Branson Manual Book

E-Plus 20kHzPlastic Welder Instruction Manual EDP 500-220-070 Rev. C Branson Ultrasonics (Shanghai) Co., Ltd. 758 Rong Le Dong Road, Songjiang Shanghai, 201613, PRC +86-021-3781-0588 E-Plus 20kHz Plastic Welder Instruction Manual 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. Information concerning any improvements will be added to the appropriate technical documentation at its next revision and printing. Therefore, when requesting service assistance for specific units, note the Revision information found on the cover of this document, and refer to the printing date which appears at the bottom of this page. © BRANSON Ultrasonics Corporation June 2013 set up. program.E-Plus 20kHz Plastic Welder Instruction Manual Foreword Congratulations on your choice of a Branson Ultrasonics Corporation system! The Branson E-Plus 20kHz Plastic Welding system is process equipment for the joining of plastic parts using ultrasonic energy. This Instruction Manual is part of the documentation set for this system. and should be kept with the equipment.4 for information on how to contact the appropriate Branson representative. Please refer to the Table of Contents and/or the Index of this manual to find the information you may be looking for. see Chapter 1. install. Thank you for choosing Branson! Introduction This manual is arranged into several structured chapters which will help you find the information you may need to know to safely handle. C . and/or maintain this product. 500-220-070 Rev. section 1. It is the newest generation of product using this sophisticated technology for a variety of customer applications. operate. In the event you require additional assistance or information. -2 ...-2 ...........4 System Control Module.4 1...............5 Upper Limit Switch ..2..-2 ...4 How to Contact Branson ....-2 .............-1 ....1 Models Covered..6 User I/O Connector.....-2 ............-1 .......-1 ..-2 ..8 500-220-070 Rev..3 2......-2 .....1 Carriage and Slide System .....4....1 1...............2.....1 Intended Use of the System .5 Front Panel Controls .....-1 .2. C i ...............-1 .-1 ....3 2......4 1.........-1 ..3 2...3 Warranty Statement............4 Features...E-Plus 20kHz Plastic Welder Instruction Manual Table of Contents Chapter 1: 1.-1 .......-2 ....3 Power Supply ......2........-1 .......1 Safety and Support Safety Requirements and Warnings .....1 Symbols Found in this Manual ...1.....4 2...................2..2.2.....1 1......2 Overview of these Models .....6 Rear Panel .........4 1.-2 .4 Setting up the Workplace ...-2 .6 1.-2 ..................2 Symbols Found on the Product ..4 2.......3 2...........................1 1.....-1 ............6 Returning Equipment for Repair .........2 1....4 1....2 2.2 General Precautions .....2.....4 2......4 2.....3 Emissions ....3 Compatibility with Branson Products....2 Safety Measures and Guards ..2 Pneumatic System ......7 The E-Plus 20kHz Welder 2.......3 1........2.-2 ..2............-2 ...6 2.............1 2..3 1.......-1 ....5 2............... Disclaimer ...............-1 ......5 Chapter 2: Before Calling Branson for Assistance .7 Dynamic Triggering and Follow-Through .......1.....2.......................... 4 Installation Requirements...........-4 ..-4 .6.......4 ............9 2.START Connector .........-2 ...-4 ..4 ......4 Chapter 4: Installation and Setup 4... Alarm Connector .2 4.....1 4..-4 .-4 .......1 User I/O..1 4....1......4 .9 4...2 EXTERNAL RESET ......7.2.....5 WELD ON Signal ........1 Glossary of Terms ..-4 .9 4....6 Start Switch Connection (Automation) ...4 Cables ......-4 ............12 4....3 4.18 500-220-070 Rev.4..2 Receiving ...4.Alarm Connector ...................................2 3..ALARM (User I/O) Connector ............4 .5 Location ....5 4.5 Installation Steps .................18 4.....-4 ........2 ........9 2...........3 Electrical Input Power Ratings ...10 2..9 2....18 4.....10 2..................-4 ..8 Guards and Safety Equipment .7 START SWITCHES/START Signal ......-2 ..-3 .........1 About Installation ..10 Delivery and Handling Shipping and Handling ........7 4..........7...10 4....-4 ......8................Alarm Connector .8 Chapter 3: 3.7 4.....3..3 Power Supply Module Options DIP Switch ..............6.4 .......1 Mounting the Stand (Welder on Base) ...............2 4.............-3 .......2.....................5........2 Take Inventory of Small Parts ...9 2.-3 ............15 4.5..4 4.......2 ......2 Input Power (Main) ........1 ii System Inputs/Outputs ......4 GENERAL ALARM .1 3...7 Accessory Input/Output Option .4.1 Unpack the Welder ...4 .....1 3....11 4...4 ..2 .2 Handling and Unpacking ............1 Emergency Stop Control .4 Factory Air .......... C .....3 READY Signal .7....4.1 Environmental Specifications ..-2 ..15 4.......................-3 ...............-4 ...7...7 4.-4 ..2 Input Power Plug ..........ALARM Connector.............7.....4 ...6......................-2 .2 Environmental Specifications ........3 Unpacking. ..2.....1 Mounting the Fixture on the Branson Base (hardware and mounting holes).....3 Controlling the Front Panel Display .2 Using Weld Modes .12.4 ............5 User I/O ....................1 Physical Description .....10 Installing the Ultrasonic Stack in the Welder ..........3 Resetting the System.3 Pneumatic Requirements ....1.......4 ......6 .-6 . C iii ..................1.........1........16 6.6 ...23 4....4 Circuit Descriptions........5 Chapter 6: 6.......6 ...................16 500-220-070 Rev........13 Testing the Installation .2.............6 6..-5 ..1 Modifying Weld Modes ......9 Assemble the Acoustic Stack....................2.......5 6...-5 ............1.4 .4 .....6 6.8 6................4 5.2..26 4......22 4...5 Weld Cycle State Displays and Alarms .1.4 .-6 .1 5......6 6....2 Clearing Weld Cycle Alarms .-5 .-6 ............30 Chapter 5: 5....2 Setting Weld Cycle Parameters .-6 .....11 6..................4 ...6 ....1 Technical Specifications Technical Specifications .4 Ultrasonic Test ...25 4...........1 Connecting Tip to Horn ......2 5...........2 6.....5............1 Setting DIP Switches ..1....................-6 ........28 4........4 Recalling Stored Parameters ..6 Converters and Boosters ............10.11 6..........1 Weld Cycle State Displays ..........4 ...6 ....-5 ............-6 ...3 5.....2 5.....8 6...7 6.....-5 ..........1 5...-5 ..1 Operation Weld Modes ....2 Electrical Requirements ....4 .-5 .......2 Modifying Parameter Values ..19 4..5...............1...2 6.4 Setup Procedure ....5.........1 Selecting a Parameter to Modify .....................E-Plus 20kHz Plastic Welder Instruction Manual 4.....15 6....1.-6 .......12 Adjusting the mechanical Stop .......-6 ...............11 Adjusting Welder Height and Aligning the Horn ..........3 Storing Parameters.-6 ..24 4........9.-6 .5.7 6.... ...1 7......2 7...4 Troubleshooting .6 ..3 Static Protection Equipment .....2 Reconditioning the Stack (Converter....6 7..4..1 Maintenance Preventive Maintenance ..1.................1 7..1 iv Hearing Protectors ..-7 ..5.....................3 Stack Reconditioning Procedure ....6 Converter Cooling ...-7 .1 A.......-7 ...1........6.8 Manufacturers of Protective Equipment A ..........2 Parts Lists..2 A..... C ..3 Circuits ..1.... Booster and Horn) .........-7 ..8 7........... 200-163-009) ......................2 500-220-070 Rev......-7 ..17 6..........A .1 7.-7 ..A ............-7 ............2 Servicing the Air Filter (Part No.6 .....1 Manual Tuning .-7 ......-7 .....2 Sound Absorbing Material .....1 A...............7 7..........5...5 Horn Down .....1......2...17 Chapter 7: 7.....1 Periodic Maintenance Procedures ........4 7..A ................... .....-2 . 7... 4....4 ...-4 ......... 4.4 ....4 500-220-070 Rev. 4........16 fig........1 Unpacking the Stand....8 fig....17 fig............17 Installing a 20kHz Stack in a Branson Welder ..... 4...........5 Base Mounting Centers ..........3 fig.. right-side view ............... 4.4 .....9 International Harmonized Line Cord Color Code ..3 Front Panel Displays ........ 6..13 fig.......... 4...........-6 ..........-2 .. 4...... 1....11 Type 2 DIP Switch Marked "ON" on face of Switch.........5 Base........ 4................13 Actuator Emergency Stop Button .. C i ..12 Accessory Input/Output Connector Pinout .............27 fig....2 Setup and Operation in Time Mode ...... 4...........14 fig.......24 fig............7 Input/Output Signals .. 2......15 Assembling the 20kHz Acoustic Stack..19 Adjusting the Mechanical Stop ..11 fig.........1 Time Mode ...........4 ....4 .... 4........... ....6 Start Switch Connection Codes . 4. 4..........E-Plus 20kHz Plastic Welder Instruction Manual List of Figures fig......... Rectangular Horn ..2 Ultrasonic Converter and Booster .-1 ...20 DIP Switch Location ...........4 ..10 fig........... Cylindrical Horn ...-4 ...... 2.....2 fig..........2 fig..4 .4 ...-2 .....-7 ........ 4..25 fig.....21 fig. 2......18 fig........2 Front Panel Controls ..5 fig..... 2..... 4. 4....10 Type 1 DIP Switch Marked "OPEN" on Top of Switch.-2 .14 Assembling the 20kHz Acoustic Stack.........21 fig....... Default Settings....3 E-Plus 20kHz Plastic Welder Dimensional Drawing .1 CJ 20 Converter ...7 fig.30 fig.16 Connecting Tip to Horn ..4 ........4 Rear Panel ...1 Reconditioning Stack Surfaces ............4 ..8 Operating Cycle Timing Table ..4 ...............9 fig..4 ....4 .........18 Mounting Circles on Base......-5 ...23 fig........6 fig.. 4.....10 fig.5 fig..6 fig..-4 ............-4 .21 Normal Front Panel Display after Power -Up .4 ..15 fig.....1 E-Plus 20kHz Plastic Welder ... Default Settings.....6 .-2 .19 fig..1 Safety Labels on theE-Plus 20kHz Plastic Welder .. 5..... 4..3 fig..... Showing START SWITCHES and Base Cable ...........28 fig... 4....8 fig.....4 ........... 6.4 .... 2....................... 4. 4....4 Hooking Up the Air Line .......4 . 4.. ........fig.-7 ..2 Disassembly of Air Filter Components.-7 .................9 ii 500-220-070 Rev..-7 . 7. 7...4 Manual Adjustment Procedure Flowchart ............5 fig. .7 fig............... 7..3 Interconnect Schematic. C .. .........4 Tab....6 ..6 500-220-070 Rev....4 Tab..7 ............. 7......4 ....11 Tab.............22 Tab.16 Tab..6 Tab......2 Pretrigger Settings ..........7 Tab.......E-Plus 20kHz Plastic Welder Instruction Manual List of Tables Tab........4 Inputs to the Power Supply from the Actuator .......6 ....3 Time Mode Parameters ...3 Inputs to the Power Supply .5 Options for Setting the Type 1 Switch Select Block Tab...6 Other items used with the E-Plus ...1 Warranty Period...2 Replacement Parts ..................2 Tab.............. 6...6 .2 Tab....7 Tab. C iii ...... 4.......6 Error Codes ......4 Input Power Requirements ..... 4.17 Tab...................4 Tab....5 .3 Tab... 4...........5 ..6 Tab....6 Options for Setting the Type 2 Switch Select Block .....4 ..........4 .13 Tab..5 E-Plus Boosters:.... 5....................4 ...... 5. 6............... 4.......22 Tab.....7 .....5 Tab.......3 Environmental Specifications ...........5 ..1 Environmental Specifications .. 4.7 Tab.. 6..................3 ...........6 ....4 ....5 ........1 Parameter Functions ...1 Small Parts Included (=x) with E-Plus 20kHz Plastic Welder .8 Stud Torque Values ................... 1.5 .. 4.1 .. 5..... 4..4 .......2 Tab.. 6................. 5......4 Tab..... ........6 ....................... 5.........20 Tab..... 4. 6....4 .....5 Tab.7 Tools ......2 Tab.....4 .......2 Electrical Requirements ... 6...4 . 3.5 ..1 Stack Reconditioning Procedure ... 7......... 4........... 5...........5 E-Plus State Displays ..............6 ..............4 ....9 Tip to Horn Torque Values..2 List of Cables .........1 Environmental Specifications ........4 Recalling Pre-defined Parameter Values . iv 500-220-070 Rev. C . 7 1.....2 General Precautions ...................-1 ..............1 Safety Requirements and Warnings This chapter contains an explanation of the different Safety Notice symbols and icons found both in this manual and on the product itself and provides additional safety information for ultrasonic welding.2........ This chapter also describes how to contact Branson for assistance..3 1.4 1........1 1...3 Warranty Statement.........4 How to Contact Branson ........ It does not alert the user to potential injury. C 1-1 ........1...... 1... but only to a situation that might eventually require additional work or modification if you ignore it initially.....4.......-1 ....-1 ...1 1......1 Safety Requirements and Warnings .-1 ....1.............1 Intended Use of the System . 500-220-070 Rev.-1 ......2 1.-1 .2 Symbols Found on the Product ......-1 ......-1 .......2.4 1....... Disclaimer ...-1 ..3 1....4 1.2 Safety Measures and Guards ..E-Plus 20kHz Plastic Welder Instruction Manual Chapter 1: Safety and Support Safety Requirements and Warnings Chapter 1: Safety and Support 1...4 1..4 Setting up the Workplace .-1 .-1 .6 Returning Equipment for Repair .....1 Symbols Found in this Manual Three symbols used throughout this manual warrant special attention: i NOTE A Note contains important information..5 Before Calling Branson for Assistance .2.6 1.......2..........3 Emissions .........1 1.............-1 ....1 Symbols Found in this Manual ...1.. 1 Safety Labels on theE-Plus 20kHz Plastic Welder DO NOT TOUCH HORN UNDER POWER WARNING CRUSH PINCH WARNING 1-2 500-220-070 Rev.1. Figure 1. The following warning symbols appear on the E-Plus 20kHz Plastic Welder. if not avoided. can result in minor or moderate injury. C . if not avoided.2 Symbols Found on the Product Familiar graphic warning symbols are used to alert the user to items of concern or hazard. can result in serious injury or death.Chapter 1: Safety and Support Safety Requirements and Warnings ! ! CAUTION A Caution indicates a potentially hazardous situation that. WARNING A Warning indicates a hazardous situation or practice that. It might also alert the user to unsafe practices or conditions that can damage equipment if not corrected. 1. • When using larger horns. shape and composition of the material being assembled. These are designed for a wide variety of welding or processing applications.1 of Appendix A. or setting DIP switches: • Be sure the power switch is in the Off position before making any electrical connections. b. Therefore. shape and material of the holding fixture.” For all other countries. • Keep hands from under the horn. do the following: • Turn off the power supply. c. use only non-grounded. • Do not cycle the welding system if either the RF cable or converter is disconnected. not chassis ground.1 Intended Use of the System The E-Plus 20kHz Plastic Welder houses all the components of an ultrasonic welding system. type of application. • Be sure power is disconnected from the power supply before setting a DIP switch. battery-powered multimeters when testing these modules. In such cases operators may need to be provided with personal protective equipment. Common points are tied to circuit reference. Down force (pressure) and ultrasonic vibrations can cause injury. • High voltage is present in the power supply. C 1-3 . tool design.95 Occupational Noise Exposure.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 1: Safety and Support General Precautions 1. “Hearing Protectors. • Unplug main power. 1. Some or all of these factors may result in an uncomfortable noise being emitted during the process. • High line voltages exist in the ultrasonic power supply module. See 29 CFR (Code of Federal Regulations) 1910. i NOTE Sound level and frequency of the noise emitted during the ultrasonic assembly process may depend upon a. avoid situations where fingers could be pinched between the horn and the fixture. Some parts vibrate at an audible frequency during the process. always plug the power supply into a grounded power source. 500-220-070 Rev. welder setup parameters and e.2. follow your local regulations. and • Allow at least 2 minutes for capacitors to discharge. d. • Be aware that the actuator is "armed" if air pressure is indicated on the front panel air pressure gauge. Also see Section 1. • Power supplies produce high voltage.2 General Precautions Take the following precautions before servicing the power supply. Using other types of test equipment can present a shock hazard. Do not operate with the cover removed. size. Before working on the power supply module. • To prevent the possibility of an electrical shock. gases or other emissions that can be hazardous to the operator’s health. can be hazardous to an operator’s health and could cause corrosion/damage to the equipment. please refer to the Terms and Conditions of Sale. Disclaimer 1. shipment.4 Setting up the Workplace Measures for setting up a workplace for safe operation of the ultrasonic welder are outlined in Section Chapter 4:: Installation and Setup. 1-4 500-220-070 Rev. certain plastic materials can emit toxic fumes. proper ventilation of the workstation is required. 1. such as PVC. Disclaimer The following excerpts from the “Terms and Conditions of Sale” are essential guidelines for the product Warranty issued with your Branson ultrasonic welding components. 1. Start Switch and Emergency Stop controls are designed to prevent undesirable startup. Where such materials are processed.3 Emissions When being processed.2.2. ! CAUTION Processing of many materials. If you have any questions. and warranty period provided.Chapter 1: Safety and Support Warranty Statement.” Buyer’s acceptance of the Products will manifest Buyer’s assent to these Terms and Conditions.2. 1. or contact your Branson representative.3 Warranty Statement. ULTRASONIC JOINING EQUIPMENT WARRANTY POLICY Each product manufactured by Branson is guaranteed to be free from defects in material and workmanship for a period of time specified in Table 1. Use proper ventilation and take protective measures. The items listed in this section specifically address issues involving the delivery. Check your materials suppliers for recommended protection when processing their materials.1 ’Warranty Period’ on page 5 from the date of invoice. contains software-controlled electronic safety devices intended to prevent the machine from operating in a fashion harmful to the user. C .2 Safety Measures and Guards The E-Plus 20kHz Plastic Welder. TERMS AND CONDITIONS OF SALE Branson Ultrasonics Corporation is herein referred to as the “Seller” and the customer or person or entity purchasing products (“Products”) from Seller is referred to as the “Buyer. accident or improper installation. Disclaimer Warranty Period E-Plus Welder 12 months Accessories 12 months Converters 12 months (limited to one-time replacement) Horns and Fixtures 3 months (limited to one-time replacement) Boosters 12 months (limited to one-time replacement for Aluminum booster) The warranty does not apply to: • any product which has been subject to misuse. • Serialized assemblies replaced during the repair of out-of-warranty equipment are warranted for a period of 3 months. Warranty Service covers the following: Repair service at Branson or a regional office • Includes parts and labor performed at Branson authorized repair facilities.5 seconds. Repair service at the customer site • Includes parts and labor at the customer site performed by a Branson technician. • Non-serialized parts replaced during the repair of out-of-warranty equipment are warranted for 3 months.1 Chapter 1: Safety and Support Warranty Statement. converters) or improperly tuned horns. horns. misapplication. • Set up/installation of equipment and software updates. neglect (including without limitation inadequate maintenance). The customer is responsible for all travel-related charges. boosters. C 1-5 . • Travel charges for Branson service personnel will be waived on service calls performed within 30 days of invoice date. The customer must return the equipment properly packed with all shipping charges prepaid. Additional Warranty Notes • Components replaced during in-warranty repair carries the remainder of the original warranty.e. 500-220-070 Rev. If you have any questions concerning the warranty coverage . • any product exposed to adverse environments.E-Plus 20kHz Plastic Welder Instruction Manual Table 1.. • non-Branson equipment (i. improper repair or repairs using non-Branson methods or material. modification or adjustment. • applications requiring metal-to-metal contact when the ultrasonic exposure time exceeds 1. please contact your Branson representative or Branson Customer Support. .. . 4.. use the following telephone numbers............ ........... 10.. what is supplying the “start” signal? 8.................. Software... Have a list of service or spare parts you have on hand (tips..... For example. Branson Product Support is here to help you........ • CSC toll free hotline: 400-118-3465 1.... .. horns....... ....... C . 5................. use the following questionnaire which lists the common questions you will be asked when you contact the Product Support department... Information about the Horn (part number.............. ... which error (give error number or name)? 9..............) 12.. or contact the field office nearest you.) or other tooling may be etched into the tooling..... Have your manual with you.......... What are the setup parameters and mode? ....... What is your application. 6......... including the materials being processed? 11. is the problem intermittent? How often does it occur? How long before it occurs if you are just powering up? If an error is occurring..... List the steps you have already taken............ Your return telephone number...... provide as much detail as possible.... Before calling.......... 2.. To help identify the problem. Is your equipment in an automated system? If so........ which may be required...... 7............................. determine the following information: 1... To contact Branson for help..1 Before Calling Branson for Assistance This manual provides information for troubleshooting and resolving problems that could occur with the equipment (see Chapter 7)............ If troubleshooting a problem..... Your company name and location........... etc... Know your equipment model and serial numbers (found on a gray data label on the units)................4 How to Contact Branson Branson is here to help you......... Notes: __________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ 1-6 500-220-070 Rev...... Describe the problem. If you still require assistance............ refer to Chapter 7......... gain................ What tooling (horn) and booster are being used? ...Chapter 1: Safety and Support How to Contact Branson 1....4...........................................or firmware-based systems may provide a BOS or software version number................... etc... We appreciate your business and are interested in helping you successfully use our products... 3.... For example. C 1-7 . provide as much detail as possible.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 1: Safety and Support Returning Equipment for Repair 1. provide as much information with the equipment to help determine the problem with the system.5 Returning Equipment for Repair Before sending equipment for repair. Describe the problem. Fill in any details below or on a separate sheet. is this a new problem? Is the problem intermittent? How often does it occur? How long before it occurs if you are just powering up? ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ 500-220-070 Rev. Chapter 1: Safety and Support Returning Equipment for Repair 1-8 500-220-070 Rev. C . ...3 READY Signal .5 2...6 Rear Panel ..-2 ......4 2...3 Power Supply .5 Front Panel Controls ..........-2 ....-2 ...4 2..2 ..7.START Connector .........3 2..........4 System Control Module.........E-Plus 20kHz Plastic Welder Instruction Manual Chapter 2: The E-Plus 20kHz Welder Models Covered Chapter 2: The E-Plus 20kHz Welder 2......2.....-2 .....7 Dynamic Triggering and Follow-Through ...-2 .. 500-220-070 Rev....2 EXTERNAL RESET ....1 Carriage and Slide System ....1 Models Covered This manual contains instructions for installing.....-2 ........................5 WELD ON Signal .6 2....4 Features...-2 ..8 Glossary of Terms ..9 2.............3 2.Alarm Connector ......8 2..... setting up and operating E-Plus 20kHz Plastic Welder for 1500 Watt output..............................-2 ..1 Models Covered.........-2 .2..2.2..-2 ......10 2......10 2..........Alarm Connector .2 Overview of these Models ..3 2..2 Pneumatic System .7....2 .....2 .9 2..4 2....7. C 2-1 ......3 Compatibility with Branson Products...7 System Inputs/Outputs ...9 2.4 2.....................2 2.......9 2..............-2 ......-2 .....2.-2 .2.-2 .................1 2..............ALARM (User I/O) Connector ......6 User I/O Connector..10 2....ALARM Connector........4 GENERAL ALARM ........5 Upper Limit Switch .......-2 .-2 .........-2 ......7.3 2...2........7...1 START SWITCHES/START Signal .... welders can contain a base assembly with 2 Palm Buttons and an Emergency Stop knob. C . i NOTE It is advisable to have non standard length columns installed at the factory.2 Overview of these Models Figure 2. insertion. The programmer consists of a control board and a keyboard/display board. An enclosure housing the carriage and slide system. the pneumatic system. 2-2 500-220-070 Rev. swaging and degating. free standing welding systems designed for upright vertical operation. They are used for welding plastic parts together by staking. The 20kHz welder is available with 1500 Watts。 •For manual applications.Chapter 2: The E-Plus 20kHz Welder Overview of these Models 2. welders can contain a hub in place of the base assembly.1E-Plus 20kHz Plastic Welder The E-Plus 20kHz Plastic Welders are ultrasonic plastic joining systems. •For Automated applications. the power supply and the programmer. These welders are self contained. A typical setup will be with a standard 40-inch column (4. 5 and 6 foot lengths are also available). 500-220-070 Rev. C 2-3 . permanently lubricated bearings. and a Pressure Regulator with an airpressure gauge. booster. 2.2. The keyboard/display board controls weld parameters via the front panel displays and switches.1 Carriage and Slide System The carriage is driven by a double-acting air cylinder.4 System Control Module The System Control Module consists of a Programmer board and a Keyboard/Display board. loose or failed horn. smooth linear motion. 2. The SPM/AT enables the power supply to track and compensate for changes in horn frequency.2. 2. The rate of ascent is fixed. Conditions that activate the SPM/AT include the following: • excessive temperature • excessive pressure. ball-bearing slide.2. cooling air from the exhaust air of the solenoid valve is directed through the carriage to the converter. The carriage’s rate of descent is adjusted by the Down Speed control on the welder’s front panel.2 Pneumatic System The pneumatic system consists of a solenoid valve. or converter • improper manual tuning • electronic failure within the power supply • harness or wiring failures between the power supply and the ultrasonic converter.2. wear on the horn face. The SPM/AT ensures maximum reliability by terminating ultrasonic energy if the welder is operated under adverse conditions. The controls the power supply and the welder’s pneumatic functions. leading to an overload • improper. and air cylinder. and long-term reliability. These provide consistent. These changes may occur due to increased temperatures. The slide system is based on eight sets of preloaded. precise alignment of the horn. mounted on a linear. As the carriage travels up and down. or material buildup on the horn. This protects both the power supply and other welder components.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 2: The E-Plus 20kHz Welder Overview of these Models 2. if necessary.3 Power Supply The power supply consists of an ultrasonic power supply module which converts 50/60 Hz line current to 20 kHz electrical energy and a module with System Protection Monitor and AutoTune (SPM/AT) features. 3 Compatibility with Branson Products The E-Plus 20kHz Plastic Welders are compatible for use with either a standard base or a hub for automation. 2-4 500-220-070 Rev. the programmer can use the ULS signal to activate ultrasonic energy before the horn contacts the workpiece.7 Dynamic Triggering and Follow-Through Many weld applications require that force be applied to the workpiece before ultrasonic energy is activated. 2. allows you to record and duplicate the dynamic triggering force. located on the front panel. Dynamic follow-through maintains a consistent force on the workpiece during the weld collapse. In addition. The programmer uses this ULS signal to perform various control functions. 2. located between the air cylinder and the carriage. a READY signal is available as both +24V DC and isolated contact closure. in automated systems. The system helps provide uniform weld quality. C . the Ready signal developed by the programmer after the ULS is activated can be used by external devices to prevent movement of the material handling equipment (indexing) when the horn is not fully retracted. Using this interface. • Electronic pretriggering. WELD ON and EXTERNAL RESET signals. Pretriggering is used with large of difficult-to-start horns and in a variety of applications.2. such as ALARMS. Tor example: • Indexing control.2.5 Upper Limit Switch The optical Upper Limit Switch (ULS) signals the control circuits in the programmer that the carriage has returned to the top of its stroke and the welder is ready to start another weld cycle.Chapter 2: The E-Plus 20kHz Welder Compatibility with Branson Products 2.2.6 User I/O Connector External controls and devices. the welder contains a Dynamic Triggering Mechanism. are available through +24V DC interface on the back panel of the welder. The Dynamic Triggering Mechanism initiates (triggers) ultrasonic energy after a preset force is applied to the workpiece. The calibrated TRIGGER PRESSURE control. To achieve this. The CJ20 converter is used for both the 1500 and 4000 Watt units. 2. selected faults or weld errors sensed by the welder can be communicated outside the welder for monitoring cycles and sorting suspect workpieces. Horn Down Mode: A manual procedure used to verify system setup and alignment. inserting. C 2-5 .E-Plus 20kHz Plastic Welder Instruction Manual Chapter 2: The E-Plus 20kHz Welder Features 2. Ramp Starting: The starting of the Power Supply and horn is done at the optimum rate to reduce electrical and mechanical stress on the system. Process: These are set values used for part quality monitoring. Alarms. swaging. will do a Seek once every minute to update horn resonant frequency to memory. semi-automated and/ or manual production operations. Start-up Diagnostics: At start-up. This is especially useful when the welding process affects the actual temperature of the horn. Timed Seek: When turned ON. English (USCS)/Metric Units: This feature allows the welder to be programmed in the local units in use. Afterburst: This feature allows you to turn on the ultrasonics after the weld and hold steps to reliably release parts from the horn. Membrane Keyboard: For high reliability and immunity from factory dust and oils. Autotuning: Ensures that the welder is running at peak efficiency. spot welding. and operates the stack at low amplitude (approximately 5%). staking.4 Features The E-Plus 20kHz Plastic Welders can perform ultrasonic welding. Downspeed: Sets the advance speed of the horn towards the workpiece. The following list describes the control features of the welder. the controls test the major system components. minimizes tuning errors. degating. then provides a means of sensing and storing the resonant operating frequency. It is designed for automated. 500-220-070 Rev. and continuous ultrasonic operations. Pretrigger: This feature allows you to turn on the ultrasonics before contact with the part to increase performance. Seek: Ensures operation at resonance. causing a resonant frequency shift. Pull to set.2 Front Panel Controls 1. multi-turn color coded. 8. dual-calibrated at 0-100psig/o-700kPa. calibrated 1-24 in half-steps/48 detents corresponding to a force range of 15-200 lbs/67-890 N. DOWN SPEED CONTROL . AUTOTUNE LABEL . adjustment is approximately 0.provides access to the converterbooster-horn stack. 6.limits the distance the carriage travels to prevent the horn from contacting the fixture or nest when no workpiece is in place. • This multi-turn control is calibrated in color rings. TRIGGER PRESSURE CONTROL .controls rate of carriage descent. secured by 4 captive hex screws.04 in/1 mm per rotation. Return rate is fixed.indicates the amount to air pressure applied to cylinder.5 Front Panel Controls Figure 2. PRESSURE GAUGE . PRESSURE REGULATOR . 7.refer to Chapter 7. 4. push to lock.1.Chapter 2: The E-Plus 20kHz Welder Front Panel Controls 2. MECHANICAL STOP LOCKING NUT . 5. 2.selects dynamic triggering pressure. MECHANICAL STOP .refer to next section.locks the mechanical stop to desired depth. each turn calibrated at 0-9. 2-6 500-220-070 Rev. push locking ring to lock. 9. Pull red locking ring to set. visible in slots.4. CARRIAGE DOOR . C . 3. range of 5-100 psig/35-700kPa. FRONT PANEL DISPLAYS .adjusts amount of air pressure applied to cylinder. 3 Chapter 2: The E-Plus 20kHz Welder Front Panel Controls Front Panel Displays 1. When pressed. While this switch is pressed.indicates that power to the welder is ON. . POWER INDICATOR . 6. TEST SWITCH . the switch LED will light. 4 2.this 20 segment Weld 11 Time bargraph displays the power level during the Test mode.12. power displays on both the NUMERIC DISPLAY and the POWER BARGRAPH.once you have 7 5 6 selected weld parameters to change. These switches will be disabled when Display Lock is active. the welder returns to the READY state. 3. Pressing these switches will have no effect until you have selected parameters to change. Refer to4. if there are no non-resettable errors.12. 100 90 80 70 60 50 40 30 20 10 500-220-070 Rev.resets any resettable or latchable alarm condition (indicated by the switch LED blinking). these four switches increase or decrease your selected parameters displayed in the NUMERIC DISPLAY. From left to right. and lights the AB TIME switch LED.1 ’Setting DIP Switches’ on page 32 for Power further information about DIP settings. the SLOW DOWN switch. Refer to 3 4. When using the 2x 2 AB 8 Time scale. 8.activates ultrasonic power and places the ultrasonic power supply into Test (Autotune) mode for approximately 6 seconds. these switches a re referred to as the FAST DOWN switch. the graph displays the peak power of the last weld AB 9 D elay cycle. At the end of the weld cycle. if enabled. UP/DOWN SWITCHES . Pressing the switch again will de-select HORN DOWN mode.1 ’Setting DIP Switches’ on page 32 for further information about DIP settings. it displays alarms. AB TIME SWITCH . 5. C 2-7 . POWER BARGRAPH . the uppermost segment will blink. the SLOW UP switch.selects the HORN DOWN mode. NUMERIC DISPLAY . or the currently selected parameter’s value. 4.selects the Afterburst TIME parameter for modification when display lock is inactive. and the FAST UP switch. Holding RESET prevents a weld cycle form starting. Releasing RESET returns the welder to the READY state. HORN DOWN SWITCH. H orn T est R eset D own indicates the current weld state code. You can select the scale factor for Test mode by setting the Test Scale Multiplier DIP switch to 1x or 2x. or the power applied to the workpiece 1 H old 10 Time during a weld cycle. 7. Pressing the START SWITCHES while in the Horn Down mode will bring the carriage down without triggering ultrasonics. displays the AB TIME parameter in the NUMERIC DISPLAY. When you release TEST.during a weld cycle. While in READY state.E-Plus 20kHz Plastic Welder Instruction Manual Figure 2. These readings can be expanded by altering DIP switch settings. RESET SWITCH . 5. Requires Accessory Input/Output kit 101-063-721. Connector 4 is a 25 pin female.25 pin D-shell connector provides a +24V DC interface for external controls and devices. AIR FILTER . 6 4. 11. and lights the Hold Time switch LED.selects the Hold Time parameter for modification when display lock is inactive. Using this connector. an advance feature option that allows connection of Power Out. 3) and the position of the mounting plate supplied in their respective kits (see below). selected faults or weld errors sensed by the welder can be communicated outside the welder for monitoring cycles and sorting suspect workpieces. connector 3 is 3 pins. Connector 2 is 15 pin female. USER I/O. GROUND DETECT. MODEL EDP NO. 101-063-343. Requires Ground Detect Kit. displays the Hold parameter in the NUMERIC DISPLAY. Connector 5 is a 9 pin male. a READY signal is available as both +24V DC and isolated contact closure. Seek.connects the welder to its base or to customer supplied start signals.filters contaminants from the air entering the welder.4Rear Panel 1 2 3 4 5 The grayed out portion shows placement of the optional Accessory Input/Output (1). and Ground Detect inputs (2. HOLD TIME SWITCH . Memory. WELD TIME SWITCH . Year & Month of Manufacture WARNING IMPORTANT 500-220-070 Rev. 3 . 10. ALARM CONNECTOR . Power Supply Status Outputs. C 2-8 . INPUT: MAX POWER: Serial Num.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 2: The E-Plus 20kHz Welder Rear Panel 9. displays the Weld parameter in the NUMERIC DISPLAY. START CONNECTOR . and lights the Hold Time switch LED. 2. displays the AB DELAY parameter in the NUMERIC DISPLAY. ACCESSORY INPUT/OUTPUT.selects the Afterburst DELAY parameter for modification when display lock is inactive. In addition. 15 pin male connector. AB DELAY SWITCH . Frequency Offset.6 Rear Panel Figure 2. Amplitude Output and Amplitude Control Input. 1. Frequency. allows ultrasonic energy to be turned off when the horn comes in contact with your electrically isolated fixture or anvil. ALARMS. WELD ON and EXTERNAL 7 RESET signals are available. and lights the AB DELAY switch LED. 2.selects the Weld Time parameter for modification when display lock is inactive. 6. connects the welder to your power source.1 START SWITCHES/START Signal . will simulate pressing RESET.3 READY Signal . To start a weld cycle. LINE CORD . C 2-9 .7.7. 2. or an error will be generated and no weld will be performed Errors will also be generated if the START SWITCHES do not remain active until the TRS input becomes active (for maintained software).ALARM Connector The welder uses the Upper Limit Switch (ULS) input to determine when the carriage has started to descend and when it has reached its “home” position on its return at the end of the weld cycle.2 EXTERNAL RESET . 2. both START SWITCH inputs must become active within 100 ms of each other.ALARM (User I/O) Connector This input. 500-220-070 Rev.7 System Inputs/Outputs The inputs provided to the welder are used to control the weld cycle and monitor the E-Plus 20kHz hardware.7. Showing START SWITCHES and Base Cable Emergency Stop Button Base Cable Start Switches 2. Monitoring this signal indicates that the welder is at rest and it is ready to cycle (for example not in TEST. latched alarm condition or system fault). HORN DOWN. The programmer evaluates other system conditions as well before generating the READY signal. when activated. You cannot start a weld cycle if the EXTERNAL RESET line is active.5 Base. or are not inactive within 4 seconds after the solenoid valve drive circuits have been disabled Figure 2.START Connector These inputs are used to start the weld cycle. It evaluates if any alarm conditions exist.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 2: The E-Plus 20kHz Welder System Inputs/Outputs 7. and remain active until TRS activates. 2. • The input does not become inactive within 4 seconds after the solenoid valves are activated. The converse is the set parameter that was requested during the setup.7. booster and horn assembly in a rigid mounting allowing it to move up and down either mechanically or pneumatically to apply a predetermined pressure on the workpiece. 2. AB Delay: Time delay between the end of the hold and the start of afterburst. an error will be generated: • The input becomes inactive while the welder is in the READY state. Resetting alarms and resolving system faults clears this alarm signal. • The input does not become active within 4 seconds after the solenoid valves are deactivated.Alarm Connector The WELD ON signal indicates you are in the Weld Time portion of the cycle and that TRS is active.Chapter 2: The E-Plus 20kHz Welder Glossary of Terms 2.4 GENERAL ALARM . 2. AB Time: The time duration of the afterburst. • The input becomes active before weld timing begins during a weld cycle. Accept-as-is: A disposition permitted for a nonconforming item when it can be established that the item is satisfactory for its intended use without violating safety or functional requirements. Automatic: A pretrigger condition indicating that pretrigger engages when the actuator leaves the upper limit switch.8 Glossary of Terms The following terminology may be encountered when using or operating a E-Plus 20kHz plastic welding system. This signal indicates when a start signal can be released.5 WELD ON Signal . Amplitude: The peak-to-peak movement at the horn face. Afterburst: Ultrasonic energy applied after the hold step.Alarm Connector GENERAL ALARM is a signal which indicates that an alarm has been sensed. Always expressed as a percentage of the maximum. In any of he following situations. Some of these terms may not be available in all Controls (Power Supply model) configurations: AB Amplitude: The amplitude at the horn face during the afterburst step. Alarm Beeper: An audible signal that sounds when a general alarm has occurred.7. Refer to Section 6. Amp Control: The ability to set amplitude digitally or by an external control.5. Weld Cycle Alarms and Error Messages for further information. 2-10 500-220-070 Rev. C . Actuator: The section of the Welder that houses the converter. Used to break away sticking parts from the tooling. Actual: A reported value that occurred during the weld cycle. Stack: Converter. Trigger Beeper: An audible signal sounded when the trigger is made. Clamping force: The pressure exerted by the horn on the workpiece. Weld Time: The time for which ultrasonics are on. Ground Detect Mode: In this mode of operation. Scrub Time: The amount of time after detection of a ground condition to the termination of ultrasonics. when a ground detect has occurred. Refer to Chapter 6. Cold Start: A user operation to establish a setup to a new. or by external reset at the User I/O. "Resetting the System". Booster: A one-half wavelength long resonant metal section mounted between the converter and horn. Reset Required: State used with alarms indicating that a reset will be required before a cycle can be run. C 2-11 . Downspeed: The rate of speed of the actuator from the home position to the part. Horn Down: A mode in which ultrasonics are locked out and the user can advance the Actuator for setup and alignment. Custom Actuator Logic: Allows the operator to choose either High (24V) or Low (0V) logic for switches to be used in interfacing the welder to an automated system. Test Scale: The magnification of the power bar scale on the front panel while the Test key is pushed. Seek: A setting where ultrasonics are on at 5% amplitude for the purpose of finding the resonant frequency of the stack. Used to alert the operator to an unexpected condition or that trigger has been reached. Booster. 500-220-070 Rev.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 2: The E-Plus 20kHz Welder Glossary of Terms Beep: An audible signal produced by the Branson control board. Mechanically alters the amplitude of vibration at the driving surface of the converter. ultrasonics are terminated after detection of a ground condition between the horn and fixture or anvil. Upper limit switch (uls): A switch when activated indicates the actuator is in the home position. Timeout: A time at which the ultrasonic energy terminates if the main control parameter has not been reached. Time Mode: Terminates the ultrasonics at a user-specified time. Ready Position: State in which the welder is retracted and ready to receive the start signal. usually having a change in cross-sectional area between the input and output surfaces. Pretrigger: The setting that causes ultrasonics to start before contact with the part.3.5. General Alarm: An alarm that occurs due to a system fault and/or tripping a limit. The reset is accomplished by using the reset key on the front of the Power Supply. Warning: Use carefully. Ground Det. Cutoff: Immediately terminates the weld process. and Horn. initial minimum set of weld parameters. including the hold step. Cycle Aborts: There are no cycle aborts except Ground Detect. Chapter 2: The E-Plus 20kHz Welder Glossary of Terms 2-12 500-220-070 Rev. C . ..-3 .........................1 Shipping and Handling ! CAUTION Caution: The Welder internal components are sensitive to static discharge..-3 ..... C 3-1 .........E-Plus 20kHz Plastic Welder Instruction Manual Chapter 3: Delivery and Handling Shipping and Handling Chapter 3: Delivery and Handling 3.................... Its internal components are sensitive to static discharge. 500-220-070 Rev.....1 3..........1 Environmental Specifications ....3 Unpacking. shipped under improper conditions or otherwise mishandled.. and many of its components can be harmed if the unit is dropped..2 3.1 Environmental Specifications The Welder is an electronic unit that converts line voltage to ultrasonic energy and controls user input for regulating the weld process.-3 .. 3..1.... shipped under improper conditions.....4 3. Many components can be harmed if the unit is dropped..1.... or otherwise mishandled.1 Shipping and Handling .-3 ..1 3.2 Receiving . non-condensing 3. unpacking. Scope of Delivery Branson Welder units are carefully checked and packed before dispatch. It is recommended.1 Environmental Specifications Environment Range Ambient Operating Temperature +5°C to +50°C Storage / Shipping Temperature –25°C to +55°C Dropping Shock Vibration ISTA2B ASTMD 3332-99 (2010) ASTMD D3580-95 (2010) Humidity 30% to 95%. however. 3-2 500-220-070 Rev. and installation may require assistance or the use of a lifting device. that you follow the inspection procedure below after delivery.2 Receiving The Welder is a sensitive electronic device. Many of its components can be harmed if the unit is dropped or otherwise mishandled. C . ! CAUTION Caution:The Welder is heavy. Table 3.Chapter 3: Delivery and Handling Receiving The following environmental guidelines should be respected in the shipping of the Power Supply. Handling. if necessary. 2 Check the packing and the unit for damage (visual inspection). unpacking.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 3: Delivery and Handling Receiving To inspect the Power Supply when it is delivered. 3 Report any damage claims to your carrier immediately. Handling. i NOTE If the goods delivered have been damaged during shipping. take the following steps: Step: Action: 1 Verify that all parts are complete according to the packing slip. please contact the forwarding agent immediately. ! CAUTION The Welder is heavy. tighten screws. . Retain packing material (for possible inspection or for sending back the unit). 4 Determine if any component has become loose during shipping and. C 3-3 . and installation may require the assistance of a colleague or the use of lifting platforms or hoists 500-220-070 Rev. Retain packing materials for inspection.Chapter 3: Delivery and Handling Unpacking 3. 3 Remove the cover of the Power Supply to check if any components became loose during shipping. 4 3-4 Store or ship the Power Supply only within a temperature range of –25oC to +55oC. It is shipped in a sturdy cardboard box. notify the shipping company immediately. i NOTE If damage has occurred. C . Some additional items are shipped in the box with the Power Supply.3 Unpacking The Welder is fully assembled. 2 Inspect the controls. indicators. 500-220-070 Rev. and surface for signs of damage. take the following steps: Step Action 1 Unpack the Power Supply as soon as it arrives. Save the packing material. When unpacking the Welder. ...2 Input Power Plug ......3...........................23 4..8.4 ......30 500-220-070 Rev........-4 .....2 Environmental Specifications ..4 4.-4 ..................2 4.................8 Guards and Safety Equipment ......-4 .1 User I/O.....5 4....7 Installation Steps ........12......................4 ............28 4.2 Handling and Unpacking .....19 4.1 About Installation ........1 Setting DIP Switches ................6...........15 4...1 4.3 Electrical Input Power Ratings ..................2 Take Inventory of Small Parts ..9 4.....-4 ...3 Power Supply Module Options DIP Switch ..13 Testing the Installation .....15 4.....2..24 4......4 ...7 4..4 .......4 ....10 4...4....4......-4 .....2 4...5 4........4 ...2 Input Power (Main) ..............-4 ..18 Assemble the Acoustic Stack.12 Adjusting the mechanical Stop .25 4.......1 4........4 .....9 Emergency Stop Control ..9...4 4.-4 ...-4 ....4 ....4 ..4 .11 4. Alarm Connector ..22 4..........-4 ......-4 .5.........4 .....4 ...1 Connecting Tip to Horn ......9 4.....6..................1 4...........5 Factory Air .............18 4...11 Adjusting Welder Height and Aligning the Horn .5..E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Chapter 4: Installation and Setup 4.......1 Mounting the Fixture on the Branson Base (hardware and mounting holes).... C 4-1 ..4.....12 4....18 4.1 Location .4 ......-4 .......4..4 Installation Requirements...4 ...7 4......6 Start Switch Connection (Automation) .............10..............3 Unpack the Welder .................4 ........4 Cables ..........26 4......7 Accessory Input/Output Option ..10 Installing the Ultrasonic Stack in the Welder ...-4 .4 ..........6....1 Mounting the Stand (Welder on Base) .......... and surfaces for signs of damage. Those that are of importance during installation of the system are identified in the figures in this and other chapters of the manuals. 3.) and packed in a protective shipping container. 1. International safety labels are found on the E-Plus 20kHz Plastic Welder. or you later discover hidden damage. Verify you have all of the equipment ordered. Save the packing material. and installation can require help or the use of lifting platforms or hoists. • Welders are shipped on a wooden pallet with a cardboard box cover over protective foam shells for support. Some components are packed inside other boxes.1 About Installation This chapter is intended to help the installer with the basic installation and setup of your new E-Plus 20kHz Plastic Welder. Inspect the controls. The packaging is designed to be removed from the assemblies from an upright orientation only. This chapter will bring the reader to the point at which the system is functionally “ready to weld”. 4-2 500-220-070 Rev. ! CAUTION The Welder weighs 145 pounds. 4. C .2 Handling and Unpacking If there are any visible signs of damage to the shipping containers or the product. Handling. NOTIFY YOUR CARRIER IMMEDIATELY. Unpack the E-Plus components as soon as they arrive. A booster.2. 4. • Heed the “This End Up” arrows and the “Open Top First” instructions. Refer to the following procedures. 2. indicators. 4. unpacking.Chapter 4: Installation and Setup About Installation 4. including the pallets and wood spacer blocks. converter and other components may be packed inside the shipping container (depending on the equipment ordered). The actuator toolkit is packed with the actuator.1 Unpack the Welder The Welder is heavy (145 lbs. Save all packing material. i NOTE The packaging may also include the converter and/or booster. Move the shipping container close to the intended installation location. 2. C Booster 4-3 . Remove the carton.2 Ultrasonic Converter and Booster Converter (J-type shown) 500-220-070 Rev. 1 FOAMS 1 3 CARTON 2 2 WOODEN CHASSIS 1. Remove the foams. right-side view .1 Chapter 4: Installation and Setup Handling and Unpacking Unpacking the Stand. Figure 4. 3.E-Plus 20kHz Plastic Welder Instruction Manual Figure 4. 4. Remove the wooden box. leave it on the floor. if ordered. Check your invoice for cable types and cable lengths. C .3 Take Inventory of Small Parts Table 4.1 Cables Two cables connect the power supply and actuator: the actuator interface cable.1 Small Parts Included (=x) with E-Plus 20kHz Plastic Welder Part or Kit 20kHz Stand (Base) Stand (Hub) T-Handle Wrench x Mylar Washer Kit x 20kHz Spanners (2) x Fixture Bolts and Washer x M8 Allen Wrench x x x 4. and the RF cable. 500-220-070 Rev.3.Chapter 4: Installation and Setup Take Inventory of Small Parts 4. 15 ft.2 List of Cables For Start/Stop control in automated machines For Status/Alarm interfacing to automated machines 4-4 101-240-020 Start Cable (J911) 8’ (req PLA) 101-240-015 Start Cable (J911) 15’ (req PLA) 101-240-010 Start Cable (J911) 25’ (req PLA) 101-240-021 Alarm Cable J971. you may also need a J911 start cable and a user I/O cable. Table 4. 101-240-016 Alarm Cable J971. 101-240-011 Alarm Cable J971. 8 ft. If the system is to be automated. 25 ft. C 4-5 . dimensions of the major assemblies. Stands (on hubs) are often used in automated systems and may be manually or automatically loaded and unloaded. and so is installed at a safe and comfortable workbench height (approximately 30-36 inches) with the operator sitting or standing in front of the system. using its base-mounted start switches. Consideration should also be given to rear electrical and pneumatic connections. so considerations must be made to be able to access the DIP switches. All dimensions are approximate and may vary between models: 500-220-070 Rev. environmental requirements. to help you plan and execute your installation successfully. dirt or material via its internal fan.4 Installation Requirements This section covers the location options.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Installation Requirements 4. The internal power supply must be accessible for user parameter changes and settings.1 Location The Welder should only be operated in the vertical position. The work surface on which a stand is installed must be sturdy enough to support it.4. Refer to the illustrations on the pages that follow for a dimensional drawing of each component. approximately 150 mm (6 in). The Welder should be positioned so it does not draw in dust. 4. and secure enough to not tip over when the stand is adjusted during installation or setup. electrical requirements and factory air requirements. if not properly secured. ! WARNING The stand may tip over if moved around the axis of its column. The Welder (on a base) is often manually operated. Chapter 4: Installation and Setup Installation Requirements Figure 4. C .3 4-6 E-Plus 20kHz Plastic Welder Dimensional Drawing 500-220-070 Rev. 4.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Installation Requirements 4.4. Use of other types of gas could lead to premature degradation of seals.4 Input Power Requirements 1500 W 200V . Table 4. dry air to run the welder. 3-wire. grounded.2 Environmental Specifications Table 4.4. Depending on your application. @ 200V / 15 Amp CB None supplied 4. the welder requires between 35 to 100 psi.4. 50 or 60 Hz power source.240V 10 Amp Max. Stands include an in-line air filter. Actuators (alone) require a customer-provided air filter.3 Environmental Specifications Environmental Concern Acceptable Range Humidity 30% to 95%.4.4 Factory Air The factory compressed air supply must be “clean. Up to +70°C for 24 hours 4.4. Contact your Branson representative if you have any concerns. ! ! WARNING Caution Synthetic air compressor lubricants containing Silicone or WD-40 will cause internal actuator damage and failure due to the solvents contained within these types of lubricants. 500-220-070 Rev. C 4-7 . WARNING There should be no substitute for clean.1 Air Filter The E-Plus 20kHz Plastic Welders have an input air filter which protects from particulate matter of 5 microns or larger.3 Electrical Input Power Ratings Plug the Power Supply into a single-phase. dry and unlubricated” air with a regulated maximum pressure of 690 kPa (100 psig). non-condensing Ambient Operating Temperature +5°C to +50°C Storage / Shipping Temperature -25°C to +55°C . lists the current and fuse ratings for the various models. Use a lockout device on the air line if required. 4. Set the pressure regulator to zero before connecting or disconnecting the air supply. self draining air filter with a 5 micron element. unlubricated. 35 to 100 psi Water leg with draincock 4-8 500-220-070 Rev.4.4 Hooking Up the Air Line Riser Non-lubricated dry air supply. use an air line hookup that includes a riser and waterleg (Refer to Figure 4.Chapter 4: Installation and Setup Installation Requirements 4. 240 to 690 kPa (35 to 100 psi).3 Compressed Air Supply Connections It is important to prevent impurities and moisture from entering through the air lines and damaging your equipment. dry.2 Pneumatic Connections Air connection to the unit is made to the AIR INLET connector on the lower rear of the Welder.4. you must provide an air filter assembly which will support to at least 100 psig and remove particulate matter of 5 microns or larger. T facilitate this when installing your welder.4.4). Caution: Permanent damage to the gauge may result if operated above the maximum gauge reading (690 kPa/100 psi) or below the minimum (240 kPa/35 psi). 4. compressed air supply. Use the supplied. Figure 4. For installations using actuator-alone assemblies. C . with plastic pneumatic tubing. Connect the air line to a clean (5 micron). 3/8 inch (US bases) or M10 (metric bases)).5. Remember that the actuator is taller than the column when fully raised. to reduce loosening due to vibration and movement. Use flat washers against the metal casting to prevent gouging.1 Mounting the Stand (Welder on Base) The base must be bolted to your workbench to prevent tipping or undesired movement. Use flat washers against the metal casting to prevent gouging. 4. Mount the base to your workbench using four socket-head cap screws (customer provided. and there are exposed connections. and will accept your 3/8 inch or M10 cap screws. Four mounting bolt holes are provided at the corners of the casting. 1. in the event the actuator is moved off-center or rotated around the column. Use a lockout device on the air line if required. Refer to Figure 4. Verify the base/start switch control cable is properly connected to the back of Welder.5. 500-220-070 Rev. Ensure there are no overhead obstructions and that no pinch or rub points exist. Keep clear of moving parts and do not loosen clamps unless directed to do so. 4.5 Installation Steps ! WARNING Warning: This product is heavy and can cause a pinching or crushing injury during installation or adjustment. Connect factory air to the air input on the rear of the Welder.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Installation Steps 4. 3. to prevent tipping or undesired movement. C 4-9 . The use of nylon lock nuts with your cap screws is suggested. 2. ! CAUTION You must secure the base to your work surface using four bolts. Close and secure the cover door.5 Base Mounting Centers 4. See “Table 4. C . which you connect to the Power Supply using the integral power cord.4. Refer to the unit’s Model Data Tag to be sure of the power rating of the Model in your system. 4-10 500-220-070 Rev. You may need to replace the circuit breaker/power switch to coincide with the voltage setting.5. Input Power Requirements” for plug and receptacle requirements for your specific power level.2 Input Power (Main) The system requires single-phase input power. Open the left side cover door of your welder and locate the Line Voltage Selector Jumper.Chapter 4: Installation and Setup Installation Steps Figure 4. depending on model. figure: Line Voltage Selector Jumper The voltage select is 200-240 Volts. normally closed. 500-220-070 Rev. or error message: (ER28 or ER29) will display. and remain closed until the WELD ON signal is active.6 Start Switch Connection (Automation) i NOTE See Appendix E for additional information about Automation. C 4-11 . A Branson E-Plus 20kHz Plastic Welder requires 2 start switches and emergency stop connection. Refer to Note above. Your cable requires a male DB-9 (D-shell) connector. but for the next cycle.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Start Switch Connection (Automation) 4.6 Start Switch Connection Codes PB2 PB1 EMER STOP START SWITCHES i P69 1 2 6 7 8 9 3 4 5 Color Codes PB2RTN PB1RTN PB1SRC PB2SRC ESTOPSRC ESTOPSRC ESTOPRTN ESTOPRTN N/C Black White Blue Orange Yellow Purple Red Green Brown NOTE Solid state devices may be used in lieu of mechanical start switches providing their leakage current does not exceed 3. PB1 and PB2 are two normally open start-switches which must be operated simultaneously to start the welding cycle. BASE/START is the DB-9 female connection on the back of the actuator. as follows: Figure 4. This doesn’t require a reset. Stands on a base include this connection (factory installed and connected from the base) while the stand on a hub applications require the user make their own start switch/E-stop connections. to effect a start condition. switches must be within time limit to preclude re-occurrence of error message. i NOTE Start Switches PB1 and PB2 must be closed within 100 to 200 milliseconds of each other. EMER STOP is an emergency stop switch.5 mA. These must be closed within 200 milliseconds of each other. READY (signal . you must first have signed a Branson Product Liability Agreement.6. The SOLENOID OUTPUT provides a negative logic output when referenced to the +24V DC source (pins 5 and 6). Pins 5 and 6 provide a +24V DC source (100mA maximum). Connection is via a J971 cable from the 25 pin connector on the welder’s rear panel. and 23 provide +24V DC return (common). The EXTERNAL RESET switch operates in exactly the same manner as the front panel RESET switch. The status outputs available from the interface are SOLENOID OUTPUT (pin 13). Pins 21. GENERAL ALARM. Refer to Figure 4.pins 9 and 10).5 m/25 ft lengths. and 23). Applying +24V DC to the EXTERNAL RESET input (pin 25) for a minimum of 20 ms will reset the welder. and WELD ON (pin 20). The cable is available in 2. GENERAL ALARM (pin 18). 22. connect a J911 cable between the connector on the rear panel and your start signal (refer to Figure 2. Alarm Connector The Alarm Connector provides status outputs and an EXTERNAL RESET switch connection to customer supplied controls.1 User I/O. 4. C . or 7. These signals can be interfaced with a customer supplied device to monitor system status and trigger some action when the signals become active or inactive.22. relay .5 m/15 ft.5 m/8 ft. To do so. The remaining pins are unused. 4-12 500-220-070 Rev. READY AND WELD ON signals provide a negative logic output when reference to 24V RTN (pins 21. 4.5).Chapter 4: Installation and Setup Start Switch Connection (Automation) The welder can also be started by an EXTERNAL START signal.7. ! WARNING warning: If you wish to use a J911 cable.pin 19. 7. and 20. 17. 8.E-Plus 20kHz Plastic Welder Instruction Manual Figure 4. 16. Typical Circuitry for Pins 18. 3. 11. 15.7 Chapter 4: Installation and Setup Start Switch Connection (Automation) Input/Output Signals. and 24 2. 12. Note: 1. 14. 2. 500-220-070 Rev. 19. 4. C 4-13 . The following pins are not connected: Pins 1. 8 CAUTION Caution: Ensure all unused wires are properly isolated. 25mA) by moving jumpers JP2. 4-14 500-220-070 Rev. note that the +24V DC signals can be switched to opencollector signals (maximum +24V DC. C . failure to do so may result in Power Supply or system failure. JP3 and JP4 on the front of the programmer circuit board from pins 1-2 to pins 2-3. Operating Cycle Timing Table If you are designing your own custom interface.Chapter 4: Installation and Setup Start Switch Connection (Automation) ! Figure 4. The output circuit ground signal can be isolated by cutting the 0 ohm resistor (R79) on the control board. When working inside the Power Supply. WARNING Unplug the welder (if previously connected) and wait at least two (2) minutes before opening the case.9 CAUTION The power supply can be permanently damaged if it is connected to the incorrect line voltage. C 4-15 .3 Power Supply Module Options DIP Switch When using the SPM/AT in automated configurations. Add the plug that is appropriate for your input power receptacle. It also presents a safety hazard if mis-wired. 500-220-070 Rev. or if the wiring connection is mis-wired.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Start Switch Connection (Automation) 4. International Harmonized Line Cord Color Code Line Cord jacket BLUE = Neutral 120v operation. ! ! CAUTION The components in the Power Supply section of the Welder are subject to damage from electro-static discharge. Use of the correct plug or connector helps prevent incorrect connections.2 Input Power Plug If you must add or change the input power plug. it might be necessary to open the welder and change the DIP (Dual In-line Package) switch on the power module. Hazardous Voltages exist and are stored in the system.6. DIP switch changes the Seek and Start functions and can affect the Amplitude Control functions.6. Default operational settings are provided in the Tables. ! Figure 4. use the following color code for the conductors found in the international harmonized line cord. Hot GREEN/Yellow trace = Earth Ground 4. Hot Line for 220v BROWN = Line. use a grounded wrist strap and minimize your movement to reduce the possibility of damage due to static electricity. There are two DIP switches that Branson uses interchangeably. The following Figures illustrate each of them. Marked “OPEN” on top of switch 1 2 3 4 5 6 7 POSITION UP DN UP UP NC DN DN 1 4 SWITCH 2 3 5 6 7 Table 4.5 UP 8 Options for Setting the Type 1 Switch Select Block Function i 8 Options Set Toggles.. 3 – Down (500 ms) 3 – Up (100 ms) Store at End of Weld – Updates horn frequency memory at the end of each weld. timed from the last activation of ultrasonics.Chapter 4: Installation and Setup Start Switch Connection (Automation) Figure 4. 7 – Up 8 – Up Seek ** The default Start setting is "Standard". 7 – Down 8 – Up Long – Sets ramp time to 105 ms. Seek on power up – Checks horn frequency upon power up and stores it in memory. 4 – Down (Off) 4 – Up (On) Amplitude Control Set for Fixed 100% Amplitude.10 Type 1 DIP Switch Marked "OPEN" on Top of Switch. 7 – Down 8 – Down Medium – Sets ramp time to 35 ms. C . 1 – Down (Off) 1 – Up (On) Auto Seek – Checks horn frequency once each minute.. 7 – Up 8 – Down Standard** – Sets ramp time to 80 ms. 2 – Down (Off) 2 – Up (On) Auto Seek Duration – Indicates the length of time the Auto Seek function is active. NOTE Toggle 5 is not used. Default Settings. 4-16 500-220-070 Rev. Variable turned Off 6 – Down (Off) Start Short – Sets ramp time to 10 ms. E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Start Switch Connection (Automation) Figure 4. 500-220-070 Rev. Seek on power up – Checks horn frequency upon power up and stores it in memory.. Marked “ON” on face of switch ON 1 2 3 4 5 6 POSITION DN UP DN DN NC UP SWITCH Table 4. 7 – Up 8 – Up Seek ** The default Start setting is "Standard". 1 – Down (Off) 1 – Up (On) Auto Seek – Checks horn frequency once each minute. C 4-17 .11 Type 2 DIP Switch Marked "ON" on face of Switch. Variable turned Off. 3 – Down (100 ms) 3 – Up (500 ms) Store at End of Weld – Updates horn frequency memory at the end of each weld. Default Settings. 7 – Up 8 – Down Standard** – Sets ramp time to 80 ms. 7 – Down 8 – Up Long – Sets ramp time to 105 ms. 2 – Down (Off) 2 – Up (On) Auto Seek Duration – Indicates the length of time the Auto Seek function is active.6 2 3 4 5 8 UP DN 7 8 6 Options for Setting the Type 2 Switch Select Block Function i 1 7 Options Set Toggles. 4 – Down (Off) 4 – Up (On) Amplitude Control Set for Fixed 100% Amplitude. NOTE Toggle 5 is not used.. 7 – Down 8 – Down Medium – Sets ramp time to 35 ms. timed from the last activation of ultrasonics. 6 – Up (On) Start Short – Sets ramp time to 10 ms. 1 Emergency Stop Control If you use the Emergency Stop button on the Welder to terminate a weld. 4-18 500-220-070 Rev.12 Accessory Input/Output Connector Pinout COMMON +10VREF POWER MEMORY RUN OUT MEMORY STORE EXT SEEK+ (-) AMPLITUDE IN AMPLITUDE OUT FREQ OUT FREQ OFFSET SEEK MEMORY CLEAR EXT SEEK- 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 4. Figure 4. twist the button to reset it.8. The signals to the pinout are illustrated in the following Figure. (The welder will not operate until this button is reset.7 Accessory Input/Output Option This feature is available as an option. this cable will plug into the male 15 pin connector mounted topmost on this plate (refer to Figure 2.) If you are running automation. It allows access to: • Power Output • Memory Output • Seek Output • Frequency Output • Frequency Offset Input • Power Supply Status Outputs • Amplitude Output • Amplitude Control Input The kit (101-063-721) provides the necessary hardware and insructions to retrofit the standard welder to utilize these features. The external cable provided (101-241-360) in the kit is a 15 pin female to an open end. When the new rear mounting plate provided in the kit is installed. C .Chapter 4: Installation and Setup Accessory Input/Output Option 4.8 Guards and Safety Equipment 4. you can use external reset that is connected to your User I/O board. usually referred to as "Advance Features".5). This procedure may require two persons. secure the largest portion of a square or rectangular horn in a soft jawed vise. ! CAUTION The following procedure must be performed by a setup person.13 Actuator Emergency Stop Button Column Base Start Switch Start Switch Emergency Stop Knob If you are using an Emergency Stop signal from the Start Switch cable. 500-220-070 Rev. If necessary. you must clear the Emergency Stop condition before the System will operate. always hold the welder in place before releasing the column clamps.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Assemble the Acoustic Stack Figure 4. C 4-19 . 4. If the converter and booster are not assembled.9 Assemble the Acoustic Stack Warning: to prevent personal injury or damage to the equipment or workpiece being welded. perform the following steps. NEVER attempt to assemble or remove a horn by holding the converter housing or the booster clamp ring in a vise. C . apply 1 or 2 drops of a light lubricating oil before installing. Torque to 450 in-lbs. 50.85 Nm.7 Tools Tool EDP Number 20 kHz Torque Wrench 101-063-617 20 kHz Spanner Wrench 201-118-019 4-20 500-220-070 Rev. Step Action 1 Raise the welding head by loosening the upper and lower column clamps and turning the elevation knob clockwise. 4 Install the threaded stud into the top of the booster. If the stud is dry. 50. and horn. re-tighten the column clamps. 2 Open the carriage door by loosening the captive screws. 6 Install a single Mylar washer (matching the size of the washer to the stud) to each interface. Torque to 450 in-lbs. booster. If the stud is dry. 7 Assemble the converter to the booster and the booster to the horn. After raising the head.84Nm. 3 Clean the mating surfaces of the converter. 5 Install the threaded stud into the top of the horn. apply 1 or 2 drops of a light lubricating oil before installing.84Nm.Chapter 4: Installation and Setup Assemble the Acoustic Stack ! CAUTION Do not use silicone grease with Mylar washers. Use only 1 (one) Mylar washer of the correct inside and outside diameters at each interface. 8 Torque to 220 in-lbs. Table 4. 24. Remove any foreign material from the threaded holes. 15 Assembling the 20kHz Acoustic Stack. C 4-21 .14 Assembling the 20kHz Acoustic Stack. P/N 101-063-617 for 20kHz systems. Rectangular Horn Converter Booster Spanner (provided) Horn See Stack Assembly Procedure Vise Jaw protectors (aluminum or soft metal) Vise Figure 4. Cylindrical Horn Stack Assembly Torque Tables i NOTE The use of a Branson torque wrench or the equivalent is recommended.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Assemble the Acoustic Stack Figure 4. 500-220-070 Rev. Use the spanner wrench and an open-end wrench (Refer to Figure 4.9. Remove foreign matter from the threaded stud and hole. 33 Nm 100-098-121 20 kHz 1/2” x 20 x 1-1/4” 450 in. 100-098-370 20 kHz 1/2” x 20 x 1-1/2” 450 in.-lbs. Clean the mating surfaces of the horn and tip.84 Nm. Hand assemble the tip to the horn.-lbs. 12. 3/8-24 180 in. 20.-lbs.33 Nm.8 Stud Torque Values Table 2: Used On Stud Size Torque EDP # 20 kHz 3/8” x 24 x 1” 290 in lbs.28 110 in. 33 Nm 100-098-120 20 kHz 3/8” x 24 x 1-1/4” 290 in lbs. 4-22 500-220-070 Rev.42 Nm.9 Tip to Horn Torque Values Table 3: Tip Thread Torque 1/4 . 3.-lbs.16) and tighten to the following torque tip specifications: Table 4. Assemble dry.1 Connecting Tip to Horn 1.84 Nm.Chapter 4: Installation and Setup Assemble the Acoustic Stack Table 4. C . Do not use any silicone grease. 2. 50. 50. 100-098-123 4. Align the horn by rotating it. always hold the welder in place before releasing the column clamps.10 Installing the Ultrasonic Stack in the Welder Warning: To prevent personal injury or damage to the equipment or workpiece being welded. 500-220-070 Rev. If necessary. 4.16 Connecting Tip to Horn 4. Take the assembled ultrasonic stack and align the ring on the booster just above the support washer in the carriage. raise the welding head by loosening the upper and lower column clamps and turning the elevation knob clockwise After raising the head. Reinstall the door assembly. 5. re-tighten the column clamps. Torque the carriage door to 20 in. This procedure may require two persons. 2. The ultrasonic stack must first be assembled. 3. 7. 6. with the acorn nut on the top of the converter making contact with the contactor in the top of the carriage. Loosen the four door screws. C 4-23 . Firmly push the stack into place. and start the four door screws.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Installing the Ultrasonic Stack in the Welder Figure 4. Make sure that the system power is turned off by disconnecting the power plug. Pull the door straight off and set it aside. if necessary. To install the stack: 1.-lbs to secure the stack. C .17 Installing a 20kHz Stack in a Branson Welder Hex Screw Carriage Door Stack Assembly Contact Terminal Carriage T-Handle Wrench Support Washer Screw Stack Assembly Main Support Assembly Carriage 4.10. Tighten your hardware only enough to prevent movement of your fixture. which can be ordered in inch or metric. Mounting holes are also provided for the optional Branson leveling plate kit. The mounting holes are arranged in three concentric bolt circles with the following dimensions. ! 4-24 CAUTION The base is cast metal and the mounting holes can become stripped if the hardware is overtightened.1 Mounting the Fixture on the Branson Base (hardware and mounting holes)The base provides mounting holes for your fixture. 500-220-070 Rev.5 hardware (indicated by an “M” on the base).Chapter 4: Installation and Setup Installing the Ultrasonic Stack in the Welder Figure 4. The base is a tapped for metric M10-1. the carriage may bottom out at maximum trigger pressure before reaching the full depth of weld. take care to ensure that the horn contacts the workpiece before the carriage is close to the limit of its travel.11 Adjusting Welder Height and Aligning the Horn For maximum welding efficiency. position the welder so that the distance between the workpiece and the horn is at a minimum.35 mm).00 in / 178 mm 4. On the base. Position the fixture loosely on the work surface.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Adjusting Welder Height and Aligning the Horn Figure 4.00 in / 229mm 7.5 threaded holes. As the maximum travel of the carriage is 4 in/101. C 4-25 . however leave enough room to allow for easy removal of the workpiece from the fixture. Set the welder height as follows: 1. 500-220-070 Rev.44 in / 113 mm Optional Guard shown for position only 12.) is shown for position only.50 inch 317. use the M 10 x 1. It extends several inches to either side of the base. 4.5 mm Leveling Plate mounting dimensions 10.18 Mounting Circles on Base M M = metric M10 hardware 9. and prevents the user from operating the welder and pinching their fingers or hands between the base and the tooling. Under such conditions.50 in 287 mm The optional guard (sometimes required with very large horns.6 mm (minimum 1/4 in/6. Adjust the air pressure to 15 psi. tighten the fixture on the base plate.Holding the welder in place. as indicated by test welding results. This procedure may require two persons. For m (mm) use M10 x 1. always hold the welder in place before releasing the column clamps. ! WARNING To prevent personal injury or damage to the equipment or workpiece being welded.Set the pressure regulator to zero and manually lower the carriage until the horn contacts the workpiece. C .Place the workpiece to be welded in the fixture. 4. 9. 3. Press HORN DOWN. Further leveling of the fixture may be required.PressHORN DOWN again to raise the horn back into its normal position. Loosen the carriage door screws and rotate the stack until the horn is properly aligned with the workpiece. 2. 2. The horn will descend and remain down under pressure. although ultrasonic energy will remain off. provide a minimum stroke length of 1/4 inch. Then tighten the column clamps. 8.12 Adjusting the mechanical Stop The mechanical stop limits the downward travel of the horn. To prevent equipment damage. 4-26 500-220-070 Rev. Tighten the carriage door screws. then the START SWITCHES. 5. loosen the two column clamps. While holding the horn against the workpiece.Use HORN DOWN to check the fixture’s position.5 cap screws. adjust the stop so that the horn will not contact the fixture or nest when no workpiece is in place.Use the elevation handle to adjust the height of the welder for the desired strike length. Check the thread ID on the base.Chapter 4: Installation and Setup Adjusting the mechanical Stop ! CAUTION Before inserting screws into the base holes: 1. 4. For proper triggering. 6. 7. 4. turn the adjusting knob counterclockwise until the stop contacts the carriage. When the desired setting is obtained. You can use Horn Down (press HORN DOWN on the front panel) to check this position while the welder is under pressure. C 4-27 . i NOTE Turning clockwise will increase the stroke length.04 in/1mm per rotation. The locknut will keep the mechanical stop adjustment from vibrating loose during operation. adjust the air pressure and perform a test weld. If the horn reaches the desired position before contacting the stop. 5. Re-adjust the mechanical stop. Recheck the clearance between the horn and the fixture and make any necessary re-adjustments to the stop. 500-220-070 Rev. 3. turning counterclockwise will shorten the stroke length. if necessary. 2. loosen the lock nut and turn the mechanical stop adjusting knob clockwise until the carriage reaches the desired position. Reduce the pressure to zero and manually lower the carriage until the horn is just above the fixture.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Adjusting the mechanical Stop Figure 4. 6.6 mm). tighten the locknut. Adjustment is approximately 0. Place a workpiece in the fixture. If the horn does not reach the fixture and has not traveled 4 in.19 Adjusting the Mechanical Stop 1. (101. • After altering a DIP switch.20 DIP Switch Location 4-28 500-220-070 Rev. C . Figure 4.Chapter 4: Installation and Setup Adjusting the mechanical Stop 4. close and secure the left side cover and plug in the power cord. • Open the left side cover to access the DIP switches which are located on the circuit board located on the lower right corner immediately behind the front panel.12. • Use an insulated probe to alter DIP switch settings.1 Setting DIP Switches ! WARNING Be sure the welder is electrically disconnected before opening the cover. SW1-7 LLS Alarm Status . SW1-8 LLS Alarm Function Status . based on the status of the Upper Limit Switch (ULS). you will never receive a WELD ON signal during the weld cycle.1 DIP Switch Settings SW2-7 LLS Logic Status . This switch is only functional if SW1. 500-220-070 Rev. weld timing starts when the Trigger switch (TRS) is active. the weld active signal will not be activated. any alarms defined as “latchable” will prevent a weld cycle from bering initiated until RESET is pressed.In Weld mode. TEST. When ON.This switch selects the condition of the LLS signal that activates the LLS alarm. 7) is functional. C 4-29 . Level defines TRS lost as TRS input becoming inactive for more than 10 ms. this switch prevents any change from being made to the weld parameters. 1) is active. 7 has been activated.When ON. 0V (Low.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 4: Installation and Setup Adjusting the mechanical Stop 4. When ON. the LLS signal (SW1. i NOTE Use SW1-3 ONLY WHEN ABSOLUTELY NECESSARY. weld timing starts when the ULS signal is inactive. this switch affects the multiplier displayed on the POWER BARGRAPH during a weld cycle or when the peak power of the last weld is being displayed in READY state.This switch allows ultrasonics to be terminated on reaching a position in the stroke. When this switch is ON. HORN DOWN. When ON.When ON. When this switch is ON. the actual power (1x) is displayed.This switch determines in which logic state. SW1-3 Timing on Pretrigger . either ON when the alarm on the LLS signal becomes active during the weld or hold time. the LLS is considered becoming active. twice (2x) the actual power is displayed. Note that when timing is on the ULS. SW1-6 Weld Scale Multiplier . SW1-2 Not used SW1-1 Pretrigger on ULS . or OFF when the alarm on the LLS signal is inactive by the end of the hold time. SW1-5 Alarm Latch Status .This switch determines when weld timing will start. this switch allows ultrasonics to be pretriggered. SW2-5 Display Lock . ON) or +24V (High OFF). It is not recommended for general use. Edge defines TRS lost as TRS input becoming inactive for more than 100 ms. This choice is only available if the pretrigger status (SW1. and RESET can still be controlled from this choice. SW1-4 TRS Edge/Level .1.This switch selects either Edge (ON) or Level (OFF) to determine when the TRS signal is defined as “lost” during Weld or Hold time.This switch is used to determine whether weld cycles will be capable of activation after the welder has detected a “latchable” alarm condition. when OFF. When OFF.12. you are ready for operation. 4-30 500-220-070 Rev. The system should now be functional and can be set up for your application. If there are no alarm messages displayed. 2. 4. Press the Horn Down key and then press and hold the two start switches. 3. Press the Start switches to complete the calibration. Ensure there are no leaks in the air supply connections. C . The horn will descend to the fixture on the base of the Actuator. Press the Test button. go on to the next step. find the alarm message definition in the Maintenance section of Chapter 7 of the power supply manual. In summary.Chapter 4: Installation and Setup Testing the Installation 4. The horn will retract. Turn on the power supply. and verify that the system has air pressure. 8. Press the Horn Down key again. if the welder does not display an alarm message and the descends and retracts correctly. Figure 4. Turn on the air supply connections. 7. This verifies specifically that the pneumatic system is working. 6. The power supply will begins its normal self-check. 5. If the power supply displays an alarm message at this point.21 Normal Front Panel Display after Power -Up. Fit a test part onto the fixture. 9.13 Testing the Installation 1. ...... and welding stand in a compact bench unit.2 5...1.. staking..3 5...1 Technical Specifications 5...1..1 5.... and controls the welding process while providing a level of user interface through a membrane keypad and alpha-numeric display........E-Plus 20kHz Plastic Welder Instruction Manual Chapter 5: Technical Specifications Technical Specifications Chapter 5: Technical Specifications 5..1 5..... C 5-1 .... spot welding.3 Pneumatic Requirements ...... indicators..4 Circuit Descriptions....1....-5 ....-5 ...2 5...1 Physical Description The Branson E-Plus 20kHz Plastic Welders are self-contained ultrasonic plastics assembly systems that combine power supply..... It employs fan-forced cooling is intended for vertical placement.. controls.... The front panel display and user controls are intended to be accessible from a comfortable position for and end user (operator).-5 ......6 Converters and Boosters ...... For physical dimensions...... The Welder’s control system is microprocessor-based.. It can be operated manually..5 5.... which means that the unit should be installed approximately 3 feet off the floor........1 Physical Description . The welder weighs approximately 65kg (145 pounds).....2 Electrical Requirements .-5 ....1...1...3 E-Plus 20kHz Plastic Welder Dimensional Drawing 500-220-070 Rev...-5 . Its compact footprint conserves work space. It can be used for ultrasonic welding.. swaging............ and degating thermoplastic parts... refer to Figure 4..-5 .....1...-5 ...4 5..1............5 User I/O .1 Technical Specifications . inserting...... semi-automated or automated systems. Chapter 5: Technical Specifications Technical Specifications Table 5. Up to +70°C for 24 hours 5.3 Pneumatic Requirements The factory compressed air supply must be “clean (to a 5 micron level).1.240V 10 Amp Max. Depending on your application. Use a lockout device on the air line if required. A quick-disconnect fitting is suggested.2 Electrical Requirements Table 5. ! ! 5-2 WARNING Caution Synthetic air compressor lubricants containing Silicone or WD-40 will cause internal actuator damage and failure due to the solvents contained within these types of lubricants. Use of other types of gas could lead to premature degradation of seals. 500-220-070 Rev.1. C . the welder requires between 240kPa~690kPa (35 to 100 psi). Contact your Branson representative if you have any concerns. The welder includes an in-line air filter. dry and unlubricated” air with a regulated maximum pressure of 690 kPa (100 psig). WARNING There should be no substitute for clean. non-condensing Ambient Operating Temperature +5°C to +50°C Storage / Shipping Temperature -25°C to +55°C.2 Electrical Requirements 1500 W 200V . dry air to run the welder.1 Environmental Specifications Environmental Concern Acceptable Range Humidity 30% to 95%. @ 200V / 15 Amp CB None supplied 5. E-Plus 20kHz Plastic Welder Instruction Manual Chapter 5: Technical Specifications Technical Specifications 5.1.4 Circuit Descriptions The Welder contains the following modules: • Line Board • System Control Board • Ultrasonic Power Module • DC Power Module • User I/O The following sections contain descriptions for each module. Line Board The Line Board performs the dual function of providing RFI filtering for the line voltage input to the power supply, and controlling the electrical current surge to the ultrasonic Power Supply Module at power up until the inrush current limiter relay engages. The filtering also blocks ultrasonic signals from entering the AC main line. Additionally, the Line Board contains a soft start circuit module which limits the effects of current inrush. System Control Board The System Control Board controls the following functions of the Power Supply: • Responding to start and stop signals • Responding to alarm and reset signals • Responding to user input from the front panel • Activating and monitoring ultrasonics • Provides information for Front Panel Displays • Generate alarms • Control communications Ultrasonic Power Supply The Ultrasonic Power Supply Module generates ultrasonic energy at the resonant frequency of your Converter-Booster-Horn Stack. The Ultrasonic Power Supply Module contains five main circuits. • 320VDC Power Supply: converts AC line voltage to +320VDC for the output power devices. • Output circuit – matches the impedance of the output power device to the Converter-Booster-Horn Stack; and provides feedback to the Control circuit. • Control circuits: perform the following functions: • Provide drive signal to output power device. • Determine true percentage of ultrasonic power used over a range of amplitudes. • Allows control of the resonant frequency. • Control starting amplitude. • System Protection Monitor (SPM) and AutoTune with Memory (AT/M) circuit do the following: 500-220-070 Rev. C 5-3 Chapter 5: Technical Specifications Technical Specifications • Provide overload protection for the Ultrasonic Power Module. • Store operating frequency of last weld (frequency memory) and use the stored frequency as a starting point for the next weld. • Check and update frequency memory on start-up. • Provide switch-selective starting ramp times (Start). DC Power Module The Switching DC Power Module rectifies, filters, and regulates the AC voltages from the Line Transformer into DC voltages for the System Control Module. 5.1.5 User I/O The following tables list inputs to the Power Supply in general, and specifically; inputs to the Power Supply from the Actuator. Table 5.3 Inputs to the Power Supply Power Supply Input Function Start Switches (PB1, PB2) Start a weld cycle. Emergency Stop (E-Stop) Halts the current weld cycle; prevents further running of weld cycles until you release the Emergency Stop switch. Reset Resets alarms. Table 5.4 Inputs to the Power Supply from the Actuator Actuator Input Function Upper Limit Switch (ULS) Signals the Power Supply control circuits when the horn returns to the top of the stroke (READY state) Trigger Switch (TRS) Indicates the horn has applied the required amount of force to the part and signals the power supply to activate ultrasonics. Ground Detect Functions as ground detect input. 5-4 500-220-070 Rev. C E-Plus 20kHz Plastic Welder Instruction Manual Chapter 5: Technical Specifications Technical Specifications 5.1.6 Converters and Boosters The E-Plus 20kHz Plastic Welders uses the CJ 20 converter, EDP No. 101-135-059R. Figure 5.1 CJ 20 Converter The E-Plus 20kHz Plastic Welder uses the boosters listed in the following table Table 5.5 E-Plus Boosters:. Item Booster Booster 500-220-070 Rev. C Description Part Number 3/8-24 Horn End Drill and Tap 1100 Watt Only Aluminum 1:0.6 (purple) 101-149-090 Aluminum 1:1 (green) 101-149-093 Aluminum 1:1.5 (gold) 101-149-092 Aluminum 1:2 (silver) 101-149-094 Titanium 1:2.5 (black) 101-149-091 1/2-20 Horn End Drill and Tap All Models, Preferred Aluminum 1:0.6 (purple) 101-149-055 Aluminum 1:1 (green) 101-149-051 5-5 20 Output Titanium 1:2.6 (purple) 101-149-095 Other items used with the E-Plus Mylar® Washers (for 20 kHz systems) Studs 5-6 Description Kit. 1/2 .6 (purple) 101-149-060 Titanium 1:1 (green) 101-149-056 Titanium 1:1. Solid Mount Table 5.6 Part Number Aluminum 1:1.5 (gold) 101-149-097 Titanium 1:1 (green) 101-149-096 Titanium 1:0.5 (black) 101-149-059 1/2 .) 100-063-357 Kit. or 3/8 in. 10 each (1/2 in.25 (titanium horns and boosters) 200-098-790 500-220-070 Rev.Chapter 5: Technical Specifications Technical Specifications Item Booster. C . 150 each (3/8 in.) 100-063-472 1/2-20 x 1-1/4 (titanium horns) 100-098-370 1/2-20 x 1-1/2 (aluminum horns) 100-098-123 3/8-24 x 1.20 Input. 150 each (1/2 in.5 (black) 101-149-099 Titanium 2:1 (silver) 101-149-098 Titanium 1:1.5 (gold) 101-149-052 Aluminum 1:2 (silver) 101-149-053 Titanium 1:0.) 100-063-471 Kit.5 (gold) 101-149-057 Titanium 1:2 (silver) 101-149-058 Titanium 1:2. E-Plus 20kHz Plastic Welder Instruction Manual Chapter 6: Operation Chapter 6: Operation 6.1 Weld Modes - - - - - - - - - - - - - - - - - - - - - - - - - - - -6 - 2 6.1.1 Modifying Weld Modes - - - - - - - - - - - - - - - - - - - - -6 - 2 6.1.2 Using Weld Modes - - - - - - - - - - - - - - - - - - - - - - -6 - 5 6.2 Setting Weld Cycle Parameters - - - - - - - - - - - - - - - - - -6 - 6 6.2.1 Selecting a Parameter to Modify - - - - - - - - - - - - - - - -6 - 6 6.2.2 Modifying Parameter Values - - - - - - - - - - - - - - - - - -6 - 6 6.2.3 Storing Parameters- - - - - - - - - - - - - - - - - - - - - - -6 - 7 6.2.4 Recalling Stored Parameters - - - - - - - - - - - - - - - - - -6 - 7 6.3 Controlling the Front Panel Display - - - - - - - - - - - - - - -6 - 8 6.4 Setup Procedure - - - - - - - - - - - - - - - - - - - - - - - - -6 - 8 6.5 Weld Cycle State Displays and Alarms - - - - - - - - - - - - - 6 - 11 6.5.1 Weld Cycle State Displays - - - - - - - - - - - - - - - - - - 6 - 11 6.5.2 Clearing Weld Cycle Alarms - - - - - - - - - - - - - - - - - 6 - 15 6.5.3 Resetting the System- - - - - - - - - - - - - - - - - - - - - 6 - 16 6.5.4 Ultrasonic Test - - - - - - - - - - - - - - - - - - - - - - - - 6 - 16 6.5.5 Horn Down - - - - - - - - - - - - - - - - - - - - - - - - - - 6 - 17 6.5.6 Converter Cooling - - - - - - - - - - - - - - - - - - - - - - 6 - 17 500-220-070 Rev. C 6-1 Chapter 6: Operation Weld Modes ! ! WARNING Warning: When setting up and operating the welder, observe the following precautions. 1. High voltage is present. Do not operate with covers open or removed. 2. To prevent the possibility of electric shock, make sure that the welder if properly grounded. 3. Do not touch a vibrating horn. 4. Large plastic workpieces may vibrate within the audible frequency range when welded. If this occurs, use hearing protectors to prevent possible injury. (For further information, refer to Appendix A, Manufacturers of Hearing Protectors. 5. Do not press the TEST switch or cycle the machine when the converter is removed from the welder. 6. When using larger horns, avoid situations where fingers could be pinched between the horn and the fixture. CAUTION Caution: Do not allow an ultrasonically activated horn to touch a metal base or a metal fixture. 6.1 Weld Modes The E-plus has one mode. • Time mode - use when cycle time repeatability is critical. 6.1.1 Modifying Weld Modes Weld modes can be modified by setting parameters for further control over the weld cycle. In addition, you can set ultrasonics to start on the trigger switch (TRS) or to be pretiggered. You can also adjust the carriage’s down speed. Refer to Section 6.1.2 ’Using Weld Modes’ on page 5 for details on how to apply the features. 6.1.1.1 Parameters Weld modes can be controlled from the front panel by adjusting Time. Hold Time and the selectable Afterburst (AB) Delay parameters can be adjusted from all three welding modes. 6-2 500-220-070 Rev. C E-Plus 20kHz Plastic Welder Instruction Manual Chapter 6: Operation Weld Modes Note that, while AB Time and AB Delay are selectable, they do not have to be set. The two parameters work in tandem - if AB Time is selected, then AB Delay must also be selected, Afterburst is used to release workpieces that stick to the horn face after welding. Table 6.1 Parameter Functions Parameter Mode Switch Function Weld Time Time Mode sets the amount of time ultrasonic energy is applied to the workpiece. Hold Time All modes HOLD TIME sets the amount of time force is applied to the workpiece after ultrasonic energy is turned off, and while the horn is still contacting the workpiece. AB Time All modes AB TIME if selected, controls the length of time ultrasonic energy is active after AB Delay. Aids in dislodging a workpiece from the horn, if necessary. Used in conjunction with AB Delay. AB Delay All modes AB DELAY if selected, controls the amount of time between the removal of force from the workpiece and the point at which AB Time starts. Aids in dislodging a workpiece from the horn, if necessary, Required with AB Time. 500-220-070 Rev. C 6-3 insertion and sheer joint welding applications.1. ultrasonic energy activates on the Upper Limit Switch (ULS) instead of the Trigger Switch (TRS) when DIP switch settings are altered. Ultrasonics start when ULS becomes inactive.Chapter 6: Operation Weld Modes 6.3 Down speed adjustment If necessary alter the carriage’s down speed by adjusting the DOWN SPEED control on the front panel. Front Panel. Pretriggering ultrasonics at the ULS is generally recommended in staking. You can also use pretriggering for large or hard-to-start horns.1.1. see Figure 2.1 ’Setting DIP Switches’ on page 32 DIP Switches. Use pretriggering in certain applications such as staking when you need ultrasonics to start (pretrigger) before contacting the workpiece. SW1-3* ON Weld Time starts when ULS becomes inactive.11 ’Adjusting Welder Height and Aligning the Horn’ on page 29. refer to Section 4.12. For further details on using this control. Table 6. 6. callout 3.2 Pretriggering In Pretriggering. * Only valid when SW1-1 is ON For further information on setting DIP switches.2 DIP Switch Pretrigger Settings Pretrigger Setting Result SW1-1 OFF Pretrigger OFF SW1-1 ON Pretrigger ON Ultrasonics pretrigger when ULS becomes inactive SW1-3* OFF Weld Time starts when TRS becomes active.1.2 Front Panel Controls. 6-4 500-220-070 Rev. C . You can also adjust the Stroke Length as described in Section 4. 1.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 6: Operation Weld Modes 6.2 Using Weld Modes The following sections describe how to use weld modes with their associated parameters.1 Time Mode 500-220-070 Rev. use in automated systems where the welder cycle time must be limited to maintain overall system speed.2. 6.1 Time Mode Use Time mode when consistency of welder cycle time is an important part of your operation. Figure 6. For example.1. C 6-5 . If you set parameters. 6. its LED will light and the selected parameter’s value will be displayed in the NUMERIC display. 6.Chapter 6: Operation Setting Weld Cycle Parameters Table 6.4. Then the next press will set the parameter to its minimum value. Note that you can recall a parameter after you have changed it. C . then hit the EMERGENCY STOP before ending the cycle. press the appropriate switch for the parameter you wish to modify. press one or both START SWITCHES. start a weld cycle. refer to Section 6.2 Modifying Parameter Values Press the UP/DOWN switches until the value you wish to modify is displayed in the LED display. set parameters by pressing the appropriate switches on the front panel. Once set. 6-6 500-220-070 Rev.3 Time Mode Parameters Parameter Control and/or Monitor Can be Disabled Weld Time Controls No Hold Time Controls No AB Delay Controls Yes AB Time Controls Yes Time 6. As you press a switch.1 Selecting a Parameter to Modify After selecting your weld mode by pressing MODE. the next press of the parameter selection switch will set the parameter you selected to is original value. For example. the parameters will be lost. (For further information. to store the current parameters.2.2. or press RESET. press MODE for the Time.2 Setting Weld Cycle Parameters When the welder is in the READY state. press HOLD TIME for the Hold Time parameter.2. If you press an UP/DOWN switch after pressing a parameter selection switch except MODE. or before you select another parameter to modify. but only either before a weld cycle is run. 2. 25% Disable Press 2 Select = Activate parameter for modification Min.2. Once one or both START SWITCHES are pressed. if you press the EMERGENCY STOP.1 Recalling pre-defined parameter values To recall predefined parameters. the parameters are stored. if the parameter can be disabled. = Set parameter to its minimum value 25% = Set parameter to 25% of full scale Disable = Disable the function controlled by this parameter.2 Recalling modified parameter values When you select a parameter to modify.4 Recalling Stored Parameters 6. This option is not available for Weld Time value. simply press the parameter key once more and the original value will be restored from the internal register. the updated parameters will be lost and the values previously stored will become the current parameter values. after pressing an UP/DOWN switch. Table 6.4. If the function is disabled.However. then released and the welder enters the READY state. the word OFF will be displayed 6. 6.2.3 Storing Parameters After parameters have been modified.4.) • press four times to disable the parameter (if the parameter can be disabled) or to set the parameter to its minimum value.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 6: Operation Setting Weld Cycle Parameters 6.4 Recalling Pre-defined Parameter Values Parameter Press 1 Press 2 Press 3 Press 4 Press 5 Hold Time Select Min. (This option is not available for weld time. or turn the welder OFF before it enters the READY state. These shortcuts are used to "speed up" navigation of numeric parameters. if it cannot be disabled. its value is stored temporarily in an internal register. sit in front of the welder and press the switch of the parameter (not MODE) that you are modifying as follows: • press two times consecutively to set the parameter to the minimum value that may be used for that parameter • press three times to set the parameter to 25% of full scale for that parameter. 25% Press 2 Not used AB Time/ Delay Select Min. they are stored. you wish to return to the value you selected initially (before pressing an UP/ DOWN switch). • press five times to set the parameter to its minimum value. as opposed to setting your own exact setting.2. C 6-7 . 500-220-070 Rev. If. 12. If your application has been analyzed in the Branson Application Laboratory. You can recall cold start parameters even if the display is locked.3 Controlling the Front Panel Display The welder has three DIP switch settings for controlling the front panel display: • Weld Scale Multiplier • Test Scale Multiplier • Display Lock The multiplier settings may be used in low power situations. the cold start operation will disable it. If these measures do not resolve your problem. This causes the carriage to retract and ultrasonic energy to shut off. If a parameter cannot be disabled. Twist the E-STOP button to return the welder to READY. However you can restore cold start parameter values with this setting. Use Display Lock when you do not want operators to change settings.1 " DIP Switches". until the mode is changed or until the welder is recycled. i NOTE If a parameter can be disabled. Otherwise. refer to Chapter 4. where the load is less than 50%. contact your local representative or Branson’s Product Support Department.2.Chapter 6: Operation Controlling the Front Panel Display 6. consult the Branson Lab Report for appropriate settings. simultaneously press and hold the FAST UP and the FAST DOWN switches. 6. C .4. 1. pressing both START SWITCHES within 100 to 200 ms of each other starts a weld cycle. It remains on until the weld parameters are met or until a general alarm or EMERGENCY STOP occurs. the cold start operation will set the parameter to its minimum value.4 Setup Procedure In Time mode. (For further information on setting these DIP switches. immediately after activating the welder. Hold until the welder displays “rdy" .3 Recalling cold start parameter values If you wish to return to the cold start (factory-set) parameters: as the welder is powered. i NOTE Push the E-STOP button to terminate the cycle at any time. start with the following welder settings: • 6-8 Mode .Time 500-220-070 Rev. Ultrasonic energy starts and you may release the START SWITCHES when trigger conditions are met. 6. The weld cycle will start. d Weld Time ends and ultrasonic energy stops.3/4 in/6.25 psig/140kPa • Trigger Pressure . C 6-9 . the horn retracts automatically and the workpiece can be removed from the fixture. as follows: a The horn advances and contacts the workpiece. After Hold Time ends. based on the quality of the weld obtained and the POWER BARGRAPH reading.12 ’Adjusting the mechanical Stop’ on page 30.Lower trigger pressure settings are generally used unless there is a need to overcome warpage or to compress internal components such as springs. activating the TRS. press both START SWITCHES simultaneously or activate the start mechanism.35 to 95. 2. Ultrasonic vibrations are activated.E-Plus 20kHz Plastic Welder Instruction Manual • Weld Time .100 ms • Air Pressure . but. Weld a few workpieces using the initial parameters and check for desired properties. You may not obtain optimum results initially. 3.5 • Down Speed . Adjust the mechanical stop (for further information. i NOTE Down Speed . e The horn continues to clamp the workpiece for the Hold Time selected. The following Figures illustrate Weld Setup and Operation for Time Mode.25mm i Chapter 6: Operation Setup Procedure NOTE Trigger Pressure . Change one setting at a time until a weld is produced in minimum time with maximum strength. see Figure 4. Ensure that the welder is in READY mode. the carriage will not descend.1/4 to 3 .1 .OFF • Stroke Length . 500-220-070 Rev.100% range).3 turns (Yellow) • Afterburst Time/Delay . you can alter settings or adjust switches to achieve satisfactory results. f 5.500 ms • Hold Time . b Pressure develops between the horn and the workpiece. 4. c Weld Time begins and you can release the START SWITCHES. With a workpiece in place. diaphragms or seals. turn the control until the yellow ring or yellow and blue rings are visible through the opening on the knob. As an initial setting.If the DOWN SPEED control is turned OFF (fully clockwise).). The POWER BARGRAPH indicates loading (usually in the 20% . C .100% INSPECT TEST PART Underweld Overweld Acceptable Weld Record Parameters OVERLOAD ERROR 19 OVERLOAD CONDITION Reduce Pressure Reduce Dynamic Trigger Force Reduce Down Speed Use Pretrigger Use lower gain booster Use Higher Power Welder UNDERWELD Increase Weld Time Increase Pressure Increase Dynamic Trigger Force Increase Down Speed Use Higher Gain booster OVERWELD Reduce Weld Time Reduce Pressure Reduce Dynamic Trigger Force Reduce Down Speed Use Lower Gain booster 6-10 500-220-070 Rev.2 Setup and Operation in Time Mode SELECT HORN SELECT BOOSTER ALIGN SYSTEM SET STROKE LENGTH SET DOWN SPEED SET MECHANICAL STOP SET DYNAMIC TRIGGER FORCE SET PRETRIGGER (IF REQUIRED) SET PRESSURE SET WELD TIME SET HOLD TIME SET AB DELAY (IF REQUIRED) SET AB TIME (IF REQUIRED) WELD PART DID WORKPIECE STICK TO HORN? YES NO MONITOR POWER BARGRAPH LOADING 20% .Chapter 6: Operation Setup Procedure Figure 6. The currently active welding parameters are stored in NOVRAM (non-volatile memory) and a 100 to 200 ms stagger timer is started. the SV circuit is activated and a 4 sec. an alarm will be generated and the SV signal deactivated. Table 6. C 6-11 . the welder enters the READY state and you will see READY displayed on the numeric display. Upon successful completion of the internal tests. An error in reading the settings will cause cold values to be used. S1 Both START SWITCHES Pressed/Wait for SV (Solenoid Valve) Active . it performs a number of internal system tests.5. if either START SWITCH input is lost (where the START SWITCH input status is defined as “Maintained”).5 Weld Cycle State Displays and Alarms When the welder is turned on.timer is started. If no errors are encountered.When the SV signal is activated within the timeout period. the eight-digit NUMERIC DISPLAY shows the current weld cycle state as indicated below. during which time the other START SWITCH must be pressed or an alarm will be generated and the welder will return to READY state. 500-220-070 Rev. S2 SV Active/Wait for ULS . If any errors are encountered.1 ’Weld Cycle Alarms and Error Messages’ on page 12 for a definition of the message. refer to 6.1 Weld Cycle State Displays During a normal weld cycle. If the welder does not successfully complete the internal tests and you receive an error message. a 4 sec. you can set weld cycle parameters (as described in Section 6. during which time the SV signal must become active or an alarm will be generated and the weld cycle aborted.When both START SWITCHES have been pressed within 100 to 200 ms of each other.1. timer is started. At this point. during which time the ULS signal must become inactive or an alarm will be generated and the SV signal deactivated. the welder will not enter the READY state. the welding parameters are set to those stored. 6. In addition.5 E-Plus State Displays State Description S0 One START SWITCH Pressed/Wait for Second START SWITCH .2 ’Setting Weld Cycle Parameters’ on page 6.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 6: Operation Weld Cycle State Displays and Alarms 6.5. If the DIP switch is ON. S5 Wait for TRS Inactive . the LLS signal becomes active (if the LLS function has been enabled). AB Delay and AB Time are applied. if there are latching alarms. error messages are displayed whenever a parameter selection switch is pressed while there are active alarms.5. 6. or hardware alarms. and overload occurs.12. Once the TRS signal becomes active.5. the welder returns to the READY state. and 6.) 500-220-070 Rev. S7 Wait for ULS Active . a 4 sec. (For further information. For further information on alarms and error messages refer to the following Sections: 6. then you must press RESET before the welder will return to the READY state. S8 Wait for START SWITCHES . refer to Chapter 4.When the ULS signal becomes inactive within the timeout period. Ultrasonic energy will remain on until the specified Weld Time has elapsed.5. end-of-sequence timer.once the weld parameters have been met. A weld cycle can run as soon as this clears. or the TRS input is lost.once the condition that caused the alarm is clear.press RESET before the next weld cycle can start.2 ’Clearing Weld Cycle Alarms’ on page 15. the ULS input must become active or an alarm will be generated.5. if either the ULS or LLS signals become active. the weld parameters established for Weld Time. a 4 sec. during which time the TRS signal must become active or an alarm will be generated and the SV signal deactivated. refer to 6.1 Weld Cycle Alarms and Error Messages Once a weld cycle ends. (For further information. Following successful completion of Weld Time. • Latching . However.2 ’Clearing Weld Cycle Alarms’ on page 15. or one of the START SWITCH inputs is lost (where the START SWITCH input status is defined as "Maintained").) There are four types of alarms. the alarm message will no longer be displayed. the NUMERIC DISPLAY shows in an error code format any error messages generated. or if no errors were detected. Responses to ar described below: 6-12 • Non-Resettable . • Latchable .power the welder OFF and then back ON to clear this alarm.1. end-of-sequence timer.1 ’Weld Cycle Alarms and Error Messages’ on page 12. the READY state will not be reached. If the DIP switch is OFF. timer is started.1.Chapter 6: Operation Weld Cycle State Displays and Alarms S4 ULS Inactive/Wait for TRS .1 "DIP Switches".During the 4 sec. If specified.During the 4 sec. this group of alarms will become latching alarms. In addition. • Non-Latching .based on the setting of the Alarm Latch Enable DIP switch. If the alarm latch feature is activated and there are latchable alarms. In addition. the SV drive circuit will remain active for the duration of the specified Hold Time (unless TRS input is lost). end-of-sequence timer is started. Once the alarms have been cleared. during which time the TRS input must become inactive or an alarm will be generated. C . Used for hardware failures. the parameters for AB Delay and AB Time are applied following successful completion of the Hold Time. an alarm will be generated and the SV signal deactivated. the START SWITCH inputs must be released or an alarm will be generated. Hold Time. this group of alarms will become non-latching alarms. Error 11 ULS Exit Non-Latching .The TRS input was active while the welder was in the READY state. Error 03 TRS Ready Error Latchable . Activated at the end of an aborted cycle.The ULS input did not become active within 4 seconds of SV drive deactivation (time after TRS has become inactive).The TRS input became inactive during weld or hold timing (before the ULS became inactive).The LLS input became active before weld timing began.The SV drive input indicates that the output was active while the welder was in the READY state. Error 06 ULS Enter Non-Latching . Error 04 LLS Ready Latchable . or trying to enter the READY state. Error 14 PBS Exit Error Non-Latching . Error 13 TRS Exit Error Non-Latching .The ULS input was not active while the welder was in the READY state.The TRS input did not become active within 4 sec. Error 05 SV Ready Non-Resettable .E-Plus 20kHz Plastic Welder Instruction Manual Table 6. Error 09 LLS Enter Non-Latching . or the START SWITCH inputs were lost before the TRS input became active and before weld timing began. Error 08 TRS Enter Error Non-Latching .The LLS input was active while the welder was in the READY state. This often indicates a blown fuse. or were still active after power-up or after E-STOP inputs have been deactivated (within 4 seconds of the ULS becoming inactive). 500-220-070 Rev. C 6-13 . Error 15 TRS Weld Error Latchable .The START SWITCHES were not pressed within 100 to 200 ms of each other. of ULS becoming inactive. Error 10 PBS Enter Non-Latching .The ULS input did not become inactive within 4 sec. of SV drive activation and remained active until weld timing began.The TRS input did not become inactive within 4 seconds of SV drive deactivation (allowed time).6 Chapter 6: Operation Weld Cycle State Displays and Alarms Error Codes Error Code Description Error 01 ULS Ready Error Latchable .The PB inputs did not become inactive within 4 seconds of SV drive deactivation. or by the external RESET input. Error 17 LLS Function Latchable .The LLS input met the conditions for an LLS error as defined by the LLS control DIP switches.After the ULS input became inactive. For further information. the PTS input became inactive again before the TRS input became active. C . Error 18 Power Supply Startup Overload Latchable .The SPM/AT (System Protection Monitor) indicated a power supply overload within the first 50 ms of operation. Error 20 NOVRAM Data Latchable . refer to Chapter 4. Error 19 Power Supply Overload Error Latchable . the factory-set settings are used. If the power supply cannot read the parameter settings stored in NOVRAM at power-up. the ULS input became active again before the TRS input became active. Error 21 SV Active Error Non-Resettable .The SV drive output did not meet the requirements for activating the SV.After the ULS input became inactive. 6-14 500-220-070 Rev.The data read from non-volatile memory did not pass a data integrity check.The AUPS indicated a power supply overload within the first 60 ms of operation.12. the ULS input became active again before the PTS input became active (PTS enabled).After the PTS input became active. Error 24 PTS Lost Waiting for TRS Latchable .Chapter 6: Operation Weld Cycle State Displays and Alarms Error Code Description Error 16 ULS Lost Waiting for TRS Latchable .1 Selecting DIP Switches. Error 23 ULS Lost Waiting for TRS Latchable . This error cannot be cleared by RESET. You must turn the welder OFF.5. C 6-15 .5 seconds. therefore if RESET is pressed for less than 30 ms.2. the welder will not return to the ready state Non-Latching alarms are displayed on the front panel and generate output signals through the accessory interface. All non-Latching alarms are cleared when the next cycle is started (by START SWITCH or start cable) or they will clear themselves after 1. correct the situation and then turn the welder back on before you can start the next weld cycle. 6.5. • hardware fails. 500-220-070 Rev. • trigger is lost. 5 Alarm Latch Status: • ON = Alarm Latch Enabled Latching • OFF = Alarm Latch Disabled Non-Latching For further information on setting DIP switches. These alarms cannot be cleared by pressing RESET or the EXTERNAL RESET signal. 6.5. refer to Chapter 4.1 Latchable alarms Latching alarms prevent a new weld cycle from starting and can only be cleared by pressing RESET or activating the EXTERNAL RESET signal. Alarms occur when: • the welder overloads.12. Alarms are classified as either Latchable (Latching or Non-Latching) or Non-Resettable.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 6: Operation Weld Cycle State Displays and Alarms 6. The Alarm Latch DIP switch setting determines whether Latchable alarms are Latching or Non-Latching.1.2 Non-Resettable alarms Non-Resettable alarms prevent the welder from cycling. The procedure used to reset the system after an alarm condition is generated depends on the type of alarm. They are caused by hardware failure.2 Clearing Weld Cycle Alarms i NOTE All alarms must be cleared before any weld parameters can be modified.2. i NOTE The reset circuitry requires 30 ms to clear an alarm before cycling. Use Switch 1. 5. C . This will set Weld and Hold Time to 50 ms (the minimum value) and disable AB Delay and AB Time.. Then press TEST. the Autotune feature is disabled and the welder enters manual tuning mode (for further information. From this point on. If an overload occurs. refer to Chapter 7. tuning is controlled by the tuning potentiometer.4.1 ’Manual Tuning’ on page 8. • Press both the FAST UP and FAST DOWN switches until the welder displays "RDY" and goes to Time mode. refer to Chapter 4.1. "DIP Switches"). as long as the welder does not overload.3 Resetting the System During powerup. the power dissipated by one specific stack in air should be consistent (±) over a long period of time. Follow the step for your welder below. This procedure also functions if you have activated Display Lock. Pressing TEST causes the POWER BARGRAPH to switch to the DIP Switch-selected multiplier (for further information.Chapter 6: Operation Weld Cycle State Displays and Alarms 6. 6-16 500-220-070 Rev. Ultrasonic energy will remain on as long as TEST remains pressed and the welder does not overload. 6. make sure that the stack is properly assembled and that all connections have been made correctly.4. Automated systems users should turn off indexing equipment for this test. "Manual Tuning"). Any change in power indicates that a problem could be developing. you can restore the weld parameters to their Cold Start (factory-set) values. When a welder is operating correctly.12.1. refer to Section 7.5. After 4 to 6 seconds. ! ! CAUTION You must have a converter-booster-horn stack installed in you welder before activating ultrasonic energy. WARNING Ensure that the cover is closes with door screws secured and that no one is in contact with the horn when you press TEST. the welder may require manual tuning. (For further information. and the stack is known to be mechanically sound.) To test the welder.4 Ultrasonic Test Use the TEST switch on the front panel to measure the ultrasonic energy dissipated by the stack in air. press the START SWITCHES simultaneously and hold until the TRS is active (indicated by a single beep). your equipment requires additional cooling. At this point you may release the START SWITCHES. i NOTE Additional heat will be generated if the converter-booster-horn interfaces need reconditioning. tape a pyrometer or similar temperature measuring device onto the front drive (nose piece) of the converter assembly. The converter front driver temperature should not exceed 50°C. Contact Branson for further assistance. If this temperature is 48°C or higher. To check the temperature.5.5 Horn Down Use the following procedure to check you horn-to-fixture alignment and/or Mechanical Stop Setting: 1. 6. press HORN DOWN again. To enter READY state and retract the horn. Wait for the device to reach the temperature of the driver. the NUMERIC DISPLAY will indicate horn travel.6 Converter Cooling The standard converter cooling method used on Branson welders is to direct the exhaust air from the cylinder. through the converter. 2. Check if your converter is operating at too high a temperature immediately after substantial welder operation and without ultrasonics applied to the horn. Be sure the stack is in good condition and properly assembled. While you are in HORN DOWN.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 6: Operation Weld Cycle State Displays and Alarms 6. Press HORN DOWN. Converter performance and reliability can be adversely affected if subjected to temperatures in excess of 60°C.5. 3. C 6-17 . 500-220-070 Rev. C .Chapter 6: Operation Weld Cycle State Displays and Alarms 6-18 500-220-070 Rev. ...1. 200-163-009) .4 Troubleshooting ....3 Circuits .....1 7...1... Booster and Horn) ......8 7...1..-7 ....1.........-7 .... • Inspecting and cleaning Air Filter components.......... C 7-1 .....6 7.....3 Servicing the Air Filter (Part No..... 7..4............1 Manual Tuning ............ If these surfaces become corroded...4 7....-7 ..... 500-220-070 Rev..2 Parts Lists...1 Preventive Maintenance The following preventive measures help assure long term operation of your Branson E-Plus 20kHz equipment..1 7......-7 .....2 7..2 Reconditioning the Stack (Converter.....-7 ....1 Periodic Maintenance Procedures ....7 7.. Do not allow cleaning solution to enter the unit... • External covers may be cleaned with a damp sponge or cloth using a solution of mild soap and water..1 Preventive Maintenance .... recondition the surfaces by following the instructions in the following Section.........E-Plus 20kHz Plastic Welder Instruction Manual Chapter 7: Maintenance Preventive Maintenance Chapter 7: Maintenance 7.....-7 .-7 ....1 Periodic Maintenance Procedures Periodic maintenance for the welder involves: • Inspecting the mating surfaces of the Converter-Booster-Horn Stack.......8 7..-7 . 1 7-2 Stack Reconditioning Procedure Step Action 1 Disassemble the Converter-Booster-Horn Stack and wipe the mating surfaces with a clean cloth or paper towel. For standard 20 kHz products. and free from fretting corrosion. Stacks using Mylar washers should be inspected every three months.1 on page 7-4. make sure that no other automated systems are active. If any mating surface shows corrosion or a hard. 5 Place the interface surface on the emery cloth. Do not apply downward pressure — the weight of the part alone provides sufficient pressure. Booster and Horn) Welding system components work most efficiently when the Converter-Booster-Horn Stack mating surfaces are flat. flat surface (such as a sheet of plate glass). WARNING When performing maintenance on the welder. 4 Tape a clean sheet of #400 (or finer) grit emery cloth to a clean. take the following steps: Table 7. increases noise and heat. with your thumb over the spanner-wrench hole. as in Figure 7. 500-220-070 Rev. Poor contact between mating surfaces wastes power output. C . and may cause damage to the converter. remove the threaded stud from the part. 3 If necessary. Replace the washer if torn or perforated. Grasp the part at the lower end. makes tuning difficult. smooth. recondition it.2. 7. and horn and converter. in solid contact. ! ! CAUTION Never clean the Converter-Booster-Horn Stack mating surfaces by using a buffing wheel or by filing.1 Stack Reconditioning Procedure To recondition stack mating surfaces.1. dark deposit. and lap the part in a straight line across the emery cloth.1. a Branson Mylar® washer should be installed between the horn and booster. 2 Examine all mating surfaces.Chapter 7: Maintenance Preventive Maintenance 7.2 Reconditioning the Stack (Converter. this should not require more than two to three complete rotations for an aluminum horn or booster.9. 10 Before re-inserting a threaded stud in an aluminum booster or horn: ! 11 a Using a file card or wire brush. c Examine the knurled end of the stud. Remember. two or three times. and repeat the lapping procedure in step 6. a titanium component may require more rotations. Replace all studs in these components. referring to Chapter 4. 8 Rotate the part another 120 degrees to the next spanner-wrench hole. and repeat the lapping procedure in step 6. clean the threaded hole. b Using a clean cloth or towel. Also. replace the stud. 500-220-070 Rev. in the same direction against the emery cloth (Figure 7. clean any aluminum bits from the knurled end of the stud. repeat steps 2-5 until you remove most of the contaminant. CAUTION Threaded studs cannot be reused in titanium horns or boosters.1 on page 7-4).E-Plus 20kHz Plastic Welder Instruction Manual Table 7.1 Chapter 7: Maintenance Preventive Maintenance Stack Reconditioning Procedure (Continued) Step Action 6 Lap the part. 9 Re-examine the mating surface. Assemble and install the stack. 7 Rotate the part 120 degrees. If worn. If necessary. placing your thumb over the spannerwrench hole. C 7-3 . examine the stud and threaded hole for stripped threads. 1 Reconditioning Stack Surfaces 7.1. you can bleed the filter by turning the brass nut on the bottom. C . follow the instructions below.3 Servicing the Air Filter (Part No. 200-163-009) The Air Filter is self-draining. If your Air Filter leaks or gets dirty. 7-4 500-220-070 Rev.Chapter 7: Maintenance Preventive Maintenance Figure 7. If contaminants build up inside the Air Filter. E-Plus 20kHz Plastic Welder Instruction Manual Figure 7. replace the Air Filter.2 1. 4. 6. ! WARNING Turn air pressure to zero and disconnect the air line connection. check both O-rings. Unscrew the bowl from the housing. 5. 3. C 7-5 . Remove the float from the bowl. If the Air Filter leaks. Inspect the O-rings. Unscrew the filter element from the housing. 500-220-070 Rev. ! WARNING Clean the bowl with household soap only. 2. Chapter 7: Maintenance Preventive Maintenance Disassembly of Air Filter Components Turn air pressure to zero and disconnect the main air supply. Failure to do this leaves the welder under potentially dangerous air pressure. Clean the inside of the bowl with household soap. Never clean the bowl with a solvent. If one or both of the O-rings is bad. 3/4 Amp 200-049-089 Circuit Breaker. • Screw the bowl into the housing. 8. Controller 101-063-718 Membrane Keypad 570-185-125 AC/DC Universal Supply 200-132-777 PC BD Line UPS 100-242-546 Kit.5kW 100-244-123 Operators Manual 500-220-070 Kit. Reassemble the Air Filter as follows: • Place the float into the bowl (Figure 7.2 Replacement Parts Description Part Number Fuse. 17A 200-167-015 Kit. Clean the float and filter element.1) • Screw the filter element into the housing until finger-tight. Power Module 1. Fan 101-063-722 Kit. Accessory Input/Output Connection 101-063-721 Spanner Wrench 201-118-019 Solenoid Valve 100-246-694 Pressure Gauge 100-246-691 Cylinder 200-034-056 Emergency Stop Knob 200-099-274 Start Switch 200-099-236R Line Filter 100-242-546R 7-6 500-220-070 Rev. 7.Chapter 7: Maintenance Parts Lists 7.2 Parts Lists Table 7. 8 A 200-167-014 Circuit Breaker. C . C 7-7 .3 Circuits Figure 7.E-Plus 20kHz Plastic Welder Instruction Manual Chapter 7: Maintenance Circuits 7.3 Interconnect Schematic. AUTOMATION START PALM BUTTON START 500-220-070 Rev. but should be used only as a last resort. Remove the Autotune label from the Front Panel.4 Troubleshooting 7. C .4. If there is an instance where Autotune does not provide proper tuning. ! 7-8 CAUTION Do not force the potentiometer beyond its stop limits. 500-220-070 Rev. The total rotation from full cw to full ccw is only 270°.Chapter 7: Maintenance Troubleshooting 7. using the following procedure.1 Manual Tuning i NOTE This should NOT be a regularly performed procedure. and repeat the procedure to the left (ccw). peel off the Autotune label to expose the potentiometer location. If you have reached the right limit stop and continue to over load.1 Verify Stack Assembly* If stack is OK. Reattach Autotune label over Front Panel Potentiometer. return to the starting mark. C 7-9 . Contact Product Support if required. 270° Maximum Rotation Before performing the Manual Adjustment Procedure. 500-220-070 Rev. **Do Not Force Potentiometer Beyond its 270° Limit Manual Adjustment Limits reached? Yes Return Front Panel potentiometer to original position. note/mark the original position of the Front Panel Potentiometer.4 Chapter 7: Maintenance Troubleshooting Manual Adjustment Procedure Flowchart *Refer to Sections 4. (cw) Press for 1 second. then release the TEST key. and troubleshoot the weld system. ccw cw Toward Higher Frequency Toward Lower Frequency Potentiometer Adjust Front Panel Potentiometer approximately 30° to the right. Overload alarm? No Manual Adjustment procedure finished.E-Plus 20kHz Plastic Welder Instruction Manual Figure 7. Yes Manual Adjustment Limits reached? No Continue to Adjust the Potentiometer in 30° increments to the right (cw)**.8 and 7. C .Chapter 7: Maintenance Troubleshooting 7-10 500-220-070 Rev. MD 20774-5351 www.....2 A.com Softcomm Products 2310-T S... Airport Blvd Chandler....A .davidclark.com David Clark 360 Franklin St....1 Hearing Protectors Safeware.. C A-1 . Inc 9475 Lottsford Rd..... Dept TR 500-220-070 Rev.... AZ Elvex Corp 13 Trowbirdge Dr........3 Static Protection Equipment .2 A... Suite 150 Largo...A ........2 Sound Absorbing Material ....... MA 01615-0054 www.A ..1 A.E-Plus 20kHz Plastic Welder Instruction Manual Appendix A Manufacturers of Protective Equipment Hearing Protectors Appendix A Manufacturers of Protective Equipment A..........1 Hearing Protectors ....Safewareinc. Box 15054 Worcester. C . MA 01746 Tamer Industries 185 Riverside Av Somerset.TerraUni. Harbor Blvd. Newark. 420-T Corporate Blvd. CA 92805 www. CT 06801 A.3 Static Protection Equipment Terra Universal 700-T N. Anaheim. Chicago. Eddystone. Inc.2 Sound Absorbing Material American Acoustical Products 6 October Hill Rd. PA 19022 Polymer Technologies. IL 60647-2023 Foamex 1501 E Second St. DE 19702 Soundcoat Company 1 Burt Drive Deer Park. Holliston. MA 02725 Singer Safety Co. NY 11729 A.com A-2 500-220-070 Rev.Appendix A Manufacturers of Protective Equipment Sound Absorbing Material Bethel. 2300 W Logan Blvd. PA 19438-2017 i NOTE The information given above is supplied with the understanding that no product discrimination is intended and that no endorsement of a product by Branson is implied. Harleysville.E-Plus 20kHz Plastic Welder Instruction Manual Appendix A Manufacturers of Protective Equipment Static Protection Equipment Polygenex PO Box 4468 Cary. 500-220-070 Rev. 352D Godshall Dr. NC 27519 Electrostatics. C A-3 . Inc. C .Appendix A Manufacturers of Protective Equipment Static Protection Equipment A-4 500-220-070 Rev.