardware). Figure 4.8 1032610 REV.
  • Page 43 4.4.2 Side Mounting Attach the mounting brackets to the power supply using four M6 bolts and washers. Figure 4.9 Mount the power supply to an electrical cabinet using four M6 bolts, with flat washers against its metal plate (customer provided hardware). Figure 4.10 1032610 REV.
  • Page 44 Figure 4.11 1032610 REV. 02...

  • Page 45: Auxiliary Box

    Auxiliary Box 4.5.1 Rear Mounting Attach the mounting bracket to the auxiliary box using four M6 bolts and washers. Figure 4.12 Mount the auxiliary to an electrical cabinet using four M6 bolts, with flat washers against its metal plate (customer provided hardware). Figure 4.13 1032610 REV.
  • Page 46 4.5.2 Side Mounting Attach the mounting bracket to the auxiliary box using four M6 bolts and washers. Figure 4.14 Mount the auxiliary to an electrical cabinet using four M6 bolts, with flat washers against its metal plate (customer provided hardware). Figure 4.15 1032610 REV.
  • Page 47 Figure 4.16 1032610 REV. 02...

  • Page 48: Hmi Monitor

    HMI Monitor 4.6.1 VESA Mounting To install the monitor to a flat surface, attach a VESA 75 mounting bracket to the back of the monitor using four M4x10mm screws (customer provided hardware). Figure 4.17 HMI Monitor Dimensions Figure 4.18 VESA 75 Mounting Holes 1032610 REV.
  • Page 49 4.6.2 Monitor Arm (optional) Table 4.4 Monitor Arm Step Instructions Step Instructions Remove the two side screws and top screw from the mount and separate the Remove the plastic front cover. mounting plate from the rest of the mount. Attach the mounting plate to a wall stud or other structural support using the screws Align the mount with the mounting plate provided.
  • Page 50 Figure 4.19 Dimensions - Monitor Arm 1032610 REV. 02...
  • Page 51 4.6.2.1 Attaching Touchscreen to Arm Table 4.5 Attaching Touchscreen to Arm Step Action Tilt the monitor back and lower onto the arm, so that the hook fits into the corresponding hole on the VESA bracket. Then rotate the bottom of the monitor back towards the arm until the tab snaps in place.
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  • Page 54 Original Instructions 1032610 - REV. 02 Branson Ultrasonics Corporation 120 Park Ridge Road Brookfield, CT 06804 (203) 796-0400 http://www.bransonultrasonics.com Copyright © 2023 Branson Ultrasonics Corporation. All rights reserved. Contents of this publication may not be reproduced in any form without the written permission of Branson Ultrasonics Corporation.